Nidec POWERDRIVE FX 100T, POWERDRIVE FX 50T Installation Manual

Document

Installation guide

POWERDRIVE FX

Part number: 4729 en - 2017.08 / c

NOTE

LEROY-SOMER reverses the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments. The information contained in this document is therefore be changed without notice.

CAUTION

For the user’s safety, the variable speed drive must be connected to an approved earth ( terminal).

If accidentally starting the installation is likely to cause a risk to personnel or the machines being driven, it is essential to comply with the power connection diagrams recommended in this manual.

The variable speed drive is fitted with safety devices which, in the event of a fault, order it to stop and, at the same time, stop the motor. The motor itself can become jammed for mechanical reasons. Voltage fluctuations, and in particular power cuts, may also cause the motor to stop. The removal of the causes of the shutdown can lead to restarting, which may be dangerous for certain machines or installations.

In such cases, it is essential that the user takes appropriate precautions against the motor restarting after an unscheduled stop.

The variable speed drive is designed to be able to supply a motor and the driven machine above its rated speed.

If the motor or the machine are not mechanically designed to withstand such speeds, the user may be exposed to serious danger resulting from their mechanical deterioration.

Before programming a high speed, it is important that the user checks that the installation can withstand it.

The variable speed drive which is the subject of this manual is designed to be integrated in an installation or an electrical machine, and can under no circumstances be considered to be a safety device. It is therefore the responsibility of the machine manufacturer, the designer of the installation or the user to take all necessary precautions to ensure that the system complies with current standards, and to provide any devices required to ensure the safety of equipment and personnel.

Using the drive for hoisting: when using this application, it is essential to follow the special instructions in an application-specific manual which is available on request. It is the responsibility of the user to obtain this manual from his usual LEROY-SOMER contact.

LEROY-SOMER declines all responsibility in the event of the above recommendations not being observed.

........................................

This manual only describes the general features, characteristics and installation of the POWERDRIVE FX. For commissioning, refer to manual ref.4617.

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SAFETY AND OPERATING INSTRUCTIONS FOR VARIABLE SPEED DRIVES

(In accordance with the low voltage directive 2006/95/EC)

Throughout the manual this symbol warns of consequences which may arise from inappropriate use of the drive, since electrical risks may lead to material or physical damage as well as constituting a fire hazard.

1 - General

Depending on their degree of protection, variable speed drives may contain unprotected live parts, which may be moving or rotating, as well as hot surfaces, during operation.

Unjustified removal of protection devices, incorrect use, faulty installation or inappropriate operation could represent a serious risk to personnel and equipment.

For further information, consult the documentation.

All work relating to transportation, installation, commissioning and maintenance must be performed by experienced, qualified personnel (see IEC 364 or CENELEC HD 384, or

DIN VDE 0100 and national specifications for installation and accident prevention).

In these basic safety instructions, qualified personnel means persons competent to install, mount, commission and operate the product, and possessing the relevant qualifications.

2 - Use

Variable speed drives are components designed for integration in installations or electrical machines.

When integrated in a machine, commissioning must not take place until it has been verified that the machine conforms with directive 2006/42/EC (Machinery Directive). It is also necessary to comply with standard EN 60204, which stipulates in particular that electrical actuators (which include variable speed drives) cannot be considered as circuit-breaking devices and certainly not as isolating switches.

Commissioning can taken place only if the requirements of the

Electromagnetic Compatibility Directive (EMC 2004/108/EC) are met.

The variable speed drives meet the requirements of the

Low Voltage Directive 2006/95/EC. The harmonised standards of the DIN VDE 0160 series in connection with standard VDE 0660, part 500 and EN 60146/VDE 0558 are also applicable.

The technical characteristics and instructions concerning the connection conditions specified on the nameplate and in the documentation provided must be observed without fail.

3 - Transportation, storage

All instructions concerning transportation, storage and correct handling must be observed.

The climatic conditions specified in the technical manual must be observed.

4 - Installation

The installation and cooling of equipment must comply with the specifications in the documentation supplied with the product.

Variable speed drives must be protected against any excessive stress. In particular, there must be no damage to parts and/or modification of the clearance between components during transportation and handling. Avoid touching electronic components and contact parts.

The variable speed drives contain parts which are sensitive to electrostatic stresses and may be easily damaged if handled incorrectly. Electrical components must not be exposed to mechanical damage or destruction (risks to health!).

5 - Electrical connection

When work is performed on variable speed drives which are powered up, national accident prevention regulations must be respected.

The electrical installation must comply with the relevant specifications (for example conductor cross-sections, protection via fused circuit-breaker, connection of protective conductor). More detailed information is given int the documentation.

Instructions for an installation which meets the requirements for electromagnetic compatibility, such as screening, earthing, presence of filters and correct insertion of cables and conductors, are given in the documentation supplied with the variable speed drives. These instructions must be followed in all cases, even if the variable speed drive carries the CE mark.

Adherence to the limits given in the EMC legislation is the responsibility of the manufacturer of the installation or the machine.

6 - Operation

Installations which incorporate variable speed drives must be fitted with additional protection and monitoring devices as specified in current relevant safety regulations, such as the law on technical equipment, accident prevention regulations, etc. Modifications to the variable speed drives using control software are permitted.

Active parts of the device and the live power connections must not be touched immediately after the variable speed drive is powered down, as the capacitors may still be charged. In view of this, the warnings fixed to the variable speed drives must be observed.

Permanent magnet motors generate electrical energy while they are rotating, even when the drive is switched off. In this case, the drive continues to be powered by the motor terminals.

If the load is capable of turning the motor, a switching device must be provided upstream of the motor to isolate the drive during maintenance operations.

During operation, all doors and protective covers must be kept closed.

7 - Servicing and maintenance

Refer to the manufacturer’s documentation.

See the Maintenance section in this document.

This manual is to be given to the end user.

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FOREWORD

This manual describes the installation of POWERDRIVE FX variable speed drives. It also gives details of all its options and extensions which the user may choose to suit his requirements.

Parameter setting

POWERDRIVE FX

Options

• RFI filter

• Encoder or resolver input

• Additional I/O

• Datalogger

• Communication options

MDX-Powerscreen parameter-setting interface

MDX-KEYPAD MDX-SOFT parameter-setting software

+ PC link cable

Gearboxes

Compabloc

• Axial output

- Helical gears

Orthobloc

• Orthogonal output

- Helical bevel gears

Motors

LS-FLS motor

LSMV motor

HPM motor

Motor options

Axial forced ventilation

Encoder/Sensor

Brake

Radial forced ventilation

LSRPM motor

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CONTENTS

1 - GENERAL INFORMATION ................................................................................................................................ 7

1.1 - General ........................................................................................................................................................ 7

1.2 - Product designation .................................................................................................................................... 7

1.3 - Environmental characteristics ...................................................................................................................... 7

1.4 - Electrical characteristics .............................................................................................................................. 8

1.4.1 - General characteristics ......................................................................................................................................... 8

1.4.2 - Electrical characteristics at +40°C ........................................................................................................................ 8

1.4.3 - Derating according to the temperature and switching frequency .......................................................................... 8

2 - MECHANICAL INSTALLATION ...................................................................................................................... 10

2.1 - Checks on receipt ..................................................................................................................................... 10

2.2 - Dimensions ................................................................................................................................................ 10

2.2.1 - Surface mounting ............................................................................................................................................... 10

2.2.2 - Through-panel mounting .................................................................................................................................... 12

2.3 - Weights ...................................................................................................................................................... 14

2.4 - Losses, ventilation flow rate and noise levels ............................................................................................ 14

3 - CONNECTIONS ................................................................................................................................................ 16

3.1 - Connection of the power ............................................................................................................................

3.1.1 - Ratings 33T to 50T (size 2) .................................................................................................................................

3.1.2 - Ratings 60T to 100T (size 3) ............................................................................................................................... 17

3.1.3 - Cables and fuses ................................................................................................................................................. 18

3.2 - Connection of the control ........................................................................................................................... 19

3.2.1 - Locationof control terminal blocks ....................................................................................................................... 19

3.2.2 - Characteristics of control terminal blocks ............................................................................................................ 19

3.2.3 - Factory configuration of control terminal blocks .................................................................................................. 21

3.3 - STO-1 / STO-2 inputs: Safe Torque Off function ........................................................................................................... 22

3.3.1 - 3-phase AC power supply, in accordance with safety standard IEC/EN62061: 2005 and EN/ISO 13849-1: 2006

- Single channel locking (SIL1 - PLb) ................................................................................................................................................ 22

3.3.2 - 3-phase AC power supply, in accordance with safety standard IEC/EN62061: 2005 and EN/ISO 13849-1: 2006

- Double channel locking with feedback (SIL3 - PLe) ...................................................................................................................... 22

4 - GENERAL EMC - HARMONICS - MAINS INTERFERENCE ......................................................................... 23

4.1 - Low-frequency harmonics .........................................................................................................................

4.2 - Radio-frequency interference: Immunity ....................................................................................................

4.2.1 - General ...............................................................................................................................................................

4.2.2 - Standards ...........................................................................................................................................................

4.2.3 - Recommendations .............................................................................................................................................

4.3 - Radio-frequency interference: Emission ....................................................................................................

4.3.1 - General ...............................................................................................................................................................

4.3.2 - Standards ...........................................................................................................................................................

4.3.3 - Recommendations .............................................................................................................................................

4.4 - Mains power supply ...................................................................................................................................

4.4.1 - General ...............................................................................................................................................................

4.4.2 - Mains transient overvoltages ..............................................................................................................................

4.4.3 - Mains short-circuit power .................................................................................................................................... 24

4.4.4 - Ground connections ........................................................................................................................................... 24

4.5 - Basic precautions for installation ............................................................................................................... 24

4.5.1 - Wiring inside the cabinet...................................................................................................................................... 24

4.5.2 - Wiring outside the cabinet ................................................................................................................................... 24

4.6 - Electromagnetic compatibility (EMC) .........................................................................................................

5 - OPTIONS ..........................................................................................................................................................26

5.1 - Operator interfaces ....................................................................................................................................

5.1.1 - Connection to the drive ........................................................................................................................................

5.1.2 - MDX-KEYPAD ....................................................................................................................................................

5.1.3 - MDX-Powerscreen ............................................................................................................................................. 27

5.1.4 - MDX-SOFT ......................................................................................................................................................... 27

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CONTENTS

5.2 - Add-on options ........................................................................................................................................... 28

5.2.1 - Connector and shielding bracket ........................................................................................................................ 28

5.2.2 - Fieldbus, speed feedback and I/O options .......................................................................................................... 28

5.2.3 - Fieldbus options ................................................................................................................................................. 28

5.2.4 - Speed feedback options ..................................................................................................................................... 29

5.2.5 - I/O options .......................................................................................................................................................... 29

5.3 - RFI filters ...................................................................................................................................................

5.3.1 - General ...............................................................................................................................................................

5.3.2 - Weight and dimensions ......................................................................................................................................

6 - TRIPS - DIAGNOSTICS ................................................................................................................................... 31

6.1 - Drive statut ................................................................................................................................................

6.2 - Alarms .......................................................................................................................................................

6.3 - Trips ..........................................................................................................................................................

7 - MAINTENANCE ............................................................................................................................................... 35

7.1 - Servicing ...................................................................................................................................................

7.2 - Storage .....................................................................................................................................................

7.3 - Exchanging products ................................................................................................................................

8 - UL LISTING INFORMATION ........................................................................................................................... 36

8.1 - Common UL information ...........................................................................................................................

8.2 - AC supply specification .............................................................................................................................

8.3 - Maximum continuous current ....................................................................................................................

8.4 - Fusing and cabling ....................................................................................................................................

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GENERAL INFORMATION

1 - GENERAL INFORMATION

1.1 - General

The POWERDRIVE FX is an electrical drive with flux vector control, designed for supplying asynchronous or synchronous

3-phase motors.

The POWERDRIVE FX has a rectifier with IGBT bridge controlled at the frequency of the mains supply, which has the following advantages:

- Motor energy feedback to the mains supply (operation in all 4 quadrants of the torque/speed plane without energy dissipation),

- Limiting of the level of current harmonics generated on the power supply line, at a much lower level than that of a conventional 6-pilse drive using a line reactor.

The POWERDRIVE FX is a variable speed drive with very high performance levels that can be used to control:

- Induction motors without speed sensor (Open loop mode select ) for applications that do not need rated torque control above 1/10th of the rated speed.

- Asynchronous or synchronous permanent magnet motors with virtual speed feedback (Flux vector mode with software sensor function ) for applications that require rated torque control from 1/20th of the rated speed.

Combined with the MDX-ENCODER option, the

POWERDRIVE FX is a drive that can also be used to control asynchronous or synchronous magnet machines for applications that require very high dynamic performances or torque control from zero speed (Closed loop vector mode with speed feedback ).

• POWERDRIVE FX drives are designed for installation in a cabinet or an enclosure to ensure protection from conducting dust and condensation.

Prevent access by unauthorised personnel.

Diagram

Control board

Microcontroller

PWM

MDX-

ENCODER

(optional)

I/O control

Nameplate

Mains supply

1.2 - Product designation

POWERDRIVE FX 33 T

Optional sensor

The nameplate is located at the bottom right-hand side of the product (front view).

1.3 - Environmental characteristics

Characteristics Level

Protection IP20

Storage and transport temperature

Ambient operating temperature

(outside the cabinet)

-30°C to +70°C

-10°C to +40°C, up to +50°C with derating

(see section 1.4.3)

Classification of environmental conditions

Relative humidity

Altitude

Vibrations

Shocks

In accordance with

IEC 60721-3-3 :

• Biological classification in accordance with class 3B1,

• Classification as regards chemically active substances in accordance with class 3C2,

• Classification as regards mechanically active substances in accordance with class 3S2

• In accordance with

IEC 60068-2-56

• < 90% non condensing

• ≤ 1000 m without derating

• > 1000 m: operating temperature derating of 0.6°C per 100 m, up to 4000 m maximum

E.g. for an altitude of 1300 m, the electrical characteristics must be taken into account for an ambient temperature of:

[40° - (3 x 0.6°)] = 38.2°C

• In accordance with

IEC 60068-2-6

• Non-packaged product: 2m/s 2

(9-200Hz), 0.6mm (2-9Hz)

• Packaged product: 10m/s 2

(9-200Hz), 3mm (2-9Hz)

Packaged product: in accordance with IEC 60068-2-29

Atmospheric pressure 700 to 1060 hPa

4-quadrant variable speed drive with flux vector control

3-phase power supply

400V to 480V (T)

Rating in kVA

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GENERAL INFORMATION

1.4 - Electrical characteristics

• All work relating to installation, commissioning and maintenance must be carried out by experienced, qualified personnel.

1.4.1 - General characteristics

Characteristics

Power supply voltage

Phase voltage imbalance

Input frequency

Maximum number of power-ups per hour (power)

Output frequency range

Mains short-circuit capability at the point of connection

ROHS conformance

Level

3-phase mains supply: 400V -10% to 480V +6%

< 3%

2% around te rated frequency (50 or 60 Hz)

• 20

0 to 200 Hz

See section 4.4.3

Conforming to standard 2002-95-EC

1.4.2 - Electrical characteristics at +40°C

I co

: Continuous output current out

I max

: Output power

(60s) : Maximum output current*

Heavy duty : For high overload constant torque machines (presses, grinders, hoists, etc) and all applications where significant inertia has to be accelerated quickly (centrifuges, translation of travelling cranes, etc).

Normal duty : For low overload constant torque or centrifugal torque machines (fans, compressors, etc).

*: Current available for 60 seconds every 600 seconds.

The output currents I co

in the table below are given for:

- A 4 kHz switching frequency,

- An ambient temperature of +40°C,

- An altitude of 1000m maximum.

POWERDRIVE FX

Size

Rating

33T

40T

50T

60T

75T

100T

P kW

Heavy duty

I co

110

145

I max

(60s)

105

135

165

200

P out kW

Normal duty

I co

110

145

175

I max

(60s)

119

157

189

1.4.3 - Derating according to the temperature and switching frequency

POWERDRIVE FX rating

33T

40T

50T

60T

75T

100T

Duty

Heavy

Normal

Heavy

Normal

Heavy

Normal

Heavy

Normal

Heavy

Normal

Heavy

Normal

4kHz

110

145

175

I co

(A)

5kHz

106

100

132

131

158

6kHz

100

116

113

137

The I co

output currents are given at an ambient temperature of +40°C. For a temperature above +40°C, derate the current by 1.5% for every additional degree up to a maximum temperature of +50°C.

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GENERAL INFORMATION

Notes

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MECHANICAL INSTALLATION

2 - MECHANICAL INSTALLATION

• It is the responsibility of the owner or user of the

POWERDRIVE FX to ensure that the installation, operation and maintenance of the drive and its options comply with legislation relating to the safety of personnel and equipment and with the current regulations of the country of use.

• POWERDRIVE FX drives must be installed in an environment free from conducting dust, corrosive fumes, gases and fluids, and condensation (class 2 according to IEC 664.1). the drive must not be installed in hazardous areas unless it is in an appropriate enclosure.

In this case, the installation must be approved.

• In atmospheres where condensation may form, install a heating system (to be switched off when the drive is operating). It is advisable to control the heating system automatically.

• The casing of the POWERDRIVE FX is not fireproof.

If necessary, use a flameproof cabinet.

2.1 - Checks on receipt

Before installing the POWERDRIVE FX , check that:

- The drive has not been damaged during transport,

- The information on the nameplate is compatible with the power supply.

2.2 - Dimensions

CAUTION:

In the cabinet, there must be a minimum distance of

100 mm between two drives, and 200 mm above and below the drive.

2.2.1 - Surface mounting

2.2.1.1 - Ratings 33T to 50T

Front view

256

200

175

Fixed with

4 M6 screws

Side view

Lifting rings Ø 15

575 587

Dimensions in mm

(*) • With MDX-I/O M2M option, add +25mm

• With MDX-ENCODER, MDX-RESOLVER, MDX-I/O Lite

or MDX-Fieldbus option, add +30mm

(the 2 option types can be combined, add +55mm)

240*

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2.2.1.2 - Ratings 60T to 100T

Front view

250

32.5

MECHANICAL INSTALLATION

Fixed with

4 M8 screws

Side view

78.5

53.5

Lifting rings Ø 17

750 692 782 788 766

50 50

188

Dimensions in mm

(*) • With MDX-I/O M2M option, add +25mm

• With MDX-ENCODER, MDX-RESOLVER, MDX-I/O Lite

or MDX-Fieldbus option, add +30mm

(the 2 option types can be combined, add +55mm)

37.4

284*

49.5

Terminal block cover

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MECHANICAL INSTALLATION

2.2.2 - Through-panel mounting

CAUTION:

To obtain IP54 protection at the back of the heatsink, an additional seal is needed (not supplied, adhesive strip of EPDM rubber or equivalent).

The POWERDRIVE FX is delivered with its fixing feed mounted, ready for surface mounting. For through-panel mounting, remove the feet, and follow the instructions below.

2.2.2.1 - Ratings 33T to 50T

Drill hole diagram Side view

Solid surface

200

Lifting rings Ø 15

18 seal seal

495

231

530

553

486

15.5

for M6 crimp

cap nuts

Dimensions in mm

(*) • With MDX-I/O M2M option, add +25mm

• With MDX-ENCODER, MDX-RESOLVER, MDX-I/O Lite

or MDX-Fieldbus option, add +30mm

(the 2 option types can be combined, add +55mm)

> 40

85.5

140*

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2.2.2.2 - Ratings 60T to 100T

Drill hole diagram

MECHANICAL INSTALLATION

for M8

crimp cap nuts

Solid surface

Side view

Back of the cabinet

78.5

53.5

Lifting rings Ø 17

Terminal block cover seal

788

700.6

750

228

709

1.5

225

Dimensions in mm

(*) • With MDX-I/O M2M option, add +25mm

• With MDX-ENCODER, MDX-RESOLVER, MDX-I/O Lite

or MDX-Fieldbus option, add +30mm

(the 2 option types can be combined, add +55mm)

> 40

106 seal

49.5

Terminal block cover

162*

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MECHANICAL INSTALLATION

2.3 - Weights

POWERDRIVE FX rating

Weight (kg)

33T 40T

50T 60T

• Suitable handling equipment must be provided according to the weight of the drives.

75T

2.4 -

Losses, ventilation flow rate and noise levels

• Losses

Losses*

(W) 33T 40T

POWERDRIVE FX

50T 60T

Total 800 980 1150 1450

Inside the cabinet

(through-panel mounting)

90 100 110 140

(*) Maximum losses for normal duty operation at the I co

output currents given in section 1.4.3.

• Forced ventilation flow rates

Forced ventilation

Flow rate

(m 3 /h)

33T 40T

230

POWERDRIVE FX

50T 60T

• Noise

Forced ventilation

Level

(dBA)

33T 40T

POWERDRIVE FX

50T 60T

75T

1850

170

75T

340

75T

100T

2200

200

100T

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MECHANICAL INSTALLATION

Notes

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CONNECTIONS

3 - CONNECTIONS

• All connection work must be performed in accordance with the laws in force in the country in which the drive is installed. This includes earthing to ensure that no directly accessible part of the drive can be at the mains voltage or any other voltage which may be dangerous, a source of serious injury, malfunctions or electromagnetic interference.

• The voltages on the cables or connections of the mains supply, the motor or the filter may cause fatal electric shocks. Contact with these items must be avoided under all circumstances.

• The drive must be supplied via a circuit-breaking device so that it can be powered down safety.

• The drive power supply must be protected against overloads and short-circuits.

• The drive stop function does not protect against high voltages on the terminal blocks.

• Check that the voltage and current of the drive, the motor and the mains supply are compatible.

• After the drive has been operating, keep away from the heatsink as it may be very hot (+70°C).

• When the drive controls a permanent magnet motor, only one motor can be connected to the drive output.

It is advisable to install a circuit-breaking device between the permanent magnet synchronous motor and the drive output. This breaker isolates the motor during maintenance work on the drive.

3.1 - Connection of the power

3.1.1 -

Ratings 33T to 50T (size 2)

Mains supply

Optional

RFI filter

L1 L2 L3 PE

MDX-ENCODER and/or

Fieldbus option

Screw terminal blocks: M6

Tightening torque: 4 Nm

Screw terminal blocks: M6

Tightening torque: 4 Nm

U V W PE

Optional sensor

3-phase motor

(asynchronous or synchronous)

QS: Fused isolator. QS must be opened before working on any electrical parts of the drive or motor.

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3.1.2 -

Ratings 60T to 100T (size 3)

Mains supply

Optional

RFI filter

Screw bolt: M8

Tightening torque: 12 Nm

L2 L3 PE

MDX-ENCODER and/or

Fieldbus option

CONNECTIONS

Screw bolt: M8

Tightening torque: 12 Nm

U V W

Optional sensor

3-phase motor

(asynchronous or synchronous)

QS: Fused isolator. QS must be opened before working on any electrical parts of the drive or motor.

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CONNECTIONS

3.1.3 - Cables and fuses

• It is the responsibilityof the user to connect and provide protection for the POWERDRIVE FX in accordance with the current legislation and regulations in the country of use. This is particularly important as regards the size of the cables, the type and rating of fuses, the earth or ground connection, powering down, acknowledging trips, isolation and protection against overcurrents.

• This table is given for information only, and must under no circumstances be used in place of the current standards.

I co

: Continuous output current

M : Maximum continuous line current permitted in motor mode (power drawn by the motor)

G : Maximum continuous line current permitted in regenerative mode (power transmitted to the mains supply)

POWERDRIVE FX

33T

40T

50T

60T

75T

100T

Rating / duty

Heavy

Normal

Heavy

Normal

Heavy

Normal

Heavy

Normal

Heavy

Normal

Heavy

Normal

Mains supply Motor (1)

(A)

400V - 50Hz

(A)

460/480V - 60Hz

Fuses

Gg type aR type

Cable crosssections

(2)

(mm 2 )

Gg type

Fuses aR type

Class

Cable crosssections

(2)

(mm 2 )

I co

(A)

Cable crosssections

(2)

(mm 2 )

50 80 3x10 + 10 37

63 100 3x16 + 16 50

80 125 3x25 + 15 59

55 80 125 3x25 + 16 59

66 100 160 3x25 + 16 72

83 66 100 160 3x25 + 16 72

100 80 125 200 3x50 + 25 87

100

125

100

125

160

200

60 3x10 + 10

100

3x16 + 16

3x25 + 16

125 3x25 + 16

125 3x35 + 16

150 3x35 + 16

110

3x10 + 10

3x16 + 16

3x25 + 16

3x35 + 16

3x50 + 25

100 80 125 200 3x50 + 25 87 70 125 200 150 3x35 + 16 110 3x50 + 25

135 108 160 250 3x70 + 35 117 94 160 250 200 3x70 + 35 145 3x70 + 35

162 130 200 350 3x95 + 50 141 113 200 350 225 3x70 + 35 175 3x95 + 50

(1) The value of the rated current and the motor cable cross-sections are given for information only. As a reminder, the motor rated current permitted by the drive varies according to the switching frequency and the temperature.

(2) The recommended cross-sections have been determined for single-conductor copper cable with a maximum length of 10 m.

For longer cables, take line drops due to the length into account.

Note:

• The cable cross-sections are defined according to the following model:

E.g. for a 100T drive in normal duty, a cable cross-section of (3 x 95 + 50) is given, i.e. 1 bundle consisting of 3 phase conductors

(cross-section 95) and 1 earth conductor (cross-section 50).

• The I co

output currents are given at an ambient temperature of 40°C. For a temperature above 40°C, derate the current by 1.5% for every additional degree up to a maximum temperature of 50°C.

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3.2 - Connection of the control

• The POWERDRIVE FX inputs have a positive logic configuration. Using a drive with a control system which has a different control logic may cause unwanted starting of the motor.

• The POWERDRIVE FX control circuit is isolated from the power circuits by single insulation. Its electronic

0V is connected to the connection terminal on the outer protective conductor (earth terminal). The installer must ensure that the external control circuits are isolated against any human contact.

• If the control circuits need to be connected to circuit conforming to SELV safety requirements, additional insulation must be inserted to maintain the SELV classification (see EN 61140).

3.2.1 - Location of control terminal blocks

Px1

RL2 status relay LED

RL1 status relay LED

P1 P2

1 1 1

Control terminal blocks

Clamps for connecting the control cable shield

Analog I/O

Px1

Px2

Control terminal block

Digital I/O

cross-section

Px3

CONNECTIONS

Px3 Relays

3.2.2 - Characteristics of control terminal blocks

3.2.2.1 - Characteristics of the PX1 terminal block

1 10V

Accuracy

+10 V internal analog source

± 2%

Maximum output current 10 mA

AI1+ Differential analog input 1 (+)

AI1Differential analog input 1 (-)

Factory setting 0-10 V speed reference

±10 V differential bipolar

Input type analog voltage (for common mode, connect terminal 3 to terminal 6)

Absolute maximum voltage range

Voltage range in common mode

Input impedence

Resolution

Sampling period

± 36 V

± 24V / 0 V

> 100 k Ω

11 bits + sign

2 ms

Input filter bandwidth ~ 200 Hz

AI2+ Differential analog input 2 (+)

AI2Differential analog input 2 (-)

Factory setting

Input type

0-20 mA speed reference

Unipolar current

(0 to 20 mA, 4 to 20 mA,

20 to 0 mA, 20 to 4 mA)

Absolute maximum current 30 mA

Voltage range in common mode

Input impedence

Resolution

Sampling period

Input filter bandwidth

± 24 V / 0 V

100 k Ω

12 bits

2 ms

~ 200 Hz

6 0V Analog circuit common 0 V

The 0 V on the electronics is connected to themetal ground of the drive

7 AI3

Factory setting

Input type

Resolution

Sampling period

Analog input 3

No assignment

± 10 V bipolar analog voltage in common mode or unipolar current

(0 to 20 mA, 4 to 20 mA)

11 bits + sign

2 ms

Input filter bandwidth ~ 200 Hz

Voltage range in common mode

Input impedence

Absolute maximum voltage range

± 24 V / 0 V

Voltage mode

> 50 k

± 30 V

Ω

Input impedence

Current mode

100 Ω

Absolute maximum current 30 mA

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8 AO1 Analog output

Factory setting 4-20 mA motor current signal

Output type

Resolution

Sampling period

Voltage range

Load resistance

Current range

Load resistance

Thresholds

Bipolar analog voltage in common mode or unipolar current in common mode

13 bits

2 ms

Voltage mode

± 10 V

1 k Ω minimum

Current mode

0 to 20 mA, 4 to 20 mA

500 Ω maximum

9 DI1/CTP

Factory setting

Sampling period

Voltage range

Trip threshold

PTC thermal sensor or

Digital input DI1

No assignment

2 ms

Motor thermal sensor input

± 10 V

> 3.3 Ω

Reset threshold < 1.8 Ω

Digital input

Type Digital input in positive logic

Voltage range

Absolute maximum voltage range

0 to + 24 V

0V to + 35 V

0: < 5 V

1: > 13 V

10 0V Analog circuit common 0 V

The 0 V on the electronics is connected to the metal ground of the drive

3.2.2.2 - Characteristics of the PX2 terminal block

+24V ref

Output current

Accuracy

Protection

+24 VDC user output or

+24 VDC external input

+24 VDC user output

100 mA

± 5%

Current limitig and setting to trip mode

+24 VDC external input

Rated voltage 24 VDC

Minimum operating voltage 22 V

Absolute maximum voltage 28 V

Recommended power

Recommended fuse

50 W

2.5 A

An external power supply connected to the +24 V Ref terminal is used to maintain the control power supply in the event of mains loss

2 DO1 Digital output

Factory setting

Characteristics

Absolute maximum voltage + 30 V / 0 V

Overload current

Zero speed

Open collector

200 mA

CONNECTIONS

STO-1

STO-2

Drive enable input 1

(Safe Torque Off function)

Drive enable input 2

(Safe Torque Off function)

Input type Positive logic only

Absolute maximum voltage + 30 V

Thresholds

Response time

0: < 5 V

1: > 13 V

< 20 ms

DI2

DI3

DI4

DI5

DI2 factory setting

DI3 factory setting

DI4 factory setting

DI5 factory setting

Digital input DI2

Digital input DI3

Digital input DI4

Digital input DI5

Selection of speed reference

Run FWD/Stop input

Run reverse/Stop input

Type Digital inputs in positive logic

Voltage range

Absolute maximum voltage range

Thresholds

0 to + 24 V

0 to + 35 V

0: < 5 V

1: > 13 V

3.2.2.3 - Characteristics of the PX3 terminal block

1 COM-RL1

N/O (normally open) relay output

2 RL1

Factory setting

Voltage

Drive status relay

250 VAC

Maximum contact current

• 2 A - 250 VAC, resistive load

• 1 A - 250 VAC, inductive load

• 2 A - 30 VDC, resistive load

3 COM-RL2

Voltage

RL2

Factory setting

N/O (normally open) relay output

Maximum contact current

Vmax alarm

250 VAC

• 2 A - 250 VAC, resistive load

• 1 A - 250 VAC, inductive load

• 2 A - 30 VDC, resistive load

• Provide a fuse or other overcurrent protection in the relay circuit.

Note:

When the RL1 or RL2 relay is activated, the corresponding status LED on the control board lights up (see diagram in section 3.2.1).

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Vitesse nulle

Sélection référence

Marche AV/arrêt

Marche AR/arrêt

PX2

+24V ref

DO1

STO-1

DI2

DI3

STO-2

DI4

DI5

+24V ref

CONNECTIONS

3.2.3 -

Factory configuration of control

terminal blocks

Note:

For details of the parameters, refer to the commissioning manual ref.4617.

Référence vitesse 0-10V

Référence vitesse 4-20mA

Image courant

4-20 mA

CTP moteur* 9

PX1

+10V ref

AI1+

AI1-

AI2+

AI2-

AI3

AO1

DI1/CTP

• Modification of the Run/Stop control logic

- For «3-wire» control (job Run/Stop) :

Marche AV 7 DI4

Arrêt 8

DI5

+24V ref

List of parameters to set:

Ctr.06 (06.04) = Run latched (1),

I/O.10 (08.25) = 06.39 Stop sequencing bit

(DI5 terminal)

- For Run/Stop control with change of direction:

Marche/Arrêt 7 DI4

Inversion de sens

DI5

+24V ref

List of parameters to set:

Ctr.06 (06.04) = Run-Fwd/Rev (2),

I/O.09 (08.24) = 06.34 Run/Stop sequencing bit

(DI4 terminal)

I/O.10 (08.25) = 06.33 FWD/Reverse sequencing bit

(DI5 terminal)

• Selection of the reference via digital inputs

DI2 DI3 Selection

Voltage speed reference (0-10 V) on analog input AI1+, AI1-

Current speed reference (4-20 mA) on analog input AI2+, AI2-

Preset reference 2 (RP2)

Spd.05 (01.22) to be set

Relais d’état du variateur (N/O)**

Relais alarme vitesse maximum

PX3

COM-RL1

RL1

COM-RL2

RL2

Note:

This configuration has been obtained from a drive with factory settings (default parameter settings).

The STO-1 and STO-2 inputs must be closed before giving a run command.

(*) By default, the motor sensor detection is disabled. If the motor thermal sensor needs to be connected to DI1/CTP, set

Mtr.06 (05.70) = Drive terminal (1).

(**) RL1 relay opens when at least one of the STO is open.

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CONNECTIONS

3.3 - STO-1/STO-2 inputs: Safe Torque

Off function

The STO-1 and STO-2 inputs are safety inputs that can be used to disable the drive output so that it cannot transmit any torque to the motor.

They are independent of one another. They drive a simple hardware not connected to the microcontroller, which acts on two different stages of the IGBT output bridge control.

To enable the drive, the STO-1 and STO-2 inputs must be connected to the +24V source.

Opening one of the inputs locks the output bridge.

These 2 inputs can be used in conjunction to create a (Safe

Torque Off) function with a 2 separate channel logic.

In this configuration, the «Safe Torque Off» function is guaranteed with a very high level of integrity in conformity with standards:

- EN 61800-5-2

- EN/ISO 13849-1: 2006; PLe

- CEI/EN 62061: 2005; SIL3

(CETIM approval no. CET0047520)

If a safety system, this built-in function enables the drive to act as a substitute for a contactor so that the motor can run in freewheel mode when disabled.

The STO-1 and STO-2 inputs are compatible with self-tested logic outputs in controllers such asPLCs, for which the test pulse lasts for 3 ms maximum.

If the data sent by the 2 inputs is not identical, this generates a drive trip. The RL1 relay opens and the drive indicates a

«t.r./35» trip on the drive 2-digit display or «STO inputs» with a parameter-setting interface.

For correct use, the power and control connection diagrams described in the following paragraphs must be implemented.

• The STO-1/STO-2 inputs are safety components which must be incorporated in the complete system dedicated to machine safety. As for any installation, the integrator must carry out a risk analysis of the whole machine, which will determine the safety category with which the installation must comply.

• The STO-1 and STO-2 inputs, when open, lock the drive, so that the dynamic braking function is no longer available. If a braking function is required before the drive secure disable lock is applied, a time-delayed safety relay must be installed to activate locking automatically after the end of braking.

If braking needs to be a machine safety function, it must be provided by an electromechanical solution since the dynamic braking by the drive function is not considered to be a safety function.

• The STO-1/STO-2 inputs do not provide the electrical isolation function. Before any work is carried out, the power supply must be cut by an approved isolating device (isolator, switch, etc).

3.3.1 - 3-phase AC power supply, in accordance with safety standard IEC/EN 62061: 2005 and

EN/ISO 13849-1: 2006 - Single channel locking

(SIL1 - PLb)

L1 L2 L3 PE

Marche AV / Arrêt

Marche AR / Arrêt

Marche AV / Arrêt

Marche AR / Arrêt

POWERDRIVE FX

Px2

+24V Ref

DO1

STO-1

DI2

DI3

STO-2

DI4

DI5

+24V Ref

U V W PE

3.3.2 - 3-phase AC power supply, in accordance with safety standard IEC/EN 62061: 2005 and

EN/ISO 13849-1: 2006 - Double channel locking with feedback (SIL3 - PLe)

L1 L2 L3 PE

POWERDRIVE FX

Px2

+24V Ref

DO1

STO-1

DI2

DI3

STO-2

DI4

DI5

+24V Ref

U V W PE

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GENERAL EMC - HARMONICS - MAINS INTERFERENCE

4 - GENERAL EMC - HARMONICS -

MAINS INTERFERENCE

The power structure of frequency inverters leads to the occurrence of two types of phenomena:

- Low-frequency harmonics fed back to the mains supply,

- Emission of radio-frequency signals (RFI).

These are independent phenomena. They have different consequences on the electrical environment.

4.1 - Low-frequency harmonics

The rectifier, at the head of the frequency inverter, generates a non-sinusoidal AC line current.

Courant de ligne consommé par un redresseur triphasé

This current carries harmonics with number 6n ± 1.

The POWERDRIVE FX THDI level is less than 32%: significantly less than the maximum level defined by standard

IEC 61000-3-12 (< 45%).

4.2 - Radio-frequency interference:

Immunity

4.2.1 - General

The immunity level of a device is defined by its ability to operate in an environment which is polluted by external elements or by its electrical connections.

4.2.2 - Standards

Each device must undergo a series of standard tests

(European standards) and meet a minimum requirement in order to be declared as compliant with the variable speed drive standards (EN 61800-3).

4.2.3 - Recommendations

An installation consisting exclusively of devices which comply with the standards concerning immunity is very unlikely to be subject to a risk of interference.

4.3 - Radio-frequency interference:

Emission

4.3.1 - General

Frequency inverters use high-speed switches (transistors, semi-conductors) which switch high voltages (around 550 V) and currents at high frequencies (several kHz). This provides better efficiency and a low level of motor noise.

As a result, they generate radio-frequency (R.F.) signals which may disturb operation of other equipment or distort measurements taken by sensors:

- Due to high-frequency leakage currents which escape to earth via the stray capacity of the drive/motor cable and that of the motor via the metal structures which support the motor;

- By conduction or feedback of R.F. signals on the power supply cable: conducted emissions ;

- By direct radiation near to the mains supply power cable or the drive/motor cable: radiated emissions .

These phenomena are of direct interest to the user.

The frequency range concerned (radio frequency) does not affect the energy supply company.

4.3.2 - Standards

The maximum emission level is set by the standards for variable speed drives (EN 61800-3).

4.3.3 - Recommendations

• Experience shows that the levels set by the standards do not necessarily need to be observed to eliminate interference phenomena.

• Following the basic precautions described in section 4.5 generally results in the correct operation of the installation.

4.4 - Mains supply power

4.4.1 - General

Each industrial power supply has its own intrinsic characteristics

(short-circuit capability, voltage value and fluctuation, phase imbalance, etc) and supplies equipment some of which can distort its voltage either permanently or temporarily (notches, voltage dips, overvoltage, etc). The quality of the mains supply has an impact on the performance and reliability of electronic equipment, especially variable speed drives.

The POWERDRIVE FX is designed to operate with mains supplies typical of industrial sites throughout the world.

However, fo each installation, it is important to know the characteristics of the mains supply in order to carry out corrective measures in the event of abnormal conditions.

4.4.2 - Mains transient overvoltages

There are numerous sources of overvoltages on an electrical installation:

• Connection/disconnection of banks of power factor correction capacitors,

• High-power thyristor-controlled equipment (oven, DC drive, etc),

• Overhead power supply.

4.4.2.1 - Connection/disconnection of a bank of cos j correction capacitors

Connecting power factor correction capacitors in parallel on the drive power supply line when the drive is running can generate transient overvoltages that are likely to trip the drive safety devices, or even damage it in extreme cases.

If banks of power factor correction capacitors are used on the power supply line, make sure that:

• The threshold between steps is low enough to avoid causing overvoltage on the line,

• The capacitors are not permanently connected.

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GENERAL EMC - HARMONICS - MAINS INTERFERENCE

4.4.2.2 - Presence of commutation notches on the line

When high-power thyristor-controlled equipment is connected on the same line as the drive, it is essential to ensure that the harmonics generated by the commutation notches do not excessively distort the mains voltage and do not create voltage peaks with amplitude higher than 1.6 x mains Vrms. If this is the case, it is essential to take corrective measures to guarantee the mains quality.

4.4.2.3 - Overhead power supply

An overhead power supply is not allowed for the

POWERDRIVE FX .

4.4.3 - Mains short-circuit power

As with all variable speed drives, the mains short-circuit power to which the POWERDRIVE FX is connected has an effect on its behaviour. Notably, when the mains short-circuit power is low, voltage oscillations may appear due to resonances between the inductive impedance of the mains and the filtering capacity of the POWERDRIVE FX . To avoid the POWERDRIVE FX tripping because of these oscillations, make sure that the ratio R

M) is higher than 50. sc

= I sc

/(n x I

Where: sc

: Mains short-circuit current at the point of connection

I n: Number of POWERDRIVE FX drives connected on the same power supply line

M: POWERDRIVE FX rated input current

As a matter of course, check that:

• The sum of the power of all POWERDRIVE FX drives connected to the same transformer does not exceed 35% of the total transformer rated power.

• The sum of the power of the POWERDRIVE FX drives installed on a generator does not exceed 20% of its rated power.

4.4.4 - Ground connections

The earth equipotential of some industrial sites is not always observed. This lack of equipotential leads to leakage currents which flow via the earth cables (green/yellow), the machine chassis, the pipework, etc, and also via the electrical equipment. In some extreme cases, these currents can trip the drive.

It is essential that the earth network is designed and implemented by the installation supervisor so that its impedance is as low as possible, so as to distribute the fault currents and high-frequency currents without them passing through electronic equipment.

Metal grounds must be mechanically connected to each other with the largest possible electrical contact area. Under no circumstances can the earth connections designed to protect people, by linking metal grounds to earth via a cable, serve as a substitute for the ground connections (see IEC 61000-5-2).

The immunity and radio-frequency emission level are directly linked to the quality of the ground connections.

4.5 - Basic precautions for installation

These are to be taken into account when wiring the cabinet and any external components. In each paragraph, they are listed in decreasing order of effect on correct operation of the installation.

4.5.1 - Wiring inside the cabinet

- Do not run the control cables and the power cables in the same cable ducts.

- For control cables, use shielded twisted cables.

4.5.2 - Wiring outside the cabinet

- Connect the motor earth terminal directly to that of the drive.

It is recommended that a shielded symmetrical cable is used: three phase conductors and coaxial or symmetrical PE conductor and shielding.

A separate PE protective conductor is mandatory if the conductivity of the cable shielding is less than 50% of the conductivity of the phase conductor.

- The shielding must be connected at both ends: drive end and motor end (completely connected).

- In the second industrial environment, the shielded motor power supply cable can be replaced by a 3-core + earth cable placed in a fully enclosed metal conduit (metal cable duct for example). This metal conduit must be mechanically connected to the electrical cabinet and the structure supporting the motor.

If the conduit consists of several pieces, these should be interconnected by braids to ensure earth continuity. The cables must be fixed securely at the bottom of the conduit.

- There is no need to shield the power supply cables between the mains supply and the drive.

- Isolate the power cables from the control cables. The power cables must intersect the other cables at an angle of 90°.

- Isolate sensitive elements (probes, sensors, etc.) from metal structures which may be shared by the motor support.

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GENERAL EMC - HARMONICS - MAINS INTERFERENCE

4.6 - Electromagnetic compatibility (EMC)

CAUTION:

Conformity of the drive is only assured when the mechanical and electrical installation instructions described in this manual are adhered to.

Standard Description

Immunity

Application Conformity

IEC/EN 61000-4-2

IEC/EN 61000-4-3

Electrostatic discharges

Immunity standards for radiated radio-frequency

Product casing

Level 3 (industrial)

Control cable Level 4 (industrially hardened)

IEC/EN 61000-4-4 Bursts of fast transients

Power cable Level 3 (industrial)

IEC/EN 61000-4-5

IEC/EN 61000-4-6

EN 50082-2

IEC/EN 61000-6-2

IEC/EN 61800-3

EN 61000-3

Shock waves

Generic immunity standards for conducted radio-frequency

Generic immunity standards for the industrial environment

Variable speed drive standards

Power cables

Control and power cables

Level 4

Level 3 (industrial)

Conforming

Conforms to categories C1, C2 and C3

Standard

EN 61800-3

Categories

Size 2*

Cable length < 10 m

Frequency < 5 kHz

Cable length < 100 m

Frequency < 8 kHz

Emission

Size 3*

Cable length < 10 m

Frequency < 5 kHz

Cable length < 100 m

Frequency < 5 kHz

Size 2 or 3 with external filter*

To be defined

Cable length < 100 m

Frequency < 5 kHz

Frequency < 16 kHz C3

* With shielded cables

• In accordance with IEC 61800-3, in a residential environment, this device may cause radio-electrical interference.

In this case, the user may be asked to take appropriate action.

Standard

Low-order harmonics

Size 2 Size 3

THD according to EN 61000-3-12 (1) Conforming to I

M > 200 (2) Non applicable

(1) Limits for harmonic currents produced by equipment connected to public low-voltage systems with input current > 16A and ≤ 75A per phase.

(2) I

: Mains short-circuit current at the interface between the user's power supply and the public mains supply.

M: see table in section 3.1.3.

It is the responsibility of the equipment user and/or the installer to ensure, if necessary by consulting the distribution system manager, that the equipment is only connected to one power supply so that the short-circuit capability is higher than that stated in the table.

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5 - OPTIONS

5.1 - Operator interfaces

5.1.1 - Connection to the drive

Connector for optional fieldbus and/or speed feeback

OPTIONS

As soon as it is swithched on , the MDX-KEYPAD is set to read mode. The buttons are used to scroll through the all parameters required for supervision and diagnostics:

- Motor current,

- Motor frequency,

- Motor voltage,

- Analog I/O levels,

- Digital I/O states,

- Logic function states,

- Timer.

D A

Connector for

MDX-KEYPAD or

MDX-Powerscreen display

P1 P2 Px1 Px2 Px3

USB connector linked to door USB socket

1 1

5.1.1.1 - P1 connector

This connector is a slave type B USB socket, and is used to communicate via PC using the MDX-SOFT software.

• In conformity with standard EN60950, the USB link can only be used via a device that provides isolation of 4kV (MDX-USB isolator option).

5.1.1.2 - P2 terminal block

This is a standard RS485/RS422 terminal block which is used to connect a parameter-setting interface or to communicate via Modbus RTU.

Terminals

Designation

Rx\, Tx\

Rx, Tx

24V

5.1.2 - MDX-KEYPAD

5.1.2.1 - General

This keypad, which is remote from the drive, makes it easy to set up the POWERDRIVE FX and provides access to all parameters. Its LCD display, consisting of one line of 12 characters and 2 lines of 16 characters, offers text which can be displayed in 5 languages (English, French, German, Italian and Spanish).

The MDX-KEYPAD has 2 main functions:

- A read mode for POWERDRIVE FX supervision and diagnostics

- Access to all the POWERDRIVE FX parameters in order to optimise settings or even configure particular applications.

Pos.

Function

3-line backlist LCD display indicating:

- The drive operating status and its lain data,

- The main adjustment parameters via a “ Quick parameter setting ” menu,

- All the drive parameters via 21 “ Advanced parameter setting ” menus (access via a code).

Green button for run command if control via the keypad is enable.

See “ Parameter setting via the keypad ”.

Red button for drive reset or to give a stop command if control via the keypad is enabled.

See parameters Ctr.05 (6.43) and 06.12

Blue button for change of direction of rotation if control via the keypad is enabled.

See parameter Ctr.05 (6.43) .

Navigation button ( , , , ) for moving through the various menus and changing the contents of parameters.

button for storing settings and changing mode

(display, read, set parameters).

G “?” button not used.

For more information, see the commissioning manual ref.4617. This manual describes configuration using the

MDX-Powerscreen parameter-setting interface, but the commissioning procedure also applies to the MDX-KEYPAD.

5.1.2.2 - Installation

The MDX-KEYPAD does not require any special installation.

Simply connect it via its 1.5 metre cable (supplied with the keypad), as shown in section 5.1.1.

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OPTIONS

5.1.3 - MDX-Powerscreen

5.1.3.1 - General

The interface is a touch screen which can be used to access various menus. It is supplied with its own connection cable

(2 metres).

After the loading phase following powering-up of the drive, the parameter-setting interface displays the screen below.

At any time and regardless of the screen displayed, the button can be used to return to previous pages, as far as the interface main page.

For further information, see the commissioning manual ref.4617.

5.1.3.3 - Installation

The interface is through-panel-mounted in the front of a cabinet (IP65/NEMA 4 pounting).

Plan de découpe

120 mm

94 mm

102 mm

128 mm

Ref.

Function

4.3” touch screen

Touch-sensitive button for access to the main menu

"PWR" LED, indicates the state of the interface power supply

Touch-sensitive buttons for language selection

(can take a few minutes to load)

5.1.3.2 - Architecture

From the welcome screen, press the button to access the main page of the parameter-setting interface, consisting of 5 touch-sensitive buttons:

- Information : Can be used to obtain information very quickly about the drive, the fieldbus option, the parameter-setting interface, and can also be used to select the language.

- Read mode : Is used to display the status of the drive when stopped or during operation, as well as its main measurement points.

- Setting : Used for reading and/or modification of all the drive parameters, as well as to set the date and time on the display.

- Control via keypad : Gives dirtect access to motor control via the touch screen (Run/Stop, direction of rotation, speed reference). These screen parameters can be set using the

Parameter setting/Parameter setting via the keypad menu.

Control via the keypad is disabled in factory-set configuration.

- Trip history : Gives a quick overview of the drive's last 10 trips.

- : This button is accessible from all screens in factoryset configuration and is used to give a stop command (can be disabled).

5.1.4 - MDX-SOFT

The MDX-SOFT enables parameter setting or supervision of the POWERDRIVE FX from a PC. Numerous functions are available:

- Fast commissioning

- LEROY-SOMER motor database

- File saving

- Online help

- Comparison of 2 files or one file with the factory settings

- Printing of a complete file or differences compared to the factory settings

- Supervision,

- Diagnostics

To connect the PC to the POWERDRIVE FX, use an

"MDX-USB Isolator" isolated USB cable.

This software can be downloaded from the Internet at the following address: http://www.emersonindustrial.com

Powerdrive FX can be set via the USB connector, even if the drive is not powered.

Attention. In this case, options modules will not be powered and settings will not be saved. To make an option module setting / backup , it is necessary to provide an auxiliary power supply.

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5.2 - Add-on options

5.2.1 - Connector and shielding bracket

OPTIONS

5.2.3 - Fieldbus options

Depending on the configuration of the speed feedback and inputs/outputs optional modules, two types of fieldbus are proposed.

pour option et/ou MDX-ENCODER

P1 P2 Px1 Px2 Px3

• To connect the optional modules to the drive control board connector, remove the back plastic protective cover.

• The bracket for connecting the option shielding is supplied with each option. To attach it, screw the bracket in the location indicated below, placing it over the control cable shielding clamps

(the shielding clamp furthest to the right should be removed).

MDX : option to be fitted to the control board (white color)

Association table:

Main option

None

MDX-ENCODER

MDX-RESOLVER

MDX-I/O Lite

MDX I/O M2M

MDX-ENCODER +

MDX I/O M2M

MDX-RESOLVER +

MDX I/O M2M

CM : compact module to be integrated in an existing

MDX board

Fieldbus

MDX version CM version

5.2.2 - Fieldbus, speed feedback and I/O options

The control board is designed to be plugged with various optional modules. Several options can be combined:

• Fieldbus options (see section 5.2.3)

• Speed feedback options (see section 5.2.4)

• I/O options (see section 5.2.5).

Fieldbus modules can be used to communicate with the corresponding networks respective. They can be integrated in and are supplied by the drive.

The following fieldbus are available on Powerdrive FX :

• MDX/CM-MODBUS : Modbus RTU (RS485/232)

• MDX/CM-ETHERNET : Modbus TCP (Ethernet)

• MDX/CM-ETHERNET-IP : EtherNet/IP

• MDX/CM-PROFIBUS : Profibus DP V1

• MDX/CM-PROFINET : ProfiNet

For more details, consult the specific documentations.

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5.2.4 - Speed feedback options

OPTIONS

Two options are available to manage the motor speed feedback:

•

MDX-ENCODER : The MDX-ENCODER option is used to manage incremental encoders with or without commuation channels (up to 500kHz).

•

MDX-RESOLVER : The MDX-RESOLVER option is used to manage 2 to 8 poles resolvers.

For more details, consult the specific documentations.

5.2.5 - Additional I/O options

Two options are available to increase the number of inputs / outputs of the Powerdrive FX :

MDX-I/O Lite MDX-I/O M2M

Functions

Analog input (V, mA)

Differential analog input (V, mA)

Analog outputs (V, mA)

Motor thermistor

KTY84-130 or PT100

Digital inputs

Digital outputs

Assignable relay

Drive forced fan's management

Real time clock

Ethernet connection:

• WEB pages: drive configuration and status

• 2 programmable emails

• Configuration backup & restoration

Datalogger



MDX-I/O

Lite

For more details, consult the specific documentations.



MDX-I/O

M2M



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5.3 -

RFI filters

5.3.1 - General

The use of RFI filters contributes to a reduction in the emission levels of radio-frequency signals. They are used to improve conformity of the drive with standard EN 61800-3 on conducted and radiated radio-frequency emissions (see section 4.6).

Depending on the drive used, install the RFI filter (recom mended in the table below) between the mains and the drive input.

RFI filter

POWERDRIVE

FX rating

Reference

I nom at 40°C

(A)

33T FS 6008-62-07 62

40T and 50T FS 6008-101-35 101

60T to 100T FN 3359-180-28 197

Leakage current

(mA)

Losses

(W)

CAUTION:

The specific design of these filters makes it possible to use them in the context of installations with a neutral IT point connection. The installer must however check that the insulation control systems dedicated to these installations are suitable for monitoring electrical equipment that may incorporate electronic variable speed drives.

OPTIONS

5.3.2 - Weight and dimensions

• FS 6008-62-07 and FS 6008-101-35

L1 L2 L3

Ø6,5mm

H H1

6,5mm

6,5

16mm 2

LINE

LOAD

M10

Type

Dimensions (mm)

L L1 H H1 H2 P P1 P2

Weight

(kg)

FS 6008-62-07 250 210 414 396 361 60 30 3.5

FS 6008-101-35 100 65 300 275 260 225 170 1.5

• FS 3359-180-28

H1 H

Ø1

L1 L1

Type

Dimensions (mm)

L L1 H H1 P Ø1 M

Masse

(kg)

FN 3359-180-28 360 120 210 185 120 12 M10 6.5

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TRIPS - DIAGNOSTICS

6 - TRIPS - DIAGNOSTICS

• The user should never attempt either to repair the drive himself, or to perform any other diagnostics than those listed in this section. If the drive malfunctions, it should be returned to LEROY-SOMER via your usual contact.

In cases where the POWERDRIVE FX is not connected to an operator interface, it is still possible to find out the drive status

(including trips and alarms) thanks to two 7-segment displays located on the drive control board.

P1 P2 Px1

Afficheurs

7 segments

Px2 Px3

6.1 - Drive status

When the drive is not in the trip or alarm state, the displays provide information about the drive status when stopped or running.

The LEDs display alternately a 2-letter code and a number that can be used to find out the drive status using the table below (this number corresponds to the value of parameter

10.98

IH : "Inhibit"

OP : "Operating"

St : "Stop"

Lt : "Limit" rd : "Ready"

CH : "Check" tr : "Trip" (see section 6.3)

Code No.

Lt rd

Meaning

Drive disabled

Drive disabled with run command present, but STO-1 and STO-2 not connected or 06.15

. Drive output set to

"Inhibit".

• Depending on the control logic selected in 06.04 (Ctr.06) , the motor can start as soon as the drive is enabled.

Drive enabled, motor (on load) 1

2 Drive enabled, generator (driving load)

27 Catch a spinning motor

28 Delay before start

29 Delay before flying restart

31 Supply voltage < minimum voltage

3 Stop on ramp, clockwise, motor

Stop on ramp, clockwise, generator

Stop on ramp, anti-clockwise, motor

Stop on ramp, anti-clockwise, generator

Stop with low-frequency current injection, clockwise, motor

Stop with low-frequency current injection, clockwise, generator

Stop with low-frequency current injection, anti-clockwise, motor

Stop with low-frequency current injection, anti-clockwise, generator

15 DC injection, clockwise, motor

16 DC injection, clockwise, generator

17 DC injection, anti-clockwise, motor

18 DC injection, anti-clockwise, generator

19 Current limit, clockwise, motor

20 Current limit, clockwise, generator

21 Current limit, anti-clockwise, motor

22 Current limit, clockwise, generator

23 BUS voltage limit, clockwise, motor

24 BUS voltage limit, clockwise, generator

25 BUS voltage limit, anti-clockwise, motor

BUS voltage limit, anti-clockwise, generator

32 Drive healthy

33 Autotune

35 Test of boards (control/interface)

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6.2 - Alarms

Alarms may appear during drive operation.

These alarms are for information only, in order to warn the user: the drive continues to operate but may switch to fault mode if no corrective action is taken.

The LEDs display alternately "A.L." and a number that can be used to identify the alarm by means of the table below (this number corresponds to the value of parameter 10.97

Code No.

1 to

A.L.

Meaning

User alarm 1 ( 10.54

) to

User alarm 4 ( 10.57

)

Motor overload ( 10.17

)

Drive overheating ( 10.18

)

Microcontroller overoccupancy

9 Rectifier

10 Emergency operation (see menu 20)

6.3 - Trips

If the drive trips, the output bridge is inactive and the drive no longer controls the motor.

TRIPS - DIAGNOSTICS

The LEDs display alternately "t.r." and a number that can be used to identify the trip by means of the table below (this number corresponds to the value of parameter 10.99

). For trips numbered higher than 100, only the last 2 digits are displayed with a point displayed on both LEDs to indicate the hundred.

Example :

/ : indicates trip no. 1

/ : indicates trip no. 101

After consulting the table, follow the procedure below:

- Make sure that the drive is disabled (STO-1 and STO-2 terminals open)

- Isolate the drive power supply

- Carry out the necessary checks in order to eliminate the reason for the trip

- Activate the STO-1 and STO-2 inputs to cancel the trip

• Opening and then closing the STO-1/STO-2 drive enable terminals may cancel the trip. If the Run FWD or

Run reverse terminal is closed at the time of resetting, the motor may or may not start immediately, depending on the setting of Ctr.06

( 06.04

No.

DC bus undervoltage

DC bus overvoltage

Motor current imbalance: vectorial sum of the 3 motor currents not zero

6 Loss of a motor phase

Reason for trip

Overcurrent at drive output

Possible cause and corrective actions

• Check the quality of the power supply (voltage dips)

• Check the input fuses

• Check that the mains voltage is within the permitted tolerance

• Check the quality of the power supply (commutation notches or transient overvoltages)

• Check the motor insulation

• Check the motor cables (connections and insulation)

• Check the quality of the mains supply

• Check the motor insulation

• Check the cable insulation

Check the motor cable and resistance values between motor phases

Check the drive settings 7

The speed is higher than (1.3 x 01.06

) or

( 01.06

+ 1000 min -1 )

The drive overload level exceeds the conditions defined in section 1.4.2

9 Internal protection of phase U IGBTs

10 Overheating of the rectifier bridge IGBTs

• Check the drive is suitable for the load

• Check the ambient temperature

Check the motor and cable insulation

• Clean the cabinet dust filters

• Check the drive ventilation units are working correctly

• Check that the product air inlet temperature is not outside the limits

• Check the encoder wiring

• Check that the motor shaft turns

The encoder u, v, w commutation signals are not connected correctly (only if the MDX-ENCODER option is present)

Check the conformity of the encoder wiring

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TRIPS - DIAGNOSTICS

No.

Reason for trip

During the autotune phase, one of the encoder U, V or W commutation channels is not present

20 Motor thermal overload

21 Overheating of the phase U IGBTs

Possible cause and corrective actions

• Check the encoder wiring

• Check the encoder connections

• Change the encoder

Repeat the autotune procedure (see 05.12

)

• Make sure that the motor duty cycle does not exceed its thermal capacity

• Check the setting of 04.15

"Thermal time constant" with respect to the application

• Clean the cabinet dust filters

• Check the drive ventilation units are working correctly

• Check that the product air inlet temperature is not outside the limits

• If the trip appears at frequencies lower than 10 Hz, check that the limit conditions given in section 1.4.3 have been complied with

• Check the ambient temperature around the motor

• Check that the motor current is less than the stated current

• Check the thermal sensor wiring

Check the I/O wiring 26 Overload on the +24V or digital output power supply

28 Loss of the current reference on analog input AI2

29 Loss of the current reference on analog input AI3

Check the input wiring ans source

33 Problem during measurement of the stator resistance

Loss of communication on the P2 connector serial link

Number of write cycles to EEPROM exceeded

(> 1,000,000)

Encoder break

Breakdown of synchronous motor in sensorless closed loop mode

39 The rectifier connot synchronise with the mains supply

• Check the cable connections

• Check the parameter 11.63 is compatible with the timing of requests from the master

• Change the control board

• Check the recurrence of write cycles from the drive controller

Check the motor wiring

• Check the fieldbus connections

• Check that parameter 15.07

is compatible with the timing of requests from the master

Check the remote control link

• Check the encoder wiring

• Check the encoder connections

Check the menu 5 parameters are compatible with the values on the motor nameplate

Check the quality of the power supply (commutation notches)

Check that the MDX-ENCODER module is properly attached

41 User trip 1 triggered by 10.61

42 User trip 2 triggered by 10.63

43 User trip 3 triggered by 10.65

44 User trip 4 triggered by 10.67

45 User trip 5 triggered by the serial link 10.38 = 45

46 User trip 6 triggered by the serial link 10.38 = 46

47 User trip 7 triggered by the serial link 10.38 = 47

48 User trip 8 triggered by the serial link 10.38 = 48

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TRIPS - DIAGNOSTICS

No.

Reason for trip

49 User trip 9 triggered by the serial link 10.38 = 49

Possible cause and corrective actions

50 User trip 10 triggered by the serial link 10.38 = 50

51 The DO2 output load current (MDX-I/O option) is > 200 mA Check that DO2 is not short-circuited

52 The DO3 output load current (MDX-I/O option) is > 200 mA Check that DO3 is not short-circuited

Communication problem between the drive and the

MDX-I/O option

Check the MDX-I/O option mounting

54 Communication problem between the drives -

56 Internal protection of phase V IGBTs

57 Internal protection of phase W IGBTs

Check the motor and cable insulation

Overheating of phase V IGBTs

Overheating of phase W IGBTs

A problem is detected during the control board and interface test

Overload on the +10 V power supply

The DO1 output load current is > 200 mA

• Clean the cabinet dust filters

• Check the drive ventilation units are working correctly

• Check that the product air inlet temperature is not outside the limits

• If the trip appears at frequencies lower than 10 Hz, check that the limit conditions given in section1.4.3 have been complied with

Refer to parameters 17.05

, 17.08 and 17.09 in the diagnostics menu in commissioning manual ref. 4617

Check the remote control link for the STO-1 and STO-2 inputs

Check the I/O wiring

Check that DO1 is not short-circuited

67 The internal ventilation is not working (50T and 100T only) Get in touch with your usual LEROY-SOMER contact

The current has exceeded the limit programmed in 05.55

The load is too high for the setting

69 The 24V load current is too high Check the MDX-I/O option I/O wiring

Loss of the current reference on analog input AI5 of the

MDX-I/O option

101 Mains loss

102 Loss of rectifier synchronisation with the mains

Check the input wiring and source of the MDX-I/O option

• Check the input fuses

• Check the quality of the power supply (voltage dips)

Check the quality of the power supply (commutation notches)

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MAINTENANCE

7 - MAINTENANCE

• All work relating to installation, commissioning and maintenance must be carried out by experienced, qualified personnel.

• When a trip detected by the drive causes it to switch off, fatal residual voltages remain at the output terminals and in the drive.

• Before carrying out any work, disconnect and lock the drive power supply.

• Switch off the drive and external control circuits before working on the control cables (the external control circuits can still retain a considerable amount of voltage).

• All protective covers must remain in place during tests.

• Before performing high voltage tests or voltage withstand tests on the motor, switch off the drive and disconnect the motor.

• After working on the motor, check that the phase order is correct when re-connecting the motor cables.

• When the drive controls a permanent magnet motor, only one motor can be connected to the drive output. It is advisable to install a safety switch between the permanent magnet synchronous motor and the drive output. This breaker isolates the motor during maintenance work on the drive.

There are very few maintenance and repair operations to be performed by the user on POWERDRIVE FX drives. Regular servicing operations are described below.

7.1 - Servicing

Printed circuits and the drive components do not normally require any maintenance. Contact your vendor or the nearest approved repair company in the event of a problem.

CAUTION:

Do not dismantle the printed circuits while the drive is still under warranty, as this would then immediately become null and void.

Do not touch the integrated circuits or the microprocessor either with your fingers or with materials which are charged or live. Earth yourself, as well as the workbench or the soldering iron, when performing any work on the circuits.

From time to time, with the drive powered down, check that the power connections are correctly tightened. The door filters must be checked and changed regulary depending on their state.

7.2 - Storage

If the drive has been stored for more than 3 years, it is essential to switch on the drive for 24 hours, and repeat this operation every 6 months.

7.3 -

Exchanging products

CAUTION:

Products must be returned in their original packaging or, if thius is not possible, in similar packaging, to prevent their being damaged. Otherwise, replacement under warranty could be refused.

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UL LISTING INFORMATION

8 - UL LISTING INFORMATION

The POWERDRIVE FX file number is E211799.

Confirmation of UL listing can be found on the UL website: www.ul.com

8.1 - Common UL information

Conformity

The drive conforms to UL listing requirements only when the following are observed:

• The drive is installed in a type 1 enclosure, or better, as defined by UL50

• The surrounding air temperature does not exceed 40°C

(104°F) when the drive is operating

• The terminal tightening torques specified in section 3.1

"Connection of the power" are respected

• If the drive control stage is supplied by an axternal power supply (+24V), the external power supply must be a UL

Class 2 power supply

Motor overload protection and Over speed protection

The drive does not incorporate solid state overload protection for the motor load. The drive provides overspeed protection.

However, it does not provide the level of protection afforded by an independent high integrity overspeed protection device.

Options

The MDX options are not UL-listed.

8.2 -

AC supply specification

The drive is suitable for use in a circuit capable of delivering not more than 18,000rms symmetrical Amperes.

8.3 -

Maximum continuous current

The drive models are listed as having the maximum continuous output currents (ISu) and maximum input currents (ILu) below

Size

Rating

33T

40T

50T

60T

75T

100T

ISu (A)

110

145

165

ILu (A)

100

115

145

8.4 - Fusing and cabling

The drive conforms to UL listing requirements only when the following is observed:

- The UL-listed class J fact acting fuses (Bussman Limitron

KTK-R series, Ferraz Shawmut ATMR series or equivalent) indicated in the section 3.1.3 are used in the AC supply.

- UL listed closed-loop connectors sized according to the field wiring are used for power connections.

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38 POWERDRIVE FX Installation guide

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IMP297NO582

Moteurs Leroy-Somer

Headquarter: Boulevard Marcellin Leroy - CS 10015

16915 ANGOULÊME Cedex 9

Limited company with capital of 65,800,512

€

RCS Angoulême 338 567 258 www.leroy-somer.com

Installation guide

POWERDRIVE FX

Parameter setting

Options

• RFI filter

• Encoder or resolver input

• Additional I/O

• Datalogger

• Communication options

MDX-Powerscreen parameter-setting interface

MDX-KEYPAD MDX-SOFT parameter-setting software

+ PC link cable

Gearboxes

Compabloc

• Axial output

- Helical gears

Orthobloc

• Orthogonal output

- Helical bevel gears

Motors

LS-FLS motor

LSMV motor

HPM motor

Motor options

Axial forced ventilation

Encoder/Sensor

Brake

Radial forced ventilation

LSRPM motor

Front view

Side view

Front view

Side view

Drill hole diagram Side view

Drill hole diagram

Side view

Losses, ventilation flow rate and noise levels

Ratings 33T to 50T (size 2)

Ratings 60T to 100T (size 3)

RL2 status relay LED

RL1 status relay LED

Control terminal blocks

Clamps for connecting the control cable shield

Factory configuration of control

Off function

POWERDRIVE FX

POWERDRIVE FX

•

•

RFI filters

Exchanging products

AC supply specification

Maximum continuous current

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