Schneider Electric Altivar 61 Variable Speed Drive
Contents
1. 29 1 1 SIMPLY START SIM 30 Faults and Troubleshooting 35 Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 3 Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 4 Setting Up the Drive Controller 1 Take delivery of the drive controller Ensure that the catalog number printed on the label is the same as that on the purchase order Remove the drive controller from its packaging and check that it has not been damaged in transit 2 Check the line voltage Ensure that the line voltage is compatible with the voltage range of the drive controller 3 Mount the drive controller Mount the drive controller according to the instructions in this document Install and connect the DC choke page 7 Install any internal and external options 4 Wire the drive controller page 16 Connect the motor ensuring that its connections correspond to the voltage With power off connect the line supply Connect the control wiring Connect the speed reference Steps 1 to 4 must be perfo2. Terminals Function Electrical characteristics P24 Input for external 24 V 424 V min 19 V max 30 V control power supply Power 30 W OV Logic input common and OV of OV P24 power supply Li Programmable logic inputs 424 V max 30 V LI2 Impedance 3 5 Reaction time 2 ms 0 5 ms LI3 Ll4 SW1 switch State 0 State 1 Source factory setting lt 5V gt 11V LIS Sink Int or Sink Ext gt 16V 10V 116 Depending on the position of SW 2 switch on LI factory setting the SW2 switch Same characteristics as logic inputs 111 to LI5 Programmable logic input or or SW2 switch on PTC Input for PTC probes Trip threshold 3 kQ reset threshold 1 8 Short circuit detection threshold lt 50 Q 24 Logic input power supply SW1 switch in Source or Sink Int position Internal 24 V power supply min 21 V max 27 V protected against short circuits and overloads 200 mA maximum current SW1 switch in Sink Ext position Input for external 24 V power supply for the logic inputs PWR Power Removal safety 24 V max 30 V When PWR is not connected State 0 if lt 2 V state 1 if gt 17 V to 24 V the motor cannot be Reaction time 10 ms started compliance with functional safety standard EN 954 1 and IEC EN 61508 function input Impedance 1 5 Note AO temperature variation Logic I O option card terminals VW3A3201 Characteristics an
3. 36 Faults that can be reset with the automatic restart function after the cause has been removed LOSS OF PERSONNEL AND EQUIPMENT PROTECTION Enabling the fault inhibition parameter InH will disable the drive controller protection features nH should not be enabled for typical applications of this equipment nH should only be enabled in extraordinary situations where a thorough risk analysis demonstrates that the presence of adjustable speed drive protection poses a greater risk than personnel injury or equipment damage Failure to follow these instructions will result in death or serious injury These faults can also be reset by turning the drive controller off then on again or by means of a logic input or control bit consult the CD ROM supplied with the drive controller APF CnF EPF1 EPF2 FCF2 LFF2 LFF3 LFF4 nFF ObF OHF OLC OLF OPF1 OPF2 OSF OtF1 OtF2 OtFL PHF PtF1 PtF2 PtFL SLF1 SLF2 SLF3 SPIF SSF tJF and ULF faults can be inhibited and cleared remotely by means of a logic input or control bit consult the CD ROM supplied with the drive controller Fault Probable cause Remedy APF Application fault Controller internal card Refer to the card documentation fault EnF Com network Communication fault Check the environment electromagnetic communication card compatibility Checkthe wiring e Check the time out Repl
4. 3 seconds Y 5 LANGUAGE English Switches to 5 LANGUAGE menu automatically Select the language and press ENT Chinese RDY Term 0 00Hz REM 2 ACCESS LEVEL Switches to 2 ACCESS LEVEL menu consult the CD ROM supplied with the drive controller Select the access level and press ENT RDY Term 0 00Hz REM 1 DRIVE MENU 1 1 SIMPLY START 1 2 MONITORING 1 3 SETTINGS 1 4 MOTOR CONTROL 1 5 INPUTS OUTPUTS CFG Switches to 1 DRIVE MENU consult the CD ROM supplied with the drive controller RDY Term 0 00Hz REM MAIN MENU 1 DRIVE MENU Press ESC to return to MAIN MENU 2 ACCESS LEVEL OPEN SAVE AS Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 28 Integrated Display Terminal Low power Altivar 61 drives see catalog feature an integrated display terminal with a 7 segment 4 digit display The graphic display terminal described on the previous pages can also be connected to these drive controllers as an option Functions of the display and the keys i Exits a menu or aa parameter or aborts the increases the displayed value to return to the previous value in the 1 ispl val M displayed value D memory Goes to the next menu 1 7 Enters a menu or a or parameter or j parameter or saves the decreases the displayed parameter or displa
5. Protect the signal conductors against damage that could result in unintentional conductor grounding Follow NFPA 79 and EN 60204 guidelines for proper control circuit grounding practices Failure to follow these instructions will result in death or serious injury Switch in Source position Switch in Source position and use of an external 424 V source SW3 or SW4 SW3 SWA Source VW3 20e Source VW3 20e sy ER sy ER Int Int x 2s 8 2 53 5 O O OQ Q 9Q Oo 24V source r a 1 1 24V 9 ovo Switch in Sink Int position Switch in Sink Ext position SW3 or SW4 SW3orSW4 A1 A1 Source VW3 A3 20e Source VW3 20e 1 J 5 8 5 ESL a 9 x Int Ve a i 8 8 HOOO 0 0 TA pedes O 24V source pue 1 uv 1 Maximum wire size 1 5 mm 16 AWG Max tightening torque 0 25 N m 2 21 Ib in to 1114 Same characteristics as for the control card Terminals Function Electrical characteristics TH2 PTC probe input Trip threshold 3 kQ reset threshold 1 8 kQ TH2 Short circuit detection threshold lt 50 Q RP Frequency input Frequency r
6. 275 lb in 2 150 mm 41 Nem 250 MCM 275 b in 2 x 250 275 Ib in 2 120 mm 24 Nem 2 x 250 MOM 275 Ib in 2 120 2 24 Nem 2 x 250 MCM 275 lb in 2 120 mm 41 Nem 2 x 250 MCM 275 Ib in 2 x 150 mm 41 Nem 2 x 250 MOM 275 lb in 2 x 150 mm 41 Nem 2 x 250 MOM 275 lb in 2 150 mm 41 Nem 2 350 375 Ib in 4 185 mm 41 Nem 2 x 350 375 Ib in 4x 185 mm 41 Nem 2 x 350 375 Ib in 4 x 185 mm 41 Nem 3 x 350 MCM 375 Ib in 4x 185 mm 41 Nem 3x 350 MOM 375 1041 4 185 mm 41 Nem 3x 350 MCM 375 Ib in 8 185 mm 41 4 500 365 Ib in 2x2x185 mm 41 Nem 4 x 500 375 Ib in 4 x 185 mm 41 Nem 4 x 500 375 1041 8 185 mm 41 Nem 4 x 500 MCM 375 Ib in 2x 4x 185 mm 41 Nem 4 x 500 MCM 375 Ib in 6 x 185 mm 41 Nem 4 x 500 MCM 375 Ib in 8 185 mm 41 Nem 3 x 500 MCM 375 Ib in 5 x 500 MCM 375 Ib in 5 x 500 MCM 375 Ib in Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 18 Control Terminals Access to the control terminals al 19 1 To access the control terminals open the cover on the control front panel 2 To ma
7. Forward Forward Forward Forward 2 wire Fault reset Reverse Fault reset Fault reset No 2 wire No Jog PID integral reset Ref 2 switching Ref 1B switching 2 wire No Fault reset 2 preset PID ref Forced local Fault reset 2 wire No Torque limitation 4 preset PID ref No No 2 wire No No No No No 3 wire Stop Stop Stop Stop Stop Forward Forward Forward Forward Forward Fault reset Reverse Fault reset Fault reset No No Jog PID integral reset Ref 2 switching Ref 1B switching No Fault reset 2 preset PID ref Forced local Fault reset No Torque limitation 4 preset PID ref No The assignment of inputs LI1 to LI6 differs in 3 wire control No Note All these can be modified adjusted and reassigned consult the CD ROM supplied with the drive controller Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 30 Adjustment range Factory setting LJ 2 3 wire control 2 wire 2C O 2 wire 2C 8 wire 3C 2 wire control This is the ATA Example UT nuper wiring inputstate Qor oredge
8. Pending PEnd Auto tuning has been requested but not yet performed In Progress PrOG Auto tuning in progress Failed FAIL Auto tuning has failed Done dOnE The stator resistance measured by the auto tuning function is used to control the motor 4 Output Ph rotation ABC AbC O ABC AbC Forward L1 ACB Reverse This parameter can be used to reverse the rotation direction of the motor without reversing the wiring Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 33 Parameters that can be changed during operation or when stopped Name Description Factory setting 1 Mot therm current Oto1 10r1 2In According to 1 according to drive rating rating Motor thermal protection current to be set to the rated current indicated on the nameplate Acceleration 0 1t09999s 30s Time to accelerate from 0 to the Rated motor freq FrS page 32 Make sure that this value is compatible with the inertia being driven _ Deceleration 0 11099995 30s Time to decelerate from the Rated motor freq FrS page 32 to 0 Make sure that this value is compatible with the inertia being driven 1 Low speed Motor frequency at minimum reference can be set between 0 and High speed HSP 1 High speed Motor frequency at maximum referen
9. 94 100 3 94 D90N4 C11N4 C13N4 C22N4 150 5 90 150 5 90 C25N4 C31N4 200 7 83 150 5 90 C40N4 C50N4 300 11 81 250 9 84 C63N4 400 15 75 250 9 84 Free space in front of the drive controller 10 mm 0 39 in minimum Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 12 Dimensions and Weights With graphic display terminal With 0 or 1 option card 1 2 option cards 1 ATV61H D55M3X to D90M3X ATV61H D90N4 to C31N4 ATV61H C25N4 to C31N4 with braking unit a 670 26 37 pen 55 3 _ CoL a 1 1 pa 1 1 8 11 NE pu 377 mm 392mm z G 540 mm 21 26 in 14 77 in 15 43 in 102 5 mm 27 5 mm 7 403in 1 08 in Dimensions ATV61H b G H K K1 K2 For weight mm mm mm mm mm mm mm mm Screws kg in in in in in in in in Ib D55M3X 320 920 250 650 150 75 30 11 5 M10 60 90 4 12 60 36 22 9 84 25 59 5 91 2 95 1 18 0 45 132 D75M3X 74 C11N4 163 C13N4 360 1022 298 758 150 72 30 11 5 M10 80 D90M3X 14 17 40 23 11 73 29 84 5 91 2 83 1 18 0 45 176 C16N4 340 1190 285 920 150 75 30 11 5
10. FrS Values between 500 Hz and 1000 Hz are only possible in V F control and for powers limited to 37 kW 50 HP for ATV61Heee and 45 kW 60 HP for ATV61Weee In this case configure Motor control type Ctt before Max frequency tFr 1 In corresponds to the rated drive controller current indicated in the Installation Manual and on the drive controller nameplate Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 32 scr seing Auto tuning No nO 7 DANGER HAZARD OF ELECTRIC SHOCK OR ARC FLASH During auto tuning the motor operates at rated current Do not service the motor during auto tuning Failure to follow these instructions will result in death or serious injury A CAUTION UNINTENDED EQUIPMENT OPERATION The following motor parameters must be correctly configured before starting auto tuning Rated motor volt UnS Rated motor freq FrS Rated mot current nCr Rated motor speed nSP and Rated motor power nPr If one or more of these parameters is modified after auto tuning has been performed Auto tuning tUn will be set to No and the procedure must be repeated Failure to follow these instructions can result in death or serious injury No nO Auto tuning not performed Yes YES Auto tuning is performed as s
11. M10 110 13 39 46 62 11 22 36 22 5 91 2 95 1 18 0 45 242 C22N4 440 1190 350 920 150 75 30 11 5 M10 140 17 32 46 62 13 78 36 22 5 91 2 95 1 18 0 45 309 C25N4 595 1190 540 920 150 75 30 11 5 M10 140 23 43 46 62 21 26 36 22 5 91 2 95 1 18 0 45 309 C31N4 215 474 Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 13 With graphic display terminal continued With 0 2 option cards 1 ATV61H C40N4 to C50N4 ATV61H C63N4 car BILL dB 7 4 9 J1 4 J1 J1 J J1 Ptr 13 1T i ERAS p LH T 7 ere MN 4 X 13x28 14 11 1 377 mm 392 mm EX 9 2 G 41 5 zn G ap G 425 14 77 in 15 43 in Dimensions ATV61H a b G J J1 H K K1 K2 7 For weight mm mm mm mm mm mm mm mm mm mm screws kg in in n 0 n n n n n n Ib C40N4 890 1390 417 5 70 380 1120 150 75 30 11 5 M10 225 35 04 54 72 16 44 2 76 14 96 44 09 5 91 2 95 1 18 0 45 496 C50N4 300 661 C63N4 1120 1390 5325 70 495 1120 150 75 30 11 5 M10 300 44 09 54 72 20 96 2 76 1949 44 09 5 91 2 95 1 18 0 45 661
12. O 128 nc 105025 to 1 or 1 to 0 which controls running or stopping 3 wire control Pulse control A forward Example of source wiring or reverse pulse is D Lo CL Lit sufficient to command EJEN E LI2 POP id starting a stop pulse is LIx reverse sufficient to command stopping A WARNING UNINTENDED EQUIPMENT OPERATION To change the assignment of 2 3 wire control tCC press the ENT key for 2 s The following function will be returned to factory settings 2 wire type tCt as will the functions assigning the logic inputs consult the CD ROM with the drive controller The macro configuration selected will also be reset if it has been customized loss of custom settings Check that this change is compatible with the wiring diagram used Failure to follow this instruction can result in death or serious injury J Macro configuration Pumps Fans PnF O Start Stop StS Start stop Gen Use GEn General use Li PID regul Pld PID regulation O Network C nEt Communication bus Pumps Fans PnF Pumps fans Av WARNING UNINTENDED EQUIPMENT OPERATION To change the assignment of Macro configuration CFG press the ENT key for 2 s Check that the selected macro configuration is compatible with the wiring diagram used Failure to follow this instruction can result in death or serious injury ccrG 1 Customized macro Read
13. Phase Loss OPL Yes YES To check the drive in a test or maintenance environment without having to switch to a motor with the same rating as the drive particularly useful in the case of high power drives deactivate motor phase loss oon Output phase loss OPL No nO Check and optimize the parameters Rated motor volt UnS and Rated mot current nCr and perform an Auto tuning tUn Mains overvoltage Line voltage too high Disturbed line supply Check the line voltage PTC1 overheat Overheating of the PTC1 probes detected 2 overheat Overheating of the PTC2 probes detected PTC LI6 overheat Overheating of PTC probes detected on input LI6 Check the motor load and motor size Check the motor ventilation Wait for the motor to cool before restarting Check the type and state of the PTC probes PTC1 probe PTC1 probes open or short circuited PTC2 probe PTC2 probes open or short circuited 116 probe PTC probes on input 116 open or short circuited Check the PTC probes and the wiring between them and the motor controller IGBT short circuit Power component fault Perform a test via the 1 10 DIAGNOSTICS menu Contact Schneider Electric Product Support Motor short circuit Short circuit at drive output Check the cables connecting the drive to the motor and the motor in
14. only parameter only visible if at least one macro configuration parameter has been modified YES Yes YES Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 31 pelusiment range actory setting LJ Standard mot freq 50 Hz IEC 50 L 50 Hz IEC 50 IEC O 60 Hz NEMA 60 NEMA This parameter modifies the presets of the following parameters Rated motor power nPr Rated motor volt UnS Rated mot current nCr Rated motor freq FrS Rated motor speed nSP and Max frequency tFr below Mot therm current ItH page 34 High speed HSP page 34 According to J Input phase loss drive rating o Ignore nO Fault ignored to be used when the drive controller is supplied via a single phase supply or by the DC bus L1 Freewheel YES Fault with freewheel stop If one phase is lost the drive controller switches to fault mode Input phase loss IPL but if 2 or 3 phases are lost the drive controller continues to operate until it trips on an undervoltage fault This parameter is only accessible in this menu on ATV61H037M3 to HU75M3 drive controllers used with a single phase supply According to According to LJ Rated motor power drive rating drive rating ated motor power given on the nameplate in kW if Standard mot freq bFr 50 Hz IEC 50 HP if Standard mo
15. to follow this instruction can result in equipment damage DANGER UNINTENDED EQUIPMENT OPERATION Before turning on and configuring the Altivar 61 drive controller ensure that the PWR POWER REMOVAL input is deactivated at state 0 in order to prevent unintended operation Before turning the drive on or on 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 Referto the characteristics and functions table in the Control Terminals section for more information about the Power Removal Input Failure to follow these instructions will result in death or serious injury The Power Removal function takes priority over any run command For use as an emergency stop this function requires the use of connection diagrams conforming to category 3 of standard EN 954 1 and safety integrity level 2 according to IEC EN 61508 Consult the ATV61 installation manual on theCD ROM supplied with the drive controller Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 7 Example of installing DC chokes on an ATV61HC22N4 97 dE T ud Cag E i aS a 22227 oe e oo Mount the DC choke chassis on the wall on top of the drive controller E
16. 1 For the addition of I O extension cards communication cards the multi pump card or the Controller Inside programmable card Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 14 DC Bus Voltage Measurement Procedure Before working on the drive controller turn it off and wait 15 minutes to allow the DC bus to discharge Then measure the DC bus voltage Measuring the DC bus voltage Ay DANGER HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH Read and understand the instructions on page 2 before performing this procedure Failure to follow this instruction will result in death or serious injury The DC bus voltage can exceed 1 000 V Use a properly rated voltage sensing device when performing this procedure To measure the DC bus voltage 1 Disconnect the drive controller power supply 2 Wait 15 minutes to allow the DC bus to discharge 3 Measure the voltage of the DC bus between the PA and PC terminals to ensure that the voltage is less than 45 V 4 If the DC bus capacitors do not discharge completely contact your local Schneider Electric representative Do not repair or operate the drive controller Red LED indicating that the DC bus is turned on The drive controller LEDs are not accurate indicators of the absence of DC bus voltage Courtesy of Steven
17. 29 M n ATV61H C40N4 E IT syst 4 Normal fter disconnected 7 filter connected o ATV61H C50N4 4 Normal IT system filter connected filter disconnected ATV61H C63N4 Normal IT system filter connected filter disconnected CAUTION EQUIPMENT DAMAGE When the filters are disconnected the drive controller switching frequency must not exceed 4 kHz Refer to the Programming Manual on the CD ROM supplied with the drive controller to set the corresponding parameter Failure to follow this instruction can result in equipment damage Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 24 Electromagnetic Compatibility Wiring Principles and best practices Grounds between drive controller motor and cable shielding must have high frequency equipotentiality Use 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 there is no break in continuity Keepthe control circuits away from the power circuits F
18. 3 Metal clamps 4 Shielded cable for motor connection with shielding connected to ground at both ends 5 Shielded cable for connecting the braking resistor if used 6 Shielded cables for connecting the control signal cables For applications requiring several conductors use with a small cross section 20 AWG 0 5 mm 7 Shielded cables for connecting the Power Removal safety function input 8 Shielded cables for connecting the encoder 9 Unshielded wires for relay contact output 10Unshielded power supply wires or cables Note f using an additional input filter it should be connected directly to the line supply via an unshielded cable Link 10 on the drive controller is then via the filter output cable The HF equipotential ground connection between the drive controller motor and cable shielding does not eliminate the need to connect the PE protective conductors green yellow to the appropriate terminals on each unit Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 25 Setup Preliminary Recommendations Drive controller settings factory configuration The Altivar 61 drive controller is factory set for the following operations Macro configuration Pumps fans Motor frequency 50 Hz Energy saving variable torque applications Normal stop mode on d
19. 61HC40NA ATV61HD90NA C16N4 Grounding strip PO 1 PA PO 2 Example 2 Example 4 ATV61HC22N4 C31N4 ATV61HC50N4 C63N4 Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 9 Mounting in a Wall Mounted or Floor Standing Enclosure Install the drive controller vertically 10 Do not place it close to heating elements Mounting with the heatsink inside the enclosure The power dissipated by the drive controller power components is given in the table below Dissipated power These levels of power dissipation are given for operation at nominal load and for a switching frequency of 2 5 Hz The drive controller has a fan for cooling the power The drive controller dissipates a great deal of power components The air is circulated from the bottom to the which must be evacuated to the outside of the top of the unit via a duct the duct is shown shaded gray enclosure on the diagram below This duct is isolated fro
20. Altivar 61 Variable speed drive controllers mpined manual for asynchronous motors 75 125 hp 55 90 kW 200 240 V 125 900 hp 90 639 kW 380 480 V Retain for future use a brand f Telemecanique Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com Before you begin Read and understand these instructions before performing any procedure on this drive controller DANGER HAZARD OF ELECTRIC SHOCK Read and understand this manual before installing or operating the Altivar 61 drive controller 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 controller 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 PC or across the DC bus capacitors Install and close all the covers before applying power or starting and stopping the drive controller Before servicing the variable speed drive controller Disconnect all power Place a DO NOT TURN label on th
21. Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 15 Wiring Power Ground the drive controller to local and national code requirements A minimum wire size of 6 AWG may be required to meet standards limiting leakage current DANGER HAZARD OF ELECTRIC SHOCK Ground equipment using the provided ground connecting point as shown in the figure below The drive panel must be properly grounded before power is applied Failure to follow this instruction will result in death or serious injury Drive Controller 2 Drive Controller Drive Controller Ensurethatthe resistance of the protective ground is 1 or less f connecting several drive controllers to the protective ground you must connect each one directly as shown in the figure to the left Do not loop the ground cables or connect them in series A WARNING EQUIPMENT DAMAGE The ATV61 controller will be damaged if input line voltage is applied to the output terminals U T1 V T2 W T3 Checkthe power connections before energizing the ATV61 drive controller f replacing another drive controller verify that all wiring connections to the ATV61 controller comply with all wiring instructions in this manual Failure to follow this instruction can result in death serious injury or equipment damage Where
22. PERATION Changes to parameters in other menus may change the 1 1 SIMPLY START SIM parameter settings Read and understand the ATV61 Programming Manual before configuring parameter values Failure to follow these instructions can result in death serious injury or equipment damage The 1 1 SIMPLY START SIM menu can be used for fast startup which is sufficient for the majority of applications Note The parameters of the 1 1 SIMPLY START SIM menu must be entered in the order in which they appear as the later ones are dependent on the first ones For example 2 3 wire control must be configured before any other parameters Macro configuration Macro configuration provides a means of speeding up the configuration of functions for a specific field of application Selecting a macro configuration assigns the Inputs Outputs in this macro configuration Start Stop Gen Use PID regul Network C Pumps Fans Ref 1 channel Ref 1 channel Ref 1 channel PID reference Ref 2 channel Ref 1 channel integrated Modbus Ref 1 channel No Summing ref 2 PID feedback No Ref 1B channel Motor freg Motor freq Motor freq Motor freq Motor freq No drive flt No drive flt No drive flt No drive flt No drive flt No No No No Drv running 2 wire Forward
23. ace the option card Contact Schneider Electric Product Support COF CAN com Interruption in Check the communication bus communication on the e Check the time out CANopen bus Refer to the CANopen user s manual External fit Ll Bit Fault triggered by an Check the device which caused the fault external device and reset depending on user EPF g External fault com Fault triggered by a Check for the cause of the fault and reset communication network FLF 2 Out contact open The output contactor Check the contactor and its wiring remains open although Check the feedback circuit the closing conditions have been met LEF input contactor The drive is not turned Check the contactor and its wiring on even though Mains Check the time out V time out LCt has Check the line contactor drive connection elapsed LFF9g 12 4 20mA loss Loss of the 4 20 mA Checkthe connection on the analog LFF 3 AI3 4 20mA loss reference on analog inputs 1 Al4 4 20mA loss input AI2 AI3 or nFF No Flow Fault Zero fluid Check and correct the cause of the fault Checkthe zero fluid detection parameters consult the CD ROM supplied with the drive Overbraking Braking ramp too short Increase the deceleration time Overhauling load Install a braking resistor if necessary Activate the Dec ramp adapt brA function consult the CD ROM supplied with the drive if it is co
24. ange 0 30 kHz Cyclic ratio 5096 1096 Maximum sampling time 5 ms 1 ms Maximum input voltage 30 V 15 mA Add a resistor if the input voltage is greater than 5V 510 Q for 12 V 910 O for 15 V 1 3 for 24 V State O if 1 2V state 1 if 2 3 5V LO3 Open collector programmable 424 V max 30 V LO4 logic outputs Max current 20 mA for internal power supply and 200 mA for external power supply Reaction time 5 ms 1ms CLO Logic output common oV 0v OV Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 21 Connection Diagrams Connection diagrams conforming to standard EN 954 1 category 1 with line contactor 3 phase power supply ATV61HD55M3X D90M3X and 61 90 4 40 4 i Note T 22 ZH 208058 Install interference suppressors on all inductive Ke 7 Si circuits near the drive controller or coupled to the 2502 0 Is m same circuit relays contactors solenoid 27 1 T H HE valves etc a NN E Ifthe PWR input has been wired up use ju RIA RIC shielded cable 0 1 Line choke if used NE OE PA NT NEN qm 2 Fault relay contacts for remote signaling of A gt 2232 222 8 8 3 drive controller status c no ree Associated components 2 S216 Refer to the c
25. atalog Power terminal connection diagram ATV61HC50N4 and ATV61HC63N4 1 Line choke if used Braking resistor connection diagram ATV61HD55M3X D90M3X and ATV61HD90N4 C22N4 Up to 220 kW power ATV61HC22N4 braking resistors are connected directly to the terminals at the base of the drive terminals PA and PB 1 Thermal overload relay braking resistor ATV61HC25N4 C63N4 For 250 kW and higher ATV61HC25N4 the braking resistors are connected on the external braking unit Refer to the braking unit User s Manual Drive controller supplied by the DC bus Consult the CD ROM supplied with the drive controller Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 22 Control connection diagrams Control card connection diagram For other types of diagram external 24 V 1 Le a power supply negative logic etc consult s 4503 amp 8 8 9 8 the CD ROM supplied with the drive 0 0 0 C E 0 o controller Reference potentiometer 4 3 0 10V or X Y mA PWR 42 1 Operation on IT and Delta Systems IT system Isolated impedance grounded neutral and Delta Use a permanent insulation monitor compatible with non linear loads such as a Merlin Gerin type XM200 or equivalent Altivar 61 drive c
26. card Check the catalog reference of the power card and its compatibility Internal serial link Communication fault between the internal cards Check the internal connections Contact Schneider Electric Product Support Internal MFG area Internal data inconsistent Recalibrate the drive Contact Schneider Electric Product Support Internal option The option installed in the drive is not recognized Check the catalog reference and compatibility of the option Internal hard init Initialization of the drive is incomplete Turn off and reset Internal ctrl supply The control section power supply is incorrect Check the control section power supply Internal measure The current measurements are incorrect Replace the current sensors or the power card Contact Schneider Electric Product Support Internal mains circuit The input stage is not operating correctly Perform the diagnostic tests via the 1 10 DIAGNOSTICS menu Contact Schneider Electric Product Support Internal th sensor The drive temperature sensor is not operating correctly Replace the temperature sensor Contact Schneider Electric Product Support Fault on the electronic time measurement component Internal microprocessor ault Internal time meas internal CPU Contact Schneider Electric Product Support Turn off and reset Contact Schneider Electric Pro
27. ce can be set between Low speed LSP and Max frequency tFr The factory setting changes to 60 Hz if Standard mot freq bFr 60 Hz 60 1 In corresponds to the rated drive controller current indicated in the Installation Manual and on the drive controller nameplate Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 34 Faults and Troubleshooting Drive does not start no fault displayed Ifthe display does not light up check the power supply to the drive controller If the drive controller displays Freewheel nSt or Fast stop FSt The Fast Stop or Freewheel functions prevent the drive controller from starting if the corresponding logic inputs are not powered up This is normal these functions are active at zero so that the drive controller will stop safely if there is a wire break Make sure that the run command input or inputs are activated according to the selected control mode For instructions on how to adjust the tCt parameter refer to ATV61 programming manual on the CD ROM Faults that cannot be reset automatically DANGER LOSS OF PERSONNEL AND EQUIPMENT PROTECTION Enabling the fault inhibition parameter InH will disable the drive controller protection features nH should not be enabled for typical applications of this equipment nH should be enabled
28. closure with IP54 protection is to follow the mounting recommendations for IP23 protection with the following 5 additional points 1 Do not make an air outlet hole for the control section Do not make an air inlet hole in the enclosure door In the power section the air will enter through the bottom of the enclosure via a plinth added for this purpose 2 Add the IP31 or UL type 1 conformity kit according to the mounting instructions Refer to the manual supplied with the kit 3 Add an enclosure baseplate designed to provide IP54 protection around the power cables 4 Add an air evacuation duct between the baseplate and the duct of the IP31 or UL type 1 conformity kit The IP31 or UL type 1 conformity kit enables an extension duct to be mounted Drill a hole in the base of the enclosure to allow air to enter Place seals around the duct that has been added to maintain IP54 protection 5 Add a 200 mm plinth at the bottom of the enclosure with grilles to allow air to enter 6 Refer to the derating tables in the installation guide to calculate the enclosure dimensions Note Ground all metal parts according to local and national codes Dust and damp proof flange mounting heatsink outside the enclosure This mounting method is used to reduce the power dissipated in the enclosure by locating the power section outside the enclosure This requires the use of the dust and damp proof flange mounting kit VW3A9509 517 refer to the catal
29. ction Emergency phone support is available 24 hours a day 365 days a year Toll free 1 888 778 2733 1 888 SquareD E mail drive products support us schneider electric com Fax Line 919 217 6508 Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 2 Contents Prod ct Support vierii Ptr REIS deae HN Le ARR ROT ODE dE 2 Setting Up the Drive 5 Receiving Handling and Storage 6 Mounting in a Wall Mounted or Floor Standing Enclosure 10 Dimensions and Weights III 13 DC Bus Voltage Measurement Procedure 15 Wiring EG n x e EROR YR e ER Sd 16 Power Terminals iisdem Renew Ra bebe pea rix REGE d eb PEE 17 Terminals IRE UR cee caw eee Pe ees 19 Connection Diagrams s esee eu esee eed eee LEE ERES 22 Operation on an IT and DELTA System 23 Electromagnetic Compatibility Wiring 25 Setup Preliminary Recommendations 26 Graphic Display Terfninal xn Leere dagen feels ig aS AD AR pan esc 27 Integrated Display Terminal
30. d Check and remove the cause of the underload Consult the CD ROM supplied with the drive Faults that can be reset as soon as their causes are removed LOSS OF PERSONNEL AND EQUIPMENT PROTECTION Enabling the fault inhibition parameter InH will disable the drive controller protection features nH should not be enabled for typical applications of this equipment nH should only be enabled in extraordinary situations where a thorough risk analysis demonstrates that the presence of adjustable speed drive protection poses a greater risk than personnel injury or equipment damage Failure to follow these instructions will result in death or serious injury The USF fault can be inhibited and cleared remotely by means of a logic input or control bit Fault inhibit assign InH Consult the CD ROM supplied with the drive controller Incorrect config Probable cause Option card changed or removed The current configuration is inconsistent Check that there are no card errors In the event of the option card being changed removed deliberately consult the CD ROM supplied with the drive Return to factory settings or retrieve the backup configuration if it is valid consult the CD ROM supplied with the drive Invalid config Invalid configuration The configuration loaded in the drive via the bus or network is inconsistent Check the configuration loaded previously Load a compatible conf
31. d functions of the terminals UNINTENDED EQUIPMENT OPERATION The accidental grounding of logic inputs configured for Sink Logic can result in unintended activation of drive controller functions Protect the signal conductors against damage that could result in unintentional conductor grounding Follow NFPA 79 and EN 60204 guidelines for proper control circuit grounding practices Failure to follow these instructions will result in death or serious injury Maximum wire size 1 5 mm 16 AWG Max tightening torque 0 25 Nem 2 21 Ib in R3A 10 1110 Same characteristics as for the control card Terminals Function Electrical characteristics TH1 PTC probe input Trip threshold 3 kO reset threshold 1 8 kQ TH1 Short circuit detection threshold 50 LO1 Open collector programmable 424 V max 30 V LO2 logic outputs Max current 200 mA for internal power supply and 200 mA for external power supply CLO Logic output common OV 0v Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 20 Extended I O option card terminals VW3A3202 Characteristics and functions of the terminals UNINTENDED EQUIPMENT OPERATION The accidental grounding of logic inputs con drive controller functions figured for Sink Logic can result in unintended activation of
32. duct Support Overcurrent Motor parameters not correct Inertia or load too great Mechanical locking Check the parameters Check the size of the motor drive load Check the state of the mechanism Power removal Fault with the drive s Power removal safety function Contact Schneider Electric Product Support Motor short circuit Impedant sh circuit Ground short circuit Short circuit or grounding at the drive output Significant earth leakage current at the drive output if several motors are connected in parallel Check the cables connecting the drive to the motor and the motor insulation Perform the diagnostic tests via the 1 10 DIAGNOSTICS menu Reduce the switching frequency Connect chokes in series with the motor Overspeed Instability or driving load too great Check the motor gain and stability parameters Add a braking resistor Check the size of the motor drive load Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com Auto tuning Special motor or motor power not suitable for the drive Motor not connected to the drive Check that the motor and drive controller are compatible Check that the motor is present during auto tuning If an output contactor is being used close it during auto tuning
33. e variable speed drive controller disconnect Lockthe disconnect in the open position Disconnect all power including external control power that may be present before servicing the drive controller WAIT 15 MINUTES for the DC bus capacitors to discharge Then follow the DC bus voltage measurement procedure on page 15 to verify that the DC voltage is less than 45 V The drive controller LEDs are not accurate indicators of the absence of DC bus voltage Electric shock will result in death or serious injury CAUTION IMPROPER DRIVE OPERATION f for prolonged period of time voltage is not applied to the drive controller the performance of its electrolytic capacitors will be reduced If it is stopped for a prolonged period turn the drive controller on every two years for at least 5 hours to restore the performance of the capacitors then check its operation It is recommended that the drive controller not be connected directly to the line voltage The voltage should be increased gradually using an adjustable AC source Failure to follow this instruction can result in equipment damage Product Support For more information call fax or write Square D AC Drives Technical Support Group P O Box 27446 Raleigh NC 27611 7446 The Technical Support Group is staffed from 8 am to 6 pm Eastern time for product selection start up assistance or diagnosis of product problems and advice for the correct course of a
34. eceleration ramp Stop mode in the event of a fault freewheel Linear acceleration and deceleration ramps 3 seconds Low speed 0 Hz High speed 50 Hz Motor thermal current rated drive current Standstill injection braking current 0 7 x rated drive current for 0 5 seconds No automatic starts after a fault Switching frequency 2 5 kHz to 12 kHz depending on drive rating Logic inputs forward 1 operating direction 2 wire control on transition LI2 inactive not assigned LI3 bera of 2 speed reference LI4 fault reset 115 116 inactive not assigned Analog inputs Alt 1 speed reference 0 10 V Al2 pra speed reference 0 20 mA Relay R1 The contact opens in the event of a fault or drive off Relay R2 The contact closes when the drive controller is running e Analog output AO1 0 20 mA motor frequency For programming instructions refer to the ATV61 programming guide located on the CD ROM included with the drive controller Option card factory settings The option card inputs outputs are not factory set Power switching via line contactor CAUTION EQUIPMENT DAMAGE Avoid operating the contactor frequently premature aging of the filter capacitors Cycle times 60 s can result in damage to the pre charge resistor Failure to follow these instructions can result in equipment damage Starting Important In factory settings mode the motor can o
35. eprom Internal memory fault Check the environment electromagnetic control card compatibility Power Eeprom Internal memory fault Turn off reset return to factory settings promi power card y Contact Schneider Electric Product Support Out contact The output contactor Check the contactor and its wiring stuck remains closed although Check the feedback circuit the opening conditions have been met IGBT Short circuit or Check the cables connecting the drive desaturation grounding at the drive controller to the motor and the motor controller output insulation Perform the diagnostic tests via the 1 10 DIAGNOSTICS menu internal com Communication fault Check the environment electromagnetic link between option card and compatibility drive controller Check the connections Check that no more than 2 option cards max permitted have been installed on the drive controller Replace the option card Contact Schneider Electric Product Support Rating error The power card is Check the catalog reference of the power card different from the card stored Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 35 Faults that cannot be reset automatically continued Incompatible PB Probable cause The power card is incompatible with the control
36. iguration Cards pairing The CARDS PAIRING PPI function has been configured and a drive card has been changed Consult the CD ROM supplied with the drive Input phase loss Drive incorrectly supplied or a fuse blown Failure of one phase 3 phase ATV61 used on a single phase line supply Unbalanced load This protection only operates with the drive on load Check the power connection and the fuses Use a 3 phase mains supply Disable the fault by Input phase loss IPL No nO Power Ident The Power Identification Prt parameter is incorrect Control card replaced by a control card configured on a drive with a different rating Enter the correct parameter reserved for Schneider Electric product support Check that there are no card errors In the event of the control card being changed deliberately consult the CD ROM supplied with the drive Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 39 Faults that can be reset as soon as their causes are removed continued Undervoltage Line supply too low Check the voltage and the voltage Transient voltage dip parameter consult the CD ROM supplied Damaged pre charge with the drive resistor Replace the pre charge resistor Contact Schneider Electric Product Support Cou
37. ime 7 ms 0 5 ms R2C one N O contact Electrical service life 100 000 operations 10 410 V power supply for 410 V 10 5 V 0 5V reference potentiometer 10mA max 1to 10 kQ Differential analog input 10 to 10 V max safe voltage 24 V AM Reaction time 2 ms 0 5 ms 11 bit resolution 1 sign bit Accuracy 0 6 for AO 60 C 140 F linearity 0 1596 of max value COM Analog I O common OV Al2 Depending on software Analog input 0 to 10 V c max safe voltage 24 V impedance configuration Analog voltage or current input Analog input X Y mA X and Y can be programmed from 0 to 20 mA impedance 250 Reaction time 2 ms 0 5 ms 11 bit resolution accuracy 0 6 for AO 60 140 F linearity 0 1596 of max value COM Analog I O common OV AO1 Depending on software Analog output 0 to 10 V min load impedance 50 configuration Analog output X Y mA X and Y can be programmed from 0 to Analog voltage or current 20 mA max load impedance 500 output 10 bit resolution reaction time 2 ms 0 5 ms Accuracy 1 for AO 60 140 F linearity 0 296 of max value Note AO temperature variation Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 19 Characteristics and functions of the control terminals continued
38. ke it easier to wire the drive control section the control terminal card can be removed Undo the screw until the spring is fully extended Remove the card by sliding it downwards Maximum wire size 2 5 mm 14 AWG Maximum tightening torque 0 6 Nem 5 3 Ib in DANGER UNINTENDED EQUIPMENT OPERATION drive controller functions The accidental grounding of logic inputs configured for Sink Logic can result in unintended activation of Protect the signal conductors against damage that could result in unintentional conductor grounding Follow NFPA 79 and EN 60204 guidelines for proper control circuit grounding practices Failure to follow these instructions will result in death or serious injury CAUTION IMPROPERLY SECURED TERMINAL CARD When replacing the control terminal card it is essential to fully tighten the captive screw Failure to follow this instruction can result in equipment damage Characteristics and functions of the control terminals Terminals Function Electrical characteristics T relay logic output one N C Minimum switching capacity mA for 24 V R1B contact and one N O contact Maximum switching capacity R1C with common point R1A to on resistive load cos 1 5 A for 250 V or 30 V R1C is N O R1B to R1C is on inductive load cos 0 4 and L R 7 ms N C 2 A for 250 V or 30 V R2A relay logic output Max response t
39. local and national codes require upstream protection by means of a residual current device use a type A device for single phase drives and a type B device for three phase drives Choose a suitable model integrating HF current filtering A time delay that prevents tripping caused by the load from stray capacitance on power up The time delay is not possible for 30 mA devices in this case choose devices with immunity against nuisance tripping for example residual current devices with reinforced immunity from the s i range Merlin Gerin brand f the installation includes several drive controllers provide one residual current device per controller A WARNING INADEQUATE OVERCURRENT PROTECTION Overcurrent protective devices must be properly coordinated The Canadian Electricity Code and the National Electrical Code require branch circuit protection Use the fuses recommended on the drive controller nameplate to achieve published short circuit current ratings Do not connect the drive controller to a power feeder whose short circuit capacity exceeds the controller short circuit current rating listed on the controller nameplate Failure to follow this instruction can result in death serious injury or equipment damage CAUTION IMPROPER USE OF A BRAKING RESISTOR Wire the thermal protection contact on the resistor so that the drive controller power supply is disconnected immediately in the event of a fault refer t
40. m the Air inlets and outlets must be provided to ensure that the control section by IP54 protection The DC choke flow of air in the enclosure is at least equal to the value extends this duct while maintaining IP54 protection given in the table below for each drive controller ATV61H Power ATV61H Power Flow rate dissipated dissipated ATV61H m hour ft min D55M3X 1715 C22N4 5482 D55M3X D75M3X 402 236 D75M3X 2233 C25N4 6379 D90N4 C11N4 D90M3X 2694 C31N4 7867 D90M3X C13N4 774 455 D90N4 2403 C40N4 9598 C16N4 745 438 C11N4 3056 C50N4 12055 C22N4 860 506 C13N4 3583 C63N4 15007 C25N4 C31N4 1260 742 C16N4 4036 C40N4 C50N4 2100 1236 C63N4 2400 1412 Figure 1 Several methods of evacuation are possible The following are proposed methods for IP23 and IP54 mounting IP23 mounting standard operating conditions Figure 1 A Install the drive controller on an enclosure baseplate B Install the DC choke according to the mounting recommendations The simplest mounting is to extend the IP54 duct between the upper outlet of the DC choke and the top of the enclosure D Mounting points are provided for this purpose on the top of the DC choke The hot air is thus evacuated to the outside and does not contribute towards increasing the internal temperature of the enclosure C It is advisable to add a plate approximately 5 905 in 150 mm from the top of the enclosure over the air outlet opening to prevent foreign bodies from falli
41. mpatible with the application Drive overheat Drive temperature too Check the motor load the drive high ventilation and the ambient temperature Wait for the drive to cool down before restarting OLE Proc Overload Fit Process overload Check and remove the cause of the overload Check the parameters of the PROCESS UNDERLOAD OLd function consult the CD ROM supplied with the drive Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 37 Faults that can be reset with the automatic restart function after the cause has been removed continued Name Motor overload 1 motor phase loss Probable cause Triggered by excessive motor current Loss of one phase at drive output Remedy Check the setting of the motor thermal protection check the motor load Wait for the drive to cool down before restarting heck the connections from the drive to the motor 8 motor phase loss Motor not connected or motor power too low Output contactor open Instantaneous instability in the motor current Check the connections from the drive to the motor If an output contactor is being used consult the CD ROM supplied with the drive Test on a low power motor or without a motor In factory settings mode motor phase loss detection is active Output
42. ng into the drive controller cooling duct D The air inlet can be via a grille on the bottom front panel of the enclosure door according to the required flow rates given in the above table ATV61 f Cooling duct for power components IP54 protection Figure 2 Figure 2 It is advisable to use a kit for IP31 UL type 1 conformity ordered as an option for attaching the power cables The design of the IP31 kit is based on the same principle as the DC choke and has an IP54 duct to help guide the ATV61 incoming air Note If the air in the power circuit is totally evacuated to the outside very little power is dissipated inside the enclosure In this case use the dissipated power table for dust and damp proof flange mounting see page 11 Ground all metal parts according to local and national codes Kit for IP31 or NEMA type 1 conformity Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 10 ATV61 Mounting with the heatsink inside the enclosure continued IP54 mounting standard operating conditions The drive controller must be mounted in an IP54 enclosure in certain environmental conditions dust corrosive gases high humidity with risk of condensation and dripping water splashing liquid etc The simplest way of obtaining an en
43. nly be supplied with power once the Forward Reverse and DC Injection Stop commands are reset On power up Onmanual fault reset After a stop command If the commands have not been reset the drive controller displays nSt and does not start Test on a low power motor or without a motor using motors in parallel Consult the CD ROM supplied with the drive controller Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 26 Graphic Display Terminal Although the graphic display terminal is optional for low power drive controllers it is a standard component on high power drive controllers see catalog The graphic display terminal can be disconnected and connected remotely on the door of an enclosure for example using the cables and accessories available as options see catalog Description of graphic display terminal 1 Graphic display 2 Function keys F1 F2 F3 F4 7 ESC key Cancels a value a parameter or a menu to return to the previous selection 3 STOP RESET button 4 RUN button 6 Button for reversing the rotation direction of the motor 5 Navigation button Press ENT To save the current value To enter the selected menu or parameter Turn CW CCW To increment or decrement a value To go to the next or previous line To increase or decrease the refe
44. nsure that the chassis is tightly secured to the drive controller to maintain the IP54 seal of the ventilation duct Install the DC choke on the chassis 1 using the nuts provided Connect the choke between the PO and terminals on the drive controller see the next page Connect the grounding strip between the DC choke chassis nd the drive controller Mount the cover 3 on the chassis and secure it with the nuts provided Mount panels 5 and using the screws provided Once the choke has been installed the degree of protection for the top of the drive controller is IP31 Note The number of DC chokes supplied with the drive controller varies according to the drive rating Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 8 Between 1 and 4 chokes can be connected in parallel as described in the following examples Table of drive choke combinations Drive Controller Number of chokes in parallel Choke model ATV61HD55M3X D75M3X 1 DC CHOKE 5 ATV61HD90M3X 1 DC CHOKE 6 ATV61HD90N4 C11N4 1 DC CHOKE 1 ATV61HC13N4 1 DC CHOKE 2 ATV61HC16N4 1 DC CHOKE 4 ATV61HC22N4 2 DC CHOKE 1 ATV61HC25N4 2 DC CHOKE 3 ATV61HC31N4 2 DC CHOKE 4 ATV61HC40N4 3 DC CHOKE 3 ATV61HC50N4 4 DC CHOKE 2 ATV61HC63N4 4 DC CHOKE 7 Example 1 Example 3 ATV61HD55M3X D90M3X ATV
45. ntroller on the pallet until it is installed Failure to follow this instruction can result in death serious injury or equipment damage 6 Installing the drive controller Mount the drive controller on a wall or the back of the enclosure according to the recommendations described in this document before installing the DC choke Installing the DC choke ATV61H D55M3XD to D90M3XD and ATV61H D9ON4D to C63N4D drives are supplied without a DC choke Drives supplied without a DC bus choke require an input line reactor For assistance contact your local Schneider Electric representative ATV61H D55M3X to D90M3X and ATV61H D90N4 to C63N4 drives are supplied with a DC choke that must be installed on top of the drive and wired according to the recommendations described in this document This choke must be used for connecting drives to the 3 phase line supply Mount the DC choke on the back of the enclosure or on the wall on top of the drive and follow the instructions for installing and connecting the choke given on page 8 Ensure that the chassis is tightly secured to the drive Before You Begin You must observe the following precautions CAUTION INCOMPATIBLE LINE VOLTAGE Before turning on and configuring the drive controller ensure that the line voltage is compatible with the supply voltage range shown on the drive controller nameplate The controller may be damaged if the line voltage is not compatible Failure
46. o the manual supplied with the resistor Failure to follow this instruction can result in equipment damage Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 16 Power Terminals Access to the power terminals To access the power terminals unscrew the front panel and remove the protective cover Terminals for DC choke Fan power supply DC bus power supply JL Power section line supply Output to the motor Connections to ground Output to braking resistor up to ATV61HC16N4 rating only Functions of power terminals Terminals Function Altivar 61 controller 3x Protective ground connection terminals All ratings R L1 S L2 T L3 1 Power section line supply All ratings PO Connection of the DC choke ATV61H D55M3X to D90M3X ATV61H D90NA4 to C31N4 PO 1 PO 2 Connection of the DC choke ATV61H C40N4 to 63 4 PA 4 DC bus polarity and connection of the DC choke All ratings PC DC bus polarity All ratings PA Output to braking resistor ATV61H D55M3X to D90M3X PB Output to braking resistor ATV61H D90N4 to C22N4 2 U T1 V T2 W T3 Output to the motor All ratings RO SO TO Separate fan supply when the drive controller is only ATV61H D75M3X D90M3X powered only by the DC bus consult
47. og To assemble the kit to the drive controller refer to the manual supplied with the kit The degree of protection for the drive controller mounted in this way becomes IP54 Refer to the derating tables in the installation guide to calculate the enclosure dimensions In this case the DC choke can be installed directly on the back of the enclosure Power dissipated by the control section inside the enclosure for calculating the enclosure dimensions These power ratings are given for operation at nominal load and for the factory set switching frequency ATV61H Dissipated power in W 1 ATV61H Dissipated power in W 1 D55M3X 154 C16N4 362 D75M3X 154 C22N4 452 D90M3X 154 C25N4 606 D90N4 237 C31N4 769 C11N4 269 C40N4 z C13N4 304 C50N4 C63N4 1 Add 7 W to this value for each option card added If the hot air exiting the drive controller is not ducted and evacuated to the outside it risks being sucked back in making the ventilation totally ineffective To avoid this leave sufficient free space around the drive controller as indicated below The enclosure must be cooled in order to get rid of the dissipated heat Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 11 ATV61H hi h2 mm in mm in D55M3X D90M3X 100 3
48. only in extraordinary situations where a thorough risk analysis demonstrates that the presence of adjustable speed drive protection poses a greater risk than personnel injury or equipment damage Failure to follow these instructions will result in death or serious injury The cause of the fault must be removed before resetting by turning off and then back on AI2F EnF SOF SPF and tnF faults can also be reset remotely by means of a logic input or control bit consult the CD ROM supplied with the drive controller EnF InFA InFb SOF SPF and tnF faults can be inhibited and cleared remotely by means of a logic input or control bit consult the CD ROM supplied with the drive controller Probable cause Remedy AI2 input Al2 signal out of range Check the wiring of analog input AI2 and the value of the signal DBR overload Incorrect DB settings Check the size of the resistor and wait for it to cool down Check parameters DB Resistor Power brP and DB Resistor value brU consult the CD ROM supplied with the drive controller DB unit sh Short circuit output from Check the wiring of the braking unit and the Circuit braking unit resistor Check the braking resistor Precharge Charging relay control Turn the drive controller off and then back on fault or charging resistor again damaged Check the internal connections Thyr soft DC bus charging fault Contact Schneider Electric Product Support charge thyristors Control E
49. ontrollers feature built in RFI filters These filters can be isolated from ground for operation on an IT system as follows Disconnection of RFI filters ATV61H D55M3X to D9OM3X ATV61H C16N4 to C22N4 and ATV61H D90N4 to C13N4 L Normal x IT system filter e x filter connected disconnected 7 5 8 Q N N xe 5 Normal filter connected X o o X 1 ilter 274 disconnected Kae H Jo o P lo o oll Ho JO 5 97 lo o N CAUTION EQUIPMENT DAMAGE When the filters are disconnected the drive controller switching frequency must not exceed 4 kHz Refer to the Programming Manual on the CD ROM supplied with the drive controller to adjust parameter SFr Failure to follow this instruction can result in equipment damage Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 23 ATV61H 25 4 to C31N4 L Normal x IT system 7 filter connected filter disconnected TONIE gt a
50. oon as possible then the parameter automatically changes to Done dOnE L1 Done dOnE Use of the values given the last time auto tuning was performed Caution Itis essential that all motor parameters Rated motor volt UnS Rated motor freq FrS Rated mot current nCr Rated motor speed nSP Rated motor power nPr are configured correctly before starting auto tuning If one or more of these parameters is modified after auto tuning has been performed Auto tuning tUn will return to No nO and the procedure must be repeated Auto tuning is performed only if no stop command has been activated If a freewheel Stop or fast stop function has been assigned to a logic input this input must be set to 1 active at 0 Auto tuning takes priority over any run or prefluxing commands which will take effect after the auto tuning sequence If auto tuning fails the drive controller displays No nO and depending on the configuration of Autotune fault mgt tnL consult the CD ROM supplied with the drive controller may switch to Auto tuning tnF fault mode Auto tuning may last for 1 to 2 seconds Do not interrupt wait for the display to change to Done dOnE or No nO Ee Note During auto tuning the motor operates at rated current 1 Auto tuning status Not done tAb for information only cannot be modified Not done tAb The default stator resistance value is used to control the motor
51. or control and speed reference circuits we recommend using shielded twisted cables with a pitch of between 25 and 50 mm 0 98 and 1 97 in Ensure maximum separation between the power supply cable line supply and the motor cable The motor cables must be at least 0 5 m 20 in long Do not use surge arresters or power factor correction capacitors on the variable speed drive controller output If using an additional input filter mount it under the drive controller and connect it directly to the line supply via an unshielded cable Link 10 on the drive controller is then via the filter output cable The HF equipotential ground connection between the drive controller motor and cable shielding does not eliminate the need to connect the PE protective conductors green yellow to the appropriate terminals on each unit Installation diagram ATV61H D55M3X to D90M3X and ATV61H D90N4 to C63N4 Attach and ground the shielding of cables of cables 4 5 6 7 and 8 as close as possible to the drive controller Strip the cable to expose the shielding Use stainless metal cable clamps to attach the parts from which the shieding has been stripped The shiedling must be clamped tightly enough to the metal sheet to ensure proper contact The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes 1 Altivar 61 drive controller 2 Sheet steel grounded plate supplied with the drive controller
52. rence if control via the terminal is activated Note Buttons 3 4 5 and 6 can be used to control the drive controller directly if control via the graphic display terminal is activated Drive controller state codes ACC Acceleration CLI Current limiting CTL Controlled stop on input phase loss DCB DC injection braking in progress DEC Deceleration FLU Motor fluxing in progress FRF Drive at fallback speed FST Fast stop NLP No line power no line supply on L1 L2 L3 NST Freewheel stop OBR Auto adapted deceleration PRA Power Removal function active drive locked RDY Drive ready RUN Drive running SOC Controlled output cut in progress TUN Auto tuning in progress USA Undervoltage alarm The first time the drive controller is powered up the user is automatically guided through the menus as far as 1 DRIVE The parameters in the 1 1 SIMPLY START submenu must be configured and auto tuning performed before the motor is started up Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 27 Only the 1 1 SIMPLY START menu is described in this document To find out the content of the other CE menus consult the CD ROM supplied with the drive controller ATV61HU22NA Displayed for 3 seconds following power up 2 2kW 3HP 380 480V Config 1
53. rmed with the power off m5 Energize the drive controller with no inputs active Removing the control terminal card ensures no active inputs page 19 6 Select the language page 28 if the drive controller is equipped with a graphic display terminal 7 Configure the menu SIMPLY START SIM page 30 2 wire or 3 wire control Macro configuration Motor parameters Note Optimize performance e To optimize performance refer to the auto Motor thermal current tuning section page 33 Acceleration and deceleration ramps cge Note Ensure that the wiring of the drive Speed variation range controller is compatible with its configuration Bi 8 Start Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 5 Receiving Handling and Storage Handling and storage Refer to Dimensions and Weights page 13 To protect the drive prior to installation handle and store the device in its packaging Ensure that the ambient conditions are acceptable A WARNING DAMAGED PACKAGING If the packaging appears damaged it can be dangerous to open it or handle it Failure to follow this instruction can result in death or serious injury A WARNING DAMAGED EQUIPMENT Do not operate or install any drive that appears damaged Failure to follow this instr
54. rtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 40 Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 41 Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 42 Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 43 30072 451 59A 30072 451 59A 04 2006 Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com
55. sulation Perform a test via the 1 10 DIAGNOSTICS menu Contact Schneider Electric Product Support Modbus com PowerSuite com Interruption in communication on the Modbus bus Fault communicating with PowerSuite Check the communication bus Check the time out Refer to the Modbus User s Manual Check the PowerSuite connecting cable Check the time out HMI com Fault communicating with the graphic display terminal Check the terminal connection Check the time out PI Feedback PID feedback below the lower limit Check the PID function feedback Check the PID feedback supervision threshold and time delay consult the CD ROM supplied with the drive Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com Torque current lim Switch to torque limitation Check if there are any mechanical problems Consult the CD ROM supplied with the drive 38 Faults that can be reset with the automatic restart function after the cause are removed continued IGBT overheat Probable cause Drive overheated Remedy Check the size of the load motor drive Reduce the switching frequency Wait for the drive controller to cool before restarting Proc Underload Fit Process underloa
56. t freq bFr 60 Hz NEMA 60 According to According to 1 Rated motor volt drive rating drive rating and Standard mot freq bFr Rated motor voltage given on the nameplate ATV61eeeM3 100 to 240 V ATV61eeeNA4 200 to 480 V According to J Rated mot current 0 2510 1 1 or 1 2 HZ drive rating and according to rating 1 Standard mot freq bFr ated motor current given on the nameplate 1 Rated motor freq 10 to 500 or 1000 Hz according to rating Rated motor frequency given on the nameplate The factory setting is 50 Hz or preset to 60 Hz if Standard mot freq bFr is set to 60 Hz According to 1 Nom motor speed 0 to 60000 RPM drive rating Rated motor speed given on the nameplate 0 to 9999 rpm then 10 00 to 60 00 krpm on the integrated display terminal If rather than the rated speed the nameplate indicates the synchronous speed and the slip in Hz or as a 96 calculate the rated speed as follows Nominal speed Synchronous speed x 100 sipas a or Jer Nominal speed Synchronous speed S0 sipin iz 02 50 Hz motors ju 60 slip in H Nominal speed Synchronous speed 2 5 03 60 Hz motors I Max frequency 10 to 1000 Hz The factory setting is 60 Hz or preset to 72 Hz if Standard mot freq bFr is set to 60 Hz The maximum value is limited by the following conditions t must not exceed 10 times the value of Rated motor freq
57. the CD ROM ATV61H C13N4 to C63N4 supplied with the drive controller BU and polarities to be connected to the braking unit ATV61H C25N4 to C63N4 X20 X92 X3 Connection of the braking unit control cable refer to the User s Manual for the braking unit 1 ATV61H C40N4 to C63N4 drives have two input bridges The power section line supply is connected on terminals R L1 1 R L1 2 S L2 1 S L2 2 and T L3 1 T L3 2 2 For ATV61HC25N4 and higher there are no braking resistor connection terminals on the drive since the braking unit is optional refer to the catalog The braking resistor is connected on the braking unit Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 17 Power Terminals Maximum wire size tightening torque The AWG MOM ratings use aluminum lugs Drive terminals ATV 61HD55M3X ATV 61HD75M3X ATV 61HD90N4 ATV 61HC11N4 ATV 61HD90M3X ATV 61HC13N4 ATV 61HC16N4 ATV 61HC22N4 ATV 61HC25N4 ATV 61HC31N4 ATV 61HC40N4 ATV 61HC50N4 ATV 61HC63N4 L1 R L2 S L3 T 2x 100 mm 24 Nem R L1 1 R L1 2 S L2 1 S L2 2 T L3 1 T L3 2 U T1 V T2 W T3 2 x 100 mm 24 Nem PC PA 2 x 100 mm 41 Nem 60 mm 12 Nem 2 x 250 MCM 275 lb in 2 x 100 mm 24 2 250 275 Ib in 2 x 100 mm 24 Nem 2 x 250
58. uction can result in death or serious injury Unpacking and handling DC choke Figure 2 Figure 4 Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com Figure 3 WA Figure 5 The packaging contains two items The drive controller ADC choke except for ATV61eeeD The drive and the DC choke are mounted on a pallet with screws figure 1 When the DC choke is present it is supplied already assembled to make it easier to transport The unit should be unpacked in the following order 1 Disassemble the components of the DC choke figure 2 for installation later and remove the choke by means of a hoist figure 3 2 Remove the retaining screws figure 3 from the choke support on the pallet A WARNING RISK OF CUTS The retaining screws that hold the choke support on the pallet are difficult to access leading to a risk of cutting oneself To avoid the risk use protective gloves Failure to follow this instruction can result in serious injury 3 Remove the screws holding the drive controller on the pallet and lift off the drive controller by means of a hoist The controller is fitted with handling lugs for this purpose figure 4 A WARNING RISK OF TOPPLING Do not stand the drive controller upright figure 5 Keep the drive co
59. yed value value Pressing v does not store the choices CS gt Note Press and hold down 22 s to scroll through the data quickly Save and store the selection ENT The display flashes when a value is stored Normal display with no fault present and no startup 43 0 Display of the parameter selected in the nSt Freewheel stop SUP menu default selection motor frequency Obr Auto adapted deceleration CLI Current limit PrA Power Removal function active drive locked CIL Controlled stop on input phase loss rdY Drive ready dCb DC injection braking in progress rUn Drive running FLU Motor fluxing in progress SOC Controlled output cut in progress FrF Drive at fallback speed tUn Auto tuning in progress FSt Fast stop USA Undervoltage alarm nLP No line power no line supply on L1 L2 L3 The display flashes to indicate the presence of a fault Accessing menus Power up Simplified menu for fast startup Menus Consult the CD ROM supplied with the drive auo A dash appears after menu and submenu codes to differentiate them from parameter codes Examples SIM menu ACC parameter Courtesy of Steven Engineering Inc 230 Ryan Way South San Francisco CA 94080 6370 Main Office 650 588 9200 Outside Local Area 800 258 9200 www stevenengineering com 29 1 1 SIMPLY START SIM Menu A WARNING UNINTENDED EQUIPMENT O
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