SIGMA TEK FDD Manuale utente

Power Installation Guide

SIGMATEK FDD

Frame 7 to 9

Issue: 12

Original Instructions

For the purposes of compliance with the EU Machinery Directive 2006/42/EC, the English version of this manual is

the Original Instructions. Manuals in other languages are Translations of the Original Instructions.

Documentation

Manuals are available to download from the following locations: https://www.sigmatek-automation.com

The information contained in this manual is believed to be correct at the time of printing and does not form part of

any contract. The manufacturer reserves the right to change the specification of the product and its performance,

and the contents of the manual, without notice.

Warranty and Liability

In no event and under no circumstances shall the manufacturer be liable for damages and failures due to misuse,

abuse, improper installation, or abnormal conditions of temperature, dust, or corrosion, or failures due to operation

outside the published ratings. The manufacturer is not liable for consequential and incidental damages. Contact the

supplier of the drive for full details of the warranty terms.

Restriction of Hazardous Substances (RoHS)

The products covered by this manual comply with European and International regulations on the Restriction of

Hazardous Substances including EU directive 2011/65/EU and the Chinese Administrative Measures for Restriction

of Hazardous Substances in Electrical and Electronic Products.

Disposal and Recycling (WEEE)

REACH legislation

EC Regulation 1907/2006 on the Registration, Evaluation, Authorisation and restriction of Chemicals (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 a Substance of Very High

Concern (SVHC) and is therefore listed by them as a candidate for compulsory authorisation.

The contents of this publication are believed to be correct at the time of printing. In the interests of a commitment to

a policy of continuous development and improvement, the manufacturer reserves the right to change the

specification of the product or its performance, or the contents of the guide, without notice.

or mechanical including photocopying, recording or by an information storage or retrieval system, without

permission in writing from the publisher.

When electronic products reach the end of their useful life, they must not be disposed of along

with domestic waste but should be recycled by a specialist recycler of electronic equipment.

Sigmatek products are designed to be easily dismantled into their major component parts for

efficient recycling. The majority of materials used in the product are suitable for recycling.

Product packaging is of good quality and can be re-used. Large products are packed in wooden

crates. Smaller products are packaged in strong cardboard cartons which have a high recycled

fibre content. Cartons can be re-used and recycled. Polythene, used in protective film and bags

for wrapping the product, can be recycled. When preparing to recycle or dispose of any product

or packaging, please observe local legislation and best practice.

Sigmatek FDD Sizes 7 to 9 Power Installation Guide

Contents

1 Safety information ....................................................................................................5

1.1 Warnings, Cautions and Notes ................................................................................................... 5

1.2 Important safety information. Hazards. Competence of designers and installers ...................... 5

1.3 Responsibility ............................................................................................................................. 5

1.4 Compliance with regulations ....................................................................................................... 5

1.5 Electrical hazards ....................................................................................................................... 6

1.6 Stored electrical charge .............................................................................................................. 6

1.7 Mechanical hazards .................................................................................................................... 6

1.8 Access to equipment .................................................................................................................. 6

1.9 Environmental limits ................................................................................................................... 6

1.10 Hazardous environments ............................................................................................................ 6

1.11 Motor .......................................................................................................................................... 7

1.12 Mechanical brake control ............................................................................................................ 7

1.13 Adjusting parameters .................................................................................................................. 7

1.14 Electromagnetic compatibility (EMC) .......................................................................................... 7

2 Product information .................................................................................................8

2.1 Introduction ................................................................................................................................. 8

2.2 Model number ............................................................................................................................. 8

2.3 Nameplate description ................................................................................................................ 9

2.4 Ratings ..................................................................................................................................... 10

2.5 Drive features ........................................................................................................................... 12

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 Enclosure design and drive ambient temperature .................................................................... 30

3.7 Heatsink fan operation .............................................................................................................. 30

3.8 Enclosing standard drive for high environmental protection ..................................................... 31

3.9 External EMC filter .................................................................................................................... 35

3.10 Terminal size and torque settings ............................................................................................. 40

3.11 Routine maintenance ................................................................................................................ 41

4 Electrical installation .............................................................................................46

4.1 Power and ground connections ................................................................................................47

4.2 AC Supply requirements ........................................................................................................... 50

4.3 Supplying the size 7, 8 and 9A drives with DC / DC bus paralleling ........................................ 54

4.4 Heatsink fan supply .................................................................................................................. 54

4.5 Ratings ..................................................................................................................................... 54

4.6 Output circuit and motor protection .......................................................................................... 55

4.7 Braking ..................................................................................................................................... 58

4.8 Ground leakage ........................................................................................................................ 61

4.9 EMC (Electromagnetic compatibility) ........................................................................................ 62

5 Technical data ........................................................................................................79

5.1 Drive technical data .................................................................................................................. 79

5.2 Optional external EMC filters .................................................................................................... 93

Sigmatek FDD Sizes 7 to 9 Power Installation Guide

6 UL lnformation ........................................................................................................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 and thermal memory retention ........................................................96

6.8 External Class 2 supply .............................................................................................................96

Sigmatek FDD Sizes 7 to 9 Power Installation Guide 5

Safety information

Product information Mechanical installation Electrical installation Technical data UL listing information

1 Safety information

1.1 Warnings, Cautions and Notes

1.2 Important safety information. Hazards. Competence of

designers and installers

This guide applies to products which control electric motors either directly (drives) or indirectly

(controllers, option modules and other auxiliary equipment and accessories). In all cases the hazards

associated with powerful electrical drives are present, and all safety information relating to drives and

associated equipment must be observed.

Specific warnings are given at the relevant places in this guide.

Drives and controllers are intended as components for professional incorporation into complete

systems. If installed incorrectly they may present a safety hazard. The drive uses high voltages and

currents, carries a high level of stored electrical energy, and is used to control equipment which can

cause injury. Close attention is required to the electrical installation and the system design to avoid

hazards either in normal operation or in the event of equipment malfunction. System design,

installation, commissioning/start-up and maintenance must be carried out by personnel who have the

necessary training and competence. 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 instructions given in this guide. They must give due consideration to the safety of the complete

system, so as to avoid the risk of injury both in normal operation and in the event of a fault or of

reasonably foreseeable misuse.

The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or

incorrect installation of the equipment.

1.4 Compliance with regulations

The installer is responsible for complying with all relevant regulations, such as national wiring

regulations, accident prevention regulations and electromagnetic compatibility (EMC) regulations.

Particular attention must be given to the cross-sectional areas of conductors, the selection of fuses

or other protection, and protective ground (earth) connections.

This guide contains instructions for achieving compliance with specific EMC standards.

All machinery to be supplied within the European Union in which this product is used must comply

with the following directives:

2006/42/EC Safety of machinery.

2014/30/EU: Electromagnetic Compatibility.

A Warning contains information which is essential for avoiding a safety hazard.

A Caution contains information which is necessary for avoiding a risk of damage to the

product or other equipment.

A Note contains information, which helps to ensure correct operation of the product.

WARNING

CAUT IO N

NOTE

6Sigmatek FDD Sizes 7 to 9 Power Installation Guide

1.5 Electrical hazards

The voltages used in the drive can cause severe electrical shock and/or burns, and could be lethal.

Extreme care is necessary at all times when working with or adjacent to the drive. Hazardous voltage

may be present in any of the following locations:

• AC and DC supply cables and connections

• Output cables and connections

• Many internal parts of the drive, and external option units

Unless otherwise indicated, control terminals are single insulated and must not be touched.

The supply must be disconnected by an approved electrical isolation device before gaining access to

the electrical connections.

The STOP and Safe Torque Off functions of the drive do not isolate dangerous voltages from the

output of the drive or from any external option unit.

The drive must be installed in accordance with the instructions given in this guide. Failure to observe

the instructions could result in a fire hazard.

1.6 Stored electrical charge

The drive contains capacitors that remain charged to a potentially lethal voltage after the AC supply

has been disconnected. If the drive has been energized, the AC supply must be isolated at least ten

minutes before work may continue.

1.7 Mechanical hazards

Careful consideration must be given to the functions of the drive or controller which might result in a

hazard, either through their intended behaviour or through incorrect operation due to a fault. In any

application where a malfunction of the drive or 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 device in case of failure of the speed control, or a

fail-safe mechanical brake in case of loss of motor braking.

With the sole exception of the Safe Torque Off function, none of the drive functions must be

used to ensure safety of personnel, i.e. they must not be used for safety-related functions.

The Safe Torque Off function may be used in a safety-related application. The system designer is

responsible for ensuring that the complete system is safe and designed correctly according to the

relevant safety standards.

The design of safety-related control systems must only be done by personnel with the required

training and experience. The Safe Torque Off function will only ensure the safety of a machine if it is

correctly incorporated into a complete safety system. The system must be subject to a risk

assessment to confirm that the residual risk of an unsafe event is at an acceptable level for the

application.

1.8 Access to equipment

Access must be restricted to authorized personnel only. Safety regulations which apply at the place

of use must be complied with.

1.9 Environmental limits

Instructions in this guide regarding transport, storage, installation and use of the equipment must be

complied with, including the specified environmental limits. This includes temperature, humidity,

contamination, shock and vibration. Drives must not be subjected to excessive physical force.

1.10 Hazardous environments

The equipment must not be installed in a hazardous environment (i.e. a potentially explosive

environment).

Sigmatek FDD Sizes 7 to 9 Power Installation Guide 7

Safety information

Product information Mechanical installation Electrical installation Technical data UL listing information

1.11 Motor

The safety of the motor under variable speed conditions must be ensured.

To avoid the risk of physical injury, do not exceed the maximum specified speed of the motor.

Low speeds may cause the motor to overheat because the cooling fan becomes less effective,

causing a fire hazard. The motor should be installed with a protection thermistor. If necessary, an

electric forced vent fan should be used.

The values of the motor parameters set in the drive affect the protection of the motor. The default

values in the drive must not be relied upon. It is essential that the correct value is entered in the

Motor Rated Current parameter.

1.12 Mechanical brake control

Any brake control functions are provided to allow well co-ordinated operation of an external brake

with the drive. While both hardware 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 where the incorrect operation of the brake release mechanism

could result in injury, independent protection devices of proven integrity must also be incorporated.

1.13 Adjusting parameters

Some parameters have a profound effect on the operation of the drive. They must not be altered

without careful consideration of the impact on the controlled system. Measures must be taken to

prevent unwanted changes due to error or tampering.

1.14 Electromagnetic compatibility (EMC)

Installation instructions for a range of EMC environments are provided in the relevant Power

Installation Guide. If the installation is poorly designed or other equipment does not comply with

suitable standards for EMC, the product might cause or suffer from disturbance due to

electromagnetic interaction with other equipment. It is the responsibility of the installer to ensure that

the equipment or system into which the product is incorporated complies with the relevant EMC

legislation in the place of use.

8Sigmatek FDD Sizes 7 to 9 Power Installation Guide

2 Product information

2.1 Introduction

This guide provides the information necessary to install the following drive models:

FDD3 frame 7 to 9

This guide focuses on the drive power section, for example: electrical installation of the supply /

motor cables and mechanical installation of the drive.

For information about the drive control section, for example: parameter set up information, control

and encoder connections, please refer to the Control User Guide.

2.2 Model number

The model numbers for the FDD product range are formed as illustrated below:

Figure 2-1 Model number

* Only shown on frame 9E and 10 identification label

For simplicity a Frame 9 drive with no internal 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 sizes 9E and 9A.

Identiﬁcation Label

Electrical Speciﬁcations

Derivative

Frame Size:

Voltage Rating:

Current Rating:

Heavy Duty current rating x 10

Power Format:

Reserved

Optional Build

Customer Code

01 A B 1 00

Customer Code:

00 = 50 Hz

01 = 60 Hz

Reserved:

Conformal Coating:

0 = Standard

IP / NEMA Rating :

1 = IP20 / NEMA 1

Brake Transistor:

N = No

= Brake

Cooling:

A = Air

Documentation

2 - 200 V (200 - 240± 10 %)

4 10 %)- 400 V (380 - 480±

Power

Format

FDD- 03 4 00078 A

Conﬁguration

A - AC in AC out (with internal choke)

D - DC in AC out (Inverter)

C - AC in DC out (Rectiﬁer)

E - AC in AC out (without internal choke)

T - AC in AC out (12P rectiﬁer plus inverter)

Conﬁguration:

1 - Standard

U - No Control

M - Master

F - Follower

Documentation:

1 - English

FDD

Product Line:

NOTE

Sigmatek FDD Sizes 7 to 9 Power Installation Guide 9

Safety information

Product information

Mechanical installation Electrical installation Technical data UL listing information

2.3 Nameplate description

Figure 2-2 Typical drive rating labels

Refer to Figure 2-1 Model number on page 8 for further information relating to the labels.

Date code format

The date code is four numbers. The first two numbers indicate the year and the

remaining numbers indicate the week of the year in which the drive was built.

Example:

A date code of 1710 would correspond 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

Approvals

Input phases & input current

Output phases & Heavy

Duty/Normal Duty rating

Serial number

Input voltage

Output voltage

Date code

110/132kW 1710

Model

Approvals

Input phases & input current

Output phases & Heavy

Duty/Normal Duty rating

Serial number

Input voltage

Output voltage

Date code

FDD-094 02240 E10 110/132kW 1710

Input frequencyInput frequency

Key to approvals

CE approval Europe

RCM regulatory

compliance mark Australia

UL / cUL approval USA & Canada

RoHS compliant Europe

Functional safety USA & Canada

Eurasian conformity Eurasia

NOTE

10 Sigmatek FDD Sizes 7 to 9 Power Installation Guide

2.4 Ratings

Table 2-1 400 V drive ratings, cable sizes and fuse ratings

* These fuses are fast acting.

** These ratings are for 2 kHz switching frequency. For ratings at 3 kHz switching frequency refer to the Power and

current ratings in section 5.1.2 Power and current ratings (Derating for switching frequency and

temperature) on page 80.

Table 2-2 Protective ground cable ratings

Fuses

The AC supply to the drive must be installed with suitable protection against overload and

short-circuits. The following section shows recommended fuse ratings. Failure to observe

this requirement will cause risk of fire.

Nominal cables sizes below are based on the cable installation method B2 (ref: IEC60364-

5-52:2001) unless otherwise specified, and are provided as a guide only. Ensure cables

used suit local wiring regulations.

Model

Max.

cont.

input

current

Fuse Nominal cable size Normal Duty Heavy Duty

European USA

IEC UL

Input Output 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

AA A mm2mm2

AWG

kcmil

AWG

kcmil

AkWhpAkWhp

074.00660 74 100

80 CC,

J or

35 35 1 1 79 37 60 66 30 50

074.00770 88 100 100 50 50 2 2 94 45 60 77 37 60

074.01000 105 125 125 70 70 1/0 1/0 112 55 75 100 45 75

084.01340 155 250 gR 225 HSJ 2 x 50 2 x 50 2 x 1 2 x 1 155 75 100 134 55 100

084.01570 177 250 225 2 x 70 2 x 70 2 x 1/0 2 x 1/0 184 90 150 157 75 125

094.02000 232

315 gR

300

HSJ

2 x 70

(B1)

2 x 95

(B2) 2 x 3/0 2 x 2/0 221 110 150 200** 90 150

094.02240 267 350 2 x 95

(B1)

2 x 120

(B2) 2 x 4/0 2 x 4/0 266** 132 200 224** 110 150

Refer to Chapter 5.1 Drive technical data on page 79 for maximum fuse rating, maximum

cable size and peak currents.

Input phase conductor size Minimum ground conductor size

≤10 mm2Either 10 mm2 or two conductors of the same cross-sectional area as the input

phase conductor

> 10 mm2and ≤16 mm2The same cross-sectional area as the input phase conductor

> 16 mm2and ≤35 mm216 mm2

> 35 mm2Half of the cross-sectional area of the input phase conductor

WARNING

NOTE

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