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Sigmatek FDD Sizes 7 to 9 Power Installation Guide

instantaneous power rating and energy rating of the braking resistor are sufficient for the most
extreme braking duty that is likely to be encountered.
Optimization of the braking resistor requires careful consideration of the braking duty.
Select a value of resistance for the braking resistor that is not less than the specified minimum
resistance. Larger resistance values may give a cost saving, as well as a safety benefit in the event
of a fault in the braking system. Braking capability will then be reduced, which could cause the drive
to trip during braking if the value chosen is too large.

Thermal protection circuit for the braking resistor

The thermal protection circuit must disconnect the AC supply from the drive if the resistor becomes
overloaded due to a fault. Figure 4-8 shows a typical circuit arrangement.

Figure 4-8 Typical protection circuit for a braking resistor

See Figure 4-1 on page 47 , Figure 4-2 on page 48 and Figure 4-3 on page 49 for the location of the
+DC and braking resistor connections.

4.7.2

Braking resistor software overload protection

The drive software contains an overload protection function for a braking resistor. In order to enable
and set-up this function, it is necessary to enter three values into the drive:
•

Braking Resistor Rated Power

(10.030)

•

Braking Resistor Thermal Time Constant

(10.031)

•

Braking Resistor Resistance

(10.061)

This data should be obtained from the manufacturer of the braking resistors. The braking resistor
thermal time constant can be calculated from resistor data sheet values using the following equation:

Pr

10.039

gives an indication of braking resistor temperature based on a simple thermal model. Zero

indicates the resistor is close to ambient and 100 % is the maximum temperature the resistor can
withstand. A ‘Brake Resistor’ alarm is given if this parameter is above 75 % and the braking IGBT is
active. A Brake R Too Hot trip will occur if Pr

10.039

reaches 100 %, when Pr

10.037

is set to 0

(default value) or 1.
If Pr

10.037

is equal to 2 or 3, a Brake R Too Hot trip will not occur when Pr

10.039

reaches 100 %,

but instead the braking IGBT will be disabled until Pr

10.039

falls below 95 %. This option is intended

for applications with parallel connected DC buses where there are several braking resistors, each of
which cannot withstand full DC bus voltage continuously. With this type of application it is unlikely the
braking energy will be shared equally between the resistors because of voltage measurement
tolerances within the individual drives. Therefore with Pr

10.037

set to 2 or 3, then as soon as a

Optional

RFI filter

Stop

Start /
Reset

Thermal
protection

device

Braking resistor

Drive

Main contactor
power supply

+DC

BR

Pr 10.031

Resistor pulse power rating x Braking time

Resistor continuous power rating

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Содержание 074.00660

Страница 1: ...Power Installation Guide SIGMATEK FDD Frame 7 to 9 Issue 12...

Страница 2: ...cals REACH requires the supplier of an article to inform the recipient if it contains more than a specified proportion of any substance which is considered by the European Chemicals Agency ECHA to be...

Страница 3: ...2 3 Mechanical installation 14 3 1 Safety information 14 3 2 Planning the installation 15 3 3 Terminal cover removal 17 3 4 Dimensions and mounting methods 19 3 5 Enclosure for standard drives 24 3 6...

Страница 4: ...mation 94 6 1 UL file reference 94 6 2 Option modules kits and accessories 94 6 3 Enclosure ratings 94 6 4 Mounting 94 6 5 Environment 95 6 6 Electrical Installation 95 6 7 Motor overload protection a...

Страница 5: ...ce They must read this safety information and this guide carefully 1 3 Responsibility It is the responsibility of the installer to ensure that the equipment is installed correctly with regard to all i...

Страница 6: ...its control system could lead to or allow damage loss or injury a risk analysis must be carried out and where necessary further measures taken to reduce the risk for example an over speed protection d...

Страница 7: ...and software are designed to high standards of quality and robustness they are not intended for use as safety functions i e where a fault or failure would result in a risk of injury In any application...

Страница 8: ...choke i e Model 09x xxxxxE is referred to as a Frame 9E and a Frame 9 drive with an internal choke i e Model 09x xxxxxA is referred to as a Frame 9A Any reference to Frame 9 is applicable to both size...

Страница 9: ...pond to week 10 of year 2017 FDD3 094 02240 E10 Model Frame Voltage Heavy Duty current rating Power format Control pod fitted Fan power supply fitted Refer to User Guide Normal Heavy Duty power rating...

Страница 10: ...utput Input Output Max cont output current Nom power 400 V Motor power 460 V Max cont output current Nom power 400 V Motor power 460 V 3ph Nom Class Nom Class A A A mm2 mm2 AWG or kcmil AWG or kcmil A...

Страница 11: ...r maximum 40 C 104 F 1000 m altitude and 3 kHz switching frequency except where shown Derating is required for higher switching frequencies ambient temperatures 40 C 104 F and higher altitude For dera...

Страница 12: ...ve features Figure 2 3 Features of the drive size 7 to 9 Key 1 Ground connections 2 AC supply connections 3 DC bus 4 DC bus 5 Rating label 6 Braking terminal 7 Motor connections 1 2 5 5 1 3 6 7 1 1 2...

Страница 13: ...with the drive The drive is supplied with a copy of the Power Installation Guide and a copy of the Control Getting Started Guide Quick Start Guide a safety information booklet the Certificate of Quali...

Страница 14: ...continue Normally the capacitors are discharged by an internal resistor Under certain unusual fault conditions it is possible that the capacitors may fail to discharge or be prevented from being disc...

Страница 15: ...operating temperature being exceeded Note that a sealed enclosure gives much reduced cooling compared with a ventilated one and may need to be larger and or use internal air circulating fans For furth...

Страница 16: ...ical industrial control equipment If it is necessary to meet strict emission limits or if it is known that electromagnetically sensitive equipment is located nearby then full precautions must be obser...

Страница 17: ...C and or DC power supply has been disconnected If the drive has been energized the power supply must be isolated at least ten minutes before work may continue Normally the capacitors are discharged by...

Страница 18: ...e finger guard and DC terminal cover break outs Figure 3 5 Removing the finger guard break outs All sizes Place the finger guard on a flat solid surface and hit relevant break outs with hammer as show...

Страница 19: ...tection to IP20 and to avoid the risk of fire in the event of a major internal failure Drive size Part number Picture Size 7 Kit of 8 x single entry grommets 3470 0086 Size 8 Kit of 8 x single entry g...

Страница 20: ...ensions Figure 3 6 Drive dimensions Size 8 shown Size H1 H2 W D mm in mm in mm in mm in 7 557 21 93 508 20 270 10 63 280 11 02 8 804 31 65 753 29 65 310 12 21 290 11 42 9E 1069 42 09 1010 39 70 310 12...

Страница 21: ...rface mounting Figure 3 7 Surface mounting dimensions size 7 to 9 220 mm 8 66 in 9mm 0 35 in 538 mm 21 18 25 mm 0 98 in 10 mm 0 39 in 784 mm 30 87 in 8 259 mm 10 20 in 0 35 in x 4 holes 9 mm 0 35 in 2...

Страница 22: ...m 0 35 in 4 holes 166 mm 6 54 in 240 mm 9 45 in 240 mm 9 45 in 32 mm 1 26 in 5 mm 0 21 in 5 6 holes 252 mm 9 92 in n5 5 typ 8 places 989 8 259 mm 10 20 in 287 1 mm 11 3 0 04 in 327 mm 12 87 in 883 mm...

Страница 23: ...parately below are the relevant part numbers Frame size Surface mounting kit supplied with drive Qty Optional through panel mounting kit Qty 7 Hole size 9 mm 0 35 in x 2 x 2 Hole size 9 mm 0 35 in x 1...

Страница 24: ...he drives Table 3 3 Spacing required between the drives 50 C derating applies refer to Table 5 3 Maximum permissible continuous output current 50 C 122 F on page 80 Drive Size Spacing A 40 C 50 C 7 30...

Страница 25: ...rances are maintained for the drive and external EMC filter Forced or convection air flow must not be restricted by any object or cabling Note For EMC compliance 1 When using an external EMC filter on...

Страница 26: ...ive 2 Power cabling must be at least 100mm 4in from the drive in all directions A B 60 mm 2 37 in 45 mm 1 77 in B B A AC supply contactor and fuses or MCB Locate as required Locate as required Enclosu...

Страница 27: ...t in contact with a wall or floor can dissipate heat Calculate the minimum required unobstructed surface area Ae for the enclosure from Where Ae Unobstructed surface area in m2 1 m2 10 9 ft2 T ext Max...

Страница 28: ...pace available it can be made smaller only by attending to one or all of the following Using a lower PWM switching frequency to reduce the dissipation in the drives Reducing the ambient temperature ou...

Страница 29: ...the installation Typically use a factor of 1 2 to 1 3 to allow also for pressure drops in dirty air filters Example To calculate the size of an enclosure for the following Three drives operating at th...

Страница 30: ...e Trate the greater of Text or Tint Where Text Temperature outside the cabinet Tint Temperature inside the cabinet Trate Temperature used to select current rating from tables in Chapter 5 Technical da...

Страница 31: ...ieve IP65 rating size 7 and 8 or IP55 size 9 NEMA 12 at the rear of the heatsink for through panel mounting This allows the front of the drive along with various switchgear to be housed in a high IP e...

Страница 32: ...cket that would otherwise prevent a good seal This procedure is described in Figure 3 14 Figure 3 14 Special procedure for size 7 only 1 Remove screw shown using T20 torque driver 2 Bend EMC bracket 9...

Страница 33: ...e 3 16 on page 34 sealing clamps are supplied in the through panel mounting kit to aid compression of the gasket The heatsink fans have conformal coated PCBs and have sealant at cable entry points Dri...

Страница 34: ...t of the drive when through panel mounted For detailed information regarding high IP through panel mounting see section 3 4 3 Through panel mounting on page 22 When designing a high IP enclosure consi...

Страница 35: ...C filter The external EMC filters for sizes 7 to 9 are designed to be mounted above the drive as shown below Figure 3 17 Size 7 to 9 mounting of the EMC filter 3 9 1 Optional external EMC filters Tabl...

Страница 36: ...upply phase to phase and phase to ground Worst case 40 C 104 F 50 C 122 F IEC UL 40 C 104 F 50 C 122 F A A V V W W mA mA M 4200 1132 117 102 7 528 480 20 50 43 7 11 7 188 1 68 4200 1972 197 172 8 528...

Страница 37: ...lter dimensions Table 3 9 Size 8 external EMC filter dimensions Part number A B C D E F H W V X Y Z 4200 1132 240 mm 9 45 in 255 mm 10 04 in 55 mm 2 17 in 150 mm 5 90 in 205 mm 8 07 in 270 mm 10 63 in...

Страница 38: ...9A Table 3 10 Size 9A external EMC filter dimensions Part number A B D E F G H I J W 4200 3021 220 mm 8 66 in 170 mm 6 70 in 120 mm 4 72 in 210 mm 8 27 in 2 mm 0 08 in 40 mm 1 57 in 339 mm 13 34 73 mm...

Страница 39: ...al external EMC Filter terminal data Part number A B C D E G H W Y 4200 4460 280 mm 11 02 180 mm 7 09 57 mm 2 24 mm 245 mm 9 65 in 225 mm 8 86 in 40 mm 1 57 in 105 mm 4 13 in 360 mm 14 7 in 11 mm 0 43...

Страница 40: ...AWG FDD All 2 way relay connector 2 5 mm2 14 AWG FDD 7 to 9 STO connector FDD All 2 way low voltage power 24V supply connector 1 5 mm2 16 AWG Terminals Maximum standard crimp mm2 Maximum standard US...

Страница 41: ...vironment Ambient temperature Ensure the enclosure temperature remains at or below maximum specified Dust Ensure the drive remains dust free check that the heatsink and drive fan are not gathering dus...

Страница 42: ...3 Disconnect fan cables from drive making a note of the order and push grommets down prior to attempting fan removal 4 Remove the mounting screws using a T20 and T25 torque driver 5 Withdraw fan hous...

Страница 43: ...fan removal procedure 1 Remove terminal cover 2 Remove finger guard 3 Disconnect fan cables from drive making a note of the order and push grommet down prior to attempting fan removal 4 Remove the mou...

Страница 44: ...que driver remove the two screws that retain the heatsink fan housing 3 Withdraw the heatsink fan housing from the drive in the direction shown 4 Pull the fan cable through the fan cable gland 5 Using...

Страница 45: ...tor bank fan replacement Auxiliary fan removal procedure 1 Disconnect fan wiring connector shown 2 Slide fan housing in the direction shown using tongue shown in enlarged diagram of fan 3 Withdraw fan...

Страница 46: ...e work may continue Normally the capacitors are discharged by an internal resistor Under certain unusual fault conditions it is possible that the capacitors may fail to discharge or be prevented from...

Страница 47: ...and ground connections size 7 shown On size 7 and 8 the supply and motor ground connections are made using the M8 studs located by the supply and motor connection terminals Refer to Figure 4 1 U V W...

Страница 48: ...und connections are made using the M10 studs located by the supply and motor connection terminals Refer to Figure 4 2 Input connections Mains Supply L1 L2 Optional EMC filter Fuses L3 L1 L2 L3 PE Supp...

Страница 49: ...r INLXXX must be used for size 9E Failure to provide sufficient reactance could damage or reduce the service life of the drive Refer to Table 4 4 Size 7 to 9 Model and Line reactor part number For pur...

Страница 50: ...Table 4 2 Supply fault current used to calculate maximum input currents Electrochemical corrosion of grounding terminals Ensure that grounding terminals are protected against corrosion i e as could be...

Страница 51: ...ur on ungrounded supplies with more than one source for example on ships Contact the supplier of the drive for more information Table 4 3 Behavior of the drive in the event of a ground earth fault wit...

Страница 52: ...use excessive peak currents to flow in the input power circuit of the drive This may cause nuisance tripping or in extreme cases failure of the drive Drives of low power rating may also be susceptible...

Страница 53: ...74 00660 INL 4014 4401 0237 074 00770 INL 4015 4401 0238 074 01000 INL 4016 4401 0239 8 084 01340 INL 4017 4401 0240 084 01570 INL 4018 4401 0241 9 094 02000 094 02240 INL 401 4401 0181 Part number Mo...

Страница 54: ...The current in the other two phases would be significantly lower The values of maximum input current are stated for a supply with a 2 negative phase sequence imbalance and rated at the maximum supply...

Страница 55: ...ltage rating for the following power connections AC supply to external EMC filter when used AC supply or external EMC filter to drive Drive to motor Drive to braking resistor 4 6 2 High capacitance re...

Страница 56: ...rated motors given in NEMA MG1 section 31 is sufficient for motoring operation but not where the motor spends significant periods braking In that case an insulation peak voltage rating of 2 2 kV is r...

Страница 57: ...run the motor The default setting of the motor rated voltage parameter is the same as the drive rated voltage i e 400 V drive 400 V rated voltage 230 V drive 230 V rated voltage A typical 3 phase mot...

Страница 58: ...braked by the drive the maximum regenerated power that the drive can absorb is equal to the power dissipation losses of the drive When the regenerated power is likely to exceed these losses the DC bus...

Страница 59: ...uous braking the continuous power dissipated in the braking resistor may be as high as the power rating of the drive The total energy dissipated in the braking resistor is dependent on the amount of e...

Страница 60: ...Resistor Rated Power 10 030 Braking Resistor Thermal Time Constant 10 031 Braking Resistor Resistance 10 061 This data should be obtained from the manufacturer of the braking resistors The braking re...

Страница 61: ...s an internal voltage surge protection device connected to ground Under normal circumstances this carries negligible current Please note that the internal filter is not removable on size 9E and 10E 4...

Страница 62: ...9 4 will usually be sufficient to avoid causing disturbance to adjacent equipment of industrial quality If particularly sensitive equipment is to be used nearby or in a non industrial environment the...

Страница 63: ...mp to the intended terminal on the drive in accordance with the connection details for the specific signal 1 A suitable clamp is the Phoenix DIN rail mounted SK14 cable clamp for cables with a maximum...

Страница 64: ...ency emission into the line power supply Where the motor cable is short it permits the requirements of EN 61800 3 2004 to be met for the second environment see section 4 9 5 and section 5 1 24 For lon...

Страница 65: ...size 7 8 and 9A internal EMC filter and line to ground varistors size 7 shown To electrically disconnect the Internal EMC filter remove the screw as highlighted above 1 To electrically disconnect the...

Страница 66: ...tors should only be removed in special circumstances such as ungrounded supplies with more than one source for example on ships Where the line to ground varistors are removed ensure that line to groun...

Страница 67: ...backplate Optional ground connection External controller 0V If the control circuit 0V is to be grounded this should be done at the system controller only to avoid injecting noise currents into the 0V...

Страница 68: ...otor cable i e motor thermistor motor brake will pick up large pulse currents via the cable capacitance The shield of these signal cables must be connected to ground close to the motor cable to avoid...

Страница 69: ...erruptions are unavoidable ensure the absolute minimum length of pigtail in the shield connections at each interruption Encoder connections Use a cable with the correct impedance Use a cable with indi...

Страница 70: ...to a ground plate or similar metallic ground surface Figure 4 14 Feedback cable twisted pair Figure 4 15 Feedback cable connections To ensure suppression of radio frequency emission observe the follow...

Страница 71: ...internal filter Key Unrestricted EN 61800 3 2004 A1 2012 second environment unrestricted distribution For longer motor cables an external filter is required Where a filter is required follow the guid...

Страница 72: ...sion standards Use the recommended filter and shielded motor cable Observe the layout rules given in Figure 4 16 Ensure the AC supply and ground cables are at least 100 mm from the power module and mo...

Страница 73: ...oduct information Mechanical installation Electrical installation Technical data UL listing information Avoid placing sensitive signal circuits in a zone 300 mm 12 in all around the power module Figur...

Страница 74: ...s a separate external ground conductor or grounding is through the shield alone An internal ground core will carry a high noise current and therefore it must be terminated as close as possible to the...

Страница 75: ...re it must be shielded and the shield s clamped to the drive using the grounding bracket as shown in Figure 4 21 Remove the outer insulating cover of the cable to ensure the shield s make contact with...

Страница 76: ...e drive enclosure Installing a motor isolator disconnect switch for safety when work is done on the motor In these cases the following guidelines should be followed Terminal block in the enclosure The...

Страница 77: ...ent voltages between nominally grounded points This is a particular risk where the circuits extend outside the protection of a building As a general rule if the circuits are to pass outside the buildi...

Страница 78: ...olar TT UKK5 D 24 AC These devices are not suitable for encoder signals or fast digital data networks because the capacitance of the diodes adversely affects the signal Most encoders have galvanic iso...

Страница 79: ...witching frequency and temperature on page 80 Table 5 1 400 V drive ratings 380 V to 480 V 10 These ratings are for 2 kHz switching frequency For ratings at 3 kHz switching frequency refer to section...

Страница 80: ...5 75 112 95 2 80 6 63 53 8 45 75 100 88 73 61 48 41 084 01340 75 100 155 132 98 77 55 100 134 130 109 91 72 57 084 01570 90 150 184 169 142 106 7 77 75 125 157 143 121 104 80 1 65 094 02000 110 150 22...

Страница 81: ...92 2842 2833 90 150 2132 2136 2370 2492 2475 2501 2538 094 02240 9A 132 200 3016 3191 3143 3063 3000 2856 2828 110 150 2424 2532 2511 2489 2474 2498 2537 094 02000 9E 110 150 2286 2565 2844 2966 2917...

Страница 82: ...Storage time is 2 years Electrolytic capacitors in any electronic product have a storage period after which they require reforming or replacing The DC bus capacitors have a storage period of 10 years...

Страница 83: ...survive environments as described by IEC60721 3 3 3C3 and EN60068 2 60 Meth 4 This corresponds to the levels typical of urban areas with industrial activities and or heavy traffic and in the immediate...

Страница 84: ...in each of three mutually perpendicular axes in turn Referenced standard IEC 60068 2 6 Test Fc Frequency range 5 to 500 Hz Severity 3 5 mm peak displacement from 5 to 9 Hz 10 m s peak acceleration fro...

Страница 85: ...e only it does not include the performance of the source of the control signals Open closed loop resolution Preset frequency reference 0 01 Hz Analog input 1 11 bit plus sign Analog input 2 11 bit Cur...

Страница 86: ...ues of maximum continuous input current are given to aid the selection of cables and fuses These values are stated for the worst case condition with the unusual combination of stiff supply with bad ba...

Страница 87: ...HSJ 094 02240 245 267 359 350 350 The nominal cable sizes below are only a guide The mounting and grouping of cables affects their current carrying capacity in some cases smaller cables may be accept...

Страница 88: ...length is reduced from that shown in Table 5 14 if high capacitance or reduced diameter motor cables are used refer to section 4 6 2 High capacitance reduced diameter cables on page 55 5 1 22 Braking...

Страница 89: ...cription Maximum cable size FDD All Control connector 1 5 mm2 16 AWG FDD All 2 way relay connector 2 5 mm2 14 AWG FDD 7 to 9 STO connector FDD All 2 way low voltage power 24V supply connector 1 5 mm2...

Страница 90: ...on frequency via coupling clamp Control lines Level 4 industrial harsh 5 50 ns 2 kV transient at 5 kHz repetition frequency by direct injection Power lines Level 3 industrial IEC61000 4 5 EN61000 4 5...

Страница 91: ...ance 400 V drives Table 5 23 Size 8 emission compliance 400 V drives Table 5 24 Size 9 emission compliance 400 V drives Motor cable length m Switching Frequency kHz 2 3 4 6 8 12 16 Using internal filt...

Страница 92: ...sales distribution in which the manufacturer restricts the supply of equipment to suppliers customers or users who separately or jointly have technical competence in the EMC requirements of the applic...

Страница 93: ...ting IP rating Power dissipation at rated current Ground leakage Discharge resistors Balanced supply phase to phase and phase to ground Worst case 40 C 104 F 50 C 122 F IEC UL 40 C 104 F 50 C 122 F A...

Страница 94: ...en fitted with a conduit box the drives comply with the requirements in the Standard for Fire Test for Heat and Visible Smoke Release for Discrete Products and Their Accessories Installed in Air Handl...

Страница 95: ...g of branch circuit Opening of the branch circuit protective device may be an indication that a fault has been interrupted To reduce the risk of fire or electric shock the equipment should be examined...

Страница 96: ...limit regenerative current limit and symmetrical current limit entered as percentage and the motor rated current parameter entered in amperes The duration of the overload is dependent on motor thermal...

Страница 97: ......

Страница 98: ...0478 0641 12...

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