Unidrive Classic Regen Installation Guide

Guide

Regen

Number:0460-0026-02Number:2

InstallationUnidrive

PartIssueGeneralInformation

Themanufactureracceptsnoliabilityforanyconsequencesresultingfrominappropriate,negligentorincorrect

installationoradjustmentoftheoptionaloperatingparametersoftheequipmentorfrommismatchingthevariablespeeddrivewiththemotor.

Thecontentsofthisguidearebelievedtobecorrectatthetimeofprinting.Intheinterestsofacommitmenttoapolicyofcontinuousdevelopmentandimprovement,themanufacturerreservestherighttochangethespecificationoftheproductoritsperformance,orthecontentsoftheguide,withoutnotice.

Allrightsreserved.Nopartsofthisguidemaybereproducedortransmittedinanyformorbyanymeans,electricalormechanicalincludingphotocopying,recordingorbyaninformationstorageorretrievalsystem,withoutpermissioninwritingfromthepublisher.

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Thisproductissuppliedwiththelatestversionofsoftware.Ifthisproductistobeusedinaneworexistingsystemwithotherdrives,theremaybesomedifferencesbetweentheirsoftwareandthesoftwareinthisproduct.Thesedifferencesmaycausethisproducttofunctiondifferently.ThismayalsoapplytodrivesreturnedfromaControlTechniquesServiceCentre.

Ifthereisanydoubt,contactaControlTechniquesDriveCentre.

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Copyright©October2002ControlTechniquesDrivesLimited

IssueNumber:2

Contents1

1.11.21.3

Introduction....................................................................................................................1

Principlesofoperation...........................................................................................................................1Powerflow.............................................................................................................................................2AdvantagesofUnidriveoperatinginRegenmode................................................................................2

23

3.13.2

SizingofaRegensystem.............................................................................................3Powerconnections........................................................................................................4

Overallsystemlayout............................................................................................................................4Nonstandardconfigurations..................................................................................................................7

4

4.14.2

Controlcircuitconnections..........................................................................................8

Digital/AnalogI/Oset-upinRegenmode............................................................................................8Regeninductorthermistors....................................................................................................................9

5

5.15.25.35.45.55.65.75.85.9

Components.................................................................................................................10

Motoringdrive......................................................................................................................................10Regendrive.........................................................................................................................................10Regeninductor....................................................................................................................................10Softstartresistor...................................................................................................................................11Contactors,MCBsandoverload..........................................................................................................11Switchingfrequencyfilter.....................................................................................................................12RFIfilter...............................................................................................................................................13Varistors...............................................................................................................................................13Fusing..................................................................................................................................................14

6

6.16.26.36.4

Importantconsiderations............................................................................................16

Fundamentals......................................................................................................................................16Unidrivesize3and4...........................................................................................................................16Ventilation............................................................................................................................................16Cablelengthrestrictions......................................................................................................................17

7

7.17.27.37.47.57.67.77.87.97.107.11

UnidriveRegenEMCinformation...............................................................................19

Immunity..............................................................................................................................................19Emission..............................................................................................................................................19Dedicatedsupplies..............................................................................................................................19Othersupplies......................................................................................................................................19Supplyvoltagenotching.......................................................................................................................19Supplyharmonics................................................................................................................................19Switchingfrequencyemission.............................................................................................................19ConductedRFemission......................................................................................................................19Radiatedemission...............................................................................................................................21Wiringguidelines.................................................................................................................................21Multi-drivesystems..............................................................................................................................21

8

8.1

Parameterdescriptions...............................................................................................22

Menu15:Sinusoidalrectifier...............................................................................................................22

9

9.19.29.39.49.5

Commissioningandoperation...................................................................................28

Regenparametersettings...................................................................................................................28Regendrivesequencing......................................................................................................................28Regendrivecommissioning.................................................................................................................29Motoringdrivecommissioning.............................................................................................................29Tripcodes............................................................................................................................................29

UnidriveRegenInstallationIssueNumber:2

AppendixAUnidriveRegenasaBrakeResistorReplacement.............................................30

A.1A.2A.3A.4A.5A.6A.7B.1B.2B.3B.4C.1D.1D.2

Introduction.........................................................................................................................................30Driveconfigurations............................................................................................................................30WhentouseaRegendriveasabrakeresistorreplacement.............................................................30Regenandmotoringdriveratings.......................................................................................................31Powercircuitconnectionsandcomponents.......................................................................................31Controlcircuitconnections..................................................................................................................34Regenbrakedrivesinoperation.........................................................................................................35SizingofMCBforswitchingfrequencyfilter.......................................................................................36Resistorsizingformultiplemotoringsystems.....................................................................................37MultipleUnidrivesize5systems.........................................................................................................38Thermal/magneticoverloadprotectionforsoftstartcircuit...............................................................38Exceedingthemaximumcablelength................................................................................................41SingleRegen,singlemotoringsystems..............................................................................................43SingleRegen,multiplemotoringandmultipleRegen,multiplemotoringsystems.............................43

AppendixBComponentsizingcalculations............................................................................36

AppendixCLongcables............................................................................................................41AppendixDRegenkits...............................................................................................................43

AppendixEUnidriveRegenspecifications.............................................................................44AppendixFPhysicaldimensions.............................................................................................45

F.1F.2F.3F.4F.5

Regeninductor...................................................................................................................................45Softstartresistor-typeTGseries.......................................................................................................47Switchingfrequencyfiltercapacitors..................................................................................................48Switchingfrequencyfilterinductor......................................................................................................51Varistors..............................................................................................................................................53

UnidriveRegenInstallationGuide

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1

•••

Introduction

PrinciplesandadvantagesofoperationinRegenmodeDetailsofadditionalcomponentsrequiredConfigurationofRegensystems

AnystandardUnidrivecanbeconfiguredasanACRegenerativeUnit(hereafterreferredtoasRegendrive).ThisInstallationguidecoversthefollowing:

AtleasttwoUnidrivesarerequiredtoformacompleteRegenerativesystem-oneconnectedtothesupplyandthesecondonetothemotor.AUnidriveinRegenmodeconvertstheACmainssupplytoacontrolledDCvoltagewhichisfedintootherdrive(s)tocontrolamotor.Figure1-1Regendrivesystemconnection

RegenInductorRRegenDriveACUMotoringDriveDCU3PhaseSupplyYBAdditionalCircuitry+DCV-DCW+DCV-DCWMDCAC1.1Principlesofoperation

Theinputstageofanon-regenerativeACdriveisusuallyanuncontrolleddioderectifier,thereforepowercannotbefedbackintotheACmainssupply.

InthecaseofaUnidriveoperatinginRegenerativemode,theIGBTbridgeisusedasasinusoidalrectifier,whichconvertstheACsupplytoa

controlledDCvoltage.ThisDCvoltagecanthenbeusedtosupplyoneormoreUnidriveswhichcontrolmotors,commonlyknownasmotoringdrives.ARegendriveproducesaPWMoutputvoltagewhichhasasinusoidalfundamentalatanamplitudeandphasewhicharealmostthesameasthoseoftheACsupplyvoltage.ThedifferencebetweenthedrivePWMlinevoltageandthesupplyvoltageoccursacrosstheRegendrive’sinductors.ThisvoltagehasahighfrequencycomponentwhichisblockedbytheRegeninductorandasmallsinusoidalcomponentatlinefrequency.Asaresult,currentsflowingintheseinductorsaresinusoidalwithasmallhighfrequencyripplecomponent.

NOTE

NTerminalsL1,L2andL3andtheassociateddioderectifierarenotconnectedandareredundantondrivesusedinaRegenconfiguration.Figure1-2Phasordiagram

PowerflowfromsupplyPowerflowbacktosupply

VsVrjωLIrIr

SupplyVoltage

VoltageatlineterminalsofRegendriveVoltageacrossRegenInductorCurrentatlineterminalsofRegendrive

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1.2Powerflow

ThephasordiagraminFigure1-2illustratestherelationshipbetweenthesupplyvoltageandtheRegendrivevoltage.Theanglebetweenthetwovoltagevectorsisapproximately5°atfullload,givingapowerfactorwhichisnearunity.

Thedirectionofthepowerflowcanbechangedrelativetothesupplyvoltage,bymakingsmallchangestotheRegendriveoutputvoltageandphase.Afasttransientresponseisachievedbymeansofaspacevectormodulator.

1.3

••••••

AdvantagesofUnidriveoperatinginRegenmode

ThemainadvantagesforanACRegensystemare:

Energysaving

Theinputcurrentwaveformissinusoidal

Theinputcurrenthasanearunitypowerfactor

TheoutputvoltageforthemotorcanbehigherthantheavailableACmainsvoltage

TheRegendrivewillsynchronisetoanyfrequencybetween30and100Hz,providedthesupplyvoltageisbetween380V-10%and480V+10%UnderconditionsofACmainsinstability,aUnidriveRegensystemcancontinuetofunctiondowntoapproximately150VacsupplyvoltagewithoutanyeffectontheDCbusvoltageandhenceontheoperationofthemotoringdrives(increasedcurrentwillbetakenfromtheACsupplytocompensateuptothecurrentlimitoftheRegendrive)TheRegenandmotoringdrivesareidentical

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UnidriveRegenInstallationGuide

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2SizingofaRegensystem

RefertoAppendixEUnidriveRegenspecificationsonpage44,forthespecificationsoftheUnidriveRegen.ThesizingofaRegensystemmusttakeintoaccountthefollowingfactors:

•Linevoltage

•Motorratedcurrent,ratedvoltageandpowerfactor•Maximumloadpowerandoverloadconditions

Ingeneral,whendesigningaRegensystem,equalRegenandmotoringdriveratedcurrentswillworkcorrectly.However,caremustbetakentoensurethatunderworstcasesupplyconditionstheRegendriveisabletosupplyorabsorballtherequiredpower.Inmulti-driveconfigurations,theRegendrivemustbeofasufficientsizetosupplythenetpeakpowerdemandedbythecombinedloadofallthemotoringdrivesandthedrivelosses.IftheRegendriveisunabletosupplythefullpowerrequiredbythemotoringdrive,theDCbusvoltagewilldropandinseverecasesmaylosesynchronisationwiththemainsandtrip.IftheRegendriveisunabletoregeneratethefullpowerfromthemotoringdriveintotheDCbus,thentheRegen/motoringdrivewilltriponover-voltage.

ThefollowingaretwoexamplesofhowtherequiredratingsofaRegendrivecanbecalculated.

TheRegendrive’scurrentlimitsaresetat150%andarenotadjustable.

Inthecaseofa25A,UNI2403operatinginRegenmodefroma400Vsupply,andaUNI2403drivinga400Vrated,0.85pfmotor:TheratedpoweroftheRegendriveis

=√3xRatedcurrentxSupplyvoltage=1.73x25x400=17.3kW

=√3xRatedcurrentxMotorvoltagexPowerfactor=1.73x25x400x0.85=14.7kW

Themotoringdrivecansupplypower

Whenthemotoringdriveissupplyingratedcurrenttothemotor,theRegendriveonlyneedstoprovide14.7kW,plusdrivelosses.TheRegendrivecansupply17.3kWatratedcurrent,whichisample,inthiscase.

Conversely,insomecases,aRegendriveofthesameratingasthemotoringdrive,maynotbeabletosupplyenoughpower,asthefollowingexampleshows:Example

Inthecaseofa156A,UNI4403operatinginRegenmode,andaUNI4403drivinga75kW,400V,0.95pfmotor:

Ifthemotoringdriveissupplying175%maximumcurrentandtheRegendrivehasits380Vsupplyatthelowerlimitsof-10%(342Vac),then,attheRegencurrentlimitof150%:

TheRegendrivemax.availablepoweris

=√3x150%xRatedcurrentxSupplyvoltage=1.73x1.5x156x342=138.6kW

=√3x175%xRatedcurrentxMotorvoltagexPowerfactor=1.73x1.75x156x400x0.95=179.7kW

Themotoringdrivemax.poweris

TheRegendriveisalsorequiredtosupplytheRegenandmotoringdrivelosses.However,thisRegendriveisonlycapableofsupplyingapproximately138.6kWandthereforeadriveofalargercurrentratingisrequired.

DuetotheeffectsofincreasedDCbuscapacitance,thereisalimittothenumberofmotoringdrivesthatcanbesuppliedfromaRegendrive.ThisistrueirrespectiveofthebalanceofpowerbetweenthemotoringdrivesandtheRegendrive.

IfthesystemconsistsofoneRegenUnidriveandmorethanthreemotoringdrives,ControlTechniquesTechnicalSupportMUSTbeconsultedaboutthedesignofthesystem.

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3

Powerconnections

ThefollowingsectioncoversthepowerconnectionsrequiredforUnidriveRegensystems.NotethatwithUnidriveRegensystemstherearenoACsupplyconnectionsmadetoL1,L2orL3driveterminals.

ForcontrolcircuitconnectionsrefertoChapter4Controlcircuitconnectionsonpage8.

3.1Overallsystemlayout

KeytoFigure3-1andFigure3-2

GroundconnectionpointEMCfilter

SwitchingfrequencyfilterinductorRegeninductor

Varistornetwork550V(linetoline)Varistornetwork680V(linetoground)Softstartresistor

Ribboncablestocontrolpod(Unidrivesize5only)

Ribboncablesbetweenpowermodules(Unidrivesize5only)ACsupplyfusing

ACRegenfusing(Unidrivesize5only)Switchingfrequencyfiltercapacitor

SwitchingfrequencyfiltercapacitordischargeresistorThermocoupleSupplycontactorMaincontactorAuxiliarycontactor

SwitchingfrequencyfiltercapacitorMCB

SwitchingfrequencyfilterMCBauxiliarythroughwhichRegendriveenableisconnected

Maincontactorauxiliaryfor“maincontactorclosedsignal”K3auxiliarywithcoilsupplyforK2Thermal,Magneticoverload

Thetablebelowshowsthekeytothefollowingsystemlayoutdiagrams.

Table3-1

ERFISFFLLregxV1,V2,V3V4,V5,V6

RsxR-controlR-parallelFsxFxSFFCxRdxTcxK1K2K3MCB1xaux1xaux2aux3Ovld

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UnidriveRegenInstallationGuide

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3.1.1StandardsingleRegen,single/multiplemotoringsystem

DCBustoMotoringDrive(s)Figure3-1Powerconnections:SingleRegen

MCB1OvldUnidriveRegenInstallationGuideIssueNumber:2

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3.1.2StandardmultipleRegen,multiplemotoringsystem

IfthetotalpowerrequirementistoogreatforoneUnidrivesize5Regendrivetosupply,morethanonedrivecanbeused.

OneRegensystemcanconsistofmultipleUnidrivesize5Regendrives,whichcansupplymultipleUnidrivesize5motoringdrives,providingthatthetotalloadpowerdoesnotexceedtheratingoftheRegendrives.Seefigure3-2foradualsize5Regenconfiguration.

Highpowerset-upsshoulduseUnidrivesize5.ThisistheonlymodulewhichisdesignedforparallelRegenoperation.ForsystemswithmorethantwoUnidrivesize5drivesinparallelRegenoperation,contactCTTechnicalSupport.Figure3-2Powerconnections:Unidrivesize5multipleRegen

CommonDCBus+DC-DC+DCE+DC-DCUnidriveSize5RegenDrive1R-parallelUnidriveSize5RegenDrive1-DCELreg1Lreg2EF4F5F6aux2K2aux3aux1bSFFC2OvldRd6MCB1baux1aSFFC1Rd4Rd3MCB1aSFFLRFIEV6V5V3V1K1FS1FS2V2RY6www.controltechniques.com

3PhaseSupplyBFS3V4EERd1Rd2ERd5ERs1K3Tc2Tc1F1F2F3ER-controlWWUUVVUnidriveRegenInstallationGuide

IssueNumber:2

3.2Nonstandardconfigurations

ThereareanumberofpossibleoptionsavailablewhendesigningaUnidriveRegensystemdependingontheuserrequirementsandthenatureoftheACsupply.Nonstandardsystemscanbecreatedwherefavourablesupplyconditionsexist,allowingcostandspacesavingstobeachievedbyreducingthenumberofcomponents.

3.2.13.2.2

SwitchingfrequencyfilterSupplyassessment

IfthesupplytotheRegendriveissharedwithotherequipment,thenitisstronglyrecommendedthataswitchingfrequencyfilterbeincorporatedinordertoavoidtheriskofinterferenceordamagetotheotherequipment.

Thefollowingguidelinesshouldbeusedwhenassessingwhetherornotaswitchingfrequencyfilterisrequired.Symbolsusedare:

IDriveNominaldrive100%currentrating.ISCShortcircuitcurrentofsupplyatpointofcouplingwithotherequipment.ISupplyRatedcurrentofsupply.

Theswitchingfrequencyfiltermaybeomittedifthefollowingrelationistrue:

IDriveISC

<140

1

Iftheshort-circuitcurrentisnotknown,thenareasonableestimatecanbemadeifitisassumedthatthefaultcurrentofthesupplyis20timestheratedcurrent.Thisisverycommonlythecasewherethesupplyisderivedthroughadistributiontransformerfromahighervoltagesupplywithahighfaultlevel.Then:

IDriveISupply

<

17

Thissecondrelationishelpfulbutmustbeusedwithcare.ItisreliablewheretheRegendriveissuppliedthroughitsowncablerunfromapointclosetothedistributiontransformerterminals.IftheRegendrivesharesalongcablerunwithotherequipment,thentheeffectofthecableimpedanceonthefaultlevelmustbetakenintoaccountifariskofdisturbancetotheotherequipmentistobeavoided.

Thisprocedurewillnormallybeappliedwhenassessinganon-dedicatedlow-voltagesupply.Itmayalsobeappliedtothemedium/highvoltagesupplywherethelow-voltagesupplyisdedicatedtothedrive.Inthatcasethecurrentsusedmustbereferredtothehighvoltagesideofthetransformer.

3.2.3RFIfilter

WhetherornotanRFIfilterisrequiredisdependentupontheuserrequirementsandtheACsupplynetwork.ForfurtherdetailsrefertoChapter7UnidriveRegenEMCinformationonpage19.AnRFIfiltermustnotbefittedwithoutaswitchingfrequencyfilterpresentinthesystem.

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4

4.1

Controlcircuitconnections

Digital/AnalogI/Oset-upinRegenmode

AllpowercircuitconnectionsshouldbemadeasshowninChapter3Powerconnectionsonpage4.

ThefollowingtableliststhedefaultfunctionsoftheanaloganddigitalI/OonaRegendrive.Theterminalswhicharelistedas“Fixed”havededicatedfunctionsforRegenoperation.Theymustbeconnectedtoperformtheirallocatedfunctionandcannotbere-programmed.Table4-1

FunctionsoftheanaloganddigitalI/O

TerminalDescriptionDriverelayDriverelayAnaloginput1Analoginput2Analoginput3Analogoutput1Analogoutput2Digitaloutput1Digitaloutput2Digitaloutput3Digitalinput1Digitalinput2Digitalinput3Enable

FixedorProgrammable

FixedFixed

User-programmableUser-programmableUser-programmableUser-programmableUser-programmable

FixedFixed

User-programmableUser-programmable

Fixed

User-programmable

Fixed

Enable

Output-SupplycurrentOutput-SupplypowerNotused

Output-EnableotherdriveDrivehealthyInput-Reset

Input-Maincontactorclosed

FunctioninRegenModeOutput-closeauxiliarycontactor*Output-closeauxiliarycontactor*

TerminalNo.

12571024252627282930

*Pr8.25mustbesetbytheuser.SeeTable4-2.

Figure4-1showstypicalcontrolconnectionsforaRegenandmotoringdrive.Inthisexamplethemotoringdriveisconfiguredfor4-20mASpeed/TorquereferenceandsequencingMode4withRunForwardandRunReverseinputs.

AllcontrolconnectionsfortheRegendrivemustbemadeasshowninFigure4-1.

TheRegendrivehealthysignalcanbetakenfromdigitaloutput3onterminal26(iftheRegendriveisdisabled,trips,ordetectsthatthemainssupplyislostthisoutputthenbecomesinactive).Table4-2

Configurationofdriverelay

Description

DriveRegendrive

Parameter

TheRegendrivesrelayonterminal1and2hastobe

Pr8.25-Relay

configuredtoclosetheauxiliarycontactoronpowerupand

Source

removethesoftstartcircuit.SetPr8.25toPr15.14

UnidriveRegenhasbeendesignedtooperateinnegativelogicasdefault.Inorderforthedrivetobeconfiguredtooperateinpositivelogicalterationsmustbemadetothecontrolconnectionsandparametersettings(contactC.T.TechnicalSupportforthisinformation).

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UnidriveRegenInstallationGuide

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4.2Regeninductorthermistors

EachoftheUnidrive3-phaseRegenInductorshasathermistorfitted;whenthesystemconsistsofmultipleRegendrivesthethermistorsshouldbeconnectedinseriesduetothereonlybeingasinglethermistorinputontheRegendrive.Figure4-1Controlconnections-(negativelogicconfiguration)ExternalpowersupplyforK2coilExternalpowersupplyforK3coil12345K2aux3K3RelayNO0VAnalog10VOutAnalogI/P1+AnalogI/P1-AnalogI/P2AnalogI/P3AnalogO/P1AnalogO/P20VAnalog(SetPr8.25toPr15.14)Tc1671011RegenDrive2122230V+24VOut0VDigitalDigitalI/O1DigitalI/O2DigitalI/O3DigitalI/P1DigitalI/P2DigitalI/P3Enable0VDigitalOutputenableDriveHealthyaux2Userenableaux1x2425262728293031DriveHealthy1234RelayNO0VAnalog10VOutAnalogI/P1+AnalogI/P1-AnalogI/P2AnalogI/P3AnalogO/P1AnalogO/P20VAnalogSpeed/TorqueRef4-20mACurrentLoop567MotorThermistor1011MotoringDrive2122230V+24VOut0VDigitalDigitalI/O1DigitalI/O2DigitalI/O3DigitalI/P1DigitalI/P2DigitalI/P3Enable0VDigitalAtZeroSpeedO/P24Reset2526FwdRev272829Userenable3031UnidriveRegenInstallationGuideIssueNumber:2

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5

•••••••••

Components

MotoringdriveRegendriveRegeninductorSoftstartresistor

Contactors,MCBsandoverloadSwitchingfrequencyfilter(optional)RFIfilter(optional)VaristorsFuses

ThefollowingpartsarerequiredtoassembleaUnidriveRegensystem:

TheRegeninductorandsoftstartresistordutycycleisveryarduous.Therefore,correctcomponentselectioniscritical.Themostsensitiveaspectsareline-inductorlinearity,saturationcurrentandresistor-energypulserating.OnlyinductorsandsoftstartresistorsasspecifiedinthisInstallationGuideshouldbeused.

5.1Motoringdrive

UnidriveinOpenLoop,ClosedLooporServomode.Anysoftwareversion.

ThiscontrolsthemotorbyconvertingtheDCbusvoltagetoavariablevoltage,variablefrequencysupply.PowerflowisbetweentheDCbusandthemotor.TherearenoACsupplyconnections.

5.2Regendrive

UnidriveinRegenmode.(Mustbesoftwareversion2.10.04orhigher).

TheRegendriveconvertstheACsupplytoaregulatedDCvoltage.Italsoprovidesbi-directionalpowerflowandsinusoidalinputcurrents.

5.3

Regeninductor

3-phaseRegeninductors

RatedpowerkW

RatedcurrentArms9.5121625344046607096124156180202300Inductance

mH6.35.03.752.41.761.51.31.00.780.630.480.380.330.300.241111111111111114401-00014401-00024401-00034401-00044401-00054401-000401-00074401-00084401-00094401-00104401-00114401-00124401-00134401-00144401-0015NumberrequiredperRegendrive

CT

partnumber

TheRegeninductorsupportsthedifferencebetweenthePWMvoltagefromtheRegendriveandsinusoidalvoltagefromthesupply.

Regeninductorsarespecialparts.UndernocircumstancesmustapartbeusedotherthanthoselistedinTable5-1.Table5-1

DriveModel

UNI1405UNI2401UNI2402UNI2403UNI3401UNI3402UNI3403UNI3404UNI3405UNI4401UNI4402UNI4403UNI4404UNI4405UNI540145.57.5111518.52230374555759011016010www.controltechniques.com

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5.4

5.4.1

Softstartresistor

Singlesystems

Thestart-upcircuitlimitstheamountofcurrentflowingintotheDCbusoftheRegendriveandintothemotoringdrives.

ThesoftstartresistorforsingleRegenapplicationsmustbeasspecifiedinthefollowingtable.Energyratingandoverloadarenon-standardandbothareimportant.Table5-2

Drivesize12345

Table5-3

SingleRegen,singlemotoring,Unidrivesize1to5

Numberofparallelresistors

11122

Softstartresistordata

Resistors1270-31571270-31571270-24831270-2483x21270-2483x2Rmscurrent

A

0.40.40.50.61.2Chargingcurrent

A

55153232Totalvalue

Ω150150482424

Resistors

CTpartnumber1270-31571270-31571270-24831270-24831270-2483

ValueΩ150150484848

Drivesize

12345Theabovefigureshavebeencalculatedassumingapeaksupplyvoltageof480Vac+10%.ReferalsotoAppendixBComponentSizingCalculations.

5.4.2Multiplesystems

Innonstandardcases,e.g.multiplemotoring,multipleRegensystems,thesoft-startresistorsizeandratingmustberecalculatedduetothechargingcharacteristicschanging.Forthemethodofcalculatingthenewresistorsizeandrating,refertoAppendixBComponentsizingcalculationsonpage36.

5.4.3Protection

Protectionforthesoftstartcircuitisprovidedusingathermaloverloadtoprotectagainstahighimpedanceshortcircuit,andaseparatemagneticoverloadtoprotectagainstadirectshortcircuit.Formultiplesystemsthesoftstartresistorsizemustberecalculatedresultinginresizingofthethermalmagneticoverloadrequired.RefertoAppendixBComponentsizingcalculationsonpage36.Table5-4

Thermalmagneticoverload

RatedCurrent

A

0.312

RatedVoltage

Vac

480480480

NumberofPoles

111

CTpartnumber4133-01174133-02174133-0277

Drivesize1&234&5

5.5

Table5-5

Contactors,MCBsandoverload

ContactorsandMCBs

RefK2K3MCB1xOvld

Description

3poleNO+auxiliaryNOcontact.Coilvoltageselectedtosuitavailablesupply.2poleNC+auxiliaryNO3pole+auxiliaryNC

Specification

Currentratingequaltototalcurrentrequirement.VoltageratingequaltoACmainssupplyvoltage.Coilmustnotexceed240Vac5Aresistiveload.Installationcategory1.

Currentratingsizedtormscurrentofswitchingfrequencyfiltercapacitorsandchargingcurrentatpowerup.(RefertoTable5-6).

Sizedtothesoftstartresistortoprotectthermallyandmagnetically.(RefertoAppendixBComponentsizingcalculationsonpage36).

ContactorsandMCBsarerequiredasfollows:

FunctionMaincontactorAuxiliarycontactorSwitchingfrequencyfilter

MCBThermalmagneticoverload

Singlepole

MCB1xisfittedbetweentheswitchingfrequencyfiltercapacitorsandtheACsupply.TheMCBshouldhaveanauxiliarywhichtheenablefortheRegenandmotoringdriveisconnectedthrough.Thiswillactasasafeguardandpreventthesystemrunningwithafaultontheswitchingfrequencyfilter.AlsorefertoAppendixBComponentsizingcalculationsonpage36.

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5.6Switchingfrequencyfilter

TheACinputterminalsofaRegendriveproduceaPWMoutputvoltage,whichhasasinusoidalcomponentatlinefrequency,plussignificantharmonicsattheswitchingfrequencyanditsmultiples.

Thisfilterpreventsswitchingfrequencyharmoniccurrentsgettingbackintothesupply.Ifthefilterisnotfitted,thepresenceofcurrentsinthekHzregioncouldcausesupplyproblemsordisturbancetootherequipment.

Theswitchingfrequencyfilterinductorsneedtoberatedtothetotalcurrentrequirement.

Thefollowinginductorsarestandard3-phaseinductors(ratedatdriveratedcurrentforasingleRegensystemorratedattotalcurrentrequirementformultipleRegensystem),theycarryonly50/60Hzcurrentwithanegligibleamountofhighfrequencycurrent.

Thecapacitorsspecifiedbelowaresuitableforoperationatanyswitchingfrequency.Thesecapacitorsaresizedforoperationat3kHzhoweveroperationabove3kHzispossiblewiththecapacitorsbeingmoreeffective.Table5-6

SwitchingfrequencyfilterDriveModelUNI1405UNI2401UNI2402UNI2403UNI3401UNI3402UNI3403UNI3404UNI3405UNI4401UNI4402UNI4403UNI4404UNI4405UNI5401UNI5402UNI5403UNI5404UNI540XRatedcurrentA9.51216253440466070961241561802023006009001200300xX3-phaseinductorLfiltmH3.1602.5001.8751.2000.8800.7500.6500.5000.3900.3150.2400.1900.1650.1350.1000.0500.0340.0250.100/XCTpartnumber4401-01624401-01634401-014401-01654401-0101-01674401-01684401-01694401-01704401-01714401-01724401-01734401-01744401-01754401-017401-01774401-01784401-017980(x1)80(x2)80(x3)80(x4)80(xX)1665-2804

35percapacitor

48

1665-2484

25

24

1665-2244

15

5.7

1610-5752

2.1

3-phasecapacitorCfiltµF

CTpartnumber

MCBratingrmscurrentA

PeakcurrentA283135106115124142160252262325348385580580580580580X=numberofsize5drives

5.6.1

Protection

AnMCBshouldbefittedbetweentheACsupplyandthecapacitor.Thisistoprotectthewiringbetweenthecapacitorandthemainbusbar.

FormultipleRegensystems,refertoAppendixBComponentsizingcalculationsonpage36forsizingoftheMCB.

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5.7RFIfilter

Incommonwithconventionaldrives,significantgroundcurrentsaregeneratedbythecapacitanceofthemotortoground,themotorcablestoground,andthedrivepowercircuitstotheirheatsinks.TheRFIfilterwillprovidearelativelyshortreturnpathforgroundcurrentsbacktothedrivespowercircuit.Table5-7

RFIfilterdata

VoltsVac

UNI1405UNI2401to2402

UNI2403UNI3401to3403

UNI3404UNI3405UNI4401to4402UNI4403to4404

UNI4405UNI5401

480480480480480480480480480480

Maximumpower

kW47.5112230375590110160

FiltercurrentratingA1016255063100150180220300

BookEndFootprintorBookEnd

BookEndFootprintorBookEnd

BookEndFootprintorBookEnd

BookEndBookEndBookEndBookEndBookEndBookEndBookEnd

Motorcablelengthm100100100100100100100100100100100100100

4200-61054200-61044200-61094200-61084200-61144200-61134200-611200-61174200-610200-61074200-61114200-61124200-6115CTpartnumber

CTModelNumber

Mountingstyle

DonotuseanRFIfilterwithoutthespecifiedswitchingfrequencyfilter,asfailureoftheRFIfilterwilloccur,duetotheswitchingcurrents.CAUTION5.8Varistors

AClinevoltagetransientscantypicallybecausedbytheswitchingoflargeitemsofplant,orbylightningstrikesonanotherpartofthesupplysystem.Ifthesetransientsarenotsuppressed,theycancausedamagetotheinsulationoftheRegeninputinductors,ortotheUnidriveRegendriveelectronics.Table5-8

Varistors

Drivesize1to51to5

VaristorvoltageVac550680

Varistorenergy

J400450

Z500NSZ680LNS

33

2482-15012482-0680

Typenumber

Quantity

CTpartnumber

ConfigurationLinetolineLinetoground

NOTE

NConfiguration

FittingofVaristors

FusesVaristorsSevenvaristorsarerequiredwhenoperatingwithanITsupplyasshowninFigure3-1onpage5,Figure3-2onpage6andFigureA-2onpage32.

5.8.1

Varistorsshouldbefittedafterthesupplyfuses,asshowninFigure5-1:Figure5-1

RYB550Vacvaristors680VacvaristorsERFIFilterSwitchingFrequencyFilterUnidriveRegenInstallationGuideIssueNumber:2

13www.controltechniques.com

5.9

•••••

Fusing

FusingfortheRegensystemisrequiredinordertoprotectthefollowing:

SupplytransformerSupplycablesRegeninductorRegendriveMotoringdrive

Intheeventoffailure,thefusingwillpreventfirebylimitingtheamountofenergyallowedintotheRegenandmotoringdriveunits.TheACsupplyfusingshouldberatedtotheRegensystem’scontinuousratedcurrent.TheRegenACfusingwhenusedwitheachmultiplesize5Regendrive

shouldberatedtothe450Acontinuousratedcurrentofthedrive.The+DCbusfusingwhenusedwithmultiplemotoringdrivesshouldberatedto2xmotoringdriveratedcurrentand>750Vdc.

5.9.1Standardsystems

FusingforastandardRegensystem,singleRegenplussinglemotoringdrive(bothdrivesofthesamerating)shouldconsistofACsupplyfusingasshownbelow:

Figure5-2Fusing:Standardsystems

ACSupplyFusingMainContactorAdditionalCircuitryRegenInductorUVW-DC-DCR3PhaseSupplyRegenDriveMotoringDriveYB+DC+DCUVWM5.9.2Multiplesize1to4motoringdrives

WhenaRegensystemconsistsofmultiplesize1to4motoringdrives,ACsupplyfusingand+DCbusfusingshouldbefittedasshownbelow:Figure5-3Fusing:Multiplesize1to4motoringdrivesRegensystem

MotoringDrive+DCACSupplyFusing-DCRegenDriveUVMMainContactorAdditionalCircuitryRegenInductorUVWWR3PhaseSupply+DC-DCDCBusFusingYBMotoringDrive+DC-DCUVWM14www.controltechniques.com

UnidriveRegenInstallationGuide

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5.9.3Multiplesize5Regen

WhenaRegensystemconsistsofmultiplesize5Regenandmotoringdrives,ACsupplyfusingand-DCbusfusingshouldbefittedasshownbelow:Figure5-4Fusing:Multiplesize5Regensystem

RegenInductorUVACSupplyFusingWMainContactorAdditionalCircuitryRegenACFusingOutputSharingChokeRegenDriveMotoringDrive+DC-DC+DC-DCUVWR3PhaseSupplyYBDCBusFusingMRegenDriveMotoringDriveUVWRegenInductor+DC-DC+DC-DCUVWOutputSharingChokeUnidriveRegenInstallationGuideIssueNumber:2

15www.controltechniques.com

6

6.1

6.1.1

••••••••

Importantconsiderations

Fundamentals

Youmust

UseRegeninductorsofthecorrecttypeandvalue,asspecified.Useastart-upresistorofthecorrecttypeandvalue,asspecified.

ConnecttheRegendriveoutputenablesignaltotheenableinputonthemotoringdrive(s).

UseaswitchingfrequencyfilterifanRFIfilterispresentortheACsupplyisnotdedicatedsolelytotheRegendrive.Fitfuseswherespecified,andensuretheyareofthecorrectrating.

Ensurethatthecubicleiscorrectlysizedandventilated,takingintoaccountthelossesgeneratedbyallofthecircuitcomponents.

6.1.2Youmustnot

ConnectacircuitofanytypebetweenaRegenandmotoringdrive’sDCbus.

AttempttouseaUnidrivesize1-4Regeninparallelconfiguration(onlyUnidrivesize5Regencanbeusedinparallelconfiguration).

6.2Unidrivesize3and4

IfaUnidrivesize3or4ofanyothervariantexcepttheRegenvariantistobeusedinaRegensystem,aninternalmodificationisrequiredtoboththeRegenandmotoringdrive(s).

Damagetothedrive(s)willresultifthismodificationisnotcarriedout.CAUTIONNOTE

NModificationofthedrivemustonlybecarriedoutbyCTauthorisedpersonnel.Ifanydetailsarerequired,contactC.T.Technicalsupport.

6.3Ventilation

WhendesigningaRegenSystem,considerationsmustbemadefortheadditionalventilationrequirementsduetotheintroductionoftheRegenandSwitchingFrequencyfilterinductors.

Theinductorshavenormaloperatingtemperaturesofapprox.150°Cdependingupontheambientandthemotorcablelengths.Caremustbetakensothatthisdoesnotcreateafirerisk.CAUTIONARegenSystemcanoperateinanambienttemperaturerangeof0°Cto50°C(32°Fto122°F)forUnidrivesizes1to5.Anoutputcurrentderatingmustbeappliedwithambienttemperaturesbetween40°Cand50°C.ForderatingfiguresseetheUnidriveSize1to5UserGuide.

VentilationforboththeRegenandmotoringdrivesinthesystemshouldbeasspecifiedintheUnidriveSize1to5UserGuide.Providedthe

maximumcablelengthsinTable6-3onpage18havenotbeenexceeded,naturalairflowventilationthroughtheRegenandswitchingfrequencyfilterinductorsisadequate.Inspecialconditions,wherethemaximumcablelength(refertoTable6-3onpage18)hasbeenexceeded,forcedcoolingshouldbeintroducedfortheRegenInductorasspecifiedinAppendixCLongcablesonpage41.Whensizingthecubicle(s)fortheRegensystemconsiderationsmustbemadeforthesystemslosses.

SystemLosses

RFIFilterRegendriveMotoringdrive

ControlModule,Unidrivesize5PowerModule,Unidrivesize5

DocumentedIn...

UnidriveSize1to5UserGuide

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Table6-13-phaseRegeninductor

Ratedcurrent

Arms

Inductance

mH6.35.03.752.41.761.51.31.00.780.630.480.380.330.300.24

NoperRegen

Drive

111111111111111

CT

partnumber4401-00014401-00024401-00034401-00044401-00054401-000401-00074401-00084401-00094401-00104401-00114401-00124401-00134401-00144401-0015

TotallossesW12514617521028531032034541551558557758451760

DrivesizeUNI1405UNI2401UNI2402UNI2403UNI3401UNI3402UNI3403UNI3404UNI3405UNI4401UNI4402UNI4403UNI4404UNI4405UNI5401

9.5121625344046607096124156180220300

Table6-23-phaseswitchingfrequencyfilterinductor

Ratedcurrent

Arms

Inductance

mH3.1602.5001.8751.2000.8800.7500.6500.5000.3900.3150.2400.1900.1650.1350.1000.0500.0340.025NoperRegen

Drive

111111111111111111CT

partnumber4401-01624401-01634401-014401-01654401-0101-01674401-01684401-01694401-01704401-01714401-01724401-01734401-01744401-01754401-017401-01774401-01784401-0179TotallossesW283537405260608090100110130170180220400530700DrivesizeUNI1405UNI2401UNI2402UNI2403UNI3401UNI3402UNI3403UNI3404UNI3405UNI4401UNI4402UNI4403UNI4404UNI4405UNI5401UNI5402UNI5403UNI54049.512162534404660709612415618022030060090012006.4

6.4.1

Cablelengthrestrictions

ACsupplyconnection

Thereare3significantcablelengthswhichmustbetakenintoaccountwhendesigningaRegensystem.RefertoFigure6-1onpage18.AistheACcablelengthbetweentheRegeninductorandtheRegendrivesterminals.

Ingeneral,nospecialprecautionsarenecessaryfortheACsupplywiringinrespecttotheRegendrive.HoweverthevoltageinthewiringbetweentheRegeninductorandtheRegendriveterminalsisasourceofradiofrequencyemission.Tominimiseemissions,thesecablesshouldbekeptasshortaspossible.Ideally,theinductorsshouldbemountedclosetothedriveterminals.

Ifitisnecessarytouseacablelongerthan5m,ascreenedcableshouldbeusedwiththescreengroundedasshowninFigure6-1onpage18.

6.4.2DCbusconnection

BistheDCbusconnectionbetweentheRegenandmotoringdrive,the+DCbusconnectionsbetweenthedrivesshouldbetreatedasasingletwocorecableandnottwoindividualcable/busbarlengths.

TheDCpoweroutputfromtheUnidrivewhichisusedastheinputstagetothemotoringdrive(s)carriesacommon-modehighfrequencyvoltagecomparablewiththeoutputvoltagefromastandarddrive.AllprecautionsrecommendedformotorcablesmustalsobeappliedtoallcablesconnectedtothisDCcircuit.

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17www.controltechniques.com

Ifitisnecessarytouseacablelongerthan5m,ascreenedcableshouldbeusedwiththescreengroundedasshowninFigure6-1.

6.4.3Motorconnection

CistheACcablelengthbetweenthemotoringdriveandthemotor.Figure6-1CalculatingthecablelengthoftheRegensystem

BRegenDriveL1L2L3UVW-DC+DCL1L2L3MotoringDriveUVW+DC-DCEEAEECERegenInductorMotorEEERBY6.4.4

Table6-3

Maximumcablelength

Cablelengths

Powerrating

kW45.5-1115-3745-110132Maximumcablelength

m50100200200200perRegendriveThesumtotallengthoftheDCbusandmotorcables(BandCinFigure6-1)mustnotexceedthevaluesshowninthetablebelow:

Regendrivesize

12345Ifthecablelengthintheabovetableisexceeded,additionalcomponentsarerequired.RefertoAppendixCLongcablesonpage41.

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7

7.1

UnidriveRegenEMCinformation

Immunity

Theimmunityoftheindividualdrivemodulesisnotaffectedbyoperationintheregenerativemode.SeedriveEMCdatasheetsforfurtherinformation.ThisGuiderecommendstheuseofvaristorsbetweentheincomingACsupplylines.Thesearestronglyrecommendedtoprotectthedrivefromsurgescausedbylightningactivityand/ormainssupplyswitchingoperations.

Sincetheregenerativeinputstagemustremainsynchronisedtothesupply,thereisalimittothepermittedrateofchangeofsupplyfrequency.Ifratesofchangeexceeding100Hz/sareexpectedthenC.T.TechnicalSupportshouldbeconsulted.Thiswouldonlyariseunderexceptionalcircumstancese.g.wherethepowersystemissuppliedfromanindividualgenerator.

7.2

•••

Emission

Emissionoccursoverawiderangeoffrequencies.Theeffectsaredividedintothreemaincategories:

Lowfrequencyeffects,suchassupplyharmonicsandnotching

Highfrequencyemissionbelow30MHzwhereemissionispredominantlybyconductionHighfrequencyemissionabove30MHzwhereemissionispredominantlybyradiation

7.3Dedicatedsupplies

ThenatureofthemainssupplyhasanimportanteffectontheEMCarrangements.Foradedicatedsupply,i.e.onewhichhasnootherelectricalequipmentfedfromthesecondaryofitsdistributiontransformer,normallyneitheranRFIfilteroraswitchingfrequencyfilterarerequired.Refertosection3.2.2Supplyassessmentonpage7.

7.4Othersupplies

Whereverotherequipmentsharesthesamelowvoltagesupply,i.e.400Vac,carefulconsiderationmustbegiventothelikelyneedforbothswitchingfrequencyandRFIfilters,asexplainedinsection7.7Switchingfrequencyemissionandsection7.8ConductedRFemission.

7.5Supplyvoltagenotching

Becauseoftheuseofinputinductorsandanactiverectifierthedrivecausesnonotching-butseesection7.7Switchingfrequencyemissionforadviceonswitchingfrequencyemission.

7.6Supplyharmonics

Whenoperatedfromabalancedsinusoidalthree-phasesupply,theregenerativeUnidrivegeneratesminimalharmoniccurrent.

Imbalancebetweenphasevoltageswillcausethedrivetogeneratesomeharmoniccurrent.Existingvoltageharmonicsonthepowersystemwillcausesomeharmoniccurrenttoflowfromthesupplyintothedrive.Notethatthislattereffectisnotanemission,butitmaybedifficulttodistinguishbetweenincomingandoutgoingharmoniccurrentinasitemeasurementunlessaccuratephaseangledataisavailablefortheharmonics.Nogeneralrulecanbegivenfortheseeffects,butthegeneratedharmoniccurrentlevelswillalwaysbesmallcomparedwiththosecausedbyaconventionaldrivewithrectifierinput.

7.7Switchingfrequencyemission

TheRegendriveusesaPWMtechniquetogenerateasinusoidalinputvoltagephase-lockedtothemainssupply.Theinputcurrenttherefore

containsnoharmonicsofthesupplyunlessthesupplyitselfcontainsharmonicsorisunbalanced.Itdoeshowevercontaincurrentattheswitchingfrequencyanditsharmonics,modulatedbythesupplyfrequency.Forexample,witha3kHzswitchingfrequencyand50Hzsupplyfrequencythereiscurrentat2.95,3.15,5.95,6.05kHzetc.Theswitchingfrequencyisnotrelatedtothatofthesupply,sotheemissionwillnotbeatrueharmonic-itissometimesreferredtoasan“interharmonic”.Thepossibleeffectofthiscurrentissimilartothatofahigh-orderharmonic,anditspreadsthroughthepowersysteminamannerdependingontheassociatedimpedances.TheinternalimpedanceoftheRegendriveisdominatedbytheseriesinductorsattheinput.Thevoltageproducedatswitchingfrequencyatthesupplypointisthereforedeterminedbythepotentialdivideractionoftheseriesinductorsandthesupplyimpedance;section3.2.2Supplyassessmentonpage7givesguidelinestohelpinassessingwhetheraswitching-frequencyfilterisrequired.Incaseofdoubt,unlessthedriveoperatesfromadedicatedsupplynotsharedwithotherloads,itisstronglyrecommendedthatthefilterbefitted.

Failuretofitaswitchingfrequencyfiltermayresultindamagetootherequipment,e.g.fluorescentlightfittings,powerfactorcorrectioncapacitorsandRFIfilters.CAUTION7.8ConductedRFemission

Radiofrequencyemissioninthefrequencyrangefrom150kHzto30MHzismainlyconductedoutoftheequipmentthroughelectricalwiring.Itisessentialforcompliancewithallemissionstandards,exceptforIEC61800-3secondenvironment,thattherecommendedRFIfilterandashielded(screened)motorcableareused.Mosttypesofcablecanbeusedprovidedithasanoverallscreen.Forexample,thescreenformedbythe

armouringofsteelwiredarmouredcableisacceptable.Thecapacitanceofthecableformsaloadonthedriveandshouldbekepttoaminimum.

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WhenanRFIfilterisusedtheswitchingfrequencyfilterdiscussedabovemustalsobeused.FailuretoobservethismayresultintheRFIfilterbecomingineffectiveandbeingdamaged.CAUTIONWhenusedwiththerecommendedfilters,theRegendrivesystemcomplieswiththerequirementsforconductedemissioninthefollowingstandards:Table7-1

Requirementsforconductedemission

Switchingfrequency(kHz)

3II

Description

Frequencyrange0.15-0.5MHz0.5-30MHz

Limits79dBµVquasipeak66dBµVaverage73dBµVquasipeak60dBµVaverage

ApplicationACsupplylines

Motorcablelength(m)

1.5100

KeytotableI

EN50081-2Standard

Genericemissionstandard

fortheindustrialenvironmentProductstandardforadjustablespeedpower

drivesystems

EN61800-3IEC1800-3

12Inputcurrent>25A:Requirementsforthefirstenvironment1:

UnrestricteddistributionInputcurrent<25A:Requirementsforthefirstenvironment2:Restricted

distribution

ThefirstenvironmentisonewherethelowvoltagesupplynetworkalsosuppliesdomesticpremisesRestricteddistributionmeansthatdrivesareavailableonlytoinstallerswithEMCcompetenceForinstallationinthe“secondenvironment”,i.e.wherethelowvoltagesupplynetworkdoesnotsupplydomesticpremises,nofilterisrequiredinordertomeetIEC61800-3(EN61800-3):1996.

Operationwithoutafilterisapracticalcost-effectivepossibilityinanindustrialinstallationwhereexistinglevelsofelectricalnoisearelikelytobehigh,andanyelectronicequipmentinoperationhasbeendesignedforsuchanenvironment.Thereissomeriskofdisturbancetootherequipment,andinthiscasetheuserandsupplierofthedrivesystemmustjointlytakeresponsibilityforcorrectinganyproblemwhichoccurs.CAUTION7.8.1

Table7-2

RecommendedRFIfilters

RecommendedfiltersDriveUNI1405UNI2401-2402UNI2403UNI3401-3403UNI3404UNI3405UNI4401-4402UNI4403-4404UNI4405UNI5401100Motorcablelengthm

RFIfilter:C.T.partnumber

4200-61054200-61094200-61144200-611200-61174200-610200-61074200-61114200-61124200-6115Thesearethesamefiltersasrecommendedforstandard(non-regenerative)operation:

7.8.2

Table7-3

Relatedproductstandards

Conductedemissionfrom150kHzto30MHz

Productstandard

EN55011ClassAGroup1CISPR11ClassAGroup1

EN55022ClassACISPR22ClassA

Industrial,scientificandmedicalequipment

Informationtechnology

equipment

TheconductedemissionlevelsspecifiedinEN50081-2areequivalenttothelevelsrequiredbythefollowingproductspecificstandards:

Genericstandard

EN50081-2

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7.9Radiatedemission

Radiofrequencyemissioninthefrequencyrangefrom30MHzto1GHzismainlyradiateddirectlyfromtheequipmentandfromthewiringinitsimmediatevicinity.Operationinregenerativemodedoesnotaltertheradiatedemissionbehaviour,andtheEMCdatasheetfortheindividualUnidrivesusedshouldbeconsultedforfurtherinformation.

Theoreticallytheuseoftwodrivesphysicallyclosetogethercancauseanincreaseinemissionlevelof3dBcomparedwithasingledrive,althoughthisisusuallynotobservedinpractice.AllUnidriveshavesufficientmargininrespectofthegenericstandardfortheindustrialenvironmentEN50081-2toallowforthisincrease.

7.10Wiringguidelines

Thewiringguidelinesprovidedfortheindividualdrivesalsoapplytoregenerativeoperation,exceptthattheswitchingfrequencyfiltermustbe

interposedbetweentheinputdriveandtheRFIfilter.Thesameprinciplesapply,themostimportantaspectbeingthattheinputconnectionstotheRFIfiltershouldbecarefullysegregatedfromthepowerwiringofthedriveswhichcarriesarelativelyhigh“noise”voltage.

7.11Multi-drivesystems

Itiscommonforregenerativedrivesystemstobeconstructedusingnumbersofdriveswithasingleinputstage,orothermorecomplex

arrangements.ItisgenerallynotpossibletolaydownspecificEMCrequirementsforsuchsystems,sincetheyaretoolargeforstandardisedteststobecarriedout.Inmanycasestheenvironmentcorrespondstothe“secondenvironment”asdescribedinIEC61800-3,inwhichcasenospecificlimittoconductedemissionisrequired.NationallegislationsuchastheEuropeanUnionEMCDirectivedoesnotusuallyrequirethatcomplexinstallationsmeetspecificstandards,butonlythattheymeettheessentialprotectionrequirements,i.e.nottocauseorsufferfromelectromagneticinterference.Wheretheenvironmentisknowntoincludeequipmentwhichissensitivetoelectromagneticdisturbance,orthelowvoltagesupplynetworkissharedwithdomesticdwellings,thenprecautionsshouldbetakentominimiseconductedradiofrequencyemissionbytheuseofafilteratthesystempowerinput.Forcurrentupto300AtheControlTechniquesfilterslistedpreviouslyaresuitable.

Forcurrentsexceeding300Aupto2400Asuitablefiltersareavailablefromthefollowingmanufacturers:

SiemensB84143.A250.S(rangeupto2500A)SchaffnerFN3359-300-99(rangeupto2400A)

ThesefiltersmaynotgivestrictconformitywithEN50081-2,butinconjunctionwiththerelevantEMCinstallationguidelinestheywillreduceemissiontosufficientlylowlevelstominimisetheriskofdisturbance.

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8Parameterdescriptions

Keytoparametercodes:

ôRangeofvaluesDefaultvalueRead/WriteReadOnlyTwostateonlyparameter,0or1.Bipolar-canhavepositiveandnegativevalues.Unipolar-canhavepositivevaluesonly.ParametervalueisrepresentedonthedisplaywithstringsofText.ParameterisProtectedfrombeingcontrolledbyprogrammableinputsandfunctions.

ðRWROBitBiUniTxtPNotethattheequivalentMenu0parameterappearsintheboxprecedingtheparameterdescription.

8.1Menu15:Sinusoidalrectifier

AUnidrivecanbeusedasasinusoidalinputcurrentpowerunittosupplyoneormoreUnidrivesviatheirDCbuses.Whenthismodeisselectedasthedrivetype,menu15appears.ThismenuisusedtosetuptheUnidrive.Atthesametime,menu0defaultstoshowingPr15.01toPr15.13asPr0.11toPr0.28.

15.01ô

0.11Supplycurrentmagnitude

±Maximumdrivecurrent

ð

AROBiP

Thisparametergivesthermsphasecurrentfromthesupply.Thesinusoidalrectifiercontrolsthecurrentsothatthefundamentalcurrentandvoltageareinphaseatthepowerterminalsofthedrive.Thereisasmallphaseshiftacrosstheinputinductors,andsothecurrentmagnitudeandtherealcomponentofcurrentareapproximatelyequal.Ifpowerisflowingintothesinusoidalrectifierthecurrentmagnitudeisnegative,andifpowerisflowingout(backintothesupply)thecurrentmagnitudeispositive.

15.02ô

0.12Supplyvoltage

0to528

ð

VacROUniP

Whenthesinusoidalrectifierunitisactivethesupplyvoltageisgivenbythisparameter.Iftheunitisnotactivethisparametershowszero.

15.030.13Supplypower

ô±Drivemax.currentx5.09x√3/1000

ðkWROBi

Totalsupplypowerofthedriveiscalculatedfromtheproductofthelinevoltageandcurrentwhichisequivalentto15.01x15.02x√3.Notethatasthepowerfactorisapproximatelyunitythepowerisequaltothevolt-amperes.Thepowershownisthatflowingoutofthedrive,hencewhenpowerisflowingfromthesupplytotheRegendrivePr15.03isnegative,andwhenpowerisflowingfromtheRegendrivebackintothesupplyPr15.03ispositive.

15.04ô0.14DCbusvoltage

0to830

ðVdcROUniP

VoltageattheDCoutputofthedrive.

15.05ô

0.15

±100

Supplyfrequency

ðHzROBiP

Whenthesinusoidalrectifierunitisactivethisparametergivesthesupplyfrequency.Positivevaluesindicatepositivephasesequenceandnegativevaluesindicatenegativephasesequence.Iftheunitisnotactivethisparametershowszero.

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15.06ô0.16Inputinductance

0.001to100

ðmHROUniP

Atpower-upthisparameteriszero.Eachtimetheunitisenabledthesupplyinductanceismeasuredanddisplayedbythisparameter.Thevaluegivenincludesthesupplyinductanceandtheinductorsinsertedatthesupplytothesinusoidalrectifierunit.Thevaluegivenisonlyapproximate,butwillgiveanindicationastowhethertheinputinductanceiscorrectforthesinusoidalrectifierunitsize.

15.07ô0.17DCbusvoltageset-point

0to800

ð700VdcRWUni

ThesinusoidalrectifierunitwillattempttoholdtheDCbusatthelevelspecifiedbythisparameter.Thehigherthebusvoltagethebetterthe

performanceoftheunitastherewillbemorevoltageavailabletocontroltheinputcurrent.Thebusvoltagemustalwaysbehigherthanthepeakofthelinetolinesupplyvoltageiftheunitistooperatecorrectly.Thevoltagecanbesettoalevelupto800V,butthisonlyleaves30Vheadroombelowtheover-voltagetriplevel.Thereforeitisbesttousethedefaultvalueof700Vunlessthesupplyvoltageissuchthatitmustberaisedabovethislevel.

Supplyvoltage

Vac

380415480MinimumVdc650680780Recommended

Vdc

700700780MaximumVdc80080080015.08ô0.18Switchingfrequency

0to4:[3,4.5,6,9,12]

ð0:[3kHz]kHzRWTxtP

ThisparametersetsthePWMfrequencyandalsodeterminesthesamplefrequencyforloops.Thesamplingfrequencyofthecontrolsystemisbasedontheswitchingfrequenciesasfollows:Currentcontrol

Switchingfrequency

kHz

34.56912DCbusvoltagecontrolandsynchronisationwiththesupply

Switchingfrequency

kHz

34.56912Controlfrequency

kHz

32.2532.253Controlfrequency

kHz

34.5.5615.09ô

••

0.19

0~1

Highstabilityspacevectormodulation

ð0RWBit

Settingthisparameterto1modifiestheIGBTswitchingpatternsoastoreducethenumberofswitchingevents.Thishasthefollowingeffects:

SlightlyreducedpowerlossintheRegendrive.Increasedacousticnoisefrominputinductors.

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15.10ô0.20

0~1

Quasi-squareoperationselect

ð0RWBit

TherateatwhichtheDCbusvoltagecanbereducedbythedrivedependsontheheadroombetweenthebusvoltageandthesupplyvoltage.Ifquasi-squaremodeisselectedthisheadroomcanbeeffectivelyincreasedatsomepointswithinasupplycycle.Thiscangivebetterperformance,particularlywhenthesupplyvoltageishighorthebusvoltageset-pointislow.

15.11ô

0.21

0~1

Sinusoidalrectifiersynchronising

ðROBit

Whenthedriveisenableditmustdetectthephaseandfrequencyofthemains.Duringthisperiodthisbitisset.Oncesynchronisationhasbeencompletedsuccessfullythisbitiscleared.Ifthesupplyisveryseverelydistortedoraphaseismissingthedrivewillrepeatedlyattempttosynchroniseuntilitisdisabledorsynchronisationiscompleted.

15.12ô0.22

0~1

Sinusoidalrectifiersynchronised

ðROBit

Whenthedrivehasbeenenabledandsuccessfullysynchronisedthisbitwillbesetto1.Ifthedriveisdisabled,theunittripsordetectsthatthemainsislost,thisbitwillbesetto0.

15.13ô

0.23

0~1

Sinusoidalrectifierphaseloss

ðROBit

Ifasupplyphaseisnotpresentthesinusoidalrectifierunitwillnotsynchronisewhenitisenabled.However,ifaphaseislostaftersynchronisationoneofthefollowingwilloccur:•••

Lightlyloaded:theunitwillcontinuetooperatenormally.

Mediumload:theunitwillcontinuetooperate,butthephaselossbitisset.

Heavyload:theunitwilldetectmainsloss,disableitselfandattempttore-synchronise.

15.14ô0.24

0~1

Closesoftstartcontactor

ðROBit

WhentheRegendrivehaspoweredupthroughthesoftstartresistorandtheDCbusvoltagestabilisedthisbitwillchangefrom0to1.Thisbitmustberoutedtoadigitaloutputterminalwhichisusedtoenergisethesoftstartcontactorcoil.

15.15ô

0.25

0~1

Softstartcontactorisclosed

ðROBit

Whentheclosecontactoroutputgoesactivethesoft-startcontactorshouldoperateandshortoutthesoft-startresistor.Thisbitshouldbesetasthedestinationparameterforadigitalinputconnectedtoanauxiliarycontactonthesoftstartcontactor.IfthisinputbecomesinactivewhenbitPr15.14issetthenaftera100ms(approx.)delaythedrivewillinhibitsoastoprotectthesoft-startcircuit.

15.16ô0.26

0~1

Enablemotordrive

ðROBit

Whentheunithasbeenenabledandsuccessfullysynchronisedthisbitwillbesetto1.IftheRegendriveisdisabled,theunittripsordetectsthatthemainsislost,thisbitwillsetto0.

Thisbitshouldberoutedtoadigitaloutputandusedtoenablethemotoringdrive(s)connectedtotheDCbusoftheRegendrive.

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UnidriveRegenInstallationGuide

IssueNumber:2

15.17ô0.27

0~1

Linesynchronisationtripenable

ð0ROBit

Whenthedriveisenabledandthemaincontactoriscloseditwilltryandsynchronisethelinesupply.Ifthisbitis0thenthedrivewillcontinuetotryandsynchronisetothelinecontinuallyuntildisabled,evenifitdoesnotsynchronisesuccessfully.Ifthisbitissettoa1andthedrivehasnotsuccessfullysynchronisedaftertryingfor30secondsthenthedrivewilltrip‘LI.SYNC’.

15.18ô

0.28

0~5

Linesynchronisationstatus

ðROTxtP

Thisparameteristhelinesupplysynchronisationstatus.Itisintendedtogivesomediagnosticinformationifthedrivefailstosynchronisetothesupply.Ifnoattempttosynchronisetothesupplyhasbeenmadesincethedrivewasswitchedon,ifthedriveissynchronisedtothesupplyand

running,orifithasbeenrunningthenthisparameterwillshow‘SYNC’.Ifthedrivecannotsynchronisetothesupplythenthisparameterwillshowthereasonwhysynchronisationfailed.Ifthedrivedoesfailtosynchronisetothesupplythemostlikelyreasonsarethatthesupplyisverydistorted,ortherearelargevoltagenotches/spikesonthesupply.

012345

SYNCPhDetFrLoFrHiPLLOIPLLPh

Successfullysynchronisedtolinesupply

FailedtocorrectlydetectthephasingofthesupplyLinefrequencytoolowLinefrequencytoohigh

OvercurrentduringfinalsynchronisationofPLLtosupplyPhasingerrorduringfinalsynchronisationofPLLtosupply

15.19ôCurrentcontrolproportionalgain

0to30,000

ð110RWUni

15.20ôCurrentcontrolintegralgain

0to30,000

ð1,000RWUni

Theseparametersareonlyavailablewhenthesoftwareversionis3.01.07orhigher

WhenthedriveisoperatedasaRegendriveitusesaDCbusvoltagecontrollerwithinnercurrentcontrollersasshownbelow:

ThegainsofthevoltageandcurrentcontrollersaffectthestabilityoftheRegendrivecontrolsystemandincorrectgainsettingscanresultinover-voltageorover-currenttrips.(ThegainofthevoltagecontrollerissetbyPr15.21).Inmostapplicationsthedefaultgainsgivenforthecurrent

conditionswillbesuitable,however,itmaybenecessaryfortheusertochangetheseiftheinductanceorresistanceofthesupplyplustheRegeninductorsvariessignificantlyfromtheexpectedvalues.

ThemostcriticalparameterforstabilityisthecurrentcontrollerproportionalgainandtherequiredvalueforthisisdependentontheRegendriveinputinductance.IftheinductanceofthesupplyisasignificantproportionoftherecommendedRegeninductor(i.e.>60mH/IDR.whereIDRisthedriveratedcurrent),thentheproportionalgainmayneedtobeincreased.ThesupplyinductanceislikelytobenegligiblecomparedtotheRegeninductorvaluewithsmalldrives,butislikelytobesignificantwithlargerdrives.Theproportionalgainshouldbeadjustedsothat

Pr15.19=1800xTotalinputLxIDR

Thecurrentcontrollerintegralgainisnotsocritical,andinamajorityofcasesthedefaultvalueissuitable.However,ifitisnecessarytoadjustthisparameteravaluebetween80xIDRxRand320xIDRxR(whereRisthesupplyresistanceofonephase)shouldbeused.

EvenwhenthegainsaresetcorrectlytherewillbeatransientchangeofDCbusvoltagewhenthereisachangeintheloadonanydriveconnectedtotheRegendrive.Ifthepowerflowfromthesupplyisincreased(i.e.morepoweristakenfromthesupplyorlesspowerisfedbackintothesupply)theDCbusvoltagewillfall,buttheminimumlevelwillbelimitedtojustbelowthepeakrectifiedlevelofthesupplyprovidedthemaximumratingofthe

UnidriveRegenInstallationGuideIssueNumber:2

25www.controltechniques.com

driveisnotexceeded.Ifthepowerflowfromthesupplyisreduced(i.e.lesspoweristakenfromthesupplyormorepowerisfedbackintothesupply)theDCbusvoltagewillrise.Duringarapidtransientthebuswillriseandthenfallasshownbelow:

Theexampleshownisforaveryrapidloadchangewherethetorquereferenceofthemotoringdrivehasbeenchangedinstantlyfromonevaluetoanother.Inmostapplicationswherethemotoringdriveisoperatingunderspeedcontrolthespeedcontrollermayonlyrequirealimitedrateofchangeoftorquedemand,reducingtherateofchangeofpowerflow,andalsoreducingthesizeofthetransientvoltage.Ifthesetpointvoltage(Pr15.07)plusthetransientriseexceedtheover-voltagetriplevel(830Vforamediumvoltagedrive)theRegendrivewilltrip.

Whena400Vmotorisoperatedabovebasespeedfromadriveinvectormode,fedfromtheRegendrivesupplyingaDCvoltageof700V,andaninstantaneouschangeoftorqueisdemanded(i.e.-100%to+100%)thepeakofthevoltagetransient(∆V)isapproximately80Vifthecurrent

controllersaresetupcorrectly.(Operatingwithmaximumvoltageonthemotor,i.e.abovebasespeed,givesthebiggesttransientofpowerandhencethebiggestvalueof∆V).

If∆Visrequiredforadifferentloadchangeitcanbecalculatedfrom∆V=80Vxloadchange/200%

Ifthemotorvoltageisnot400VortheDCbusvoltagesetpointisnot700V,∆Viscalculatedfrom∆V=80Vx(motorvoltage/400)x(700/DCbusvoltagesetpoint)

Insomeapplications,particularlywithahighDCbusvoltagesetpointandlowswitchingfrequencyitmaybenecessarytolimittherateofchangeofpowerflowtopreventovervoltagetrips.Afirstorderfilteronthetorquereferenceofthemotoringdrive(i.e.usingPr4.12)isthemosteffective

methodtoreducethetransientfurther.(Afixedlimitoftherateofchangeoftorquedemandislesseffective).Thefollowingtablegivesanapproximateindicationofthereductionin∆Vfordifferenttimeconstants.Asalreadymentionedthevalueof∆Vgivenifforaninstantaneouschangeoftorquerepresentingtheworstcase.Inmostapplicationswhereaspeedcontrollerisusedinthemotoringdrivethetransientwillalreadyincludeafilter.

Timeconstant

20ms40msChangein∆V

x0.75x0.515.21ô

NOTE

VoltagecontrolPgain

0to30000

ð4000RWUni

NThisparameterisonlyavailablewhenthesoftwareversionis3.01.07orhigher.

Thevoltagecontrollergainissettoavaluethatissuitableformostapplications.Theperdrivecapacitanceofeachsizeofdriveisnotalwaysthesame,andsothedrivecompensatessothatthegainissetfortwicethecapacitanceofanindividualdriveasthisisthenormalsituationwithaRegendriveandmotoringdriveofequalrating.Thetransientvoltagewithasuddenchangeofload,∆V,isaffectedproportionallybythisparameter.

ThereforethegainmaybechangedwhentheDCbuscapacitanceisnotequaltotwicetheRegendrivecapacitance.However,caremustbetakentoensurethatthegainisnottoohighasthiscancauseexcessiverippleintheDCbusvoltage.

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UnidriveRegenInstallationGuide

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Figure8-1Menu15logicdiagramClosesoftstartcontactor15.14SequencerMenu615.16Softstartcontactorisclosed15.15EnablemotoringDriveContactorclosedRegensequencerEnable15.12SinusoidalrectifiersynchronisedSinusoidalrectifiersynchronisingSinusoidalrectifierphaseloss15.11DCBusvoltage15.0415.13ModulationSupplycurrentmagnitude15.01Regencurrentandvoltagecontrollers15.0715.21DCBusvoltageset-pointVoltagegainCurrentcontrolproportionalgainCurrentcontrolintegralgain15.0815.0915.10SwitchingfrequencyHighstabilityspacevectormodulationQuasi-squareoperationselectUVWSupplyvoltage15.1915.0215.2015.05Supplyfrequency15.06InputinductancePowercalculationsVxIx315.03SupplypowerKeyInputterminalsOutputterminals0.XXRead-write(RW)parameterRead-only(RO)parameter0.XXTheparametersareallshownattheirdefaultsettingsUnidriveRegenInstallationGuideIssueNumber:2

27www.controltechniques.com

9

9.1

9.1.1

Commissioningandoperation

Regenparametersettings

SwitchingfrequencyPr15.08(Pr0.18)

SettheswitchingfrequencyontheRegendrivetotherequiredvalue(3kHzdefaultvalue).Ahigherswitchingfrequencysettinghasthefollowingadvantages:•••

Linecurrentrippleattheswitchingfrequencyisreduced,givingimprovedwaveformquality.Acousticnoiseproducedbythelineinductorsisreduced.DynamicDCbusvoltageresponseisimproved.

Insomecases,settingtheswitchingfrequencytoavaluegreaterthanthedefault3kHzresultsincurrentderating.RefertotheUnidrivesize1to4/5InstallationGuide.

9.1.2DCbusvoltagesetpoint

TheDCbusvoltagesetpoint,seePr15.07(Pr0.17),shouldbesettoalevelthatissuitablefortheACsupplyvoltagebeingused.Thetablebelowdefinestheselevels,assumingatoleranceof±10%onthesupplyvoltage(defaultvalueis700V).Theminimumvalueisdefinedasthepeakinputvoltageplussomeheadroom.Headroomisrequiredbythedrivetoallowcorrectcontrolofthecurrent.Itisadvisabletosetthevoltagebelowthemaximumvaluetogivemoreallowancefortransientvoltageovershoots.NotethatPr15.07(Pr0.17)canbesettoanyvaluebetween0and800V.Table9-1

DCbusvoltagesetpoint-Pr15.07(Pr0.17)

MinimumVdc650680780Recommended

Vdc700700780MaximumVdc800800800SupplyVoltage

Vac3804154809.2Regendrivesequencing

WhenaRegendriveisenabled,itgoesthroughalinesynchronisationsequence.Duringthisprocedure,testpulsesareappliedtotheincominglinetodeterminethevoltageandphase.Whenithasbeensuccessfullysynchronisedtotheline,theDCbusvoltagecontrollerisenabledandtheDCbusvoltagerisestothetargetvoltage.

Onlywhenallofthesestageshavebeencompletedsuccessfullyisthemotoringdriveenabled.Ifatanytimethereisafault,ortheRegendriveisdisabled,themotoringdrivewillalsobedisabled.

ThissequenceofeventsisimportanttopreventdamagetotheRegendrive,motoringdriveorexternalpowercircuitcomponents.Thesequenceofeventsisasfollows:Powerapplied:••••

bothcontactorsde-energised

DCbuschargesthroughstart-upresistorDCbusvoltageequals√2Vac

ifDCbusvoltage>UUtriplevelthenauxiliarycontactorisenergised.Thisclosesthemaincontactorandshortsoutthestart-upcircuit.Enableinputmadeactive:

•waitforDCbusvoltagetostabilise

•applytestpulsestolinetodeterminemagnitudeandphase•attempttosynchronisetotheline

•ifsynchronisationissuccessfulthenenabletheDCbusvoltagecontroller

DCbusvoltagecontrolleractive:

•DCbusvoltagerisestoreferencelevel

•MotoringdriveenabledbydigitaloutputfromRegendrive

Motoringdriveactive:

•themotormaynowbeenergisedandrotated

•powerflowstoandfromthelineasnecessaryviaRegendrive•DCbusvoltageremainsstable

Whilstrunningif:

thelinevoltagedipstoolowORtheDCbusvoltagegoesoutofregulationORthereisanytripontheRegendriveORthemaincontactorisde-energisedORtheRegendriveisdisabledORtheMCBtripsthen:

•theRegendrivewillinhibit

•themotoringdrivewillbedisabledbytheRegendrive•theDCbusvoltagewillfallto√2Vac

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UnidriveRegenInstallationGuide

IssueNumber:2

9.3

•••••••••

Regendrivecommissioning

EnsurepowerandcontrolconnectionsaremadeasspecifiedinthisInstallationGuide.EnsuretheRegenandmotoringdrivesarenotenabled.SwitchontheACsupply.

BoththeRegenandmotoringdrivesshouldnowpowerupthroughthestart-upcircuitinstandardopenloopmode.

OntheRegendrive,configurethedrivetypePr11.31(Pr0.48)toREGENandsettheadditionalparametersupfortheauxiliarycontactor(refertoChapter4Controlcircuitconnectionsonpage8).

TheAuxiliaryandMaincontactorsshouldnowclose;thestart-upcircuitisdisabledatthispoint.

OntheRegendrive,setuptheswitchingfrequencyandDCbussetpointvoltagetotherequiredvaluesineitherMenu0orMenu15,refertoChapter8Parameterdescriptionsonpage22.Savetheparameters.

TheRegendrivecannowbeenabled,theRegendriveshoulddisplayACT.Thecommissioningofthemotoringdrive(s)cannowbecarriedout.

9.4Motoringdrivecommissioning

ThesettingofcertainparametersinthemotoringdrivemustbegivenspecialconsiderationwhenusedinaRegensystem.RampMode-Pr2.04(Pr0.15)

WhenamotoringdriveisusedinaRegensystem,therampmodeshouldbesettoFAST.Thedefaultsettingofstandardcontrolwillresultinincorrectoperation.

VoltageControlMode-OpenlooponlyPr5.14(Pr0.07)

ThedefaultsettingofUR_IdoesnotfunctioncorrectlyinthemotoringdrivewhenusedinaRegensystem.Whenthesystemispoweredup,themotoringdriveisdisabledwhiletheRegensynchronisestotheACsupply.Theresultantdelaybeforethemotoringdriveisenabledmeansthatthestatorresistancetestcannotbecompleted.WhenopenloopvectoroperationisrequiredthevoltagemodeshouldbesettoUR_S.DriveEnableFunction-OpenlooponlyPr8.07

Thedefaultsettingforterminal30intheopenloopmotoringdriveisanexternaltrip(Et)function.WhentheRegendrivehassynchronisedtotheACsupplyandtheenablesignalisappliedtotheopenloopdrive,adriveresetisrequiredtocleartheexternaltrip.Ifaresetsignalisnotavailableordesirable,thenPr8.09shouldbesettoa1.Terminal30thenactsasanonlatchinginputwiththedrivedisplayingINHwhendisabled.ACSupplyLossMode-Pr6.03

ThemotoringdrivewillnotoperatecorrectlyiftheACsupplylossmodeissettoSTOP.IftheACsupplyislost,theRegendrivedisablesthemotoringdriveandpreventsacontrolledstopfrombeingcompleted.AutoStart-Pr6.02

TheAutoStartfunctionwillnotoperatecorrectlywhenusedinaRegensystemduetothedelayinapplyingtheenablesignaltothemotoringdriveasdescribedaboveinVoltageControlMode.Thedelaymeansthattherunlatchhasalreadyclearedwhentheenablesignalisapplied.

9.5

Table9-2

Tripcodes

Tripcodes

Description

RegensinusoidalrectifierfailedtosynchronisetolinevoltageFailedtocorrectlydetectthephasingofthesupplyLinefrequencytolowLinefrequencytohigh

OvercurrentduringfinalsynchronisationofPLLtosupplyPhasingerrorduringfinalsynchronisationofPLLtosupply

BelowarethetripcodeswhicharespecifictoUnidriveinRegenmode.TheseareinadditiontothetripslistedintheUnidrivesize1to5UserGuide.

TripCodeLI.SYNCPhDetFrLoFrHiPLLOIPLLPhTable9-3

Statusdisplay

Description

DriveEnabledbutACvoltagetoolow,orDCbusvoltagestillrising,orDCbusvoltagestillfalling.WaitingforcorrectconditionstosynchroniseontolineDriveenabledandsynchronisingtolineDriveenabled,synchronisedandactive

StatusDisplay

STOPSCANACT

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AppendixA

A.1

UnidriveRegenasaBrakeResistorReplacement

Introduction

TheRegendrivehasbeendesignedtoprovidearegulatedDCsupplytoothermotoringdrives.TheRegendrivegivesbi-directionalpowerflowwithsinusoidalcurrentsandanearunity.

Inmanyapplications,themotoringpowercanbesignificantlyhigherthanthebrakingpower.Ifsinusoidalinputcurrentsarenotrequired,itisdifficulttojustifythecostofaRegendriveratedatthefullmotoringpower.IntheseapplicationsitmaybedesirabletotakethelowercostoptionofasmallerRegendrivewhichisonlyusedtoreturnthebrakingenergytotheACsupply.ThisisthemodeofoperationdescribedinthisAppendix.

WhenusingtheRegendriveasabrakeresistorreplacement,theinformationgiveninearliersectionsofthisguidemustalsobereferredto.

A.2Driveconfigurations

Brakeresistorreplacementsystemconnection

RegenDrivefusingWhenaRegendriveisusedasadynamicbrakeresistorreplacement,connectionsmustbemadeasshowninFigureA-1.FigureA-1

MotoringDrivefusingNOTE

NThesingleRFIfiltershownintheaboveconfigurationshouldberatedtothemotoringdrive’sratedcurrent.

TheACsupplyisconnectedtoboththeRegendriveandthemotoringdrive.Note,however,thattheRegendrivereceivesitssupplyviaan

isolatingtransformer.ThisisnecessarybecausewhentheRegendriveisswitching,itsDCbusvoltagemoveswithrespecttobothgroundandthesupplyneutralpoint.However,onthemotoringdrive,theDCbusvoltageremainsrelativelyfixedwithrespecttoground.Asaresultofthedifferencebetweenthetwovoltages,itisnotpossibletoconnectbothdrivestothesameACsupply.ADCbusdiodeisfittedtoensurethatpowerflowsfromthemotoringdrivetotheRegendriveonly.

A.3WhentouseaRegendriveasabrakeresistorreplacement

TheimportantfactorwhenconsideringtheuseofaRegenasabrake-resistorreplacementistheratioofmotoringpowertobrakingpower,asthishasimplicationsforthepowerratingoftheRegendrive.

Motoringpower≤1.5×Brakingpower.

Ifthemaximummotoringandbrakingpowerareapproximatelyequal,aRegendriveshouldbeusedasthemainsupplyandnotsolelyasabrake-resistorreplacement.Thisisbecause,inthisinstance,theRegendriveandmotoringdriveratingsareequal,sothefulladvantageofastandardRegenconfigurationcanbeexploited.

1.5×BrakingpowerInthisrangeofmotoringandbrakingpower,aRegendrivewillworkwellasabrake-resistorreplacement.TheRegendrivepowerratingisequaltothebrakingpower.

Motoringpower>4×Brakingpower.

Ifthemotoringpowerisgreaterthanapproximatelyfourtimesthebrakingpower,itisnotpossibletouseaRegendriveratedonlyforitsbrakingpower.ThisisbecausethesmallRegendriveisunsuitableforconnectiontothelargecapacitanceofthemotoringdrives.Ifthemotoringpowerisgreaterthanfourtimesthebrakingpower,thenthefollowingcanbeused.••

Anover-ratedRegendrivewithacurrentratingatleastequalto0.25xmotoringdrivepower.Conventionalbrakeresistor.

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UnidriveRegenInstallationGuide

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A.4

Regenandmotoringdriveratings

TheRegendrive’scurrentlimitsaresetat150%andarenotadjustable.

IngeneraltheRegendrivemustberatedatapowergreaterthan,orequalto,themaximumbrakingpower.Example:•

Two30kWmotoringdrivesareeachdriving30kWmotors.Theloadissuchthatonlyonedriveisbrakingatatime.

Ifeachmotorsuppliesbetween20and30kWmotoring,andthebrakingpowervariesfrom0to30kW,themaximumtotalbrakingpoweris30-20=10kW,whichiswhattheRegendriveshouldberatedfor.

Indriveconfigurationswherethemotoringdrivepowerratingisseveraltimestheexpectedbrakingpower,itisnecessarytoconsiderthepeakbrakingpowerreturnedfromtheload.Example:•

Themotoringdriveisa75kWUnidrive.Motoringpoweris75kW.Steadystatebrakingpoweris20kW.

Fromthesefigures,itmayappearthata22kWRegendrivewillprovidesufficientbrakingpower.However,dynamicallythepeakbrakingpowercouldbemuchgreater.Ifthe75kWdrivecurrentlimitsaresetat150%formotoringandbraking(defaultsettings),thepeakbrakepowercouldbe:

√3×156A×400V×150%=162kW

Thisismuchgreaterthanthe22kWRegendriveisabletoreturntothesupply,hencealargerdriveisrequired.

IftheRegendriveisnotratedfortherequiredbrakingpower,thenthedriveswilltriponDCbusover-voltage.

A.5Powercircuitconnectionsandcomponents

FigureA-2showsthepowerconnectionsrequiredwhenusingaUnidrive,operatinginRegenmodeasadynamicbrakeresistorreplacement.TheRegendrivecontrolterminalsareconnectedasshowninFigureA-3.TableA-1showsthekeytothefollowingsystemlayoutdiagram.TableA-1

ERFII.TxSFFLLregxV1,V2,V3V4,V5,V6RsxFsxSFFCxRdxTcxK1K2K3MCB1xaux1xaux2aux3OvldKeytoFigureA-2

GroundconnectionpointEMCfilterIsolatedtransformerSwitchingfrequencyfilterinductorRegeninductorVaristornetwork550V(linetoline)Varistornetwork680V(linetoground)SoftstartresistorACsupplyfusingSwitchingfrequencyfiltercapacitorSwitchingfrequencyfiltercapacitordischargeresistorThermocoupleSupplycontactorMaincontactorAuxiliarycontactorSwitchingfrequencyfiltercapacitorMCBSwitchingfrequencyfilterMCBauxiliarythroughwhichRegendriveenableisconnected

Maincontactorauxiliaryfor“maincontactorclosedsignal”K3auxiliarywithcoilsupplyforK2Thermal,MagneticoverloadUnidriveRegenInstallationGuideIssueNumber:2

31www.controltechniques.com

FigureA-2Powerconnections:SingleRegen

Motoraux2aux3MCB1OvldFS832www.controltechniques.com

FS9FS7UnidriveRegenInstallationGuide

IssueNumber:2

Therearethreemainconnectiondifferencescomparedwithnormaloperation.•••

ThereareACsupplyconnectionstoboththeRegenandmotoringdrives.

TheDCbusconnectionbetweentheRegenandmotoringdrivesisviadiodeD1.

TheswitchingfrequencyfilterinductorsarereplacedwithanisolatingtransformerT1withadefinedleakageinductance

FordetailsofthestandardRegencomponentsandtheirconnections,refertoChapter3Powerconnectionsonpage4andChapter5Componentsonpage10.

A.5.1DCbusdiode

DCbusdiode

Recoverytime

µS<1

Currentrating

A

3xcurrentratingofRegendrive

Voltagerating

V1,200

TableA-2

DiodetypeFastorUltraFast

AsuitablesupplierfortheabovediodecanbeSemikronTMwiththeSKKDxxxF12orSKKExxxF12diodemodules.Thediodemustbemountedonasuitableheatsink.Heatsinksizingshouldbebasedon:••

Maximumdevicecasetemperatureof80°CPowerloss=2VxRegendriveratedcurrent

A.5.2IsolatingtransformerT1

ThisisathreephasetransformerwhichprovidesisolationbetweentheACsupplyandtheRegendrive.OneisolatingtransformercanonlysupplyoneRegendrivewiththecurrentratingequaltotheRegendrivecontinuouscurrentrating.Thetransformerleakageinductanceformstheswitchingfrequencyfilterinductance.TheinductancevaluefortheswitchingfrequencyfilterisspecifiedinChapter5Componentsonpage10.

Anonisolatingtransformercannotbeusedunderanycircumstances.

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A.6Controlcircuitconnections

ControlCircuitConnections.ExternalpowersupplyforK2coilExternalpowersupplyforK3coil12345FigureA-3showsthecontrolconnectionsthatshouldbemadebetweentheRegenandmotoringdrive.FigureA-3K2aux3K3RelayNO0VAnalog10VOutAnalogI/P1+AnalogI/P1-AnalogI/P2AnalogI/P3AnalogO/P1AnalogO/P20VAnalog(SetPr8.25toPr15.14)Tc1671011RegenDrive2122230V+24VOut0VDigitalDigitalI/O1DigitalI/O2DigitalI/O3DigitalI/P1DigitalI/P2DigitalI/P3Enable0VDigitalOutputenableDriveHealthyaux2Userenableaux1x2425262728293031DriveHealthy1234RelayNO0VAnalog10VOutAnalogI/P1+AnalogI/P1-AnalogI/P2AnalogI/P3AnalogO/P1AnalogO/P20VAnalogSpeed/TorqueRef4-20mACurrentLoop567MotorThermistor1011MotoringDrive2122230V+24VOut0VDigitalDigitalI/O1DigitalI/O2DigitalI/O3DigitalI/P1DigitalI/P2DigitalI/P3Enable0VDigitalAtZeroSpeedO/P24Reset2526FwdRev272829Userenable303134www.controltechniques.com

UnidriveRegenInstallationGuide

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A.7

A.7.1

Regenbrakedrivesinoperation

Sequence

IftheRegenbrakedriveandmotoringdrivearesuppliedfromaseparatelyswitchedACsupplythentheRegenbrakedrivesupplyshouldbeenergisedfirst(orbothatthesametime).SimilarlytheRegenbrakedriveshouldalsobepowereddownfirst(orbothatthesametime).

ThemotoringdrivemustonlybeenabledwhentheRegendriveisenabled,healthy,andsynchronisedtotheACsupply.ThiswillpreventanydamagetotheRegenstart-upcircuitandpreventOUtrips.

A.7.2Regenparametersettings

ItisveryimportantthattheRegendriveDCbusvoltagesetpointissetabovethepeakACsupplyvoltage.IfthisisnotdonethenpowerwillflowfromtheACsupplyintothemotoringdrive,throughtheDCbusdiodeandbackthroughtheRegendrivetotheACsupply.Thiswillcontinueuntilthe

Regendrivetripsorpartofthecircuitisdamaged.IfpossibletheDCbusvoltagesetpointshouldbeatleast50VabovethepeakACsupplyvoltage.WithalargerdifferencebetweenthepeakACsupplyvoltageandtheDCbusvoltagesetpointthereismoreenergystorageavailablefortransientpeaksinthebrakingpower.TableA-3givesrecommendedDCbusvoltagesetpoints.TableA-3

DCbusvoltagesetpoints-Pr15.07(Pr0.17)SupplyVoltage

Vac380415480

Recommended

Vdc700700780

MaximumVdc800800800

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AppendixB

B.1

L=2xLfC=3Cf/2Vc=VLLpeakZc=

L---C

Componentsizingcalculations

SizingofMCBforswitchingfrequencyfilter

Lf=SwitchingfrequencyfilterinductanceCf=SwitchingfrequencyfiltercapacitanceVc=ChargingvoltageZc=ChargingimpedanceTc=ChargingtimeIc=Chargingcurrent

ThecurrentratingoftheMCBmustbecalculated;takingintoaccounttheswitchingfrequencyfilterinductanceandcapacitance,theinitialchargingcurrentandtheACsupplyvoltage.switchingfrequencyfilterinductanceandcapacitancevaluescanbefoundinChapter5Componentsonpage10.

Tc=πLCIc=Vc/ZcExample:

Unidrivesize5Regen

SwitchingfrequencyfilterInductance100µHSwitchingfrequencyfilterCapacitance80µFSupplyVoltage480v+10%L=C=Vc=Zc=Tc=Ic=

2x100µH=3x80µF/2=480+10%x√2=200µH------------------=120µF

π200µH×120µF=747/1.29=

200µH120µF747Vpk1.29Ω487µs579A

TheMCBshouldberatedtothepeakchargingcurrentof579Afor487µs,withanrmscurrentof35A.RefertoTable5-6forafulllistofratings.AsuitableMCBshouldhavethefollowingratingsandfeatures:

Voltagerating:480+10%Peakcurrentrating:579Armscurrentrating:35A

3polewithauxiliary(forenable)

TableB-1

Drivesize

12

Powerrating

(kW)

4.05.57.511.015.018.5

3

22.030.037.04555

4

7590110

5

150

TotalDCbuscapacitance

(µF)

3404704706801,1001,1002,2002,2002,2003,3003,3004,4006,6006,6008,800

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B.2Resistorsizingformultiplemotoringsystems

Thesoftstartresistormustberecalculatedforthemultiplemotoringsystemduetotheincreasedinrushcurrentandthereforeincreasedpowerdissipation.

ForapplicationswherethetotalDCbuscapacitanceofthemotoringdrivesisgreaterthanthatoftheRegendrive(onelargedrivesupplyingseveralsmallerdrives).Thefollowingprocedureandtablesshouldbeusedtorecalculatetheresistor(s)required:

B.2.1

1.2.3.4.

Procedure

Calculatethetotalcapacitorbankenergyratingofthesystem(TableB-3).

Calculatetheminimumnumberofresistorsrequiredtomeetthisenergyvalue(rounduptothenearestone),(TableB-2).

Calculatetheseriesparallelarrangementofresistorstoproducethetotalresistorvalueintherequiredrange(TableB-5andTableB-2).Calculatethetotalrmsresistorcurrent(TableB-4).thengobacktostep3(TableB-2).

5.Calculatethepowerdissipationintheresistorbank[Irms2xR].Ifthepowerdissipationexceedstheratingoftheresistorbank,addmoreresistors,TableB-2

Resistordata

Resistorvalue

Ω

15048

TableB-3

Capacitorbank

Drivesize

12345

TableB-4

RMSresistorcurrentdataDrivesize

12345

TableB-5

TotalresistorvaluedataDrivesize

12345

Example:

Unidrivesize4Regenwith(3xUnidrivesize3)and(5xUnidrivesize1)motoringdrives1.2.3.4.5.

Capacitorbankenergy=1800+(3x600)+(5x95)=4075J

Usingresistors1270-2483(4,075/1,700)youwillneedatleast2.39resistors=3

Three48Ωresistorscanbearrangedtoachieve16Ω.Inthiscase16ΩissatisfactoryforaUnidrivesize4,soparallelconnectioncanbeused.Totalrmscurrentneeded=0.6+(3x0.5)+(5x0.4)=4.1A

Powerlossin16Ωbank(85Wperresistor)=256W,resistorbankmaximumrating=3x148W=444W,sothe16Ω resistorarrangementissuitable.

Totalsoftstartresistor

valueW

75to15028to1509to483to242to24RMScurrent

A

0.40.40.50.60.6

Energyperdrive

J

7520060018002500

Powerrating

W

53148

Energyrating

J

1701,700

CTpartnumber1270-31571270-2483

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B.3

TableB-6

MultipleUnidrivesize5systems

ResistorsforUnidrivesize5multiplesystems

Numberofparallelresistors

Equaltototalnumberofmodulesinthesystem(Regenandmotoring)

CTpartnumber1270-2483

Drivesize

5

B.4Thermal/magneticoverloadprotectionforsoftstartcircuit

Thermal/magneticprotectionforthesoftstartresistorshouldbeprovidedtoprotectagainstahigh/lowimpedanceshortcircuitandtheriskoffire.Arecommendeddevicebeingathermalmagneticoverload.Theoverloadshouldbesizedasfollowingtoprovidethermalandmagneticprotection:

B.4.1Thermal/magneticoverloadcharacteristics

FigureB-1

Exampleoftrippingcharacteristic

1206040ThermalTripAreaMagneticTripArea20106Minutes4Trippingtime214020Cold10Seconds210.60.40.2Hot0.10.060.040.020.0111.523456810101514202130MultipleofratedcurrentB.4.2Sizingofmagneticoverload

Themagneticoverloadshouldbeselectedtothepeakcurrentandchargingtimeatpowerupwiththetripbeingatforexample20timesthenominalratedcurrentoftheoverload.Thereforefora20Apeakcurrenta1Aoverloadcouldbeused.

Thechargingofasystemtakesatotalof5timeconstantswiththishavingadecayingexponentialcurrentduetotheRCnetwork,thereforeat5timeconstantsthesystemwillhavechargedupwiththecurrentbeingatapproximatelyzeroasshowninFigureB-2onpage39.Thepeakcurrentandchargetimeduringpowerupcanbecalculatedusingthefollowingformula.

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UnidriveRegenInstallationGuide

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Peakcurrent

Unidrive5401x4,480Vacsupply+10%,totalsoftstartresistanceof6Ω (4x24Ωinparallel):

Ipeak=Vac(+10%)x1.414/Resistancesoftstart(480+48)x1.414/6=124.08AIpeakChargingtime

Unidrive5401x4,totalsoftstartresistanceof6Ω(4x24Ω)inparallel,andatotalDCbuscapacitanceof4x8,800µF=35,200µF

Tconstant=ResistancesoftstartxTotalCapacitanceDCbusTconstantx5=Tcharge

6x(35,200x10-6)x5=1.056secSelection

Fromtheabovecalculationsforapeakchargingcurrentof124.08Awithachargetimeof1.056secamagneticoverloadwiththefollowingcharacteristicscanbeused:

8AnominalratingO/L=15.5

Plottingtheexponentialchargingcurrentforthesoftstartcircuitagainstthetripcharacteristiccurvefortheoverloadwillalsoensurenospurioustrippingduringchargingtime.FigureB-2

Exampleofchargingcharacteristics

100%ChargingCurrent7550250012345MultiplesofTimeConstantCalculatingcurrentlevelonexponentialcurve

AsshowninFigureB-2,after5timeconstantsthechargingcurrentisapproximatelyzero.Insomecases,duetothecharacteristicoftheoverload,thecurrentmayhavetobecalculatedafter4timeconstantstoensurethatthethermaltripareaoftheoverloadisnotactivated.Refertothefollowingformula:

IatgivenTimeConstant=Exp[-1(TimeConstants)]xIpeak

Thefollowingexamplecalculatesthecurrentlevelafter3timeconstantswithapeakchargingcurrentof100A:

Exp[-1(3)]x100=4.97A

B.4.3Sizingofthermaloverload

Thethermaloverloadshouldbesizedtoprovideprotectionagainstahighimpedanceshortcircuit.Underthisconditionthecurrentflowingwouldnotbehighenoughtoresultinthemagneticoverloadtripping,butthepowerdissipatedwouldexceedthenominalpowerratingresultinginheatingoftheresistor.

Inordertosizethethermaloverloadcorrectly,thepowerratingandoverloadcharacteristicsoftheresistorarerequired.Thepowercharacteristiccurvefortheresistorshouldbeconvertedfrommultiplesofpowertocurrentinordertosizethethermaloverloadcorrectly.

√P/R=ICalculationtoconvertfrompowertocurrentExample:

Assumingasystemfaultwhichresultsinacontinuouspowerof10xthenominalpowerbeingdissipatedbytheresistor.Resistor,24Ω296W

Peakcurrentatpowerup=528Vac/24Ω=22A

Thermal/Magneticoverloadcurrentrating=22A/20=1.1A(use1.6A)10xnominalpower=2.960kW

Currentflowingduringoverload√2960/24=11.01A

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FromFigureB-3itcanbeseenthatanoverloadof10timesthenominalpowerisallowablefor5seconds.Fromthisplottingthe10timesoverloadonFigureB-1itcanbeseenthatforacurrentof11.10Awhenusinga1.6Abreakerthattheoverloadwilltripat7xthenominalcurrent(11.10/1.6=6.9),whichequatestoapproximately5secondstriplevelworstcase.FigureB-3

Exampleofoverloadcharacteristic

100%MultiplesofratedPower101012510202550100DurationofLoad(seconds)40www.controltechniques.com

UnidriveRegenInstallationGuide

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AppendixC

C.1

C.1.1

Longcables

Exceedingthemaximumcablelength

Regeninductor

Ifthetotalmaximumlengthspecifiedisexceeded,theincreasedcirculatingcurrentscausedbytheextracablecapacitancewillhaveaneffectontheotherpartsofthesystem.Thiswillnecessitateadditionalcomponentstobeaddedtothestandardarrangement.

IfthemaximumcablelengthspecifiedisexceededthiswillintroduceunnecessaryheatingoftheRegenInductor.Toovercometheadditionalheatingforcedcoolingshouldbeintroducedintothesystemasspecifiedinthefollowingtable.

TheforcedcoolingshouldbepositionedtoprovidethespecifiedairflowdirectlyontotheRegeninductorwindings.TableC-1

Maximumcablelength

Drivesize

withoutadditionalventilation

m

50100200200200perRegen

drive

withadditionalcoolingm

2505001,0001,0001,000perRegendrive

Coolingrequirement

12345

One120mmfan,airflow>160m3/hr.One120mmfan,airflow>160m3/hr.One120mmfan,airflow>160m3/hr.

Two120mmfans,airflow>160m3/hr.,perfanTwo120mmfans,airflow>160m3/hr.,perfan

C.1.2RFIfilter

WhenanRFIfilterisusedthecapacitorstogroundcarrycommonmodecurrent.

Whenthemaximumcablelengthwithoutadditionalventilationspecifiedisexceeded,extracirculatingcurrentscanresultinheatingandsaturationoftheRFIfilter.Topreventthis,somecapacitancelinetogroundshouldbeprovidedasanadditionalpathforthiscurrent,asshowninFigureC-1.

UnidriveRegenlayout

Ifthemaximumcablelengthexceedsthemaximumcablelengthwithadditionalcooling,ControlTechniquesTechnicalSupportmustbeconsulted.FigureC-1

RFISFFLRegenInductorR3PhaseSupplyYBFS1FS2FS3V1V2V3ToRegenDriveV4V5EV6EEEERFIFilterLinetogroundcapacitorsSwitchingFrequencyFilterC.1.3Linetogroundcapacitorsformulti-drivesystems

SelectionoflinetogroundcapacitorsforRegensystemswithlongcables.

Inordertoselecttheappropriatecapacitors,thermsvalueofthecurrentlinetoground,theACsupplyvoltageandminimumcapacitancevaluesarerequired.

Aminimumcapacitancevalueof1µFperphaseshouldbeusedwiththefinalcapacitancevaluebeingdeterminedbythevalueofthecurrentlinetoground.Inpractice,tocarrytherequiredlevelofcurrentthecapacitorwillgenerallyhaveahighercapacitivevalue.Thecurrentratingofthe

capacitorsshouldbeatahighfrequencysuchas100kHzattherelevantsupplyvoltage.Polypropylenetypecapacitorsarethemostsuitablebecauseoftheirlowlossathighfrequency.

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Thermsvalueofthecurrentcanbeestimatedfromthefollowingformula:

IRMS=2.8×10kVDCWhere:

kis1forsimplerectifier-inputsystems,√2forRegensystemsVDCisDCbusvoltage

–4

Σlfs

ålfsisthesumoftheproductsofmotorcablelengthsandswitchingfrequenciesofalldrivesinthesystem,includinginthecaseofregenerative

systemstheRegendrivewiththetotalDCcablelengthlistotalcablelengthinmetresfsisswitchingfrequencyinkHz

Ifalldrivesoperateat3kHz,theexpressioncanbesimplifiedto:

IRMS=4.85x10-4kVDC√l

Example

ARegensystemoperatingwithasupplyof400VacgivingaDCbusvoltageof620Vat3kHzswitchingfrequencyandacablelengthof1km(motors+DC)hasanIRMSof:

IRMS=4.85x10-4kVDC√l

IRMS=4.85x10-4x√2x620x√1,000

IRMS=13.4A

TheIRMSisthetotalcurrentlinetoground,thereforeeachcapacitorwillhavetocarry4.5A.

GroundleakagecurrentThevalueofcapacitancerequiredmeansthatthegroundleakagecurrentexceedstheusualsafetylimitof3.5mA.Theusershouldbeawareofthehighleakagecurrent.Apermanentfixedgroundconnectionmustbeprovidedtothesystem.WARNINGDischargetimeResistorsmustbefittedinparallelwiththecapacitorstoensurethattheydischargewhenthesupplyisremoved.Theresistorvaluesshouldbechosensothatthedischargetimeisnolongerthanforthedriveitself.Typicallyvaluesofabout5MΩaresuitable,andarehighenoughnottocausethesystemtofailasimpleinsulationtest.WARNING42www.controltechniques.com

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AppendixD

D.1

Regenkits

SingleRegen,singlemotoringsystems

StandardkitsofRegencomponentsforUnidriveRegensystemswhichconsistofasingleRegendriveandasinglemotoringdrive.RefertoTableD-1fordetails.TableD-1Drivesize12345

Standardkits

CTkitpartnumber8070000000940080700000009500807000000096008070000000970080700000009800

9500-0023kitbagVaristors

Contentofkit

SSResistor1270-3157x11270-3157x11270-2483x11270-2483x21270-2483x2

SFFCap1610-5752x11665-2244x11665-2484x11665-2804x1

SoftStartO/L4133-01174133-02174133-0277

Regeninductorsandswitchingfrequencyfilterinductorsarealsoavailablebutmustbeorderedseparately.RefertoTableD-2fordetails.TableD-2

StandardkitsDrivekW140524012402240334013402340334043405440144024403440444055401540254035404

Regeninductor4401-00014401-00024401-00034401-00044401-00054401-000401-00074401-00084401-00094401-00104401-00114401-00124401-00134401-00144401-0015x14401-0015x24401-0015x34401-0015x4

Switchingfrequencyfilterinductor

4401-01624401-01634401-014401-01654401-0101-01674401-01684401-01694401-01704401-01714401-01724401-01734401-01744401-01754401-017401-01774401-01784401-0179

D.2SingleRegen,multiplemotoringandmultipleRegen,multiplemotoringsystems

Standardkitsofpartsarenotavailablefornonstandardsystems.Alloftheitemsusedinastandardsystemarestillrequired,however,somecomponentsmayneedresizing.RefertoAppendixBComponentsizingcalculationsonpage36fordetails.Fornonstandardsystems,componentsshouldbeorderedindependently.

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AppendixE

TableE-1

ModelUNI1405UNI2401UNI2402UNI2403UNI3401UNI3402UNI3403UNI3404UNI3405UNI4401UNI4402UNI4403UNI4404UNI4405UNI5401TableE-2

ModelUNI1405UNI2401UNI2402UNI2403UNI3401UNI3402UNI3403UNI3404UNI3405UNI4401UNI4402UNI4403UNI4404UNI4405UNI5401Rating4kW5.5kW7.5kW11kW15kW18.5kW22kW30kW37kW45kW55kW75kW90kW110kWUnidriveRegenspecifications

Maximumpermissiblecontinuousoutput

current3kHz

4.5kHz9.5A12A16A25A40A46A60A70A96A124A156A180A202A300A104A124A175A175A47A56A21.7A34A37A40A40A46A88A88A105A145A145A18.2A14.2A14.2A28A28A32A32A35A70A70A80A110A110A120%6kHz8.5A9kHz7A12kHz5.5A11.7A11.7A11.7A23A23A26.6A26.7A28A150%Maximumoverloadtime

60sec

Driveratingsin40°Cambient

Driveratingsin50°Cambient

Rating4kW5.5kW7.5kW11kW15kW18.5kW22kW30kW37kW45kW55kW75kW90kW110kW40A44A44A50A95A105A135A180A190A240A*20A34A34A36A36A41A85A85A105A150A150A16A17.3AMaximumpermissiblecontinuousoutput

current3kHz6.9A4.5kHz5.9A12A14.7A14.7A28A28A31A31A34A75A75A85A125A125A6kHz5.1A9kHz4.0A11.6A11.6A11.6A21A21A24A24A26A60A60A65A95A95A150%12kHz3.3A9.7A9.7A9.7A17.9A17.9A20.6A20.9A23A150%Maximumoverloadtime

60sec

*NoULapprovalforUnidrivesize5with240Acontinuousina50°Cambient.

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UnidriveRegenInstallationGuide

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AppendixFPhysicaldimensions

Thedimensionslistedareforthefollowingitems,allofwhicharerequiredtocompleteaRegensystem.Notethatthedimensionsgivenapplyonlytothepartsspecifiedinthisguide.

RegeninductorSoftstartresistor

SwitchingfrequencyfiltercapacitorSwitchingfrequencyfilterinductor

RFIfilter(RefertotheUnidriveSize1to5UserGuide)Varistors

F.1

Driverating(kW)45.57.5111518.522303745557590110160

Regeninductor

WTKg1214172432333955657595110120130140

CTpartnumber4401-00014401-00024401-00034401-00044401-00054401-000401-00074401-00084401-00094401-00104401-00114401-00124401-001344014401-0015

Typenumber

111222222333333

TableF-1Specifications

Amps9.5121625344046607096124156180220300

mH6.325.003.752.401.761.501.301.000.780.630.480.380.330.300.24

L200200240240320320320360360360360410410480480

D180180180180220220220260260280280300300320320

H215215270270325325325370370370370430430490490

FigureF-1Type1dimensionsAPPXWEIGHT:12kgC205H4OFF9FIXINGHOLE20120fixingcentresL200140fixingcentres180DUnidriveRegenInstallationGuide

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FigureF-2Type2dimensionsA1B1C1HA2B2C2LDFigureF-3Type3dimensionsCL160160A1B1C1H11HOLEA2B2C24OFFHOLESLD46www.controltechniques.com

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F.2Softstartresistor-typeTGseries

Dimensions

FigureF-4

ØATableF-2SpecificationsDrivesize1&234&5

Resistance150Ω48Ω x148Ω x2

Diameter(A)

mm19.122.222.2

BLength(B)

mm73165.1165.1

CT

partnumber1270-31571270-24831270-2483

FigureF-5Resistormountingbracketdimensions

TableF-3Resistormountingbracketdimensions

Mountingbracketdimensions

A24.0mm

B33.5mm

C21.45mm±0.2

D∅5.0

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F.3

F.3.1

Switchingfrequencyfiltercapacitors

3-phasecapacitors(size1and2)

DimensionsFigureF-6BeforeprotectiondeviceoperationMax1611.8±0.5AfterprotectiondeviceoperationL+2-0Marking16±1mmM8toØ=53mmFast-onterminal(6.35mm)InternalconnectionØDTableF-4Specifications

CN

Drivesize

(µF)

1&23x5.7(mm)53x116(kgs)0.3M8Stud1610-5752∅xL

Weight

Mounting

CTpartnumber

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F.3.23-phasecapacitors(size3to5)

Dimensions

MarkingFigureF-7

h+40h16+1M12TorqueT=10NmImpregnatingHoleTorqueT=1.2Nm19.6±0.5d5±0.516.8±0.5Ø2218SW17TableF-5Specifications

Drivesize

345

CN(µF)3x243x483x80

dxh(mm)121x1121x1142x200

Weight(kgs)1.11.52.2

MountingM12StudM12StudM12Stud

CTpartnumber1665-22441665-24841665-2804

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F.3.3Dischargeresistors

Dischargeresistorsfortheswitchingfrequencyfiltercapacitors,forUnidrivesize3,4and5,aresuppliedwiththecapacitor.TheseshouldbefittedduringinstallationasshowninFigureF-8.ForUnidrivesize1and2thedischargeresistorsarefittedinternallytothecapacitor.FigureF-8

Dischargeresistorarrangement

TableF-6Specifications

Drivesize1&2345

Capacitorvalue

5.7µF24µF48µF80µF

Resistorvalue

Internal3x390kΩ3x390kΩ3x270kΩ

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F.4Switchingfrequencyfilterinductor

DrivesizeUNI1405UNI2401UNI2402UNI2403UNI3401UNI3402UNI3403UNI3404UNI3405UNI4401UNI4402UNI4403UNI4404UNI4405UNI5401UNI5402UNI5403UNI5404Amps9.51216253440466070961241561802203006009001200mH3.1602.5001.8751.2000.8800.7500.6500.5000.3900.3150.2400.1900.1650.1350.1000.0500.0340.025LossesW283537405260608090100110130170180220400530700L150150180180180180180240240240240300300300300410480480D9090100150160160160160170180190180180190200300320320H150150190190190190190255255255255300300300300430500560WeightKg446101212131620222537374950110140170C.Tpartnumber4401-01624401-01634401-014401-01654401-0101-01674401-01684401-01694401-01704401-01714401-01724401-01734401-01744401-01754401-017401-01774401-01784401-0179Typenumber111222222223333444TableF-7Specifications

FigureF-9Switchingfrequencyfilterinductor(Type1)150128HL120150D7490FigureF-10Switchingfrequencyfilterinductor(Type2)9HOLEAPPXWEIGHT:25kg255H4offsl10mmL200100D130UnidriveRegenInstallationGuide

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FigureF-11Switchingfrequencyfilterinductor(Type3)100100200300HA1B1C1A2B2C24OFFS10mmW204300L133D163FigureF-12Switchingfrequencyfilterinductor(Type4)160160500H560(REF)4OFF14HOLESINEACHFLAG4OFF11FIXINGHOLE320fixingcentresL480240fixingcentres280D52www.controltechniques.com

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F.5Varistors

Dimensions1Nom21max60maxCoatline8dia.hole34max6.35FigureF-1325°8minTableF-8Specification

Drivesize1to51to5

VoltageVac550680

EnergyJ400450

CTpartnumber2482-15012482-0680

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Index

A

ACsupplylossmode..............................................................29Advantages...............................................................................2AnalogI/Oset-up......................................................................8Autostart.................................................................................29

Maximumcablelength-exceeding.........................................41MCBsizing..............................................................................36MCBs......................................................................................11Menu15-Sinusoidalrectifier..................................................22Motorconnection.....................................................................18MultipleRegen..........................................................................6

B

Brakeresistorreplacement.....................................................30

O

Operation................................................................................28Overload..................................................................................11

C

Cablelength-maximum.........................................................18Cablelengthrestrictions.........................................................17Cablelengths..........................................................................18Chargingcharacteristics.........................................................39Commissioning.................................................................28,29Componentsizing...................................................................36Configurations.........................................................................30Configurations-nonstandard...................................................7Contactors...............................................................................11Controlcircuitconnections........................................................8Controlconnections............................................................9,34

P

Parameterdescriptions...........................................................22Phaseloss...............................................................................24Powerconnections....................................................................4PrinciplesofRegenoperation...................................................1

R

Rampmode.............................................................................29Ratings-40°C.........................................................................44Ratings-50°C.........................................................................44Regeninductorspecifications.................................................45Resistorsizing.........................................................................37RFIfilter..................................................................7,13,20,41RFIfilter-Multi-drive...............................................................21

D

DCbusdiode..........................................................................33DCbusvoltagesetpoint............................................23,28,35DigitalI/Oset-up.......................................................................8Dimensions.............................................................................45Dischargeresistors.................................................................50Dischargetime........................................................................42Driveenablefunction..............................................................29

S

Sequencing-Regendrive.......................................................28SingleRegen......................................................................5,32SizingofaRegensystem.........................................................3Softstartresistor...............................................................11,47Specifications..........................................................................44Standardkits...........................................................................43Supplyassessment...................................................................7Switchingfrequencyfilter...................................................7,12Switchingfrequencyfiltercapacitors.......................................48Switchingfrequencyfilterinductor..........................................51Synchronisationstatus............................................................25Systemslosses.......................................................................16

E

EMCinformation.....................................................................19

F

Fittingofvaristors....................................................................13Fusing.....................................................................................14Fusing-Multiplesystems.......................................................14Fusing-Size5Regensystem................................................15Fusing-Standardsystems.....................................................14

T

Thermaloverload....................................................................38Thermaloverloadsizing..........................................................39Tripcodes...............................................................................29

G

Groundleakagecurrent..........................................................42

I

Importantconsiderations.........................................................16Inductorthermistors..................................................................9Inductors.................................................................................10Isolatingtransformer...............................................................33

V

Varistors...........................................................................13,53Ventilation...............................................................................16Voltagecontrolmode..............................................................29

K

Kits..........................................................................................43

W

Wiringguidelines.....................................................................21

L

Linetogroundcapacitors........................................................41Logicdiagram.........................................................................27Longcables.............................................................................41

M

Magneticoverload...................................................................38Magneticoverloadsizing........................................................38

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