RESPONDOR 9000 AF CRANE CONTROL USER MANUAL
Contents
1. sae 7 5 7 5 GC 7 6 7 6 Programmable push button menu eene tentent tentent 7 7 1 1 Ac ve NU 7 8 7 3 7 8 7 9 Active warning display EE 7 9 7 10 Controlling the motor from the eu 7 10 E 8 1 8 1 ETGEN 8 1 8 2 Sequence of operation 8 1 NOTE For parameter details and other application specific information please consult the following Respondor 9000 AF Crane Control Application Manuals Publication No 49485 for AFDs with the standard 24VDC inputs Publication No 50248 for AFDs with the 120VAC input card Cutler Hammer RESPONDOR 9000 Contents Page 0 2 Cutler Hammer March 7 2002 RESPONDOR 9000 Safety Page 1 1 1 SAFETY ONLY A QUALIFIED ELECTRICIAN SHOULD PERFORM THE ELECTRICAL INSTALLATION 1 1 Warnings 1 Internal components and circuit boards except the isolated 1 0 terminals are at utility potential when the RESPONDOR 9000 is connected to the line This voltage is extremely dangerous and may cause death or severe injury if you come in contact with it When the RESPONDOR 9000 is connected to the utility the motor connections U T1 V T2 W T3 and DC link brake resistor connections are live even if the motor is not running 3 The control 1 0 terminals are isolated from the2. GH98A and GH99A have the same HP Ict Dimensions and Weight Table 4 1 2 March 7 2002 Cutler Hammer 4 4 Technical Data RESPONDOR 9000 440 500 VAC 10 15 50 60 Hz 3 phase Input NEMA 1 Catalog Rated Horsepower and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD Ibs Bes HP Ict inches GH97A40005RS 3 5 GH97A40008RS 5 8 M4 NEMA 1 4 1 x 15 4 x 8 5 17 6 GH97A40011RS 15 11 GH97A40015RS 10 15 GH97A40021RS 15 21 5 1 6 2 x 20 3 x 9 4 35 3 GH97A40027RS 20 27 GH97A40034RS 25 34 GH97A40040RS 30 40 GH97A40052RS 40 52 1 87 x25 6x 11 4 83 8 GH97A40065RS 50 65 GH97A40077RS 60 77 GH97A40096RS 75 96 GH97A40125RS 100 125 7 1 147 x 39 4 x 13 221 GH97A40160RS 125 160 GH97A40180RS 150 180 8 1 19 5 47 6 13 9 309 GH97A40260RS 200 260 GH97A40320RS 250 320 M9 NEMA 1 27 6 56 1 x 154 574 GH97A40400RS 300 400 GH97A40480R 5 400 480 Contact Factory GH97A40600RS 500 600 380 440 VAC 10 15 50 60 Hz 3 phase Input NEMA 1 Catalog Rated Power and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD Ibs id KW Ict inches GH97A30006RS 2 2 6 5 GH97A30008RS 3 8
3. Common for DIB4 DIB6 Must be connected to GND or 24V of I O terminal or to external 24 V or GND 18 out Analog signal output Signal range 0 4 20 mA 19 out Analog signal output max 500 ohm 20 001 Open collector output Transistor output max Vin 48 VDC Max current 50 mA 21 RO1 Relay output1 Max switch Voltage 250 VAC 300 VDC 22 1 2 um Max switch Current 8 A 24 VDC 23 RO1 3 1 0 4 250 VDC 24 RO2 1 Relay output2 Max switch Power lt 2 kVA 250 VAC 25 RO2 2 cont current lt 2 A RMS 26 RO2 3 Figure 6 2 1 Control I O terminal signals March 7 2002 Cutler Hammer 6 10 Wiring RESPONDOR 9000 Control ground DIA 4 Ze Digtal input DIAS group DIB4 DIBE CMB Digital input lout lou 601 RO1 1 RO1 2 RO1 3 RO2 1 RO22 RO23 Figure 6 2 2 1 6 2 3 Digital input function inversion The active signal level of the digital input logic depends on how the common input CMA CMB of the input group is connected The connection can be either to 24 V or to ground See figure 6 2 3 1 Utility Li 1213 circuits Motor The 24V or ground for the digital inputs and common terminals CMA CMB can be either external or internal terminals 6 and 12 of the drive 24 DA I DIA2 DIA3 I Ground Positive logic 24 V active signal
4. Ict inches GH97A20003RC 0 75 3 6 GH97A20004RC 1 47 M3 Compact NEMA 1 4 7 12 0 5 9 9 9 GH97A20006RC 15 5 6 GH97A20007RC 2 7 GH97A20010RC 3 10 GH97A20016RC 5 16 M4B Compact NEMA 1 5 3 15 4 x 8 1 15 4 GH97A20022RC 7 5 22 GH97A20030RC 10 30 GH97A20043RC 15 43 M5B Compact NEMA 1 7 3 22 8 x 8 5 33 1 GH97A20057RC 20 57 Table 4 1 10 200 240 VAC 10 15 50 60 Hz 3 phase Input STANDARD PROTECTED CHASSIS Catalog Rated Horsepower and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD Ibs an HP inches GH97A20007RP 2 7 4 Protected 4 1 x114 x8 5 154 GH97A20010R P 3 10 GH97A20016R P 5 16 GH97A20022RP 75 22 M5 Protected 6 2 x 15 9 x 9 4 33 1 GH97A20030R P 10 30 GH97A20043RP 15 43 GH97A20057RP 20 57 M6 Protected 8 7 20 7 x 114 712 GH97A20070R P 25 70 GH97A20083RP 30 83 GH97A20113RP 40 113 GH97A20139RP 50 139 M7 Chassis 9 8 x 31 5 x 12 4 135 GH97A20165RP 60 165 GH97A20200RN 75 200 8 Chassis 19 5 35 x 13 9 300 Table 4 1 11 Cutler Hammer March 7 2002 RESPONDOR 9000 Technical Data Page 4 9 200 240 VAC 10 15 50 60 Hz 3 phase Input NEMA 12 Catalog Rated Horsepower and output current Frame Size Dimensions Weight Number Consta
5. M2 Parameter Cutler Hammer ENS zm P1 1 p Several parameters are locked i e uneditable when the drive is in RUN status If you try to change the value of such a parameter the text locked will appear on the display You can return to the main menu anytime by pressing the Menu button left for 2 3 seconds The basic application embodies only those parameters necessary for operating the device The parameter group 0 is accessible only by opening the Application package lock Once in the last parameter of a parameter group you can move directly to the first parameter of that group by pressing the browser button up e P1 1 Min frequency 13 34 Hz d A M March 7 2002 RESPONDOR 9000 Control Panel Page 7 5 7 5 Reference menu Move deeper in the menu with the menu button right until the symbol R1 starts to blink Now you are able to alter the frequency reference value with the browser buttons The reference menu can be entered from the main menu when the symbol is visible on the first line of the panek Pressing the Enter button is not necessary Motor speed changes as soon as the frequency reference changes or If the control panel is the active control source the the load inertia allows the motor to accelerate or frequency reference can be changed by changing the value decelerate on the display with the browser buttons for the selection of the active control source see Ch
6. Table 4 1 1 Cutler Hammer March 7 2002 RESPONDOR 9000 Technical Data Page 4 3 380 440 VAC 10 15 50 60 Hz 3 phase Input Standard Protected Chassis Catalog Rated Power and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD 105 FR KW EES inches GH97A30006RP 2 2 6 5 6 97 30008 3 8 4 Protected 4 1x11 4 x 8 5 154 GH97A30010RP 4 10 GH97A30013RP 5 5 13 GH97A30018RP 7 5 18 GH97A30024R P 11 24 M5 Protected 6 2 x 15 9 x 9 4 33 1 GH97A30032RP 15 32 GH97A30042RP 18 5 42 GH97A30048RP 22 48 GH97A30060RP 30 60 M6 Protected 87 x 20 7 x 114 77 2 GH97A30075RP 37 75 GH97A30090RN 45 90 GH97A30110RN 55 110 GH97A30150RN 75 150 M7 Chassis 9 8 31 5 12 4 133 GH97A30180RN 90 180 GH97A30210RN 110 210 GH97A30270RN 132 270 8 Chassis 19 5 x 35 0x13 9 309 GH97A30325RN 160 325 GH97A30410RN 200 410 9 Chassis 27 6 39 4 15 4 485 GH97A30510RN 250 510 GH97A30600RN 315 600 M10 Chassis 38 9 x 39 4 15 4 684 GH97A30750RN 400 750 GH97A30840RN 500 840 M11 Chassis 55 1 x 39 4 15 4 948 GH97A31050RN 630 1050 GH97A31270RN 710 1270 GH97A31330RN 800 1330 M12 Chassis 77 9 39 4 15 4 1212 GH97A31480RN 900 1480 GH97A31600RN 1000 1600 Ict rated input and output current Protected Enclosure with Optional Cover
7. Compact NEMA 1 contact factory March 7 2002 Cutler Hammer 6 8 Wiring RESPONDOR 9000 6 1 5 Cable and motor insulation checks 1 Motor cable insulation checks Disconnect the motor cable from the terminals U V and W of the RESPONDOR 9000 unit and from the motor Measure the insulation resistance of the motor cable between each phase conductor Also measure the insulation resistance between each phase conductor and the protective ground conductor The insulation resistance must be gt 1 2 Utility cable insulation checks Disconnect the utility cable from terminals L1 L2 and L3 ofthe RESPONDOR 9000 unit and from the utility Measure the insulation resistance of the utility cable between each phase conductor Also measure the insulation resistance between each phase conductor and the protective ground conductor The insulation resistance must be gt 3 Motor insulation checks Disconnect the motor cable from the motor and open any bridging connections in the motor connection box Measure insulation resistance of each motor winding The measurement voltage has to be atleast equal to the utility voltage but not exceed 1000V The insulation resistance must be gt 1 MQ Cutler Hammer 6 2 Control connections Basic connection diagram is shown in the figure 6 2 1 6 2 1 Control cables The control cables should be minimum of 20 gauge Shielded multicore cables see table 6 1 1 T
8. input is active when the switch is closed Ground DIA1 DIA2 24V Negative logic 0 V active signal input is active when the switch is closed Figure Cutler Hammer 6 2 3 1 March 7 2002 RESPONDOR 9000 7 1 7 CONTROL PANEL 7 1 Introduction The control panel of the RESPONDOR 9000 drive features an alphanumeric Multiline Display with five indicator for the Run status Run Ready Fault Stop and two indicators for the control source Additional the panel embodies three indicator lines for the menu submenu description and the Control panel with LED display button left Move forward in menu Menu button right Move backward in the menu Browser button up Moves in the main menu and between pages inside the same submenu Change value Browser button down Move in the main menu and between pages inside the same submenu Change value March 7 2002 value amount of the submenus The eight push buttons on the panel are used for panel programming and monitoring The panel is detachable and isolated for the input line potential The display examples in this chapter present the alphanumeric par to the Multiline Display only The indicators are not included in the examples Drive Status Indicators RUN Lights when motor is running Shows the selected
9. 10 15 50 60 Hz 3 phase Input COMPACT NEMA 1 Catalog Rated Horsepower and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD Ibs inches GH97A40002RC 1 2 5 GH97A40003RC 15 3 GH97A40004RC 2 3 5 Compact NEMA 1 4 7 12 0 5 9 9 9 GH97A40005RC 3 5 GH97A40008RC 5 8 GH97A40011RC 7 5 11 M4B Compact NEMA 1 5 3 15 4 x 8 1 15 4 GH97A40015RC 10 15 GH97A40021RC 15 21 GH97A40027RC 20 27 GH97A40034RC 25 34 M5B Compact NEMA 1 7 3 x 22 8 x 8 5 331 GH97A40040RC 30 40 Table 4 1 8 380 440 VAC 10 15 50 60 Hz 3 phase Input COMPACT NEMA 1 Catalog Rated Power and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD Ibs Er KW inches GH97A30002RC 0 75 2 5 GH97A30003RC 11 3 5 GH97A30004RC 15 45 M3 Compact NEMA 1 4 7 12 0 x5 9 9 9 GH97A30006RC 2 2 6 5 GH97A30008RC 3 8 GH97A30010RC 4 10 GH97A30013RC 5 5 13 M4B Compact NEMA 1 5 3x15 4x8 1 15 4 GH97A30018RC 75 18 GH97A30024RC 11 24 GH97A30032RC 15 32 GH97A30042RC 18 5 42 M5B Compact NEMA 1 7 3 X 22 8 x 8 5 33 1 GH97A30048RC 22 48 Table 4 1 9 March 7 2002 Cutler Hammer 4 8 Technical Data RESPONDOR 9000 200 240 VAC 10 15 50 60 Hz 3 phase Input COMPACT NEMA 1 Catalog Rated Horsepower and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD Ibs ei
10. 66 Hz Connection to the mains Once per minute or less normally Motor Output Voltage 0 Vin Connection Continuous output Itambient max 50 C open chassis current Overload 1 5 x la 1 min 10 min Starting torque 20096 Starting current 2 5 X le 2 5 every 20 x if output frequency lt 30 Hz and if the heatsink temperature lt 60 C Output frequency 0 500 Hz Frequency resolution 0 01 Hz Control Control method Frequency Control V Hz characteristics Open Loop Sensorless Vector Control Closed Loop Vector Control Switching frequency 1 16 KHz depending on horsepower rating Frequency Analog 1 Resolution 12 bit accuracy 1 96 reference Panelrefer Resolution 0 01 Hz Field weakening point 30 500 Hz Acceleration time 0 1 3000 s Deceleration time 0 1 3000 s Braking torque DC brake 30 T jy without brake option Environmetal Ambient operating 10 no frost 50 at 1 5 x Icy max 1min 10min Limits temperature Storage temperature 40 C 60 C Relative humidity lt 95 no condensation allowed Air quality chemical vapors 721 3 3 unit in operation class 3C2 mechanical particles IEC 721 3 3 unit in operation class 352 Altitude 1000m 3300 ft maximum without derating Vibration Operation max displacement amplitude 3 mm at 2 9 Hz IEC 721 3 3 Max acceleration amplitude 0 5 at 9 200 Hz Shock Operation max 8 G 11 ms IEC 68 2 27 Storage and shipping max 15 G 11 ms in the package E
11. Compact NEMA 1 3 10 480 Protected amp NEMA 1 12 i 2 15 600 Protected 5 2 Cooling 3 15 230 Compact NEMA 1 ifi q 5 10 230 Protected amp NEMA 1 12 The specified space around the drive ensures proper GEET cooling air circulation See table 5 2 1 for dimensions 11 30 380 Protected amp NEMA 1 12 100 1 10 25 480 Compact NEMA 1 If multiple units are to be installed above each other En re the dimensions must be b c and air from the outlet of 20 60 600 Protected i i i 20 230 Compact NEMA 1 the lower unit must be directed away from the inlet of e the upper unit 22 380 Compact NEMA 1 Got 30 480 Compact NEMA 1 218 When switching frequencies are above 5 KHz the 37 45 380 Protected amp NEMA 1 12 maximum continuous output current needs to be derated Contact Cutler Hammer Crane group for 40 75 230 Chassis amp NEMA 1 12 55 90 380 Chassis amp NEMA 1 12 383 assistance 15 125 480 Chassis amp NEMA 1 12 are 110 160 380 Chassis amp NEMA 1 12 Frame Size EE 150 200 480 Chassis amp NEMA 1 12 765 Enclosure Style 100 150 600 Chassis 3 Comp NEMA 1 1 0 5 4 2 200 250 380 Chassis amp NEMA 1 12 NEMA 12 250 300 480 Chassis amp NEMA 1 12 1148 ANEMA 1 1 1 41 2 175 200 600 Chassis 4B 5B Comp NEMA 1 1 05 ES 315 400 380 Chassis amp NEMA 1 12 400 500 480 Chassis amp NEMA 1 12 173
12. 11 600 480 400 600 Contact Factory 630 1000 380 12 700 1100 480 500 800 600 NEMA 1 12 maximum 3 parallel connected cables can be used Table 6 1 6 Maximum cable sizes of the power terminals March 7 2002 Cutler Hammer 6 4 Wiring RESPONDOR 9000 6 1 4 Installation instructions If RESPONDOR 9000 open chassis unit is to be installed outside a control 1 cabinet or a separate cubicle a protective IP20 cover should be installed to cover the cable connections The protective cover may not be needed if the unit is mounted inside a control cabinet or a separate cubicle All open chassis RESPONDOR 9000 units should always be mounted inside a control cabinet or a separate cubicle 2 Locate the motor cable away from the other cables Avoid long parallel runs with other cables If the motor cable runs in parallel with the other cables the minimum distances given in table 6 1 4 1 between the motor cable and control cables should be followed These minimum distances apply also between the motor cable and signal cable of other systems The maximum length of a motor cable can be 600ft 180 m except for ratings 1 5 Hp and below max length is 160 ft 50 m and 2 Hp max length 330 ft 100 m The power cables should cross other cables at an angle of 90 degrees An output dv dt filter option should be considered for motor cable lengths exceeding 33ft 10m for drive 2 Hp and below and 100ft 33m
13. 25 00 E T N Cutler Hammer GH97A OPEN LOOP INVERTER ae GH98A CLOSED LOOP VECTOR DRI GH99A OPEN LOOP SENSORLESS VECTOR DRIVE RESPONDOR 9000 AF CRANE CONTROL USER MANUAL March 7 2002 March 7 2002 Publication No 49484 Publication 49484 7 2002 RESPONDOR 9000 Contents Page 0 1 CUTLER HAMMER RESPONDOR 9000 USERS MANUAL CONTENTS 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 March 7 2002 Safejn ee ee ae 1 1 1 1 EE 1 1 1 2 SE le 1 1 1 3 Grounding and ground fault protection e see ea 1 2 1 4 Running the MOtOT ERE 1 2 b E 2 1 2 1 zr 727 2 1 2 2 BC IIS CV es 2 1 IWIN ee d 3 1 3 1 Catelog 3 1 3 2 3 2 3 3 3 2 TE NIC AO EE 4 1 4 1 General urnana Eet 4 1 4 2 E 4 2 43 SEHR ea ee 4 10 Installation Nine 5 1 5 1 Lille TEE 5 1 5 2 EE 5 1 5 3 RTR 5 2 WIN ee een ee 6 1 6 1 POWENCOMMECUONS De 6 1 6 2 Gel Reie IC 6 8 a ale 7 1 7 1 NO ON ars ta TOTEM 7 1 7 2 Panel 7 2 7 3 Monitoring emer 7 3 7 4
14. 6 243 3 9 114 035 0 18 8 Protected 230 380 480 9 8 8 7 336 329 315 124 035 0 18 9 230 380 480 600 19 5 18 374 365 35 13 9 045 0 24 M10 230 380 480 27 6 26 411 402 39 4 154 045 0 24 M11 230 380 480 38 9 37 3 41 1 40 2 39 4 15 4 0 45 0 24 M12 230 380 480 Table 5 3 1 CORRECT Unit sizes 150 500 Hp do not lift without a rod through the lifting holes the unit see above MSNOSTO Figure 5 3 2 Lifting of 25 125 HP units Figure 5 3 3 Lifting of 150 500 HP units March 7 2002 Cutler Hammer 5 4 Installation RESPONDOR 9000 Cutler Hammer March 7 2002 RESPONDOR 9000 Wiring Page 6 1 6 1 Power connections Use heat resistant cables 60 C or higher The cable and the fuses must be sized in accordance with the rated output current of the unit Installation of the cable consistent with the UL instructions is explained in chapter 6 1 4 1 The minimum dimensions for the Cu cables and corresponding fuses are given in the tables 6 1 2 6 1 5 The fuses have been selected so that they will also function as overload protection for the cables Consistent with UL requirements for maximum protection of the RESPONDOR 9000 UL recognized fuses type RK or industrial thermal magnetic circuit breakers should be used If the motor temperature protection Pt is used as overload protection the cables may be selected according to th
15. 9000 drive is connected to the utility line 4 After disconnecting the utility wait until the cooling fan on the unit stops and the indicators in the panel are turned off if no panel is present check the indicators on AN the cover Wait atleast5 minutes before doing any work on the RESPONDOR 9000 drive connections Do not open cover before this time has run out 5 The control 1 0 terminals are isolated from the utility potential but the relay outputs and other I O s if jumper X4 is in the OFF position see fig 6 2 2 1 may have dangerous external voltages connected even if the power is off from the RESPONDOR 9000 drive 6 Before connecting the utility make sure that the cover of the RESPONDOR 9000 drive is closed 8 2 Sequence of operation 1 Readand follow the safety precautions 2 After installation ensure that the Drive and motor are connected to ground Utility and motor cables are in accordance with the installation and connection instructions chapter 6 1 Control cables are located as far as possible from the power cables table 6 1 3 1 shields of the control cables are connected to the protective ground and wires do not have contact with any electrical components in the RESPONDOR 9000 The common input of digital input groups is connected to 424 V or ground of the I O terminal or external supply See 6 2 3 3 Check the quantity and quality of the cooling air chapters 5 1 and 5 2 March 7 2002 Cutler Ham
16. Drive 99 Sensorless Vector Drive Series A Respondor 9000 Series Voltage 2 200 240 VAC 3 380 440 VAC 4 440 500 VAC 5 515 690 VAC Regeneration R Resistor Line Core Drive Compact NEMA 1 Enclosure N Std Chassis P Std Protected Chassis 5 Std NEMA 1 Std NEMA 12 March 7 2002 Keypad M Multi line Alphanumeric G Graphic Control 00 No Modifications Communication 05 Encoder Board 03 Encoder Board w add l inputs Others Consult Factory Construction 00 Customer Mount Drive only Cutler Hammer 3 2 Receiving RESPONDOR 9000 3 2 Storing 3 3 Warranty If the RESPONDOR 9000 must be stored before This equipment is covered by the Cutler Hammer installation and startup check that the ambient Standard drive warranty policy conditions in the storage area are acceptable temperature 40 C 60 C 40 F 140 F relative humidity lt 95 no condensation allowed Cutler Hammer March 7 2002 RESPONDOR 9000 Technical Data Page 4 1 4 TECHNICAL DATA 4 1 General Figure 4 1 shows a block diagram of the RESPONDOR 9000 drive The three phase AC Choke with the DC link capacitor forms an LC filter which together with the Diode Bridge produce the DC voltage for the IGBT Inverter Bridge block The AC Choke smooths the HF disturbances from the utility to the drive and HF disturbances caused by the drive to the utility It also improves the waveform of the input current to the drive The IG
17. FRAME HP KW VOLTAGE Tightening torque in Ibs 4 All 380 480 7 M5 All 20 M6 18 5 22 380 35 M6 25 30 480 35 M6 30 45 380 44 M6 40 60 480 44 M7 All 44 M8 All 380 480 610 M9 All 610 The isolated standoff of the bussbar does not withstand the listed tightening torque Use a wrench to apply counter torque when tightening Table 6 1 4 1 2 Tightening torque Cutler Hammer March 7 2002 RESPONDOR 9000 Wiring Page 6 7 L4 L1 Frame HP KW Voltage Shipping Lengths in L1 L2 L3 L4 M3 ALL 230 380 480 47 22 22 4 4 ALL 230 380 480 24 14 24 6 M4B ALL 230 380 480 35 1 6 4 6 M5 ALL 230 380 480 600 131 L2 10 20 230 braind Utility 15 22 380 conductor cables 20 30 480 15 30 230 6 16 4 6 18 5 22 380 25 30 480 M6 30 50 600 30 45 380 40 60 480 1 16 4 6 60 75 600 40 75 230 GC 7 55 90 380 2 1 Figure 6 1 4 1 Stripping motor and utility cables 100 150 480 110 160 380 M8 150 200 480 100 150 600 200 250 380 M9 250 300 480 200 600 315 400 380 M10 400 500 480 250 300 600 500 380 M11 600 480 400 600 630 1000 380 M12 700 1100 480 500 800 600 1 Loosen screws 2 pcs 2 Pull cover bottom outwards 3 Push cover upwards NEMA 1 12 maximum 3 parallel connected cables can be used Table 6 1 4 2 Stripping lengths of the cables in
18. 23 25 10 10 33646 1417 25 26 35 15 56 10 16 16 31 5415 30 35 35 8 8 310410 3 3 we 40 42 50 3 50 52 60 6 6 3 16 16 5 16 15 14 14 13 2 542 5 60 62 60 75 22 25 10 10 3 6 75 85 100 216 33516 10 30 35 8 8 3310410 100 100 100 15 43 50 150 145 150 00 2 3 70 35 75 70 80 4 6 395416 200 222 250 300MCM 00 3 150 70 30 83 100 2 6 3335416 250 Contact Factory 4 13 15 0 4 3550425 6 1 4 Mains motor cables and Protection Rating A nn recommendations according to output currents 600V range s 000 0 3 65450 Cutler Hammer Table 6 1 5 Mains motor cables and Protection Rating recommendations according to output currents Ict 230V range March 7 2002 RESPONDOR 9000 Wiring Page 6 3 Frame HP KW Voltage CABLE AWG MCM Main Ground M3 ALL 230 380 480 14 14 M4 ALL 230 380 480 10 10 M4B ALL 230 380 480 6 6 M5 ALL 230 380 480 600 10 20 230 M5B 15 22 380 20 30 480 15 30 230 2 00 18 5 22 380 25 30 480 M6 30 50 600 30 45 380 40 60 480 0 Cu 00 AL 00 60 75 600 40 75 230 1 55 90 380 350 MCM 000 100 150 480 110 160 380 2x350 MCM Cu 8 150 200 480 2x500 MCM Al 2x500 MCM 100 150 600 200 250 380 9 250 300 480 2x600 MCM 2x500 MCM 200 600 315 400 380 10 400 500 480 4x500 MCM 2x500 MCM 250 300 600 500 380
19. 4 1 4 7 x 15 4 x 8 5 17 6 GH97A30010RS 4 10 GH97A30013RS 5 5 13 GH97A30018RS 75 18 GH97A30024RS 11 24 5 1 6 2 x 20 3 x 9 4 35 3 GH97A30032RS 15 32 GH97A30042RS 18 5 42 GH97A30048RS 22 48 GH97A30060RS 30 60 1 87 25 6 114 84 GH97A30075RS 37 75 GH97A30090RS 45 90 GH97A30110RS 55 110 GH97A30150RS 75 150 7 1 14 7 x 39 4 x 13 221 GH97A30180RS 90 180 GH97A30210RS 110 210 GH97A30270RS 132 270 8 1 19 5 x 35 0 x 13 9 309 GH97A30325RS 160 325 GH97A30410RS 200 410 M9 NEMA1 27 6 x 39 4 x 15 4 485 GH97A30510RS 250 510 GH97A30600RS 315 600 Contact Factory GH97A30750RS 400 750 Table 4 1 3 and Table 4 1 4 Cutler Hammer March 7 2002 RESPONDOR 9000 Technical Data Page 4 5 440 500 VAC 10 15 50 60 Hz 3 phase Input NEMA 12 Catalog Rated Horsepower and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD 105 MS HP Ict inches GH97A40005RJ 3 5 GH97A40008R 5 8 4 12 4 1 x 15 4 x 8 5 17 6 GH97A40011RJ 15 11 GH97A40015RJ 10 15 GH97A40021R 15 21 M5 NEMA 12 6 2 x 20 3 x 9 4 35 3 GH97A40027RJ 20 27 GH97A40034R 25 34 6 97 400408 30 40 GH97A40052R 40 52 12 87 x25 6x 11 4 83 8 GH97A40065RJ 50 65 GH97A400
20. 4 5 3 5 2 2 6 5 10 16 16 3 1 5 1 5 5 8 3 8 7 5 11 15 14 14 32 542 5 4 10 10 15 20 12 12 34 4 5 5 13 15 14 14 32 542 5 15 21 25 10 10 3 6 6 7 5 18 20 12 12 34 4 20 27 35 11 24 25 10 10 3 6 6 25 34 50 8 8 331010 15 32 35 30 40 50 18 5 42 50 8 8 310 10 40 52 60 6 6 3 16 16 22 48 50 65 80 4 6 325416 30 60 60 6 6 3 16 16 60 77 100 2 6 3335416 37 75 80 4 6 325416 75 96 125 0 4 3550425 45 90 100 2 6 3335416 100 125 150 00 2 3 70 35 55 110 125 0 4 3550425 125 160 200 000 0 395450 75 150 150 00 2 3 70 35 150 180 200 90 180 200 000 0 3 95 50 200 260 300 350 3 185 95 110 210 250 300MCM 00 3 150 70 250 320 400 2x 250M CM 00 132 270 300 350MCM 3 185 95 2 3 120 70 160 325 400 2x 250M CM 00 300 400 500 2x 350MC M 000 2 3 120 70 2 3 185495 200 410 500 2x 350MC M 000 400 480 2431 8595 500 Contact Factory 250 510 600 2x 500MCM 250MCM 1100 2 3 240 120 Table 6 1 2 Mains motor cables and Protection Rating 315 Contact Factory recommendations according to output currents 500V range 1000 600V Ict Protection Cu cable Table 6 1 3 Mains motor cables and Protection Rating HP Rating Line amp Motor recommendations according to output currents Ict 400V range ground mm 230V Ict Protection Cu cable 1 5 10 10 16 16 3 1 5 1 5 HP Rating Line amp Motor 10 14 15 14 14 32 542 5 ground mm 15 19 20 12 12 34 4 75 36 20
21. 6 GN i 5 25 250 300 600 Chassis 6Prot amp NEMA 12 15 4 65 35 500 380 Chassis SNEMAT 12 600 480 Chassis 2296 7iChassis amp NEMA 12 3 1 5 305 2 4 400 600 Chassis TINEMA 1 MEE ewe 3 Sal Si chest amp NEMA 12 89439 3 12 500800 Chassis 9 NEMA 1 Protected enclosures with optional cover 10 Chassis amp 12 3 12 Table 5 2 2 Required cooling air 10 NEMA 1 11 Chassis amp NEMA 12 Contacts as AA M11 NEMA 1 Factory 12 Chassis amp NEMA 12 12 NEMA 1 a2 Distance from inverter to inverter in multiple inverter installations Protected enclosure with optional cover Minimum allowable space No space available for fan change Space for fan change on sides of inverter Table 5 2 1 Installation space dimensions ud March 7 2002 Figure 5 2 1 Installation space Cutler Hammer 5 2 Installation RESPONDOR 9000 5 3 Mounting The Respondor 9000 should be mounted in a vertical position on the wall or on the back plane of a cubicle Follow the requirementfor cooling see table 5 2 1 and figure 5 2 1 for dimensions To ensure a safe installation make sure that the mounting surface is relatively flat Mounting holes can be marked on the wall using the template on the cover of the cardboard shipping package Mounting is done with four screws or bolts depending on the size of the unit see tables 5 3 1 and figure 5 3 1 for dimensions Un
22. 77R 60 77 6 97 400968 75 96 GH97A40125R 100 125 7 12 14 7 x 39 4 x 13 221 6 97 401608 125 160 6 97 401808 150 180 M8 12 19 5 47 6 13 9 309 6 97 402608 200 260 97 403208 250 320 9 NEMA 12 27 6 96 1 15 4 574 GH97A40400R 300 400 GH97A40480R 400 480 Contact Factory GH97A40600R 500 600 380 440 VAC 10 15 50 60 Hz 3 phase Input NEMA 12 Catalog Rated Power and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD Ibs ter KW Ict inches GH97A30006R 22 6 5 GH97A30008R 3 8 M4 NEMA 12 4 1 15 4 x 8 5 17 6 GH97A30010R 4 10 GH97A30013RJ 5 5 13 GH97A30018RJ 7 5 18 6 97 00248 11 24 5 12 6 2 x 20 3 x 9 4 35 3 GH97A30032R 15 32 GH97A30042RJ 18 5 42 GH97A30048RJ 22 48 GH97A30060R 30 60 12 87 25 6 114 84 GH97A30075RJ 37 15 GH97A30090R 45 90 GH97A30110RJ 55 110 GH97A30150RJ 75 150 7 12 14 7 x 39 4 x 13 221 GH97A30180RJ 90 180 GH97A30210RJ 110 210 GH97A30270RJ 132 210 M8 NEMA 12 19 5 x 35 0 x 13 9 309 GH97A30325R 160 325 6 97 04108 200 410 9 12 27 6 x 39 4 x 15 4 485 GH97A30510R 250 510 GH97A30600R 315 600 Contact Factory GH97A30750R 400 750 Table 4 1 5 and Table 4 1 6 March 7 2002 Cutler Hammer 4 6 Technical Data RESPONDOR 9000 525 690 VAC 10 15 50 60 Hz phase Inp
23. BT bridge produces a symmetrical three phase pulse width modulated AC voltage to the motor The power drawn from the supply is almost entirely active power The Motor and Application Control block is based on microprocessor software The microprocessor controls the motor according to measured signals parameter value settings and commands from the Control block and the Control Panel The Motor and Application Control block gives commands to the Motor Control ASIC which calculates the IGBT switching positions Gate Drivers amplify these signals for driving the IGBT inverter bridge The Control Panel is a link between the user and the drive With the panel the user can set parameter values read status data and give control commands The panel is removable and can be mounted externally and connected via a cable to the drive The Control 1 0 block is isolated from line potential and is connected to ground via a 1 MW resistor and 4 7 nF capacitor If needed the Control 1 0 block can be grounded without a resistor by changing the position of the jumper X4 GND ON OFF on the control board An optional Brake Chopper can be mounted in the unit at the factory Optional I O expander boards are also available Input and Output EMC filters are not required for the functionality of the drive they are only required for compliance with the EU EMC directive Brake Resistors Control Panel March 7 2002 IGBT rter Converte Curre
24. RESPONDOR 9000 Wiring Page 6 5 shielded power cable is used connect its shield to the ground terminals of the drive motor and supply panel Mount the cable cover open chassis units and the unit cover Ensure the control cables and internal wiring are not trapped between the cover and the body of the unit 5 NOTE The connection of the transformer inside the unit in frame sizes M7 MY12 has to be changed if other than the default supply voltage of the drive is used Contact your Cutler Hammer distributor if more information is needed Voltage Code VC Default Supply Voltage 2 230V 4 380V 5 460V 6 600V March 7 2002 Cutler Hammer 6 6 Wiring RESPONDOR 9000 6 1 4 1 Cable selection and installation for the UL listing For Installation and cable connections the following must be noted Use only with copper wire temperature rating of at least 60 75 C Units are suitable for use on a circuit capable of delivering not more than the fault RMS symmetrical amperes mentioned in the table 6 1 4 1 1 480V maximum In addition to the connecting information the tightening torque of the terminals are defined in the table 6 1 4 1 2 FRAME Voltage Maximum RMS symmetrical amperes on connecting circuitry M4 M5 5000 M6 M7 380 480 10000 M8 M9 18000 Table 6 1 4 1 1 Maximum symmetrical supply current
25. XVn 135 Utility voltage 525 V 575V 6007 660 V 690 V Trip limit 1717 1 62 1 55xVn 1 41XVn 1 35 Undervoltage protection Trip limit 0 65 x Vn Ground fault protection Protects the inverter from an ground fault in the output motor or motor cable Motor phase supervision Trip if any of the output phases is missing Unit over temperature Yes protection Motor overload protection Yes Stall protection Yes Motor underload protection Yes Short circuit protection of Yes 24V and 10V reference voltages Table 4 1 14 March 7 2002 Cutler Hammer 4 12 Technical Data RESPONDOR 9000 RESPONDOR 9000 3 KHZ APPROXIMATE WATTS PER AMP DATA DRIVE FRAME 240 VAC 380 480VAC 575 M3 12 18 M4 12 18 M4B 12 18 M5 12 18 M5B 12 16 6 12 18 7 12 16 8 12 16 9 16 M10 N A 16 Table 4 1 15 Cutler Hammer RESPONDOR 9000 Installation Page 5 1 5 INSTALLATION 51 Ambient conditions HP kw Voltage Enclosure ini S 0 75 2 230 Compact NEMA 1 The environmental limits mentioned in table 4 3 1 228 920 Profacted amp NEMA 1 19 must not be exceeded 0 75 55 380 Compact NEMA 1 2 2 7 5 380 Protected amp NEMA 1 12 42 1 75 480
26. anges take effect immediately See figure 7 8 1 The contrast menu can be entered from the main menu when the symbol M7 is visible on the first line of the Multiline display Use the menu button right to enter the edit menu oc 9 Figure 7 8 1 Contrast setting M7 Contrast 15 7 9 Fault and Active warning display When a fault occurs a text with a symbol F appears on the The display does not have to be cleared in any special way display When a warning occurs a text with a symbol A for warnings Faults require resetting of the drive appears on the display A warning on the display does not disable the normal functions of the push buttons For the table of fault and warning codes please consult Appendix 1 of the following Respondor 9000 AF Crane Control Application Manuals Publication No 49485 for AFDs with the standard 24VDC inputs Publication No 50248 for AFDs with the 120VAC input card March 7 2002 Cutler Hammer 7 8 Control Panel RESPONDOR 9000 7 11 Controlling the motor from the panel The RESPONDOR 9000 can be controlled from either the 1 0 terminals or the control panel The active control source can be changed with the programmable push button b2 see chapter 7 6 The motor can be started stopped and the direction of rotation can be changed from the active control source Warning Use extreme caution and observers if line of sight is impaired 7111 Control source change fr
27. apter 7 6 Programmable push button menu See Figure 7 5 1 In some applications there might be several references M3 Reference RI Figure 7 5 1 Reference setting the control panel March 7 2002 Cutler Hammer 7 6 Control Panel RESPONDOR 9000 7 6 Programmable push button menu The programmable push button menu can be entered from the main menu when the symbol 4 is visible on the first line of the Multiline display In this menu there are four functions for the Enter button The functions are available in this menu only In other menus the button is used for its original purpose The status of the controlled function is shown through a feedback signal AV M4 B1 Buttons Reverse BE lt gt iy lt gt Enter the edit menu with the menu button right Then the symbol 1 starts to blink To change the button value push the Enter button after which the new feedback value appears and the button sign B is replaced with a black square blinking together with the button number After releasing the Enter button the black square reverts to B The new value stops blinking when the new value e g reverse direction has been received and put into operation See Figure 7 6 Figure 7 6 1 Programmable push button menu Button Button Function Feedback information Number Description 0 1 Note See 7 11 Bl Reverse Changes the rotation Forward Backward Feedback direction f the motor
28. at If 3 or more cables are used in parallel on the larger units every cable must have it s own overload protection These instructions cover the case where one motor is connected with one cable to the drive Always pay attention to the local authority regulations and installation conditions 6 1 1 Utility cable Utility cables for the different EU EMC levels are defined in table 6 1 1 6 1 2 Motor cable Motor cables for the different EU EMC levels are defined in table 6 1 1 6 1 3 Control cable Control cables are specified in chapter 6 2 1 Cable Level N Level Utility cable 1 1 Motor cable 2 2 Control cable 3 3 Table 6 1 1 1 The power cable which is suitable for the installation ampacity and voltage Shielded cable is not required 2 The power cable contains a concentric protection wire and is suitable for the ampacity and voltage 3 The control cable is a compact low impedance shielded cable March 7 2002 Cutler Hammer 6 2 Wiring RESPONDOR 9000 480V Ict Protection Cu cable 360V Ict Protection Cu cable HP Rating Line amp Motor HP Rating Line amp Motor ground mm ground mm 1 2 5 15 2 5 1 5 3 11 3 5 2 3 5 10 16 16 3 1 5 1 5 1 5
29. ating to the product Cutler Hammer RESPONDOR 9000s are available with the CE label in accordance with the Low Voltage Directive LVD and the EMC directive 2 2 EMC directive 2 2 1 General The EMC directive Electro Magnetic Compatibility States that the electrical equipment must not disturb the environment and must be immune to other Electro Magnetic Disturbances in the environment A Technical Construction File TCF exists which demonstrates that the RESPONDOR 9000 drives fulfill the requirements of the EMC directive A Technical Construction File has been used as a Statement of conformity with the EMC directive as itis not possible to test all combinations of installation 2 2 2 Technical criteria The design intent was to develop a family of drives which is user friendly and cost effective while fulfilling the customer needs EMC compliance was a major consideration from the outset of the design The RESPONDOR 9000 series is targeted at the world market To ensure maximum flexibility yet meet the EMC needs of different regions all drives meet the highest immunity levels while emission levels are left to the user s choice The RESPONDOR 9000 does not include the required EMC filter which is available as an option For use within the EU the end user takes personal responsibility for EMC compliance March 7 2002 2 2 3 EMC levels The RESPONDOR 9000 series does not fulfil any EMC emission requirements without an
30. d the Multiline display How to browse through the here See 7 4 Parameter group menu monitored values is presented in Figure 7 3 1 All monitored Figure 7 3 1 Monitoring menu For the table of monitoring data that is displayed under the Monitor menu please consult Appendix 2 of the following Respondor 9000 AF Crane Control Application Manuals Publication No 49485 for AFDs with the standard 24VDC inputs Publication No 50248 for AFDs with the 120VAC input card March 7 2002 Cutler Hammer 7 4 Control Panel RESPONDOR 9000 7 4 Parameter group menu The parameter group menu can be entered from the main menu when the symbol 2 is visible on the first line of the Multiline display Parameter values are changed in the parameter menu as shown in Figure 7 4 1 Push the menu button right once to move into the parameter group menu G and twice to enter the desired parameter menu Locate the parameter you want to change by using the browser buttons Push the menu button right once again to enter the edit menu Once you are in the edit menu the symbol of the parameter starts to blink Set the desired new value with the browser buttons and confirm the change by pushing the Enter button Consequently the blinking stops and the new value is visible in the value field The value will not change unless the Enter button is pushed Figure 7 4 1 Parameter value change procedure G2 i Special param G12 s
31. for drives 3Hp and larger if the motor is not designed for inverter duty per NEMA 1 part 31 Distance Motor between cables cable length ft m ft m 1 0 3 165 50 3 3 1 600 180 Table 6 1 4 1 3 See chapter 6 1 5 for cable insulation checks 4 Connecting cables Motor and utility cables should be stripped according to figure 6 1 4 2 and table 6 1 4 2 Open the cover of the RESPONDOR 9000 according to figure 6 1 4 3 Remove sufficient plugs from the cable cover open chassis or from the bottom of the NEMA 1 12 units Pass cables through the holes in the cable cover Connect the utility motor and control cables to the correct terminals See figures 6 1 4 3 16 RESPONDOR 9000 external RFI filter See RFI filter option manual The installation instructions for M11 and M12 frames are explained in the separate manual for M11 M12 units Contact your Cutler Hammer distributor for more information Cable installation consistent with UL instructions is explained in chapter 6 1 4 1 Check that control cable wires do not make contact with electrical components in the device Connect optional brake resistor cable if required Ensure the ground cable is connected to the terminal of the frequency converter and motor For open chassis units 150 500 Hp connect the isolator plates of the protective cover and terminals according to figure 6 1 4 11 Cutler Hammer March 7 2002
32. he maximum wire size rating ofthe terminals is 14 6 2 2 Galvanic isolation barriers The control connections are isolated from the utility potential and the I O ground is connected to the frame of the RESPONDOR 9000 via 1 MQ resistor and 4 7 nF capacitor The control 1 0 ground can also be connected directly to the frame by changing the position of the jumper X4 to ON position see figure 6 2 2 1 Digital inputs and relay outputs are isolated from the 1 0 ground Specific connections for crane applications are found in the Respondor 9000 Application Manual publication 49485 figures A 2 1 through 6 March 7 2002 RESPONDOR 9000 Wiring Page 6 9 Terminal Function Specification 1 10V ref Reference voltage output Burden max 10 mA 2 Vin Analog signal input Signal range 10 V 10 V DC 3 GND 1 0 ground 4 lin Analog signal input Signal range 0 4 20 mA 5 lin Analog signal input 6 24 V out 24 V supply voltage 20 load max 100 mA 7 GND 1 0 ground 8 DIA1 Digital input 1 Ri 2 min 5 k ohm 9 DIA2 Digital input 2 10 DIA3 Digital input 3 6 11 CMA Common for DIA1 DIA3 Must be connected to GND or 24V of I O terminal or to external 24 V or GND 12 24V out 24 V supply voltage Same as 6 13 GND 1 0 ground Same as 7 14 0184 Digital input 4 Ri min 5 k ohm 15 DIB5 Digital input 5 16 DIB6 Digital input 6 17
33. information N Available only when the flashes as long control panel is the active as the command control source is carried out See 7 11 B2 Active control Selection between 1 0 Control via I O Control from source terminals and control terminals the panel panel B3 Operating Resets the operating No resetting Reset of the hours trip hours trip counter when operating counterreset pushed hours trip counter B4 MWh trip Resets the MWh trip No resetting Reset of the counter reset counter when pushed MWh trip counter Cutler Hammer March 7 2002 RESPONDOR 9000 Control Panel Page 7 7 7 7 Active Faults Fault history menu If there are 9 uncleared faults in the memory the next fault ag will erase the oldest from the memory The active Faults are discussed in the application section Pressing the Enter button for about 2 3 seconds will reset The fault history MENU can be entered from the al nenn the whole fault history Then the symbol F will change to when the symbol M6 is displayed on the first line of the 0 See figure 7 7 1 Multiline panel The memory of the drive can store the up to the 9 latest faults in the order of appearance The most recent fault has the number 1 the second latest number 2 etc M6 A F1 9 v Figure 7 7 1 Fault history menu 7 8 Contrast menu You are in the edit menu when the symbol C starts to blink Then change the contrast using the browser buttons The ch
34. its from 25 Hp to 500 Hp have special lifting eyes which must be used see figures 5 3 2 and 5 3 3 The mounting instructions for units over 500 Hp are given in a separate manual If further information is needed contact your Cutler Hammer distributor w2 D1 R2 Hi H2 R2 WI Figure 5 3 1 see Table 5 3 1 for dimensional information Cutler Hammer March 7 2002 RESPONDOR 9000 Installation Page 5 3 Frame Enclosure Voltage Dimensions WI W2 H1 H2 H3 H4 Dl R1 R2 M3B Compact 230 380 480 37 13 5 13 1 12 5 9 0 28 0 14 M4B 1 230 380 480 5 3 3 7 17 16 5 15 4 8 1 0 28 0 14 M5B 230 380 480 7 3 5 5 234 228 21 7 85 0 35 0 18 4 230 380 480 4 7 3 7 16 7 162 15 4 8 5 0 28 0 14 5 230 380 480 6 2 5 221 21 5 203 94 0 35 0 18 M6 230 380 480 8 7 7 1 216 26 9 25 6 11 4 035 0 18 7 1 12 230 380 480 14 7 136 413 406 39 4 13 0 35 0 18 8 230 380 480 19 5 18 531 365 50 8 13 9 045 0 24 9 380 480 27 6 26 579 40 2 561 154 045 0 24 M10 380 480 M4 230 380 480 4 7 3 7 12 7 12 3 11 4 16 85 0 28 0 14 M5 230 380 480 6 2 5 178 71 15 9 18 94 035 018 M5 600 6 2 5 19 1 185 1173 18 104 035 018 M6 230 380 480 8 7 7 1 226 22 20 7 3 9 114 035 0 18 7 Chassis 600 8 7 7 1 26 3 25
35. line potential but the relay outputs and other I O s if jumper X4 is in OFF position see figure 6 2 2 1 N may have dangerous external voltages connected even if the power is disconnected from the RESPONDOR 9000 The RESPONDOR 9000 has a large capacitive leakage current An upstream disconnect protection device is to be used as noted in the National Electric Code NEC 6 Only spare parts obtained from a Cutler Hammer authorized distributor can be used 1 2 Safety Instructions 1 The RESPONDOR 9000 is meant only for fixed installation Do not make any connections or measurements when the RESPONDOR 9000 is connected to the utility J After disconnecting the utility wait until the unit cooling fan stops and the indicators on the control panel are extinguished if no keypad is present check the indicators in the cover Wait 5 more minutes before doing any work on the RESPONDOR 9000 connections Do not open the cover before this time has run out Do not make any voltage withstand or megger tests on any part of the RESPONDOR 9000 A 4 Disconnect the motor cables from the RESPONDOR 9000 before meggering the motor cables 5 Do not touch the IC circuits on the circuit boards Static voltage discharge may destroy the components 6 Before connecting to the utility make sure that the cover of the RESPONDOR 9000 is closed 7 Make sure that nothing but a three phase motor is connected to the motor termi
36. mer 8 2 Start Up RESPONDOR 9000 4 Check that moisture has not condensed inside the RESPONDOR 9000 drive 5 Check that all Start Stop switches connected to the 1 0 terminals are in the Stop state 6 Connect the RESPONDOR 9000 to the utility and switch the power ON 7 Ensure that the parameters of the Group 1 match the application Set the following parameters to match the motor nameplate nominal voltage of the motor nominal frequency of the motor nominal speed of the motor nominal current of the motor supply voltage Look up the values from the nameplate of the motor 8 Start up test without motor Perform either test A or B A Control from the I O terminals turn Start Stop switch to ON position change the frequency reference check from the Monitoring page of the control panel that the output frequency follows the frequency reference turn Start Stop switch to OFF position B Control from the Control Panel change control from the 1 0 terminals to the control panel with the programmable button B2 see chapter 7 6 push the Start button go to the Reference Page and change the frequency reference with the buttons see chapter 7 5 go to the Monitoring Page and check that the output frequency follows the reference see chapter 7 3 push the Stop button Cutler Hammer March 7 2002 RESPONDOR 9000 Start Up Page 8 3 If the inverter has to be tested on a motor connected to the process ensure i
37. nal with the exception of factory recommended filters March 7 2002 Cutler Hammer 1 2 Safety RESPONDOR 9000 1 3 Grounding and ground fault protection The RESPONDOR 9000 must always be grounded with a grounding conductor connected to the grounding terminal The RESPONDOR 90005 ground fault protection protects only the RESPONDOR 9000 if a ground fault occurs in the motor or in the motor cable Due to the high leakage current fault current protective devices do not necessarily operate correctly with drives When using this type of device its function should be tested in the actual installation 1 4 Running the motor Warning Symbols For your own safety please pay special attention to the instructions marked with these warning symbols Dangerous voltage General warning Before running the motor make sure that the motor is mounted properly driven machine s capability safely 2 Maximum motor speed frequency should never be set to exceed the motor s and 3 Before reversing the rotations of the motor shaft make sure that this can be done Cutler Hammer March 7 2002 RESPONDOR 9000 EU directive Page 2 1 2 EU DIRECTIVE 2 1 CE label The optional CE label on the product guarantees the free movement of the product in the EU area According to the EU rules this guarantees that the product is manufactured in accordance with different directives rel
38. nclosure Protected Chassis IP 20 and Chassis IP 20 Compact NEMA 1 IP 20 NEMA 1 IP21 NEMA 12 IP54 Table 4 1 14 Cutler Hammer March 7 2002 RESPONDOR 9000 RESPONDOR 9000 Technical Data Page 4 11 EMC Noise immunity Fulfils EN50082 1 2 EN61800 3 Emissions Equipped with an optional external RFI Filter fulfils EN50081 2 EN61800 3 Safety Fulfils EN50178 EN60204 LCE UL C UL FI GOST R check from the unit nameplate specified approvals for each unit Control Analog voltage 0 10 V Ri 200 single ended connections 10 10 joystick control resoluton12 bit accur 1 Analog current 0 4 20 mA 250 differential Digital inputs 6 Positive or negative logic Aux voltage 24 V 520 max 100 mA Pot meter reference 10 V 0 43 max 10 mA Analog output 0 4 20 mA 500 resolution 10 bit accur 3 Digital output Open collector output 50 mA 48 V Relay outputs Max switching voltage 300 V DC 250 V AC Max switching load 24 V 0 4 A 250 V DC 2 KVA 250 V Max continuous load 2 rms Protective Overcurrent protection Trip limit 4 x ICT functions Overvoltage protection Utility voltage 220 V 230V 2404 380 V 400 VTrip limit 147 1 41XVn L35xVg 147 140 Utility voltage 415 V 440V 460V 480 V 500 V Trip limit 135xVn 127xVg 1 47XVp 1 41
39. nt Cutler Hammer 4 2 Technical Data RESPONDOR 9000 4 2 Power Ratings 440 500 VAC 10 15 50 60 Hz 3 phase Input Standard Protected Chassis Catalog Rated Horsepower and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD Ibs Had HP inches GH97A40005R P 3 5 GH97A40008R P 5 8 4 Protected 4 71 x114x8 5 15 4 GH97A40011RP 7 5 11 GH97A40015RP 10 15 GH97A40021RP 15 21 M5 Protected 6 2 15 9 9 4 33 1 GH97A40027RP 20 27 GH97A40034R P 25 34 GH97A40040RP 30 40 GH97A40052RP 40 52 Protected 87 x207 x 114 713 GH97A40065R P 50 65 GH97A40077RP 60 77 GH97A40096RN 75 96 GH97A40125RN 100 125 M7 Chassis 9 8 x 31 5 x 12 4 133 GH97A40160RN 125 160 GH97A40180RN 150 180 M8 Chassis 19 5 x 35 0 x 13 9 309 GH97A40260RN 200 260 GH97A40320RN 250 320 9 Chassis 27 6 x 39 4 x 15 4 485 GH97A40400RN 300 400 GH97A40480RN 400 480 M10 Chassis 38 9 x 39 4 x 15 4 684 GH97A40600RN 500 600 GH97A40700RN 600 700 M11 Chassis 55 1 x 39 4 x 15 4 948 GH97A40880RN 700 880 GH97A41020RN 800 1020 GH97A41070RN 900 1070 M12 Chassis 77 9 x 39 4 x 15 4 1212 GH97A41200RN 1000 1200 GH97A41300RN 1100 1300 Ict rated input and output current Protected Enclosure with Optional Cover 97 GH98A and GH99A have the same Dimensions and Weight
40. nt Torque Enclosure Style WxHxD Ibs inches GH97A20007RJ 2 7 4 12 4 7 15 4 x 8 5 17 6 6 97 200108 3 10 6 97 200168 5 16 GH97A20022R 75 22 M5 NEMA12 6 2 x 20 3 x 9 4 35 3 6 97 200308 10 30 GH97A20043R 15 43 GH97A20057R 20 57 12 8 7 25 6 11 4 84 6 97 200708 25 70 GH97A20083R 30 83 GH97A20113R 40 113 GH97A20139RJ 50 139 7 12 14 7 X 39 4 X 13 180 GH97A20165RJ 60 165 GH97A20200R 75 200 8 12 19 5 X 50 8 X 14 337 Table 4 1 12 230 VAC 10 15 50 60 Hz 3 phase Input NEMA 12 Catalog Rated Horsepower and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD Ibs ib HP inches GH97A20007RS 2 7 M4 NEMA1 4 1 x 15 4 x8 5 17 6 GH97A20010RS 3 10 GH97A20016RS 5 16 GH97A20022RS 7 5 22 5 1 6 2 x 20 3 x 9 4 35 3 GH97A20030RS 10 30 GH97A20043RS 15 43 GH97A20057RS 20 57 1 8 7 25 6 11 4 84 GH97A20070RS 25 70 GH97A20083RS 30 83 GH97A20113RS 40 113 GH97A20139RS 50 139 7 1 14 7 X 39 4 X 13 180 GH97A20165RS 60 165 GH97A20200RS 75 200 M8 1 19 5 X 50 8 X 14 337 Table 4 1 13 March 7 2002 Cutler Hammer 4 10 Technical Data 4 3 Specifications Utility Input voltage Vin 380 480V 460 500V 525 690V 200 240V 15 10 Connection Input frequency 45
41. om UO terminals to the panel After changing the control source the motor is Stopped The direction of rotation remains the same as with 1 0 control Cutler Hammer If the Start button is pushed at the same time as the programmable pushbutton B2 the Run state direction of rotation and reference value are copied from the I O terminals to the panel 7 11 2 Control source change from panel to I O After changing the control source the 1 0 terminals determine the run state direction of rotation and reference value If the motor potentiometer is used in the application the panel reference value can be copied as the motor potentiometer reference by pushing the start button at the same time as the programmable push button B2 The motor potentiometer function mode must be resetting at stop state Local Remote Application param 1 5 4 Multi purpose Application param 1 5 9 March 7 2002 9000 Start Up Page 8 1 8 START UP 1 Internal components and circuit boards except the isolated 1 0 terminals are at utility potential when the RESPONDOR 9000 is connected to the line This voltage is extremely dangerous and may cause death or severe injury if you come in contact with it When the RESPONDOR 9000 drive 15 connected to the utility the motor connections U V W and DC link brake resistor connections are live even if the motor is not running 3 Do not make any connections when the RESPONDOR
42. optional R F filter either built in or separate With an RFI filter the drive fulfils the EMC emission requirements in the heavy industrial environment standards EN50081 2 EN61800 3 All products fulfil all EMC immunity requirements standards EN50082 1 2 EN61800 3 2 2 4 Manufacturer s Declaration of Conformity Manufacturer s Declaration of Conformity are available upon request Cutler Hammer 2 2 EU directive RESPONDOR 9000 Cutler Hammer March 7 2002 RESPONDOR 9000 Receiving Page 3 1 3 RECEIVING This Cutler Hammer RESPONDOR 9000 drive has been subjected to demanding factory tests before Shipment After unpacking check that the device does not show any signs of damage and that the RESPONDOR 9000 is as ordered refer to the model designation code in figure 3 1 3 1 Catalog Number GH 98 A 40000R 00XX X In the event of damage please contact and file a claim with the carrier involved immediately If the received equipment is not the same as ordered please contact Cutler Hammer immediately Note Do not destroy the packing The template printed on the protective cardboard can be used for marking the mounting points of the RESPONDOR 9000 on the panel Br Panel Enclosure Construction Type Expansion Board Options Keypad Core Drive Enclosure Regeneration Type Continuous Drive Amps Voltage Series Drive Type Drive 97 Inverter Drive 98 Closed Loop Flux Vector
43. rotation STOP Lights when motor is not running READY Lights when input voltage is supplied and the unit is ready for use FAULT Lights when a fault in frequency converter occurs Panel Shows the achieve control source Remote Enter button Acknowledgment of changed value Fault history reset Function as programmable button Reset button Fault resetting Start button Starts the motor if the panel is the active control source Stop button Stops the motor if the panel is the active control source Cutler Hammer 7 2 Control Panel RESPONDOR 9000 7 2 Panel operation The panel is arranged in menus and submenus The menus are used for measurement and control signals parameter settings reference values fault displays contrast and the programmable buttons The desired submenu can also be entered from the main menu by using the menu buttons when the letter and the number of the menu in question are visible on the first line of the display See the RESPONDOR 9000 User s and Application Manual for the specific parameters available for the RESPONDOR 9000 setup needed Cutler Hammer March 7 2002 RESPONDOR 9000 7 3 7 3 Monitoring menu The monitoring menu can be entered from the main Signals are listed in Table 7 3 1 This menu is meant menu when the symbol M1 is visible on the first line of only for signal checking The values cannot be altere
44. t is safe to 9 If possible make a start up test with motor which is not connected to the process be powered up Inform all possible co workers about the tests Switch the utility power OFF and wait until the RESPONDOR 9000 has powered down according to chapter 8 1 point 4 connect the motor cable to the motor and the power terminals of the RESPONDOR 9000 check that all start stop switches connected to the 1 0 terminals are in the OFF state switch the utility power ON repeat test A or B of the test 8 10 Connect the motor to the process if the previous tests were done without the process ensure itis safe to power up inform all possible co workers about the tests repeat test A or B of the test 8 8 March 7 2002 Cutler Hammer 8 4 Start Up RESPONDOR 9000 Cutler Hammer March 7 2002 March 7 2002 Publication 49484 Cutler Hammer Cutler Hammer Crane Controls Group U S A 4201 North 27 Street Milwaukee Wisconsin 53216 Tel 800 782 9875 or 414 449 7611 Fax 414 449 7672 Cutler Hammer Crane Controls Group England Elstow Road Bedford MK42 9LH England Tel 1234 267 433 Fax 1234 350 210 Publication No 49484 March 7 2002
45. ut Standard Protected Chassis Catalog Rated Horsepower and output current Frame Size Dimensions Weight Number Constant Torque Enclosure Style WxHxD Ibs Fr HP Ict inches GH97A50003RP 2 3 5 GH97A50005RP 3 45 GH97A50007RP 5 75 GH97A50010RP 7 5 10 GH97A50014RP 10 14 M5 Protected 6 2 x 17 3 x 10 4 33 1 GH97A50019RP 15 19 GH97A50023RP 20 23 GH97A50026RP 25 26 GH97A50035RP 30 35 GH97A50042R P 40 42 GH97A50052RP 50 52 M6 Protected 87 x24 3x 114 83 8 GH97A50062RN 60 62 GH97A50085RN 75 85 GH97A50100RN 100 100 GH97A50122RN 125 122 8 Chassis 19 5 x 35 0 x 13 9 300 GH97A50145RN 150 145 GH97A50222RN 200 222 9 Chassis 27 6 x 39 4 x 15 4 485 GH97A50287RN 250 287 GH97A50325RN 300 325 M10 Chassis 38 9 x 39 4 x 15 4 684 GH97A50400RN 400 400 GH97A50490RN 500 490 M11 Chassis 55 1 x 39 4 x 15 4 948 GH97A50620RN 600 620 GH97A50700RN 700 700 GH97A50780RN 800 780 M12 Chassis 77 9 x 39 4 x 15 4 1212 Ict rated input and output current Protected Enclosure with Optional Cover GH97A GH98A and GH99A have the same HP Ict Dimensions and Weight UL listed up to 600 volts Table 4 1 7 Cutler Hammer March 7 2002 RESPONDOR 9000 Technical Data Page 4 7 440 500 VAC
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