Altivar 71 Variable speed drives for synchronous motors and asynchronous motors Installation Manual 03/2011 1755849 55 kW (75 Hp) 75 kW (100 Hp) / 200 - 240 V 90 kW (125 Hp) 500 kW (700 Hp) / 380 - 480 V 90 kW (125 Hp) 630 kW (700 Hp) / 500 - 690 V www.schneider-electric.com Table of Contents Important information Before you begin Steps for setting up the drive Preliminary recommendations _ Drive ratings 11 Dimensions and weights _ 14 Mounting the DC choke on the pppM3X and ATV71HpppN4 17 Connecting the DC choke on ATV71HpppM3X and ATV71HpppN4 drives _ 18 Mounting the transformer(s) on ATV71HpppY drives _ 19 Connecting the transformer(s) on ATV71HpppY drives 20 Derating as a function of temperature and switching frequency _ 22 Mounting in a wall-mounted or floor-standing enclosure 25 Installing the kit for IP31/NEMA type conformity _ 28 Position of the charging LED _ 30 Installing option cards _ 31 Wiring recommendations 33 Power terminals _ 35 Control terminals _ 52 Option terminals _ 54 Connection diagrams _ 60 Use on an IT system and corner grounded system 73 Electromagnetic compatibility, wiring _ 76 1755849 03/2011 Important information WARNING Please read these instructions carefully and examine the equipment in order to familiarize yourself with the device before installing, operating or carrying out any maintenance work on it The following special messages that you will come across in this document or on the device are designed to warn you about potential risks or draw your attention to information that will clarify or simplify a procedure The addition of this symbol to a "Danger" or "Warning" safety label indicates that there is an electrical risk that will result in injury if the instructions are not followed This is a safety warning symbol It warns you of potential risks of injury You must comply with all safety messages that follow this symbol in order to avoid the risk of injury or death DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or equipment damage WARNING WARNING indicates a potentially hazardous situation which, if not avoided, can result in death, serious injury or equipment damage CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, can result in injury or equipment damage PLEASE NOTE: Only qualified personnel are authorized to carry out maintenance work on electrical equipment Schneider Electric accepts no responsibility for the consequences of using this device This document does not constitute an instruction manual for inexperienced personnel © 2009 Schneider Electric All rights reserved 1755849 03/2011 Before you begin Read and understand these instructions before performing any procedure on this drive DANGER RISK OF ELECTRIC SHOCK • Read and understand this manual before installing or operating the Altivar 71 drive Installation, adjustment, repair and maintenance must be performed by qualified personnel • The user is responsible for compliance with all international and national electrical standards in force concerning protective grounding of all equipment • Many parts of this variable speed drive, including the printed circuit boards, operate at the line voltage DO NOT TOUCH Use only electrically insulated tools • DO NOT touch unshielded components or terminal strip screw connections with voltage present • DO NOT short across terminals PA and PB or across the DC bus capacitors • Install and close all covers before applying power or starting and stopping the drive • Before servicing the variable speed drive - Disconnect all power - Place a “DO NOT TURN ON” label on the variable speed drive disconnect - Lock the disconnect in the open position • Disconnect all power including external control power that may be present before servicing the drive Wait for the charging LED to go off Then follow the DC bus voltage measurement procedure on page 28 to verify that the DC voltage is less than 45 V The drive LEDs are not accurate indicators of the absence of DC bus voltage Failure to follow these instructions will result in death or serious injury CAUTION IMPROPER DRIVE OPERATION • If the drive is not turned on for a long period, the performance of its electrolytic capacitors will be reduced • If it is stopped for a prolonged period, turn the drive on every two years for at least hours to restore the performance of the capacitors, then check its operation It is recommended that the drive is not connected directly to the line voltage The voltage should be increased gradually using an adjustable AC source Failure to follow these instructions can result in injury and/or equipment damage 1755849 03/2011 Steps for setting up the drive INSTALLATION b Receive and inspect the drive controller v Check that the catalog number printed on the label is the same as that on the purchase order v Remove the Altivar from its packaging and check that it has not been damaged in transit b Check the line voltage Steps to must be performed with the power off v Check that the line voltage is compatible with the voltage range of the drive (see pages 11 and 13) b Mount the drive v Mount the drive in accordance with the instructions in this document v Install and connect the DC choke (see page 16) or the transformer(s) (see page 19) and the AC choke v Install any internal and external options b Wire the drive v Connect the motor, ensuring that its connections correspond to the voltage v Connect the line supply, after making sure that the power is off v Connect the control v Connect the speed reference PROGRAMMING v Please refer to the Programming Manual 1755849 03/2011 Preliminary recommendations On receipt Package contents will vary depending on the model: • ATV71HpppM3X and ATV71HpppN4 contain: - The drive and a DC choke mounted on the same pallet The DC choke will comprise to components depending on the drive rating • ATV71HpppM3XD and ATV71HpppN4D contain: - The drive only • ATV71HpppY contains: - The drive and one or two DC chokes mounted on the same pallet Handling/Storage To protect the drive prior to installation, handle and store the device in its packaging Ensure that the ambient conditions are acceptable WARNING DAMAGED PACKAGING If the packaging appears damaged, it can be dangerous to open it or handle it Take precautions against all risks when opening or handling the packaging Failure to follow this instruction can result in death, serious injury or equipment damage WARNING DAMAGED EQUIPMENT Do not install or operate any drive that appears damaged Failure to follow this instruction can result in death, serious injury or equipment damage 1755849 03/2011 Preliminary recommendations Unpacking/Handling ATV71HpppM3X and ATV71HpppN4 drives DC choke The drive and the DC choke are mounted on a pallet with screws (Figure 1) The DC choke is supplied already assembled to make it easier to transport It will comprise to components depending on the drive rating The unit should be unpacked in the following order: ATV71 Figure 1 Disassemble the components of the DC choke (Figure 2) for installation later, and use a hoist to remove the choke (Figure 3) Remove the fixing screws (Figure 3) from the choke support on the pallet WARNING RISK OF CUTS The fixing screws that hold the choke support on the pallet are difficult to access, leading to a risk of cutting oneself Take all possible measures to avoid this risk, and use protective gloves Failure to follow this instruction can result in death, serious injury or equipment damage Figure Figure Remove the screws holding the drive on the pallet and use a hoist to lift the drive off It has lifting lugs for this purpose (Figure 4) WARNING 60° max RISK OF TOPPLING Never stand the drive upright (Figure 5) without keeping hold of it, or it will topple over Failure to follow this instruction can result in death, serious injury or equipment damage Figure Figure Unpacking/Handling ATV71HpppM3XD and ATV71HpppN4D drives As these models not feature a DC choke, you only need to follow instruction above 1755849 03/2011 Preliminary recommendations Unpacking/Handling ATV71HpppY drives Transformer(s) ATV71 The drive and one or two transformers are mounted on a pallet with screws (Figure 1) The transformer(s) are supplied ready-assembled to make transport easier The unit should be unpacked in the following order: Figure 1 Disassemble the components of the transformer(s) (Figure 2) for installation later, and use a hoist to remove the transformer(s) (Figure 3) Remove the fixing screws (Figure 3) from the transformer(s) WARNING RISK OF CUTS The fixing screws that hold the transformer(s) support on the pallet are difficult to access, leading to a risk of cutting oneself Take all possible measures to avoid this risk, and use protective gloves Failure to follow this instruction can result in death, serious injury or equipment damage Figure Figure Remove the screws holding the drive on the pallet and use a hoist to lift it off It has lifting lugs for this purpose (Figure 4) WARNING 60° max RISK OF TOPPLING Never stand the drive upright (Figure 5) without keeping hold of it, or it will topple over Failure to follow this instruction can result in death, serious injury or equipment damage Figure 1755849 03/2011 Figure Preliminary recommendations Installing the drive - Mount the drive first on a wall or the back of the enclosure in accordance with the recommendations described in this document, before installing the DC choke or transformer(s) Installing the DC choke on ATV71HpppM3X and ATV71HpppN4 drives ATV71H D55M3XD to D75M3XD and ATV71H D90N4D to C50N4D drives are not supplied with a DC choke ATV71H D55M3X to D75M3X and ATV71H D90N4 to C50N4 drives are supplied with a DC choke that must be installed on top of the drive and wired in accordance with the recommendations described in this document This choke must be used for connecting drives to the threephase line supply - Mount the DC choke on the back of the enclosure or on the wall above the drive and connect it up The instructions for installing and connecting the choke are given on page 16 - Make sure that the seal between the drive and the choke chassis is doing its job properly Installing the transformer(s) on ATV71HpppY drives ATV71H C11Y to C63Y drives are supplied with one or two transformers for the fan power supply; these must be installed on top of the drive and wired in accordance with the recommendations described in this document Installing the AC choke on ATV71HpppY drives The use of an AC choke, which must be ordered separately, is mandatory on these drives if a special transformer is not used (e.g., 12-pulse) Recommendations Read and understand the instructions in the "Programming Manual" CAUTION INCOMPATIBLE LINE VOLTAGE Before powering up and configuring the drive, ensure that the line voltage is compatible with the supply voltage shown on the drive nameplate The drive may be damaged if the line voltage is not compatible Failure to follow this instruction can result in injury and/or equipment damage DANGER UNINTENDED EQUIPMENT OPERATION • Before turning on and configuring the Altivar 71, check that the PWR (POWER REMOVAL) input is deactivated (at state 0) in order to prevent unintended operation Do not forget to reactivate the Power Removal input to start the motor • Before turning on the drive, or when exiting the configuration menus, check that the inputs assigned to the run command are deactivated (at state 0) since they can cause the motor to start immediately Failure to follow these instructions will result in death or serious injury If the safety of personnel requires the prohibition of unwanted or unintended operation, provision for electronic locking is provided by the Altivar 71's Power Removal function This function requires the use of connection diagrams conforming to category of standard EN 954-1, ISO 13849-1 and safety integrity level according to IEC/EN 61508 The Power Removal function takes priority over any run command 10 1755849 03/2011 Connection diagrams Control connection diagrams Control card connection diagram A1 COM AO1 COM AI AI1- AI1+ +10 0V LI6 LI5 LI4 LI3 LI2 LI1 +24 PWR ATV71Hppppp Reference potentiometer ± 10 V or X-Y mA Logic input switch (SW1) The logic input switch (SW1) is used to adapt the operation of the logic inputs to the technology of the programmable controller outputs • Set the switch to Source (factory setting) if using PLC outputs with PNP transistors • Set the switch to Sink Int or Sink Ext if using PLC outputs with NPN transistors • Switch SW1 set to "Source" position and use of an external power supply for the LIs 0V LI6 LI5 LI4 LI3 Int 0V LI6 LI5 LI4 LI3 LI2 LI1 Sink ATV71Hppppp Ext LI2 SW1 Ext Int A1 Source ATV71Hppppp +24 Sink A1 +24 Source SW1 LI1 • Switch SW1 set to "Source" position 24 V c source +24 V 0V ATV71Hppppp 0V LI6 LI5 LI4 Int LI3 Ext 0V LI6 LI5 LI4 LI3 LI2 Sink LI1 Int A1 Source LI2 ATV71Hppppp SW1 +24 Sink A1 Ext +24 Source SW1 • Switch SW1 set to "Sink Ext" position LI1 • Switch SW1 set to "Sink Int" position 24 V c source +24 V 0V WARNING UNINTENDED EQUIPMENT OPERATION When switch SW1 is set to "Sink Int" or "Sink Ext", the common must never be connected to ground or to protective ground, as there is then a risk of unintended equipment operation on the first insulation fault Failure to follow this instruction can result in death, serious injury or equipment damage 64 1755849 03/2011 Connection diagrams Bipolar speed reference A1 - 10 V COM + 10 V AI1- AI1+ ATV71Hppppp ±10 V c source Speed reference using axis control A1 AI1- COM 0V + - AI1+ ATV71Hppppp Axis control ±10 V reference Switch SW2 The LI6 logic input switch (SW2) makes it possible to use the LI6 input: - Either as a logic input by setting the switch to LI (factory setting) - Or for motor protection via PTC probes by setting the switch to PTC A1 0V LI6 ATV71Hppppp SW2 PTC LI Motor Control power supply via an external source The control card can be supplied via an external +24 V c source A1 ATV71Hppppp 0V P24 24 V c source 0V +24 V 1755849 03/2011 65 Connection diagrams I/O extension card connection diagrams R4B TH2- TH2+ AI3+ AI3- COM AI4 AO3 AO2 0V RP CLO VW3A3202 LO4 LO3 R4C LI11 0V +24 A1 R4A Connection diagram for extended I/O option card (VW3A3202) Motor ± 10 V or X-Y mA R3B TH1- TH1+ CLO VW3A3201 LO2 LO1 R3C LI7 0V +24 A1 R3A Connection diagram for logic I/O option card (VW3A3201) Motor 66 1755849 03/2011 Connection diagrams SW3/SW4 logic I/O switch • Switch in "Source" position • Switch in "Source" position and use of an external + 24 V c source SW3 or SW4 SW3 or SW4 VW3 A3 20p CLO LOp Ext Int CLO LOp +24 Int LIp Sink LIp Ext 0V Sink A1 Source VW3 A3 20p +24 Source 0V A1 24 V c source +24V 0V • Switch in "Sink Int" position • Switch in "Sink Ext" position SW3 or SW4 SW3 or SW4 CLO Int LOp CLO LOp +24 LIp Sink Int VW3 A3 20p Ext LIp Ext 0V Sink A1 Source VW3 A3 20p +24 Source 0V A1 24 V c source +24V 0V WARNING UNINTENDED EQUIPMENT OPERATION When switches SW3 or SW4 are set to "Sink Int" or "Sink Ext", the common must never be connected to ground or to protective ground, as there is then a risk of unintended equipment operation on the first insulation fault Failure to follow this instruction can result in death, serious injury or equipment damage 1755849 03/2011 67 Connection diagrams Connection of several drives in parallel on the DC bus It is essential that these drives all have the same voltage rating Connection on DC bus between drives with equivalent ratings Each drive uses its own charging circuit a and T / L3 W / T3 PC/- W3 V / T2 U / T1 U3 V3 W / T3 S / L2 R / L1 T / L3 R / L1 S / L2 W2 V / T2 U / T1 V2 U2 W / T3 V / T2 V1 , F3 PA/+ ATV71Hppppp PC/- M2 a M1 a Drives (1) F2 PA/+ ATV71Hppppp PC/- W1 U / T1 PA/+ ATV71Hppppp U1 (1) F1 T / L3 S / L2 R / L1 (1) M3 a must not be more than one size apart when they are connected in this way F1, F2, F3: Fast-acting semiconductor fuses for protection on the DC bus side Connection on DC bus between drives with different ratings a F2 F3 (3) M1 a W/T3 V/T2 SO TO W3 V3 U3 RO ATV 71Hppppp (2) U/T1 W/T3 V/T2 W2 PC/- PA/+ PC/- PA/+ V2 W/T3 W1 V/T2 V1 U/T1 U1 ATV 71Hppppp (2) PC/- U/T1 ATV 71Hppppp F1 PA/+ U2 T/L3 S/L2 R/L1 (1) M3 a M2 a (1) Line choke, optional for ATV71HpppM3X and ATV71HpppN4, compulsory for ATV71HpppY (to be ordered separately) if a special transformer is not used (e.g., 12-pulse) (2) Drives and Catalog number powered only by their DC bus not have to have a DC choke (catalog number ATV71HpppM3XD or ATV71HpppN4D) (3) Separate fan power supply for certain ratings, please refer to the warning below F1, F2, F3: Fast-acting semiconductor fuses for protection on the DC bus side CAUTION RISK OF DAMAGE TO DRIVES • Drive must be large enough to supply all the motors capable of operating simultaneously • When ratings D75M3X, C11N4 to C50N4 and C11Y to C63Y (drive in the diagram above) are powered only by their DC bus and not their R/L1, S/L2, T/L3 terminals, it is essential to provide a separate three-phase power supply 380…480 V, 50 / 60 Hz (RO, SO, TO terminals) for the fans, protected with fuses or a motor disconnect Power and connection are detailed on the following page Failure to follow these instructions can result in injury and/or equipment damage 68 1755849 03/2011 Connection diagrams Power consumed by the fans ATV71H drive D75M3X, C11N4, C13N4, C16N4, C11Y, C13Y, C16Y C20N4, C25N4, C28N4, C20Y, C25Y, C31Y C31N4, C40N4, C50N4, C40Y, C50Y, C63Y Power consumed by the fans 550 VA 1,100 VA 2,200 VA Connecting fans for a separate power supply In order to remove the link between the fans and power supply terminals R/L1, S/L2, T/L3 and relocate it at terminals RO, SO, TO, connectors X1 and X4 must be crossed as indicated on the diagrams below ATV71H D75M3X, C11N4 to C16N4 and C11Y to C16Y Factory wiring: Fans powered internally by R/L1, S/L2, T/L3 INPUT X1 PARKING X4 Terminals R0, S0, T0 Modification for fans powered externally by R0, S0, T0 INPUT X1 PARKING X4 Terminals R0, S0, 1755849 03/2011 69 Connection diagrams ATV71H C20N4 to C28N4 and C20Y to C31Y Factory wiring: Fans powered internally by R/L1, S/L2, T/L3 Terminals R0, S0, T0 Terminals R0, S0, T0 Modification for fans powered externally by R0, S0, T0 70 1755849 03/2011 Connection diagrams ATV71H C31N4, C40N4 Terminals R0, S0, T0 Factory wiring: Fans powered internally by R/L1, S/L2, T/L3 1755849 03/2011 Terminals R0, S0, T0 Modification for fans powered externally by R0, S0, T0 71 Connection diagrams ATV71H C50N4, C40Y to C63Y Terminals R0, S0, T0 Factory wiring: Fans powered internally by R/L1, S/L2, T/L3 72 Terminals R0, S0, T0 Modification for fans powered externally by R0, S0, T0 1755849 03/2011 Use on an IT system and corner grounded system IT system: Isolated or impedance grounded neutral system Use a permanent insulation monitor compatible with non-linear loads such as a Merlin Gerin type XM200 or equivalent Altivar 71 drives feature built-in RFI filters In order to be able to use ATV71H C11Y to C63Y drives on an IT system, the link between these filters and ground must be removed as shown in the connection diagrams below For other drives, removal of the link is possible but not mandatory: Corner grounded system: System with one phase grounded WARNING RISK OF ELECTRIC SHOCK ATV71H C11Y to C63Y drives must not be connected on a corner grounded system Failure to follow this instruction can result in death, serious injury or equipment damage Disconnection of RFI filters ATV71H D90N4 to C11N4: Normal (filter connected) IT system (filter disconnected) ATV71H C13N4 to C16N4 and ATV71H C11Y to C16Y: Normal (filter connected) IT system (filter disconnected) CAUTION RISK OF DAMAGE TO DRIVE The filter must be disconnected if the drive is to be used on an IT or corner grounded system Failure to follow this instruction can result in injury and/or equipment damage 1755849 03/2011 73 Use on an IT system and corner grounded system ATV71H C20N4 to C28N4 and ATV71H C20Y to C31Y: Normal (filter connected) IT system (filter disconnected) ATV71HC31N4: Normal (filter connected) IT system (filter disconnected) CAUTION RISK OF DAMAGE TO DRIVE The filter must be disconnected if the drive is to be used on an IT or corner grounded system Failure to follow this instruction can result in injury and/or equipment damage 74 1755849 03/2011 Use on an IT system and corner grounded system ATV71HC40N4: Normal (filter connected) IT system (filter disconnected) ATV71H C50N4 and ATV71H C40Y to C63Y: Normal (filter connected) IT system (filter disconnected) CAUTION RISK OF DAMAGE TO DRIVE The filter must be disconnected if the drive is to be used on an IT or corner grounded system Failure to follow this instruction can result in injury and/or equipment damage 1755849 03/2011 75 Electromagnetic compatibility, wiring Electromagnetic compatibility Principle • Grounds between drive, motor and cable shielding must have "high frequency" equipotentiality • Use of shielded cables with shielding connected to ground at both ends for the motor cables, braking resistor (if used) and control-signal wiring Metal ducting or conduit can be used for part of the shielding length provided that there is no break in continuity • Ensure maximum separation between the power cable (line supply) and the motor cable Installation diagram ATV71H D55M3X to D75M3X, ATV71H D90N4 to C50N4 and ATV71H C11Y to C63Y Altivar 71 Sheet steel grounded plate Metal clamps 10 Shielded cable for motor connection, with shielding connected to ground at both ends The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes Shielded cable for connecting the braking resistor (if used) The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes Shielded cables for connecting the control-signal cables For applications requiring several conductors, use cables with a small cross-section (0.5 mm2) Shielded cables for connecting the Power Removal safety function input The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes Shielded cables for connecting the encoder The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes Unshielded wires for relay contact output 10 Unshielded drive power supply cables Note: • If using an additional input filter, it should be connected directly to the line supply via an unshielded cable Link 10 on the drive is made via the filter output cable • The HF equipotential ground connection between the drive, motor and cable shielding does not remove the need to connect the PE protective conductors (green-yellow) to the appropriate terminals on each unit 76 1755849 03/2011 Electromagnetic compatibility, wiring Installing the encoder cable for the VW3 A3 408, VW3 A3 409 and VW3 A3 411 cards (1 cable) Strip the cable shielding Select the appropriate clamp for the cable diameter and attach it to the cable Attach the clamp to the bracket using one of the screws supplied with the card Use the ground screw to attach the bracket to the grounding point located next to the encoder card Note: The cable must be mounted on the EMC plate as shown in the diagram on page 76 The cable must be stripped for mounting on the EMC plate Installing the ESIM and encoder cables for the VW3 A3 411 card (2 cables) Repeat steps to above Strip the shielding from the ESIM cable Attach the clamp to the cable Attach the clamp to the bracket using the second screw supplied with the card 1755849 03/2011 77 ATV71E_installation_manual_EN_1755849_05 1755849 03/2011 ... begin Read and understand these instructions before performing any procedure on this drive DANGER RISK OF ELECTRIC SHOCK • Read and understand this manual before installing or operating the Altivar. .. drives feature transformers Make this connection for each transformer CAUTION IMPROPER WIRING PRACTICES Making a connection inappropriate for the line voltage will damage the transformer(s) and. .. a "residual current device" is required by installation standards, a type A device should be used for single-phase drives and type B for three-phase drives Choose a suitable model integrating: