Control Techniques UNIDRIVE

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Installation Guide
Unidrive
Regen
Part Number: 0460-0026-02 Issue Number: 2
General Information
The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional operating parameters of the equipment or from mismatching the variable speed drive with the motor. The contents of this guide are believed to be correct at the time of printing. In the interests of a commitment to a policy of continuous development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or the contents of the guide, without notice. All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by an information storage or retrieval system, without permission in writing from the publisher.
Drive software version

This product is supplied with the latest version of software. If this product is to be used in a new or existing system with other drives, there may be some differences between their software and the software in this product. These differences may cause this product to function differently. This may also apply to drives returned from a Control Techniques Service Centre. If there is any doubt, contact a Control Techniques Drive Centre.
Environmental statement
Control Techniques is committed to minimising the environmental impacts of its manufacturing operations and of its products throughout their life cycle. To this end, we operate an Environmental Management System (EMS) which is certified to the International Standard ISO 14001. Further information on the EMS, our Environmental Policy and other relevant information is available on request, or can be found at www.greendrives.com. The electronic variable-speed drives manufactured by Control Techniques have the potential to save energy and (through increased machine/process efficiency) reduce raw material consumption and scrap throughout their long working lifetime. In typical applications, these positive environmental effects far outweigh the negative impacts of product manufacture and end-of-life disposal. Nevertheless, when the products eventually reach the end of their useful life, they can very easily be dismantled into their major component parts for efficient recycling. Many parts snap together and can be separated without the use of tools, while other parts are secured with conventional screws. Virtually all parts of the product are suitable for recycling. Product packaging is of good quality and can be re-used. Large products are packed in wooden crates, while smaller products come in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, these containers can be recycled. Polyethylene, used on the protective film and bags for wrapping product, can be recycled in the same way. Control Techniques' packaging strategy favours easily-recyclable materials of low environmental impact, and regular reviews identify opportunities for improvement. When preparing to recycle or dispose of any product or packaging, please observe local legislation and best practice.
Copyright
October 2002 Control Techniques Drives Limited
Issue Number: 2
Contents
1
1.1 1.2 1.3
Introduction....................................................................................................................1
Principles of operation ...........................................................................................................................1 Power flow .............................................................................................................................................2 Advantages of Unidrive operating in Regen mode ................................................................................2
2 3
3.1 3.2
Sizing of a Regen system .............................................................................................3 Power connections........................................................................................................4

Overall system layout ............................................................................................................................4 Non standard configurations ..................................................................................................................7
4
4.1 4.2
Control circuit connections ..........................................................................................8

Digital / Analog I/O set-up in Regen mode ............................................................................................8 Regen inductor thermistors ....................................................................................................................9
5
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9
Components.................................................................................................................10
Motoring drive ......................................................................................................................................10 Regen drive .........................................................................................................................................10 Regen inductor ....................................................................................................................................10 Softstart resistor ...................................................................................................................................11 Contactors, MCBs and overload ..........................................................................................................11 Switching frequency filter .....................................................................................................................12 RFI filter ...............................................................................................................................................13 Varistors ...............................................................................................................................................13 Fusing ..................................................................................................................................................14
6
6.1 6.2 6.3 6.4
Important considerations............................................................................................16
Fundamentals ......................................................................................................................................16 Unidrive size 3 and 4 ...........................................................................................................................16 Ventilation ............................................................................................................................................16 Cable length restrictions ......................................................................................................................17
7
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11
Unidrive Regen EMC information...............................................................................19

Immunity ..............................................................................................................................................19 Emission ..............................................................................................................................................19 Dedicated supplies ..............................................................................................................................19 Other supplies ......................................................................................................................................19 Supply voltage notching .......................................................................................................................19 Supply harmonics ................................................................................................................................19 Switching frequency emission .............................................................................................................19 Conducted RF emission ......................................................................................................................19 Radiated emission ...............................................................................................................................21 Wiring guidelines .................................................................................................................................21 Multi-drive systems ..............................................................................................................................21
8
8.1
Parameter descriptions...............................................................................................22
Menu 15: Sinusoidal rectifier ...............................................................................................................22
9
9.1 9.2 9.3 9.4 9.5
Commissioning and operation ...................................................................................28

Regen parameter settings ...................................................................................................................28 Regen drive sequencing ......................................................................................................................28 Regen drive commissioning .................................................................................................................29 Motoring drive commissioning .............................................................................................................29 Trip codes ............................................................................................................................................29
Unidrive Regen Installation Issue Number: 2
Appendix A Unidrive Regen as a Brake Resistor Replacement ............................................. 30

A.1 A.2 A.3 A.4 A.5 A.6 A.7 B.1 B.2 B.3 B.4 C.1 D.1 D.2 Introduction ......................................................................................................................................... 30 Drive configurations ............................................................................................................................ 30 When to use a Regen drive as a brake resistor replacement ............................................................. 30 Regen and motoring drive ratings ....................................................................................................... 31 Power circuit connections and components ....................................................................................... 31 Control circuit connections .................................................................................................................. 34 Regen brake drives in operation ......................................................................................................... 35 Sizing of MCB for switching frequency filter ....................................................................................... 36 Resistor sizing for multiple motoring systems ..................................................................................... 37 Multiple Unidrive size 5 systems ......................................................................................................... 38 Thermal / magnetic overload protection for soft start circuit ............................................................... 38 Exceeding the maximum cable length ................................................................................................ 41 Single Regen, single motoring systems .............................................................................................. 43 Single Regen, multiple motoring and multiple Regen, multiple motoring systems ............................. 43
Appendix B Component sizing calculations ............................................................................ 36
Appendix C Long cables ............................................................................................................ 41 Appendix D Regen kits ............................................................................................................... 43
Appendix E Unidrive Regen specifications ............................................................................. 44 Appendix F Physical dimensions ............................................................................................. 45

F.1 F.2 F.3 F.4 F.5 Regen inductor ................................................................................................................................... 45 Softstart resistor - type TG series ....................................................................................................... 47 Switching frequency filter capacitors .................................................................................................. 48 Switching frequency filter inductor ...................................................................................................... 51 Varistors .............................................................................................................................................. 53
Unidrive Regen Installation Guide Issue Number: 2
Introduction
Principles and advantages of operation in Regen mode Details of additional components required Configuration of Regen systems
Any standard Unidrive can be configured as an AC Regenerative Unit (hereafter referred to as Regen drive). This Installation guide covers the following:
At least two Unidrives are required to form a complete Regenerative system - one connected to the supply and the second one to the motor. A Unidrive in Regen mode converts the AC mains supply to a controlled DC voltage which is fed into other drive(s) to control a motor. Figure 1-1 Regen drive system connection
Regen Inductor
R
Regen Drive AC
U
Motoring Drive DC
U
3 Phase Supply
Y B
Additional Circuitry
+DC V -DC W
+DC V -DC W
DC
AC
1.1
Principles of operation
The input stage of a non-regenerative AC drive is usually an uncontrolled diode rectifier, therefore power cannot be fed back into the AC mains supply. In the case of a Unidrive operating in Regenerative mode, the IGBT bridge is used as a sinusoidal rectifier, which converts the AC supply to a controlled DC voltage. This DC voltage can then be used to supply one or more Unidrives which control motors, commonly known as motoring drives. A Regen drive produces a PWM output voltage which has a sinusoidal fundamental at an amplitude and phase which are almost the same as those of the AC supply voltage. The difference between the drive PWM line voltage and the supply voltage occurs across the Regen drives inductors. This voltage has a high frequency component which is blocked by the Regen inductor and a small sinusoidal component at line frequency. As a result, currents flowing in these inductors are sinusoidal with a small high frequency ripple component.
NOTE
Terminals L1, L2 and L3 and the associated diode rectifier are not connected and are redundant on drives used in a Regen configuration. Figure 1-2 Phasor diagram
Power flow from supply
Power flow back to supply
Vs Vr jLI r Ir
Supply Voltage Voltage at line terminals of Regen drive Voltage across Regen Inductor Current at line terminals of Regen drive
1
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1.2
Power flow
The phasor diagram in Figure 1-2 illustrates the relationship between the supply voltage and the Regen drive voltage. The angle between the two voltage vectors is approximately 5 at full load, giving a power factor which is near unity. The direction of the power flow can be changed relative to the supply voltage, by making small changes to the Regen drive output voltage and phase. A fast transient response is achieved by means of a space vector modulator.
1.3

Advantages of Unidrive operating in Regen mode
The main advantages for an AC Regen system are: Energy saving The input current waveform is sinusoidal The input current has a near unity power factor The output voltage for the motor can be higher than the available AC mains voltage The Regen drive will synchronise to any frequency between 30 and 100Hz, provided the supply voltage is between 380V -10% and 480V +10% Under conditions of AC mains instability, a Unidrive Regen system can continue to function down to approximately 150Vac supply voltage without any effect on the DC bus voltage and hence on the operation of the motoring drives (increased current will be taken from the AC supply to compensate up to the current limit of the Regen drive) The Regen and motoring drives are identical
2
Sizing of a Regen system
Refer to Appendix E Unidrive Regen specifications on page 44, for the specifications of the Unidrive Regen. The sizing of a Regen system must take into account the following factors: Line voltage Motor rated current, rated voltage and power factor Maximum load power and overload conditions In general, when designing a Regen system, equal Regen and motoring drive rated currents will work correctly. However, care must be taken to ensure that under worst case supply conditions the Regen drive is able to supply or absorb all the required power. In multi-drive configurations, the Regen drive must be of a sufficient size to supply the net peak power demanded by the combined load of all the motoring drives and the drive losses. If the Regen drive is unable to supply the full power required by the motoring drive, the DC bus voltage will drop and in severe cases may lose synchronisation with the mains and trip. If the Regen drive is unable to regenerate the full power from the motoring drive into the DC bus, then the Regen/motoring drive will trip on over-voltage. The following are two examples of how the required ratings of a Regen drive can be calculated.
NOTE
The Regen drives current limits are set at 150% and are not adjustable. In the case of a 25A, UNI2403 operating in Regen mode from a 400V supply, and a UNI2403 driving a 400V rated, 0.85 pf motor: The rated power of the Regen drive is = 3 x Rated current x Supply voltage = 1.73 x 25 x 400 = 17.3kW = 3 x Rated current x Motor voltage x Power factor = 1.73 x 25 x 400 x 0.85 = 14.7kW
The motoring drive can supply power
When the motoring drive is supplying rated current to the motor, the Regen drive only needs to provide 14.7kW, plus drive losses. The Regen drive can supply 17.3kW at rated current, which is ample, in this case. Conversely, in some cases, a Regen drive of the same rating as the motoring drive, may not be able to supply enough power, as the following example shows: Example In the case of a 156A, UNI4403 operating in Regen mode, and a UNI4403 driving a 75kW, 400V, 0.95pf motor: If the motoring drive is supplying 175% maximum current and the Regen drive has its 380V supply at the lower limits of -10% (342Vac), then, at the Regen current limit of 150%: The Regen drive max. available power is = 3 x 150% x Rated current x Supply voltage = 1.73 x 1.5 x 156 x 342 = 138.6kW = 3 x 175% x Rated current x Motor voltage x Power factor = 1.73 x 1.75 x 156 x 400 x 0.95 = 179.7kW
The motoring drive max. power is
The Regen drive is also required to supply the Regen and motoring drive losses. However, this Regen drive is only capable of supplying approximately 138.6kW and therefore a drive of a larger current rating is required. Due to the effects of increased DC bus capacitance, there is a limit to the number of motoring drives that can be supplied from a Regen drive. This is true irrespective of the balance of power between the motoring drives and the Regen drive.
NOTE
If the system consists of one Regen Unidrive and more than three motoring drives, Control Techniques Technical Support MUST be consulted about the design of the system.
3
3
NOTE
Power connections
N
The following section covers the power connections required for Unidrive Regen systems. Note that with Unidrive Regen systems there are no AC supply connections made to L1, L2 or L3 drive terminals. For control circuit connections refer to Chapter 4 Control circuit connections on page 8.
3.1
Overall system layout

Key to Figure 3-1 and Figure 3-2
Ground connection point EMC filter Switching frequency filter inductor Regen inductor Varistor network 550V (line to line) Varistor network 680V (line to ground) Softstart resistor Ribbon cables to control pod (Unidrive size 5 only) Ribbon cables between power modules (Unidrive size 5 only) AC supply fusing AC Regen fusing (Unidrive size 5 only) Switching frequency filter capacitor Switching frequency filter capacitor discharge resistor Thermocouple Supply contactor Main contactor Auxiliary contactor Switching frequency filter capacitor MCB Switching frequency filter MCB auxiliary through which Regen drive enable is connected Main contactor auxiliary for main contactor closed signal K3 auxiliary with coil supply for K2 Thermal, Magnetic overload
The table below shows the key to the following system layout diagrams.
Table 3-1
E RFI SFFL L regx V1, V2, V3 V4, V5, V6 Rsx R-control R-parallel Fsx Fx SFF Cx Rdx Tcx K1 K2 K3 MCB1x aux1x aux2 aux3 Ovld
4
3.1.1
Standard single Regen, single/multiple motoring system

DC Bus to Motoring Drive(s)
Figure 3-1 Power connections: Single Regen
MCB1
Ovld
5
3.1.2
Standard multiple Regen, multiple motoring system
If the total power requirement is too great for one Unidrive size 5 Regen drive to supply, more than one drive can be used. One Regen system can consist of multiple Unidrive size 5 Regen drives, which can supply multiple Unidrive size 5 motoring drives, providing that the total load power does not exceed the rating of the Regen drives. See figure 3-2 for a dual size 5 Regen configuration.
NOTE
High power set-ups should use Unidrive size 5. This is the only module which is designed for parallel Regen operation. For systems with more than two Unidrive size 5 drives in parallel Regen operation, contact CT Technical Support. Figure 3-2 Power connections: Unidrive size 5 multiple Regen
Common DC Bus +DC -DC
+DC
+DC
-DC
Unidrive Size 5 Regen Drive 1
R-parallel
Unidrive Size 5 Regen Drive 1
-DC
L reg 1
L reg 2
F4
F5
F6
aux 2
K2
aux 3
aux 1b
SFF C2
Ovld
Rd6
MCB 1b
aux 1a
SFF C1
Rd4
Rd3
MCB 1a
SFFL
RFI
V6
V5
V3
V1
K1
FS1
FS2
V2
6
3 Phase Supply
FS3
V4
Rd1
Rd2
Rd5
Rs1
K3
Tc2
Tc1
F1
F2
F3
R - control
3.2
Non standard configurations
There are a number of possible options available when designing a Unidrive Regen system depending on the user requirements and the nature of the AC supply. Non standard systems can be created where favourable supply conditions exist, allowing cost and space savings to be achieved by reducing the number of components.
3.2.1
Switching frequency filter
If the supply to the Regen drive is shared with other equipment, then it is strongly recommended that a switching frequency filter be incorporated in order to avoid the risk of interference or damage to the other equipment.
3.2.2
Supply assessment
The following guidelines should be used when assessing whether or not a switching frequency filter is required. Symbols used are: IDrive Nominal drive 100% current rating. ISC Short circuit current of supply at point of coupling with other equipment. ISupply Rated current of supply. The switching frequency filter may be omitted if the following relation is true: IDrive ISC
< 140
If the short-circuit current is not known, then a reasonable estimate can be made if it is assumed that the fault current of the supply is 20 times the rated current. This is very commonly the case where the supply is derived through a distribution transformer from a higher voltage supply with a high fault level. Then: IDrive ISupply
<
1 7
This second relation is helpful but must be used with care. It is reliable where the Regen drive is supplied through its own cable run from a point close to the distribution transformer terminals. If the Regen drive shares a long cable run with other equipment, then the effect of the cable impedance on the fault level must be taken into account if a risk of disturbance to the other equipment is to be avoided. This procedure will normally be applied when assessing a non-dedicated low-voltage supply. It may also be applied to the medium/high voltage supply where the low-voltage supply is dedicated to the drive. In that case the currents used must be referred to the high voltage side of the transformer.
3.2.3
RFI filter
Whether or not an RFI filter is required is dependent upon the user requirements and the AC supply network. For further details refer to Chapter 7 Unidrive Regen EMC information on page 19. An RFI filter must not be fitted without a switching frequency filter present in the system.
7
4
4.1
Control circuit connections

Digital / Analog I/O set-up in Regen mode
All power circuit connections should be made as shown in Chapter 3 Power connections on page 4.
The following table lists the default functions of the analog and digital I/O on a Regen drive. The terminals which are listed as Fixed have dedicated functions for Regen operation. They must be connected to perform their allocated function and cannot be re-programmed. Table 4-1 Functions of the analog and digital I/O Terminal Description Drive relay Drive relay Analog input 1 Analog input 2 Analog input 3 Analog output 1 Analog output 2 Digital output 1 Digital output 2 Digital output 3 Digital input 1 Digital input 2 Digital input 3 Enable Fixed or Programmable Fixed Fixed User-programmable User-programmable User-programmable User-programmable User-programmable Fixed Fixed User-programmable User-programmable Fixed User-programmable Fixed Enable Output - Supply current Output - Supply power Not used Output - Enable other drive Drive healthy Input - Reset Input - Main contactor closed Function in Regen Mode Output - close auxiliary contactor* Output - close auxiliary contactor*
Terminal No. 1 2 5 7 8 9 10 24 25 26 27 28 29 30
* Pr 8.25 must be set by the user. See Table 4-2. Figure 4-1 shows typical control connections for a Regen and motoring drive. In this example the motoring drive is configured for 4-20mA Speed / Torque reference and sequencing Mode 4 with Run Forward and Run Reverse inputs.
NOTE
All control connections for the Regen drive must be made as shown in Figure 4-1. The Regen drive healthy signal can be taken from digital output 3 on terminal 26 (if the Regen drive is disabled, trips, or detects that the mains supply is lost this output then becomes inactive). Table 4-2 Configuration of drive relay Description Drive Regen drive
Parameter
The Regen drives relay on terminal 1 and 2 has to be Pr 8.25 - Relay configured to close the auxiliary contactor on power up and Source remove the softstart circuit. Set Pr 8.25 to Pr 15.14
NOTE
Unidrive Regen has been designed to operate in negative logic as default. In order for the drive to be configured to operate in positive logic alterations must be made to the control connections and parameter settings (contact C.T. Technical Support for this information).
8
4.2
Regen inductor thermistors
Each of the Unidrive 3-phase Regen Inductors has a thermistor fitted; when the system consists of multiple Regen drives the thermistors should be connected in series due to there only being a single thermistor input on the Regen drive. Figure 4-1 Control connections - (negative logic configuration)
External power supply for K2 coil External power supply for K3 coil
1
K2
aux3
K3
2 3 4 5
Relay NO 0V Analog 10V Out Analog I/P 1+ Analog I/P 1Analog I/P 2 Analog I/P 3 Analog O/P 1 Analog O/P 2 0V Analog
(Set Pr 8.25 to Pr 15.14)
Tc1
6 7 8 9 10 11
Regen Drive
21 22 23 24
0V +24V Out 0V Digital Digital I/O 1 Digital I/O 2 Digital I/O 3 Digital I/P 1 Digital I/P 2 Digital I/P 3 Enable 0V Digital
Output enable
25
Drive Healthy aux2 User enable aux 1x
26 27 28 29 30 31
Drive Healthy
Relay NO
2 3 4
0V Analog 10V Out Analog I/P 1+ Analog I/P 1Analog I/P 2 Analog I/P 3 Analog O/P 1 Analog O/P 2 0V Analog
Speed/Torque Ref 4 - 20mA Current Loop
5 6 7 8 9
Motor Thermistor
10 11
Motoring Drive
21 22 23
At Zero Speed O/P Reset
24 25 26
Fwd Rev
27 28 29 30
User enable
31
9
Components
Motoring drive Regen drive Regen inductor Softstart resistor Contactors, MCBs and overload Switching frequency filter (optional) RFI filter (optional) Varistors Fuses
The following parts are required to assemble a Unidrive Regen system:
NOTE
The Regen inductor and softstart resistor duty cycle is very arduous. Therefore, correct component selection is critical. The most sensitive aspects are line-inductor linearity, saturation current and resistor-energy pulse rating. Only inductors and softstart resistors as specified in this Installation Guide should be used.
5.1
Motoring drive
Unidrive in Open Loop, Closed Loop or Servo mode. Any software version. This controls the motor by converting the DC bus voltage to a variable voltage, variable frequency supply. Power flow is between the DC bus and the motor. There are no AC supply connections.
5.2
Regen drive
Unidrive in Regen mode. (Must be software version 2.10.04 or higher). The Regen drive converts the AC supply to a regulated DC voltage. It also provides bi-directional power flow and sinusoidal input currents.
5.3
NOTE
Regen inductor
N
3-phase Regen inductors Rated power kW Rated current A rms 9.5 12 16 25 34 40 46 60 70 96 124 156 180 202 300 Inductance mH 6.3 5.0 3.75 2.4 1.76 1.5 1.3 1.0 0.78 0.63 0.48 0.38 0.33 0.30 0.24 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4401-0001 4401-0002 4401-0003 4401-0004 4401-0005 4401-0006 4401-0007 4401-0008 4401-0009 4401-0010 4401-0011 4401-0012 4401-0013 4401-0014 4401-0015 Number required per Regen drive CT part number
The Regen inductor supports the difference between the PWM voltage from the Regen drive and sinusoidal voltage from the supply.
Regen inductors are special parts. Under no circumstances must a part be used other than those listed in Table 5-1. Table 5-1
Drive Model
UNI 1405 UNI 2401 UNI 2402 UNI 2403 UNI 3401 UNI 3402 UNI 3403 UNI 3404 UNI 3405 UNI 4401 UNI 4402 UNI 4403 UNI 4404 UNI 4405 UNI 5401
4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 160
10
5.4
5.4.1
Softstart resistor
Single systems
The start-up circuit limits the amount of current flowing into the DC bus of the Regen drive and into the motoring drives. The softstart resistor for single Regen applications must be as specified in the following table. Energy rating and overload are non-standard and both are important. Table 5-2 Drive size 1 2 3 4 5 Table 5-3 Single Regen, single motoring, Unidrive size 1 to 5 Number of parallel resistors 1 1 1 2 2 Softstart resistor data Resistors 1270-3157 1270-3157 1270-2483 1270-2483 x 2 1270-2483 x 2 Rms current A 0.4 0.4 0.5 0.6 1.2 Charging current A 5 5 15 32 32 Total value 150 150 48 24 24 Resistors CT part number 1270-3157 1270-3157 1270-2483 1270-2483 1270-2483 Value 150 150 48 48 48
Drive size 1 2 3 4 5
The above figures have been calculated assuming a peak supply voltage of 480 Vac +10%. Refer also to Appendix B Component Sizing Calculations.
5.4.2
Multiple systems
In non standard cases, e.g. multiple motoring, multiple Regen systems, the soft-start resistor size and rating must be recalculated due to the charging characteristics changing. For the method of calculating the new resistor size and rating, refer to Appendix B Component sizing calculations on page 36.
5.4.3
Protection
Protection for the softstart circuit is provided using a thermal overload to protect against a high impedance short circuit, and a separate magnetic overload to protect against a direct short circuit. For multiple systems the softstart resistor size must be recalculated resulting in resizing of the thermal magnetic overload required. Refer to Appendix B Component sizing calculations on page 36. Table 5-4 Thermal magnetic overload Rated Current A 0.3 1 2 Rated Voltage Vac 480 480 480 Number of Poles 1 1 1 CT part number 4133-0117 4133-0217 4133-0277
Drive size 1&2 3 4&5
5.5
Table 5-5
Contactors, MCBs and overload

Contactors and MCBs Ref K2 K3 MCB 1x Ovld Description 3 pole NO + auxiliary NO contact. Coil voltage selected to suit available supply. 2 pole NC + auxiliary NO 3 pole + auxiliary NC Specification Current rating equal to total current requirement. Voltage rating equal to AC mains supply voltage. Coil must not exceed 240Vac 5A resistive load. Installation category 1. Current rating sized to rms current of switching frequency filter capacitors and charging current at power up. (Refer to Table 5-6). Sized to the softstart resistor to protect thermally and magnetically. (Refer to Appendix B Component sizing calculations on page 36).
Contactors and MCBs are required as follows:
Function Main contactor Auxiliary contactor Switching frequency filter MCB Thermal magnetic overload
Single pole
MCB 1x is fitted between the switching frequency filter capacitors and the AC supply. The MCB should have an auxiliary which the enable for the Regen and motoring drive is connected through. This will act as a safe guard and prevent the system running with a fault on the switching frequency filter. Also refer to Appendix B Component sizing calculations on page 36.
11
5.6
Switching frequency filter
The AC input terminals of a Regen drive produce a PWM output voltage, which has a sinusoidal component at line frequency, plus significant harmonics at the switching frequency and its multiples. This filter prevents switching frequency harmonic currents getting back into the supply. If the filter is not fitted, the presence of currents in the kHz region could cause supply problems or disturbance to other equipment.
NOTE
The switching frequency filter inductors need to be rated to the total current requirement. The following inductors are standard 3-phase inductors (rated at drive rated current for a single Regen system or rated at total current requirement for multiple Regen system), they carry only 50/60Hz current with a negligible amount of high frequency current. The capacitors specified below are suitable for operation at any switching frequency. These capacitors are sized for operation at 3kHz however operation above 3kHz is possible with the capacitors being more effective. Table 5-6 Switching frequency filter Drive Model UNI 1405 UNI 2401 UNI 2402 UNI 2403 UNI 3401 UNI 3402 UNI 3403 UNI 3404 UNI 3405 UNI 4401 UNI 4402 UNI 4403 UNI 4404 UNI 4405 UNI 5401 UNI 5402 UNI 5403 UNI 540X UNI 5404 Rated current A 9.5 12 16 25 34 40 46 60 70 96 124 156 180 202 300 600 900 300 x X 1200 3-phase inductor Lfilt mH 3.160 2.500 1.875 1.200 0.880 0.750 0.650 0.500 0.390 0.315 0.240 0.190 0.165 0.135 0.100 0.050 0.034 0.100 / X 0.025 CT part number 4401-0162 4401-0163 4401-0164 4401-0165 4401-0166 4401-0167 4401-0168 4401-0169 4401-0170 4401-0171 4401-0172 4401-0173 4401-0174 4401-0175 4401-0176 4401-0177 4401-0178 4401-0179 80 (x1) 80 (x2) 80 (x3) 80 (xX) 80 (x4) 1665 - 2804 35 per capacitor 48 1665 - 2484 25 24 1665 - 2244 15 5.7 1610 - 5752 2.1 3-phase capacitor Cfilt F CT part number MCB rating rms current A Peak current A 28 31 36 45 106 115 124 142 160 252 262 325 348 385 580 580 580 580 580
X = number of size 5 drives

5.6.1
NOTE
Protection
An MCB should be fitted between the AC supply and the capacitor. This is to protect the wiring between the capacitor and the main bus bar.
For multiple Regen systems, refer to Appendix B Component sizing calculations on page 36 for sizing of the MCB.
12
5.7
RFI filter
In common with conventional drives, significant ground currents are generated by the capacitance of the motor to ground, the motor cables to ground, and the drive power circuits to their heatsinks.The RFI filter will provide a relatively short return path for ground currents back to the drives power circuit. Table 5-7 RFI filter data Volts Vac UNI1405 UNI2401 to 2402 UNI2403 UNI3401 to 3403 UNI3404 UNI3405 UNI4401 to 4402 UNI4403 to 4404 UNI4405 UNI5401 480 480 480 480 480 480 480 480 480 480 Maximum power kW 4 7.5 11 22 30 37 55 90 110 160 Filter current rating A 10 16 25 50 63 100 150 180 220 300 Book End Footprint or Book End Book End Footprint or Book End Book End Footprint or Book End Book End Book End Book End Book End Book End Book End Book End Motor cable length m 100 100 100 100 100 100 100 100 100 100 100 100 100 4200-6105 4200-6104 4200-6109 4200-6108 4200-6114 4200-6113 4200-6116 4200-6117 4200-6106 4200-6107 4200-6111 4200-6112 4200-6115
CT Model Number
Mounting style
CT part number
Do not use an RFI filter without the specified switching frequency filter, as failure of the RFI filter will occur, due to the switching currents.
CAUTION
5.8
Varistors
AC line voltage transients can typically be caused by the switching of large items of plant, or by lightning strikes on another part of the supply system. If these transients are not suppressed, they can cause damage to the insulation of the Regen input inductors, or to the Unidrive Regen drive electronics. Table 5-8 Varistors Drive size 1 to 5 1 to 5 Varistor voltage Vac 550 680 Varistor energy J 400 450 Z500NS Z680LNS 3 3 2482-1501 2482-0680
Configuration Line to line Line to ground

NOTE
Type number
Quantity
CT part number
N
Configuration
Fitting of Varistors
Fuses Varistors
Seven varistors are required when operating with an IT supply as shown in Figure 3-1 on page 5, Figure 3-2 on page 6 and Figure A-2 on page 32.
5.8.1
Varistors should be fitted after the supply fuses, as shown in Figure 5-1: Figure 5-1
RFI Filter
Switching Frequency Filter
B 550Vac varistors 680Vac varistors E
13
5.9

Fusing
Fusing for the Regen system is required in order to protect the following: Supply transformer Supply cables Regen inductor Regen drive Motoring drive
In the event of failure, the fusing will prevent fire by limiting the amount of energy allowed into the Regen and motoring drive units. The AC supply fusing should be rated to the Regen systems continuous rated current. The Regen AC fusing when used with each multiple size 5 Regen drive should be rated to the 450A continuous rated current of the drive. The +DC bus fusing when used with multiple motoring drives should be rated to 2 x motoring drive rated current and > 750Vdc.
5.9.1
Standard systems
Fusing for a standard Regen system, single Regen plus single motoring drive (both drives of the same rating) should consist of AC supply fusing as shown below: Figure 5-2 Fusing: Standard systems
AC Supply Fusing Main Contactor Additional Circuitry Regen Inductor U V W -DC -DC
R
3 Phase Supply
Regen Drive
Motoring Drive
+DC
+DC
U V W
Y B
5.9.2
Multiple size 1 to 4 motoring drives
When a Regen system consists of multiple size 1 to 4 motoring drives, AC supply fusing and +DC bus fusing should be fitted as shown below: Figure 5-3 Fusing: Multiple size 1 to 4 motoring drives Regen system
Motoring Drive
+DC AC Supply Fusing -DC

Regen Drive
U V
Main Contactor Additional Circuitry
Regen Inductor U V W
R
3 Phase Supply
+DC -DC DC Bus Fusing
Y B
Motoring Drive
+DC -DC
U V W
14
5.9.3
Multiple size 5 Regen
When a Regen system consists of multiple size 5 Regen and motoring drives, AC supply fusing and -DC bus fusing should be fitted as shown below: Figure 5-4 Fusing: Multiple size 5 Regen system
Regen Inductor U V AC Supply Fusing W Main Contactor Additional Circuitry Regen AC Fusing Output Sharing Choke U V -DC -DC W
Regen Drive
Motoring Drive
+DC
+DC
R
3 Phase Supply
Y B
DC Bus Fusing
Regen Drive
Motoring Drive
U V W Regen Inductor
+DC -DC
+DC -DC
U V W Output Sharing Choke
15
6
6.1
6.1.1

Important considerations
Fundamentals
You must
Use Regen inductors of the correct type and value, as specified. Use a start-up resistor of the correct type and value, as specified. Connect the Regen drive output enable signal to the enable input on the motoring drive(s). Use a switching frequency filter if an RFI filter is present or the AC supply is not dedicated solely to the Regen drive. Fit fuses where specified, and ensure they are of the correct rating. Ensure that the cubicle is correctly sized and ventilated, taking into account the losses generated by all of the circuit components.
6.1.2
You must not
Connect a circuit of any type between a Regen and motoring drives DC bus. Attempt to use a Unidrive size 1-4 Regen in parallel configuration (only Unidrive size 5 Regen can be used in parallel configuration).
6.2
Unidrive size 3 and 4
If a Unidrive size 3 or 4 of any other variant except the Regen variant is to be used in a Regen system, an internal modification is required to both the Regen and motoring drive(s).
Damage to the drive(s) will result if this modification is not carried out.
CAUTION
NOTE
Modification of the drive must only be carried out by CT authorised personnel. If any details are required, contact C.T. Technical support.
6.3
Ventilation
When designing a Regen System, considerations must be made for the additional ventilation requirements due to the introduction of the Regen and Switching Frequency filter inductors.
The inductors have normal operating temperatures of approx. 150C depending upon the ambient and the motor cable lengths. Care must be taken so that this does not create a fire risk.
CAUTION
A Regen System can operate in an ambient temperature range of 0C to 50C (32F to 122F) for Unidrive sizes 1 to 5. An output current derating must be applied with ambient temperatures between 40C and 50C. For derating figures see the Unidrive Size 1 to 5 User Guide. Ventilation for both the Regen and motoring drives in the system should be as specified in the Unidrive Size 1 to 5 User Guide. Provided the maximum cable lengths in Table 6-3 on page 18 have not been exceeded, natural air flow ventilation through the Regen and switching frequency filter inductors is adequate. In special conditions, where the maximum cable length (refer to Table 6-3 on page 18) has been exceeded, forced cooling should be introduced for the Regen Inductor as specified in Appendix C Long cables on page 41. When sizing the cubicle(s) for the Regen system considerations must be made for the systems losses.
System Losses RFI Filter Regen drive Motoring drive Control Module, Unidrive size 5 Power Module, Unidrive size 5
Documented In...
Unidrive Size 1 to 5 User Guide
16
Table 6-1
3-phase Regen inductor Rated current A rms Inductance mH 6.3 5.0 3.75 2.4 1.76 1.5 1.3 1.0 0.78 0.63 0.48 0.38 0.33 0.30 0.24 No per Regen Drive 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CT part number 4401-0001 4401-0002 4401-0003 4401-0004 4401-0005 4401-0006 4401-0007 4401-0008 4401-0009 4401-0010 4401-0011 4401-0012 4401-0013 4401-0014 4401-0015 Total losses W 125 146 175 210 285 310 320 345 415 515 585 645 775 845 1760
Drive size UNI 1405 UNI 2401 UNI 2402 UNI 2403 UNI 3401 UNI 3402 UNI 3403 UNI 3404 UNI 3405 UNI 4401 UNI 4402 UNI 4403 UNI 4404 UNI 4405 UNI 5401
9.5 12 16 25 34 40 46 60 70 96 124 156 180 220 300
Table 6-2
3-phase switching frequency filter inductor Rated current A rms Inductance mH 3.160 2.500 1.875 1.200 0.880 0.750 0.650 0.500 0.390 0.315 0.240 0.190 0.165 0.135 0.100 0.050 0.034 0.025 No per Regen Drive 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CT part number 4401-0162 4401-0163 4401-0164 4401-0165 4401-0166 4401-0167 4401-0168 4401-0169 4401-0170 4401-0171 4401-0172 4401-0173 4401-0174 4401-0175 4401-0176 4401-0177 4401-0178 4401-0179 Total losses W 28 35 37 40 52 60 60 80 90 100 110 130 170 180 220 400 530 700
Drive size UNI 1405 UNI 2401 UNI 2402 UNI 2403 UNI 3401 UNI 3402 UNI 3403 UNI 3404 UNI 3405 UNI 4401 UNI 4402 UNI 4403 UNI 4404 UNI 4405 UNI 5401 UNI 5402 UNI 5403 UNI 5404
9.5 12 16 25 34 40 46 60 70 96 124 156 180 220 300 600 900 1200
6.4
6.4.1
Cable length restrictions

AC supply connection
There are 3 significant cable lengths which must be taken into account when designing a Regen system. Refer to Figure 6-1 on page 18. A is the AC cable length between the Regen inductor and the Regen drives terminals. In general, no special precautions are necessary for the AC supply wiring in respect to the Regen drive. However the voltage in the wiring between the Regen inductor and the Regen drive terminals is a source of radio frequency emission. To minimise emissions, these cables should be kept as short as possible. Ideally, the inductors should be mounted close to the drive terminals. If it is necessary to use a cable longer than 5m, a screened cable should be used with the screen grounded as shown in Figure 6-1 on page 18.
6.4.2
DC bus connection
B is the DC bus connection between the Regen and motoring drive, the + DC bus connections between the drives should be treated as a single two core cable and not two individual cable / bus bar lengths. The DC power output from the Unidrive which is used as the input stage to the motoring drive(s) carries a common-mode high frequency voltage comparable with the output voltage from a standard drive. All precautions recommended for motor cables must also be applied to all cables connected to this DC circuit.
17
If it is necessary to use a cable longer than 5m, a screened cable should be used with the screen grounded as shown in Figure 6-1.
6.4.3
Motor connection
C is the AC cable length between the motoring drive and the motor. Figure 6-1 Calculating the cable length of the Regen system
B
Regen Drive
L1 L2 L3 U V W -DC +DC L1 L2 L3
Motoring Drive
U V W +DC -DC
E E A
E E C
E Regen Inductor Motor
E R B Y
6.4.4
Table 6-3
Maximum cable length

Cable lengths Power rating kW 4 5.5 - 11 15 - 37 45 - 110 132 Maximum cable length m 50 100 200 200 200 per Regen drive
The sum total length of the DC bus and motor cables (B and C in Figure 6-1) must not exceed the values shown in the table below:
Regen drive size 1 2 3 4 5
If the cable length in the above table is exceeded, additional components are required. Refer to Appendix C Long cables on page 41.
18
7
7.1
Unidrive Regen EMC information

Immunity
The immunity of the individual drive modules is not affected by operation in the regenerative mode. See drive EMC data sheets for further information. This Guide recommends the use of varistors between the incoming AC supply lines. These are strongly recommended to protect the drive from surges caused by lightning activity and/or mains supply switching operations. Since the regenerative input stage must remain synchronised to the supply, there is a limit to the permitted rate of change of supply frequency. If rates of change exceeding 100Hz/s are expected then C.T. Technical Support should be consulted. This would only arise under exceptional circumstances e.g. where the power system is supplied from an individual generator.
7.2

Emission
Emission occurs over a wide range of frequencies. The effects are divided into three main categories: Low frequency effects, such as supply harmonics and notching High frequency emission below 30MHz where emission is predominantly by conduction High frequency emission above 30MHz where emission is predominantly by radiation
7.3
Dedicated supplies
The nature of the mains supply has an important effect on the EMC arrangements. For a dedicated supply, i.e. one which has no other electrical equipment fed from the secondary of its distribution transformer, normally neither an RFI filter or a switching frequency filter are required. Refer to section 3.2.2 Supply assessment on page 7.
7.4
Other supplies
Wherever other equipment shares the same low voltage supply, i.e. 400Vac, careful consideration must be given to the likely need for both switching frequency and RFI filters, as explained in section 7.7 Switching frequency emission and section 7.8 Conducted RF emission .
7.5
Supply voltage notching
Because of the use of input inductors and an active rectifier the drive causes no notching - but see section 7.7 Switching frequency emission for advice on switching frequency emission.
7.6
Supply harmonics
When operated from a balanced sinusoidal three-phase supply, the regenerative Unidrive generates minimal harmonic current. Imbalance between phase voltages will cause the drive to generate some harmonic current. Existing voltage harmonics on the power system will cause some harmonic current to flow from the supply into the drive. Note that this latter effect is not an emission, but it may be difficult to distinguish between incoming and outgoing harmonic current in a site measurement unless accurate phase angle data is available for the harmonics. No general rule can be given for these effects, but the generated harmonic current levels will always be small compared with those caused by a conventional drive with rectifier input.
7.7
Switching frequency emission
The Regen drive uses a PWM technique to generate a sinusoidal input voltage phase-locked to the mains supply. The input current therefore contains no harmonics of the supply unless the supply itself contains harmonics or is unbalanced. It does however contain current at the switching frequency and its harmonics, modulated by the supply frequency. For example, with a 3kHz switching frequency and 50Hz supply frequency there is current at 2.95, 3.15, 5.95, 6.05kHz etc. The switching frequency is not related to that of the supply, so the emission will not be a true harmonic - it is sometimes referred to as an interharmonic. The possible effect of this current is similar to that of a high-order harmonic, and it spreads through the power system in a manner depending on the associated impedances. The internal impedance of the Regen drive is dominated by the series inductors at the input. The voltage produced at switching frequency at the supply point is therefore determined by the potential divider action of the series inductors and the supply impedance; section 3.2.2 Supply assessment on page 7 gives guidelines to help in assessing whether a switchingfrequency filter is required. In case of doubt, unless the drive operates from a dedicated supply not shared with other loads, it is strongly recommended that the filter be fitted.
Failure to fit a switching frequency filter may result in damage to other equipment, e.g. fluorescent light fittings, power factor correction capacitors and RFI filters.
CAUTION
7.8
Conducted RF emission
Radio frequency emission in the frequency range from 150kHz to 30MHz is mainly conducted out of the equipment through electrical wiring. It is essential for compliance with all emission standards, except for IEC61800-3 second environment, that the recommended RFI filter and a shielded (screened) motor cable are used. Most types of cable can be used provided it has an overall screen. For example, the screen formed by the armouring of steel wired armoured cable is acceptable. The capacitance of the cable forms a load on the drive and should be kept to a minimum.
19
When an RFI filter is used the switching frequency filter discussed above must also be used. Failure to observe this may result in the RFI filter becoming ineffective and being damaged.
CAUTION
When used with the recommended filters, the Regen drive system complies with the requirements for conducted emission in the following standards: Table 7-1 Requirements for conducted emission Switching frequency (kHz) 3 I I Description Frequency range 0.15 - 0.5MHz 0.5 -30MHz Limits 79dB V quasi peak 66dB V average 73dBV quasi peak 60dB V average Application AC supply lines
Motor cable length (m) 1.5 100 Key to table I EN50081-2 Standard
Generic emission standard for the industrial environment Product standard for adjustable speed power drive systems
EN61800-3 IEC1800-3 1 2
Input current >25A: Requirements for the first environment1: Unrestricted distribution Input current <25A: Requirements for the first environment2: Restricted distribution
The first environment is one where the low voltage supply network also supplies domestic premises Restricted distribution means that drives are available only to installers with EMC competence
For installation in the second environment, i.e. where the low voltage supply network does not supply domestic premises, no filter is required in order to meet IEC61800-3 (EN61800-3):1996. Operation without a filter is a practical cost-effective possibility in an industrial installation where existing levels of electrical noise are likely to be high, and any electronic equipment in operation has been designed for such an environment. There is some risk of disturbance to other equipment, and in this case the user and supplier of the drive system must jointly take responsibility for correcting any problem which occurs.
CAUTION
7.8.1
Table 7-2
Recommended RFI filters

Recommended filters Drive UNI 1405 UNI 2401 - 2402 UNI 2403 UNI 3401 - 3403 UNI 3404 UNI 3405 UNI 4401 - 4402 UNI 4403 - 4404 UNI 4405 UNI 5401 100 Motor cable length m RFI filter: C.T. part number 4200-6105 4200-6109 4200-6114 4200-6116 4200-6117 4200-6106 4200-6107 4200-6111 4200-6112 4200-6115
These are the same filters as recommended for standard (non-regenerative) operation:
7.8.2
Table 7-3
Related product standards

Conducted emission from 150kHz to 30MHz Product standard EN55011 Class A Group 1 CISPR 11 Class A Group 1 EN55022 Class A CISPR 22 Class A Industrial, scientific and medical equipment Information technology equipment
The conducted emission levels specified in EN50081-2 are equivalent to the levels required by the following product specific standards:
Generic standard EN50081-2
20
7.9
Radiated emission
Radio frequency emission in the frequency range from 30MHz to 1GHz is mainly radiated directly from the equipment and from the wiring in its immediate vicinity. Operation in regenerative mode does not alter the radiated emission behaviour, and the EMC data sheet for the individual Unidrives used should be consulted for further information.
NOTE
Theoretically the use of two drives physically close together can cause an increase in emission level of 3dB compared with a single drive, although this is usually not observed in practice. All Unidrives have sufficient margin in respect of the generic standard for the industrial environment EN500812 to allow for this increase.
7.10
Wiring guidelines
The wiring guidelines provided for the individual drives also apply to regenerative operation, except that the switching frequency filter must be interposed between the input drive and the RFI filter. The same principles apply, the most important aspect being that the input connections to the RFI filter should be carefully segregated from the power wiring of the drives which carries a relatively high noise voltage.
7.11
Multi-drive systems
It is common for regenerative drive systems to be constructed using numbers of drives with a single input stage, or other more complex arrangements. It is generally not possible to lay down specific EMC requirements for such systems, since they are too large for standardised tests to be carried out. In many cases the environment corresponds to the second environment as described in IEC61800-3, in which case no specific limit to conducted emission is required. National legislation such as the European Union EMC Directive does not usually require that complex installations meet specific standards, but only that they meet the essential protection requirements, i.e. not to cause or suffer from electromagnetic interference. Where the environment is known to include equipment which is sensitive to electromagnetic disturbance, or the low voltage supply network is shared with domestic dwellings, then precautions should be taken to minimise conducted radio frequency emission by the use of a filter at the system power input. For current up to 300A the Control Techniques filters listed previously are suitable. For currents exceeding 300A up to 2400A suitable filters are available from the following manufacturers: Siemens B84143.A250.S (range up to 2500A) Schaffner FN3359-300-99 (range up to 2400A) These filters may not give strict conformity with EN50081-2, but in conjunction with the relevant EMC installation guidelines they will reduce emission to sufficiently low levels to minimise the risk of disturbance.
21
Parameter descriptions
Key to parameter codes: Range of values Default value RW RO Bit Bi Uni Txt P Read/Write Read Only Two state only parameter, 0 or 1. Bipolar - can have positive and negative values. Unipolar - can have positive values only. Parameter value is represented on the display with strings of Text. Parameter is Protected from being controlled by programmable inputs and functions.
Note that the equivalent Menu 0 parameter appears in the box preceding the parameter description.
8.1
Menu 15: Sinusoidal rectifier
A Unidrive can be used as a sinusoidal input current power unit to supply one or more Unidrives via their DC buses. When this mode is selected as the drive type, menu 15 appears. This menu is used to set up the Unidrive. At the same time, menu 0 defaults to showing Pr 15.01 to Pr 15.13 as Pr 0.11 to Pr 0.28.
15.01
0.11
Supply current magnitude

A RO Bi P
Maximum drive current
This parameter gives the rms phase current from the supply. The sinusoidal rectifier controls the current so that the fundamental current and voltage are in phase at the power terminals of the drive. There is a small phase shift across the input inductors, and so the current magnitude and the real component of current are approximately equal. If power is flowing into the sinusoidal rectifier the current magnitude is negative, and if power is flowing out (back into the supply) the current magnitude is positive.
15.02
0.12
Supply voltage
Vac RO Uni P
0 to 528
When the sinusoidal rectifier unit is active the supply voltage is given by this parameter. If the unit is not active this parameter shows zero.
15.03
0.13
Supply power
kW RO Bi
Drive max. current x 5.09 x 3/1000
Total supply power of the drive is calculated from the product of the line voltage and current which is equivalent to 15.01 x 15.02 x 3. Note that as the power factor is approximately unity the power is equal to the volt-amperes. The power shown is that flowing out of the drive, hence when power is flowing from the supply to the Regen drive Pr 15.03 is negative, and when power is flowing from the Regen drive back into the supply Pr 15.03 is positive.
15.04
0.14
DC bus voltage
Vdc RO Uni P
0 to 830 Voltage at the DC output of the drive.
15.05
0.15
100
Supply frequency
Hz RO Bi P
When the sinusoidal rectifier unit is active this parameter gives the supply frequency. Positive values indicate positive phase sequence and negative values indicate negative phase sequence. If the unit is not active this parameter shows zero.
22
15.06
0.16
Input inductance
mH RO Uni P
0.001 to 100
At power-up this parameter is zero. Each time the unit is enabled the supply inductance is measured and displayed by this parameter. The value given includes the supply inductance and the inductors inserted at the supply to the sinusoidal rectifier unit. The value given is only approximate, but will give an indication as to whether the input inductance is correct for the sinusoidal rectifier unit size.
15.07
0.17
DC bus voltage set-point

700 Vdc RW Uni
0 to 800
The sinusoidal rectifier unit will attempt to hold the DC bus at the level specified by this parameter. The higher the bus voltage the better the performance of the unit as there will be more voltage available to control the input current. The bus voltage must always be higher than the peak of the line to line supply voltage if the unit is to operate correctly. The voltage can be set to a level up to 800V, but this only leaves 30V headroom below the over-voltage trip level. Therefore it is best to use the default value of 700V unless the supply voltage is such that it must be raised above this level. Supply voltage Vac 380 415 480 Minimum Vdc 650 680 780 Recommended Vdc 700 700 780 Maximum Vdc 800 800 800
15.08
0.18
Switching frequency
0:[3kHz] kHz RW Txt P
0 to 4: [3, 4.5, 6, 9, 12]
This parameter sets the PWM frequency and also determines the sample frequency for loops. The sampling frequency of the control system is based on the switching frequencies as follows: Current control Switching frequency kHz 3 4.5 6 9 12 DC bus voltage control and synchronisation with the supply Switching frequency kHz 3 4.5 6 9 12 Control frequency kHz 3 2.25 3 2.25 3 Control frequency kHz 3 4.5 6 4.5 6
15.09
0.19
0~1
High stability space vector modulation

0 RW Bit
Setting this parameter to 1 modifies the IGBT switching pattern so as to reduce the number of switching events. This has the following effects: Slightly reduced power loss in the Regen drive. Increased acoustic noise from input inductors.
23
15.10
0.20
0~1
Quasi-square operation select

0 RW Bit
The rate at which the DC bus voltage can be reduced by the drive depends on the headroom between the bus voltage and the supply voltage. If quasi-square mode is selected this headroom can be effectively increased at some points within a supply cycle. This can give better performance, particularly when the supply voltage is high or the bus voltage set-point is low.
15.11
0.21
0~1
Sinusoidal rectifier synchronising

RO Bit
When the drive is enabled it must detect the phase and frequency of the mains. During this period this bit is set. Once synchronisation has been completed successfully this bit is cleared. If the supply is very severely distorted or a phase is missing the drive will repeatedly attempt to synchronise until it is disabled or synchronisation is completed.
15.12
0.22
0~1
Sinusoidal rectifier synchronised

RO Bit
When the drive has been enabled and successfully synchronised this bit will be set to 1. If the drive is disabled, the unit trips or detects that the mains is lost, this bit will be set to 0.
15.13
0.23
0~1
Sinusoidal rectifier phase loss

RO Bit
If a supply phase is not present the sinusoidal rectifier unit will not synchronise when it is enabled. However, if a phase is lost after synchronisation one of the following will occur: Lightly loaded: the unit will continue to operate normally. Medium load: the unit will continue to operate, but the phase loss bit is set. Heavy load: the unit will detect mains loss, disable itself and attempt to re-synchronise.
15.14
0.24
0~1
Close soft start contactor

RO Bit
When the Regen drive has powered up through the soft start resistor and the DC bus voltage stabilised this bit will change from 0 to 1. This bit must be routed to a digital output terminal which is used to energise the soft start contactor coil.
15.15
0.25
0~1
Soft start contactor is closed

RO Bit
When the close contactor output goes active the soft-start contactor should operate and short out the soft-start resistor. This bit should be set as the destination parameter for a digital input connected to an auxiliary contact on the soft start contactor. If this input becomes inactive when bit Pr 15.14 is set then after a 100ms (approx.) delay the drive will inhibit so as to protect the soft-start circuit.
15.16
0.26
0~1
Enable motor drive

RO Bit
When the unit has been enabled and successfully synchronised this bit will be set to 1. If the Regen drive is disabled, the unit trips or detects that the mains is lost, this bit will set to 0. This bit should be routed to a digital output and used to enable the motoring drive(s) connected to the DC bus of the Regen drive.
24
15.17
0.27
0~1
Line synchronisation trip enable

0 RO Bit
When the drive is enabled and the main contactor is closed it will try and synchronise the line supply. If this bit is 0 then the drive will continue to try and synchronise to the line continually until disabled, even if it does not synchronise successfully. If this bit is set to a 1 and the drive has not successfully synchronised after trying for 30 seconds then the drive will trip LI.SYNC.
15.18
0.28
0~5
Line synchronisation status

RO Txt P
This parameter is the line supply synchronisation status. It is intended to give some diagnostic information if the drive fails to synchronise to the supply. If no attempt to synchronise to the supply has been made since the drive was switched on, if the drive is synchronised to the supply and running, or if it has been running then this parameter will show SYNC. If the drive can not synchronise to the supply then this parameter will show the reason why synchronisation failed. If the drive does fail to synchronise to the supply the most likely reasons are that the supply is very distorted, or there are large voltage notches / spikes on the supply. 0 1 2 3 4 5 SYNC Ph Det Fr Lo Fr Hi PLL OI PLL Ph Successfully synchronised to line supply Failed to correctly detect the phasing of the supply Line frequency too low Line frequency too high Over current during final synchronisation of PLL to supply Phasing error during final synchronisation of PLL to supply
15.19
Current control proportional gain

0 to 30,000 110 RW Uni
15.20
Current control integral gain

0 to 30,000 1,000 RW Uni
NOTE
These parameters are only available when the software version is 3.01.07 or higher When the drive is operated as a Regen drive it uses a DC bus voltage controller with inner current controllers as shown below:
The gains of the voltage and current controllers affect the stability of the Regen drive control system and incorrect gain settings can result in overvoltage or over-current trips. (The gain of the voltage controller is set by Pr 15.21). In most applications the default gains given for the current conditions will be suitable, however, it may be necessary for the user to change these if the inductance or resistance of the supply plus the Regen inductors varies significantly from the expected values. The most critical parameter for stability is the current controller proportional gain and the required value for this is dependent on the Regen drive input inductance. If the inductance of the supply is a significant proportion of the recommended Regen inductor (i.e. >60mH/IDR . where IDR is the drive rated current), then the proportional gain may need to be increased. The supply inductance is likely to be negligible compared to the Regen inductor value with small drives, but is likely to be significant with larger drives. The proportional gain should be adjusted so that Pr 15.19 = 1800 x Total input L x IDR The current controller integral gain is not so critical, and in a majority of cases the default value is suitable. However, if it is necessary to adjust this parameter a value between 80 x IDR x R and 320 x IDR x R (where R is the supply resistance of one phase) should be used. Even when the gains are set correctly there will be a transient change of DC bus voltage when there is a change in the load on any drive connected to the Regen drive. If the power flow from the supply is increased (i.e. more power is taken from the supply or less power is fed back into the supply) the DC bus voltage will fall, but the minimum level will be limited to just below the peak rectified level of the supply provided the maximum rating of the
25
drive is not exceeded. If the power flow from the supply is reduced (i.e. less power is taken from the supply or more power is fed back into the supply) the DC bus voltage will rise. During a rapid transient the bus will rise and then fall as shown below:
The example shown is for a very rapid load change where the torque reference of the motoring drive has been changed instantly from one value to another. In most applications where the motoring drive is operating under speed control the speed controller may only require a limited rate of change of torque demand, reducing the rate of change of power flow, and also reducing the size of the transient voltage. If the set point voltage (Pr 15.07) plus the transient rise exceed the over-voltage trip level (830V for a medium voltage drive) the Regen drive will trip. When a 400V motor is operated above base speed from a drive in vector mode, fed from the Regen drive supplying a DC voltage of 700V, and an instantaneous change of torque is demanded (i.e. - 100% to +100%) the peak of the voltage transient (V) is approximately 80V if the current controllers are set up correctly. (Operating with maximum voltage on the motor, i.e. above base speed, gives the biggest transient of power and hence the biggest value of V). If V is required for a different load change it can be calculated from V = 80V x load change / 200% If the motor voltage is not 400V or the DC bus voltage set point is not 700V, V is calculated from V = 80V x (motor voltage / 400) x (700 / DC bus voltage set point) In some applications, particularly with a high DC bus voltage set point and low switching frequency it may be necessary to limit the rate of change of power flow to prevent over voltage trips. A first order filter on the torque reference of the motoring drive (i.e. using Pr 4.12) is the most effective method to reduce the transient further. (A fixed limit of the rate of change of torque demand is less effective). The following table gives an approximate indication of the reduction in V for different time constants. As already mentioned the value of V given if for an instantaneous change of torque representing the worst case. In most applications where a speed controller is used in the motoring drive the transient will already include a filter. Time constant 20ms 40ms Change in V x 0.75 x 0.5
15.21
Voltage control P gain

0 to 30000 4000 RW Uni
NOTE
This parameter is only available when the software version is 3.01.07 or higher. The voltage controller gain is set to a value that is suitable for most applications. The per drive capacitance of each size of drive is not always the same, and so the drive compensates so that the gain is set for twice the capacitance of an individual drive as this is the normal situation with a Regen drive and motoring drive of equal rating. The transient voltage with a sudden change of load, V, is affected proportionally by this parameter. Therefore the gain may be changed when the DC bus capacitance is not equal to twice the Regen drive capacitance. However, care must be taken to ensure that the gain is not too high as this can cause excessive ripple in the DC bus voltage.
26
Figure 8-1 Menu 15 logic diagram

Close soft start contactor 15.14
Sequencer Menu 6
15.16 Soft start contactor is closed 15.15 Enable motoring Drive
Contactor closed
Regen sequencer
Enable
15.12
Sinusoidal rectifier synchronised Sinusoidal rectifier synchronising
15.11 DC Bus voltage 15.13 15.04
Sinusoidal rectifier phase loss
Modulation
Supply current magnitude 15.01
Regen current and voltage controllers

15.07 15.21 DC Bus voltage set-point Voltage gain Current control proportional gain Current control integral gain
15.08 15.09 15.10
Switching frequency High stability space vector modulation Quasi-square operation select
U V W
Supply voltage 15.19 15.02 15.20
15.05
Supply frequency
15.06
Input inductance
Power calculations VxIx3
15.03
Supply power
Key Input terminals Output terminals Read-write (RW) parameter Read-only (RO) parameter
0.XX
0.XX
The parameters are all shown at their default settings
27
9
9.1
9.1.1
Commissioning and operation

Regen parameter settings
Switching frequency Pr 15.08 (Pr 0.18)
Set the switching frequency on the Regen drive to the required value (3kHz default value). A higher switching frequency setting has the following advantages: Line current ripple at the switching frequency is reduced, giving improved waveform quality. Acoustic noise produced by the line inductors is reduced. Dynamic DC bus voltage response is improved.
NOTE
In some cases, setting the switching frequency to a value greater than the default 3kHz results in current derating. Refer to the Unidrive size 1 to 4 / 5 Installation Guide.
9.1.2
DC bus voltage set point
The DC bus voltage set point, see Pr 15.07 (Pr 0.17), should be set to a level that is suitable for the AC supply voltage being used. The table below defines these levels, assuming a tolerance of 10% on the supply voltage (default value is 700V). The minimum value is defined as the peak input voltage plus some headroom. Headroom is required by the drive to allow correct control of the current. It is advisable to set the voltage below the maximum value to give more allowance for transient voltage overshoots. Note that Pr 15.07 (Pr 0.17) can be set to any value between 0 and 800V. Table 9-1 DC bus voltage set point - Pr 15.07 (Pr 0.17) Minimum Vdc 650 680 780 Recommended Vdc 700 700 780 Maximum Vdc 800 800 800
Supply Voltage Vac 380 415 480
9.2
Regen drive sequencing
When a Regen drive is enabled, it goes through a line synchronisation sequence. During this procedure, test pulses are applied to the incoming line to determine the voltage and phase. When it has been successfully synchronised to the line, the DC bus voltage controller is enabled and the DC bus voltage rises to the target voltage. Only when all of these stages have been completed successfully is the motoring drive enabled. If at any time there is a fault, or the Regen drive is disabled, the motoring drive will also be disabled. This sequence of events is important to prevent damage to the Regen drive, motoring drive or external power circuit components. The sequence of events is as follows: Power applied: both contactors de-energised DC bus charges through start-up resistor DC bus voltage equals 2 Vac if DC bus voltage > UU trip level then auxiliary contactor is energised. This closes the main contactor and shorts out the start-up circuit. Enable input made active: wait for DC bus voltage to stabilise apply test pulses to line to determine magnitude and phase attempt to synchronise to the line if synchronisation is successful then enable the DC bus voltage controller DC bus voltage controller active: DC bus voltage rises to reference level Motoring drive enabled by digital output from Regen drive Motoring drive active: the motor may now be energised and rotated power flows to and from the line as necessary via Regen drive DC bus voltage remains stable Whilst running if: the line voltage dips too low OR the DC bus voltage goes out of regulation OR there is any trip on the Regen drive OR the main contactor is de-energised OR the Regen drive is disabled OR the MCB trips then: the Regen drive will inhibit the motoring drive will be disabled by the Regen drive the DC bus voltage will fall to 2 Vac
28
9.3

Regen drive commissioning
Ensure power and control connections are made as specified in this Installation Guide. Ensure the Regen and motoring drives are not enabled. Switch on the AC supply. Both the Regen and motoring drives should now power up through the start-up circuit in standard open loop mode. On the Regen drive, configure the drive type Pr 11.31 (Pr 0.48) to REGEN and set the additional parameters up for the auxiliary contactor (refer to Chapter 4 Control circuit connections on page 8). The Auxiliary and Main contactors should now close; the start-up circuit is disabled at this point. On the Regen drive, set up the switching frequency and DC bus set point voltage to the required values in either Menu 0 or Menu 15, refer to Chapter 8 Parameter descriptions on page 22. Save the parameters. The Regen drive can now be enabled, the Regen drive should display ACT. The commissioning of the motoring drive(s) can now be carried out.
9.4
Motoring drive commissioning
The setting of certain parameters in the motoring drive must be given special consideration when used in a Regen system. Ramp Mode - Pr 2.04 (Pr 0.15) When a motoring drive is used in a Regen system, the ramp mode should be set to FAST. The default setting of standard control will result in incorrect operation. Voltage Control Mode - Open loop only Pr 5.14 (Pr 0.07) The default setting of UR_I does not function correctly in the motoring drive when used in a Regen system. When the system is powered up, the motoring drive is disabled while the Regen synchronises to the AC supply. The resultant delay before the motoring drive is enabled means that the stator resistance test cannot be completed. When open loop vector operation is required the voltage mode should be set to UR_S. Drive Enable Function - Open loop only Pr 8.07 The default setting for terminal 30 in the open loop motoring drive is an external trip (Et) function. When the Regen drive has synchronised to the AC supply and the enable signal is applied to the open loop drive, a drive reset is required to clear the external trip. If a reset signal is not available or desirable, then Pr 8.09 should be set to a 1. Terminal 30 then acts as a non latching input with the drive displaying INH when disabled. AC Supply Loss Mode - Pr 6.03 The motoring drive will not operate correctly if the AC supply loss mode is set to STOP. If the AC supply is lost, the Regen drive disables the motoring drive and prevents a controlled stop from being completed. Auto Start - Pr 6.02 The Auto Start function will not operate correctly when used in a Regen system due to the delay in applying the enable signal to the motoring drive as described above in Voltage Control Mode. The delay means that the run latch has already cleared when the enable signal is applied.
9.5
Table 9-2
Trip codes
Trip codes Description Regen sinusoidal rectifier failed to synchronise to line voltage Failed to correctly detect the phasing of the supply Line frequency to low Line frequency to high Overcurrent during final synchronisation of PLL to supply Phasing error during final synchronisation of PLL to supply
Below are the trip codes which are specific to Unidrive in Regen mode. These are in addition to the trips listed in the Unidrive size 1 to 5 User Guide.
Trip Code LI.SYNC Ph Det Fr Lo Fr Hi PLL OI PLL Ph Table 9-3
Status display Description Drive Enabled but AC voltage too low, or DC bus voltage still rising, or DC bus voltage still falling. Waiting for correct conditions to synchronise onto line Drive enabled and synchronising to line Drive enabled, synchronised and active
Status Display STOP SCAN ACT
29
Appendix A
A.1
Unidrive Regen as a Brake Resistor Replacement
Introduction
The Regen drive has been designed to provide a regulated DC supply to other motoring drives. The Regen drive gives bi-directional power flow with sinusoidal currents and a near unity. In many applications, the motoring power can be significantly higher than the braking power. If sinusoidal input currents are not required, it is difficult to justify the cost of a Regen drive rated at the full motoring power. In these applications it may be desirable to take the lower cost option of a smaller Regen drive which is only used to return the braking energy to the AC supply. This is the mode of operation described in this Appendix.
NOTE
When using the Regen drive as a brake resistor replacement, the information given in earlier sections of this guide must also be referred to.
A.2
Drive configurations
Brake resistor replacement system connection
Regen Drive fusing
When a Regen drive is used as a dynamic brake resistor replacement, connections must be made as shown in Figure A-1. Figure A-1
Motoring Drive fusing
NOTE
The single RFI filter shown in the above configuration should be rated to the motoring drives rated current. The AC supply is connected to both the Regen drive and the motoring drive. Note, however, that the Regen drive receives its supply via an isolating transformer. This is necessary because when the Regen drive is switching, its DC bus voltage moves with respect to both ground and the supply neutral point. However, on the motoring drive, the DC bus voltage remains relatively fixed with respect to ground. As a result of the difference between the two voltages, it is not possible to connect both drives to the same AC supply. A DC bus diode is fitted to ensure that power flows from the motoring drive to the Regen drive only.
A.3
When to use a Regen drive as a brake resistor replacement
The important factor when considering the use of a Regen as a brake-resistor replacement is the ratio of motoring power to braking power, as this has implications for the power rating of the Regen drive. Motoring power 1.5 Braking power. If the maximum motoring and braking power are approximately equal, a Regen drive should be used as the main supply and not solely as a brakeresistor replacement. This is because, in this instance, the Regen drive and motoring drive ratings are equal, so the full advantage of a standard Regen configuration can be exploited. 1.5 Braking power < Motoring power 4 Braking power. In this range of motoring and braking power, a Regen drive will work well as a brake-resistor replacement. The Regen drive power rating is equal to the braking power. Motoring power > 4 Braking power. If the motoring power is greater than approximately four times the braking power, it is not possible to use a Regen drive rated only for its braking power. This is because the small Regen drive is unsuitable for connection to the large capacitance of the motoring drives. If the motoring power is greater than four times the braking power, then the following can be used. An over-rated Regen drive with a current rating at least equal to 0.25 x motoring drive power. Conventional brake resistor.
30
A.4
NOTE
Regen and motoring drive ratings

N
The Regen drives current limits are set at 150% and are not adjustable. In general the Regen drive must be rated at a power greater than, or equal to, the maximum braking power. Example: Two 30kW motoring drives are each driving 30kW motors. The load is such that only one drive is braking at a time. If each motor supplies between 20 and 30kW motoring, and the braking power varies from 0 to 30kW, the maximum total braking power is 30 - 20 = 10kW, which is what the Regen drive should be rated for. In drive configurations where the motoring drive power rating is several times the expected braking power, it is necessary to consider the peak braking power returned from the load. Example: The motoring drive is a 75kW Unidrive. Motoring power is 75kW. Steady state braking power is 20kW. From these figures, it may appear that a 22kW Regen drive will provide sufficient braking power. However, dynamically the peak braking power could be much greater. If the 75kW drive current limits are set at 150% for motoring and braking (default settings), the peak brake power could be: 3 156A 400V 150% = 162kW This is much greater than the 22kW Regen drive is able to return to the supply, hence a larger drive is required.
NOTE
If the Regen drive is not rated for the required braking power, then the drives will trip on DC bus over-voltage.
A.5
Power circuit connections and components
Figure A-2 shows the power connections required when using a Unidrive, operating in Regen mode as a dynamic brake resistor replacement. The Regen drive control terminals are connected as shown in Figure A-3. Table A-1 shows the key to the following system layout diagram. Table A-1 E RFI I.Tx SFFL L regx V1, V2, V3 V4, V5, V6 Rsx Fsx SFF Cx Rdx Tcx K1 K2 K3 MCB1x aux1x aux2 aux3 Ovld Key to Figure A-2 Ground connection point EMC filter Isolated transformer Switching frequency filter inductor Regen inductor Varistor network 550V (line to line) Varistor network 680V (line to ground) Softstart resistor AC supply fusing Switching frequency filter capacitor Switching frequency filter capacitor discharge resistor Thermocouple Supply contactor Main contactor Auxiliary contactor Switching frequency filter capacitor MCB Switching frequency filter MCB auxiliary through which Regen drive enable is connected Main contactor auxiliary for main contactor closed signal K3 auxiliary with coil supply for K2 Thermal, Magnetic overload
31
Figure A-2
Power connections: Single Regen

Motor
aux 2 aux 3 MCB1 Ovld FS8
32
FS9
FS7
There are three main connection differences compared with normal operation. There are AC supply connections to both the Regen and motoring drives. The DC bus connection between the Regen and motoring drives is via diode D1. The switching frequency filter inductors are replaced with an isolating transformer T1 with a defined leakage inductance
For details of the standard Regen components and their connections, refer to Chapter 3 Power connections on page 4 and Chapter 5 Components on page 10.
A.5.1
DC bus diode
DC bus diode Recovery time S <1 Current rating A 3 x current rating of Regen drive Voltage rating V 1,200
Table A-2
Diode type Fast or Ultra Fast
A suitable supplier for the above diode can be SemikronTM with the SKKD xxx F 12 or SKKE xxx F 12 diode modules. The diode must be mounted on a suitable heatsink. Heatsink sizing should be based on: Maximum device case temperature of 80C Power loss = 2V x Regen drive rated current
A.5.2
Isolating transformer T1
This is a three phase transformer which provides isolation between the AC supply and the Regen drive. One isolating transformer can only supply one Regen drive with the current rating equal to the Regen drive continuous current rating. The transformer leakage inductance forms the switching frequency filter inductance. The inductance value for the switching frequency filter is specified in Chapter 5 Components on page 10.
NOTE
A non isolating transformer cannot be used under any circumstances.
33
A.6
Control circuit connections

Control Circuit Connections.
External power supply for K2 coil External power supply for K3 coil
1
Figure A-3 shows the control connections that should be made between the Regen and motoring drive. Figure A-3
K2
aux3
K3
2 3 4 5
Relay NO 0V Analog 10V Out Analog I/P 1+ Analog I/P 1Analog I/P 2 Analog I/P 3 Analog O/P 1 Analog O/P 2 0V Analog
(Set Pr 8.25 to Pr 15.14)
Tc1
6 7 8 9 10 11
Regen Drive
21 22 23 24
Output enable
25
Drive Healthy aux2 User enable aux 1x
26 27 28 29 30 31
Drive Healthy
Relay NO
2 3 4
0V Analog 10V Out Analog I/P 1+ Analog I/P 1Analog I/P 2 Analog I/P 3 Analog O/P 1 Analog O/P 2 0V Analog
Speed/Torque Ref 4 - 20mA Current Loop
5 6 7 8 9
Motor Thermistor
10 11
Motoring Drive
21 22 23
At Zero Speed O/P Reset
24 25 26
Fwd Rev
27 28 29 30
User enable
31
34
A.7
A.7.1
Regen brake drives in operation

Sequence
If the Regen brake drive and motoring drive are supplied from a separately switched AC supply then the Regen brake drive supply should be energised first (or both at the same time). Similarly the Regen brake drive should also be powered down first (or both at the same time). The motoring drive must only be enabled when the Regen drive is enabled, healthy, and synchronised to the AC supply. This will prevent any damage to the Regen start-up circuit and prevent OU trips.
A.7.2
Regen parameter settings
It is very important that the Regen drive DC bus voltage set point is set above the peak AC supply voltage. If this is not done then power will flow from the AC supply into the motoring drive, through the DC bus diode and back through the Regen drive to the AC supply. This will continue until the Regen drive trips or part of the circuit is damaged. If possible the DC bus voltage set point should be at least 50V above the peak AC supply voltage. With a larger difference between the peak AC supply voltage and the DC bus voltage set point there is more energy storage available for transient peaks in the braking power. Table A-3 gives recommended DC bus voltage set points. Table A-3 DC bus voltage set points - Pr 15.07 (Pr 0.17) Supply Voltage Vac 380 415 480 Recommended Vdc 700 700 780 Maximum Vdc 800 800 800
35
Appendix B
B.1
L = 2 x Lf C = 3Cf / 2 Vc = VLL peak Zc = L --C
Component sizing calculations
Sizing of MCB for switching frequency filter

Lf = Switching frequency filter inductance Cf = Switching frequency filter capacitance Vc = Charging voltage Zc = Charging impedance Tc = Charging time Ic = Charging current
The current rating of the MCB must be calculated; taking into account the switching frequency filter inductance and capacitance, the initial charging current and the AC supply voltage. switching frequency filter inductance and capacitance values can be found in Chapter 5 Components on page 10.
Tc = LC Ic = Vc / Zc Example: Unidrive size 5 Regen
Switching frequency filter Inductance 100 H Switching frequency filter Capacitance 80 F Supply Voltage 480v + 10% L= C= Vc = Zc = Tc = Ic = 2 x 100H = 3 x 80F / 2 = 480 + 10% x 2 = 200 H ----------------- = 120 F 200 H 120 F = 747 / 1.29 = 200 H 120 F 747V pk 1.29 487 s 579A
The MCB should be rated to the peak charging current of 579A for 487s, with an rms current of 35A. Refer to Table 5-6 for a full list of ratings. A suitable MCB should have the following ratings and features: Voltage rating: 480 + 10% Peak current rating: 579A rms current rating: 35A 3 pole with auxiliary (for enable) Table B-1 Drive size 1 2 Power rating (kW) 4.0 5.5 7.5 11.0 15.0 18.5 3 22.0 30.0 37.0 45 55 4 75 90 110 5 150 Total DC bus capacitance (F) 340 470 470 680 1,100 1,100 2,200 2,200 2,200 3,300 3,300 4,400 6,600 6,600 8,800
36
B.2
Resistor sizing for multiple motoring systems
The softstart resistor must be recalculated for the multiple motoring system due to the increased inrush current and therefore increased power dissipation. For applications where the total DC bus capacitance of the motoring drives is greater than that of the Regen drive (one large drive supplying several smaller drives). The following procedure and tables should be used to recalculate the resistor(s) required:
B.2.1
1. 2. 3. 4.
Procedure
Calculate the total capacitor bank energy rating of the system (Table B-3). Calculate the minimum number of resistors required to meet this energy value (round up to the nearest one), (Table B-2). Calculate the series parallel arrangement of resistors to produce the total resistor value in the required range (Table B-5 and Table B-2). Calculate the total rms resistor current (Table B-4). then go back to step 3 (Table B-2).
5. Calculate the power dissipation in the resistor bank [Irms 2 x R]. If the power dissipation exceeds the rating of the resistor bank, add more resistors, Table B-2 Resistor data Resistor value 150 48 Table B-3 Capacitor bank Drive size 1 2 3 4 5 Table B-4 RMS resistor current data Drive size 1 2 3 4 5 Table B-5 Total resistor value data Drive size Total softstart resistor value W 75 to 150 28 to 150 9 to 48 3 to 24 2 to 24 RMS current A 0.4 0.4 0.5 0.6 0.6 Energy per drive J 75 200 600 1800 2500 Power rating W 53 148 Energy rating J 170 1,700 CT part number 1270-3157 1270-2483
1 2 3 4 5
Example: Unidrive size 4 Regen with (3 x Unidrive size 3) and (5 x Unidrive size 1) motoring drives 1. 2. 3. 4. 5. Capacitor bank energy = 1800 + (3 x 600) + (5 x 95) = 4075J Using resistors 1270-2483 (4,075 / 1,700) you will need at least 2.39 resistors = 3 Three 48 resistors can be arranged to achieve 16. In this case 16 is satisfactory for a Unidrive size 4, so parallel connection can be used. Total rms current needed = 0.6 + (3 x 0.5) + (5 x 0.4) = 4.1A Power loss in 16 bank (85W per resistor) = 256W, resistor bank maximum rating = 3 x 148W = 444W, so the 16 resistor arrangement is suitable.
37
B.3
Table B-6
Multiple Unidrive size 5 systems

Resistors for Unidrive size 5 multiple systems Number of parallel resistors Equal to total number of modules in the system (Regen and motoring) CT part number 1270-2483
Drive size 5
B.4
Thermal / magnetic overload protection for soft start circuit
Thermal / magnetic protection for the softstart resistor should be provided to protect against a high / low impedance short circuit and the risk of fire. A recommended device being a thermal magnetic overload. The overload should be sized as following to provide thermal and magnetic protection:
B.4.1 Thermal / magnetic overload characteristics

Figure B-1 Example of tripping characteristic
120 60 40
Thermal Trip Area
Magnetic Trip Area
20
10 6
Minutes
Tripping time
1 40
20
Cold
10
Seconds
6 4
1 0.6 0.4
Hot
0.2
0.1 0.06 0.04
0.02
0.01 1 1.5 2 3 4 5 6 8 10 10 15 14 20 21 30
Multiple of rated current
B.4.2
Sizing of magnetic overload
The magnetic overload should be selected to the peak current and charging time at power up with the trip being at for example 20 times the nominal rated current of the overload. Therefore for a 20A peak current a 1A overload could be used. The charging of a system takes a total of 5 time constants with this having a decaying exponential current due to the RC network, therefore at 5 time constants the system will have charged up with the current being at approximately zero as shown in Figure B-2 on page 39. The peak current and charge time during power up can be calculated using the following formula.
38
Peak current Unidrive 5401 x 4, 480Vac supply +10%, total softstart resistance of 6 (4 x 24 in parallel): Ipeak = Vac(+10%) x 1.414 / Resistancesoftstart (480 + 48) x 1.414 / 6 = 124.08A Ipeak Charging time Unidrive 5401 x 4, total softstart resistance of 6 (4 x 24) in parallel, and a total DC bus capacitance of 4 x 8,800F = 35,200 F Tconstant = Resistance softstart x Total CapacitanceDC bus Tconstant x 5 = Tcharge 6 x (35,200 x 10-6) x 5 = 1.056sec Selection From the above calculations for a peak charging current of 124.08A with a charge time of 1.056sec a magnetic overload with the following characteristics can be used: 8A nominal rating O/L = 15.5 Plotting the exponential charging current for the soft start circuit against the trip characteristic curve for the overload will also ensure no spurious tripping during charging time. Figure B-2 Example of charging characteristics
100
% Charging Current
75
50
25
0 0 1 2 3 4 5
Multiples of Time Constant
Calculating current level on exponential curve As shown in Figure B-2, after 5 time constants the charging current is approximately zero. In some cases, due to the characteristic of the overload, the current may have to be calculated after 4 time constants to ensure that the thermal trip area of the overload is not activated. Refer to the following formula: I at given Time Constant = Exp [-1 (Time Constants)] x Ipeak The following example calculates the current level after 3 time constants with a peak charging current of 100A: Exp [-1 (3)] x 100 = 4.97A
B.4.3
Sizing of thermal overload
The thermal overload should be sized to provide protection against a high impedance short circuit. Under this condition the current flowing would not be high enough to result in the magnetic overload tripping, but the power dissipated would exceed the nominal power rating resulting in heating of the resistor. In order to size the thermal overload correctly, the power rating and overload characteristics of the resistor are required. The power characteristic curve for the resistor should be converted from multiples of power to current in order to size the thermal overload correctly. P / R = ICalculation to convert from power to current Example: Assuming a system fault which results in a continuous power of 10 x the nominal power being dissipated by the resistor. Resistor, 24 296W Peak current at power up = 528Vac / 24 = 22A Thermal / Magnetic overload current rating = 22A / 20 = 1.1A (use 1.6A) 10 x nominal power = 2.960kW Current flowing during overload 2960 / 24 = 11.01A
39
From Figure B-3 it can be seen that an overload of 10 times the nominal power is allowable for 5 seconds. From this plotting the 10 times overload on Figure B-1 it can be seen that for a current of 11.10A when using a 1.6A breaker that the overload will trip at 7 x the nominal current (11.10/1.6 = 6.9), which equates to approximately 5 seconds trip level worst case. Figure B-3 Example of overload characteristic
100
% Multiples of rated Power
10
1 0 1 2 5 10 20 25 50 100
Duration of Load (seconds)
40
Appendix C
C.1
Long cables
Exceeding the maximum cable length
If the total maximum length specified is exceeded, the increased circulating currents caused by the extra cable capacitance will have an effect on the other parts of the system. This will necessitate additional components to be added to the standard arrangement.
C.1.1
Regen inductor
If the maximum cable length specified is exceeded this will introduce unnecessary heating of the Regen Inductor. To overcome the additional heating forced cooling should be introduced into the system as specified in the following table. The forced cooling should be positioned to provide the specified airflow directly onto the Regen inductor windings. Table C-1 Maximum cable length Drive size without additional ventilation m 50 100 200 200 200 per Regen drive with additional cooling m 250 500 1,000 1,000 1,000 per Regen drive Cooling requirement
1 2 3 4 5
One 120mm fan, air flow > 160m3 / hr. One 120mm fan, air flow > 160m3 / hr. One 120mm fan, air flow > 160m3 / hr. Two 120mm fans, air flow > 160m3 / hr., per fan Two 120mm fans, air flow > 160m3 / hr., per fan
C.1.2
RFI filter
When an RFI filter is used the capacitors to ground carry common mode current. When the maximum cable length without additional ventilation specified is exceeded, extra circulating currents can result in heating and saturation of the RFI filter. To prevent this, some capacitance line to ground should be provided as an additional path for this current, as shown in Figure C-1.
NOTE
N
Unidrive Regen layout
If the maximum cable length exceeds the maximum cable length with additional cooling, Control Techniques Technical Support must be consulted. Figure C-1
RFI SFFL Regen Inductor
R 3 Phase Supply FS1 Y FS2 B FS3 V4 V5

E E E E E
V1 V2
V3
To Regen Drive
V6
RFI Filter
Line to ground capacitors
Switching Frequency Filter
C.1.3
Line to ground capacitors for multi-drive systems
Selection of line to ground capacitors for Regen systems with long cables. In order to select the appropriate capacitors, the rms value of the current line to ground, the AC supply voltage and minimum capacitance values are required. A minimum capacitance value of 1F per phase should be used with the final capacitance value being determined by the value of the current line to ground. In practice, to carry the required level of current the capacitor will generally have a higher capacitive value. The current rating of the capacitors should be at a high frequency such as 100kHz at the relevant supply voltage. Polypropylene type capacitors are the most suitable because of their low loss at high frequency.
41
The rms value of the current can be estimated from the following formula: IRMS = 2.8 10 kV DC Where: k is 1 for simple rectifier-input systems, 2 for Regen systems VDC is DC bus voltage lf s is the sum of the products of motor cable lengths and switching frequencies of all drives in the system, including in the case of regenerative systems the Regen drive with the total DC cable length l is total cable length in metres f s is switching frequency in kHz If all drives operate at 3kHz, the expression can be simplified to: IRMS = 4.85 x 10-4kVDC l Example A Regen system operating with a supply of 400Vac giving a DC bus voltage of 620V at 3kHz switching frequency and a cable length of 1km (motors + DC) has an IRMS of: IRMS = 4.85 x 10-4kVDC l IRMS = 4.85 x 10-4 x 2 x 620 x 1,000 IRMS= 13.4A The IRMS is the total current line to ground, therefore each capacitor will have to carry 4.5A.
4
lfs
Ground leakage current The value of capacitance required means that the ground leakage current exceeds the usual safety limit of 3.5mA. The user should be aware of the high leakage current. A permanent fixed ground connection must be provided to the system.
WARNING
Discharge time Resistors must be fitted in parallel with the capacitors to ensure that they discharge when the supply is removed. The resistor values should be chosen so that the discharge time is no longer than for the drive itself. Typically values of about 5M are suitable, and are high enough not to cause the system to fail a simple insulation test.
WARNING
42
Appendix D
D.1
Regen kits
Single Regen, single motoring systems
Standard kits of Regen components for Unidrive Regen systems which consist of a single Regen drive and a single motoring drive. Refer to Table D1 for details. Table D-1 Drive size 1 2 3 4 5 Standard kits CT kit part number 80700000009400 80700000009500 80700000009600 80700000009700 80700000009800 9500-0023 kit bag Varistors Content of kit SS Resistor 1270-3157 x 1 1270-3157 x 1 1270-2483 x 1 1270-2483 x 2 1270-2483 x 2 SFF Cap 1610-5752 x 1 1665-2244 x 1 1665-2484 x 1 1665-2804 x 1 Soft Start O/L 4133-0117 4133-0217 4133-0277
Regen inductors and switching frequency filter inductors are also available but must be ordered separately. Refer to Table D-2 for details. Table D-2 Standard kits Drive kW 1405 2401 2402 2403 3401 3402 3403 3404 3405 4401 4402 4403 4404 4405 5401 5402 5403 5404 Regen inductor 4401 - 0001 4401 - 0002 4401 - 0003 4401 - 0004 4401 - 0005 4401 - 0006 4401 - 0007 4401 - 0008 4401 - 0009 4401 - 0010 4401 - 0011 4401 - 0012 4401 - 0013 4401 - 0014 4401-0015 x 1 4401-0015 x 2 4401-0015 x 3 4401-0015 x 4 Switching frequency filter inductor 4401-0162 4401-0163 4401-0164 4401-0165 4401-0166 4401-0167 4401-0168 4401-0169 4401-0170 4401-0171 4401-0172 4401-0173 4401-0174 4401-0175 4401-0176 4401-0177 4401-0178 4401-0179
D.2
Single Regen, multiple motoring and multiple Regen, multiple motoring systems
Standard kits of parts are not available for non standard systems. All of the items used in a standard system are still required, however, some components may need resizing. Refer to Appendix B Component sizing calculations on page 36 for details. For non standard systems, components should be ordered independently.
43
Appendix E
Table E-1 Model UNI 1405 UNI 2401 UNI 2402 UNI 2403 UNI 3401 UNI 3402 UNI 3403 UNI 3404 UNI 3405 UNI 4401 UNI 4402 UNI 4403 UNI 4404 UNI 4405 UNI 5401 Table E-2 Model UNI 1405 UNI 2401 UNI 2402 UNI 2403 UNI 3401 UNI 3402 UNI 3403 UNI 3404 UNI 3405 UNI 4401 UNI 4402 UNI 4403 UNI 4404 UNI 4405 UNI 5401 Rating 4kW 5.5kW 7.5kW 11kW 15kW 18.5kW 22kW 30kW 37kW 45kW 55kW 75kW 90kW 110kW
Unidrive Regen specifications

Maximum permissible continuous output current 3kHz 4.5kHz 9.5A 12A 16A 25A 40A 46A 60A 70A 96A 124A 156A 180A 202A 300A 104A 124A 175A 175A 47A 56A 21.7A 34A 37A 40A 40A 46A 88A 88A 105A 145A 145A 18.2A 14.2A 14.2A 28A 28A 32A 32A 35A 70A 70A 80A 110A 110A 120% 6kHz 8.5A 9kHz 7A 12kHz 5.5A 11.7A 11.7A 11.7A 23A 23A 26.6A 26.7A 28A 150% Maximum overload time 60sec
Drive ratings in 40C ambient
Drive ratings in 50C ambient Rating 4kW 5.5kW 7.5kW 11kW 15kW 18.5kW 22kW 30kW 37kW 45kW 55kW 75kW 90kW 110kW 40A 44A 44A 50A 95A 105A 135A 180A 190A 240A* 20A 34A 34A 36A 36A 41A 85A 85A 105A 150A 150A 16A 17.3A Maximum permissible continuous output current 3kHz 6.9A 4.5kHz 5.9A 12A 14.7A 14.7A 28A 28A 31A 31A 34A 75A 75A 85A 125A 125A 6kHz 5.1A 9kHz 4.0A 11.6A 11.6A 11.6A 21A 21A 24A 24A 26A 60A 60A 65A 95A 95A 150% 12kHz 3.3A 9.7A 9.7A 9.7A 17.9A 17.9A 20.6A 20.9A 23A 150% Maximum overload time 60sec
*No UL approval for Unidrive size 5 with 240A continuous in a 50C ambient.
44
Appendix F
Physical dimensions
The dimensions listed are for the following items, all of which are required to complete a Regen system. Note that the dimensions given apply only to the parts specified in this guide. Regen inductor Soft start resistor Switching frequency filter capacitor Switching frequency filter inductor RFI filter (Refer to the Unidrive Size 1 to 5 User Guide) Varistors
F.1
Drive rating (kW) 4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 160
Regen inductor
WT Kg 12 14 17 24 32 33 39 55 65 75 95 110 120 130 140 CT part number 4401-0001 4401-0002 4401-0003 4401-0004 4401-0005 4401-0006 4401-0007 4401-0008 4401-0009 4401-0010 4401-0011 4401-0012 4401-0013 4401-0014 4401-0015 Type number 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3
Table F-1 Specifications Amps 9.5 12 16 25 34 40 46 60 70 96 124 156 180 220 300 mH 6.32 5.00 3.75 2.40 1.76 1.50 1.30 1.00 0.78 0.63 0.48 0.38 0.33 0.30 0.24 L 200 200 240 240 320 320 320 360 360 360 360 410 410 480 480 D 180 180 180 180 220 220 220 260 260 280 280 300 300 320 320 H 215 215 270 270 325 325 325 370 370 370 370 430 430 490 490
Figure F-1 Type 1 dimensions

APPX WEIGHT: 12kg
SKOT TRANSFORMER LTD. COPYRIGHT
6 way terminal block for lead termination. (mk6)
PROJECTION
2 way terminal block for thermister termination (mk3)
205
4 OFF 9 FIXING HOLE
20
120 fixing centres

L 200
140 fixing centres 180 D
45
Figure F-2
Type 2 dimensions
PROJECTION
11 HOLE
SKOT TRANSFO RME R LTD. COPYRIGHT
A1
B1
C1
A2
B2
C2
4 OFF 11 FIXING HOLE
Figure F-3
Type 3 dimensions
C L
160
160
SKOT TRANSFORMER LT COPYRIGHT
A1
B1
C1
11 HOLE
A2
B2
C2
4 OFF HOLES
46
F.2
Softstart resistor - type TG series

Dimensions
Figure F-4
A
Table F-2 Specifications Drive size 1&2 3 4&5 Resistance 150 48 x 1 48 x 2 Diameter (A) mm 19.1 22.2 22.2
Length (B) mm 73 165.1 165.1
CT part number 1270-3157 1270-2483 1270-2483
Figure F-5
Resistor mounting bracket dimensions
Table F-3 Resistor mounting bracket dimensions Mounting bracket dimensions A 24.0mm B 33.5mm C 21.45mm 0.2 D 5.0
47
F.3
F.3.1
Switching frequency filter capacitors

3-phase capacitors (size 1 and 2)
Dimensions
Figure F-6
Before protection device operation

Max 16 11.8 0.5
After protection device operation
L +2-0
Marking
16 1mm M8 to = 53mm Fast-on terminal (6.35mm)
Internal connection
D
Table F-4 Specifications CN Drive size (F) 1&2 3 x 5.7 (mm) 53 x 116 (kgs) 0.3 M8 Stud 1610-5752 xL Weight Mounting CT part number
48
F.3.2
3-phase capacitors (size 3 to 5)

Dimensions
Marking
Figure F-7
h +40
h 16 +1 M12 Torque T = 10 Nm Impregnating Hole Torque T = 1.2 Nm d 19.6 0.5
5 0.5
16.8 0.5
22 18 SW 17
Table F-5 Specifications Drive size 3 4 5 CN (F) 3 x 24 3 x 48 3 x 80 dxh (mm) 121 x 164 121 x 164 142 x 200 Weight (kgs) 1.1 1.5 2.2 Mounting M12 Stud M12 Stud M12 Stud CT part number 1665-2244 1665-2484 1665-2804
49
F.3.3
Discharge resistors
Discharge resistors for the switching frequency filter capacitors, for Unidrive size 3, 4 and 5, are supplied with the capacitor. These should be fitted during installation as shown in Figure F-8. For Unidrive size 1 and 2 the discharge resistors are fitted internally to the capacitor. Figure F-8 Discharge resistor arrangement
Table F-6 Specifications Drive size 1&2 3 4 5 Capacitor value 5.7 F 24F 48F 80F Resistor value Internal 3 x 390k 3 x 390k 3 x 270k
50
F.4
Switching frequency filter inductor

Drive size UNI 1405 UNI 2401 UNI 2402 UNI 2403 UNI 3401 UNI 3402 UNI 3403 UNI 3404 UNI 3405 UNI 4401 UNI 4402 UNI 4403 UNI 4404 UNI 4405 UNI 5401 UNI 5402 UNI 5403 UNI 5404 Amps 9.5 12 16 25 34 40 46 60 70 96 124 156 180 220 300 600 900 1200 mH 3.160 2.500 1.875 1.200 0.880 0.750 0.650 0.500 0.390 0.315 0.240 0.190 0.165 0.135 0.100 0.050 0.034 0.025 Losses W 28 35 37 40 52 60 60 80 90 100 110 130 170 180 220 400 530 700 L 150 150 180 180 180 180 180 240 240 240 240 300 300 300 300 410 480 480 D 90 90 100 150 160 160 160 160 170 180 190 180 180 190 200 300 320 320 H 150 150 190 190 190 190 190 255 255 255 255 300 300 300 300 430 500 560 Weight Kg 4 4 6 10 12 12 13 16 20 22 25 37 37 49 50 110 140 170 C.T part number 4401-0162 4401-0163 4401-0164 4401-0165 4401-0166 4401-0167 4401-0168 4401-0169 4401-0170 4401-0171 4401-0172 4401-0173 4401-0174 4401-0175 4401-0176 4401-0177 4401-0178 4401-0179 Type number 1 1 1 2 2 2 2 2 2 2 2 3 3 3 3 4 4 4
Table F-7 Specifications
Figure F-9
Switching frequency filter inductor (Type 1)
150
128
4 OFF SL 8mm WID
L 120
150
D 74
90
Figure F-10

9 HOLE
SK
APPX WEIGHT: 25kg
255
4 off sl 10mm
L
200
100 D 130
51
Figure F-11

100 100
200
A1
300
B1
C1
A2
B2
C2
4 OFF S 10mm W
204
L
300
133
D 163
Figure F-12

160 160
500
560(REF)
4 OFF 14 HOLES IN EACH FLAG
4 OFF 11 FIXING HOLE
320 fixing centres 240 fixing centres 480
280
52
F.5
Varistors
Dimensions
1 Nom 21 max 60 max Coat line 8 dia. hole 34 max
6.3 5
Figure F-13
25
8m in
Table F-8 Specification Drive size 1 to 5 1 to 5 Voltage Vac 550 680 Energy J 400 450 CT part number 2482-1501 2482-0680
13
1.6
53
Index
A
AC supply loss mode .............................................................. 29 Advantages ............................................................................... 2 Analog I/O set-up ...................................................................... 8 Auto start ................................................................................. 29 Maximum cable length - exceeding .........................................41 MCB sizing .............................................................................. 36 MCBs ...................................................................................... 11 Menu 15 - Sinusoidal rectifier ..................................................22 Motor connection ..................................................................... 18 Multiple Regen ..........................................................................6
B
Brake resistor replacement ..................................................... 30
O
Operation ................................................................................28 Overload ..................................................................................11
C
Cable length - maximum ......................................................... 18 Cable length restrictions ......................................................... 17 Cable lengths .......................................................................... 18 Charging characteristics ......................................................... 39 Commissioning .................................................................28 , 29 Component sizing ................................................................... 36 Configurations ......................................................................... 30 Configurations - non standard ................................................... 7 Contactors ............................................................................... 11 Control circuit connections ........................................................ 8 Control connections ............................................................9, 34
P
Parameter descriptions ........................................................... 22 Phase loss ...............................................................................24 Power connections .................................................................... 4 Principles of Regen operation ................................................... 1
R
Ramp mode .............................................................................29 Ratings - 40C ......................................................................... 44 Ratings - 50C ......................................................................... 44 Regen inductor specifications ................................................. 45 Resistor sizing ......................................................................... 37 RFI filter ..................................................................7, 13, 20, 41 RFI filter - Multi-drive ...............................................................21
D
DC bus diode .......................................................................... 33 DC bus voltage set point ............................................ 23, 28 , 35 Digital I/O set-up ....................................................................... 8 Dimensions ............................................................................. 45 Discharge resistors ................................................................. 50 Discharge time ........................................................................ 42 Drive enable function .............................................................. 29
S
Sequencing - Regen drive .......................................................28 Single Regen ...................................................................... 5, 32 Sizing of a Regen system .........................................................3 Softstart resistor ............................................................... 11, 47 Specifications .......................................................................... 44 Standard kits ...........................................................................43 Supply assessment ...................................................................7 Switching frequency filter ................................................... 7, 12 Switching frequency filter capacitors ....................................... 48 Switching frequency filter inductor .......................................... 51 Synchronisation status ............................................................25 Systems losses ....................................................................... 16
E
EMC information ..................................................................... 19
F
Fitting of varistors .................................................................... 13 Fusing ..................................................................................... 14 Fusing - Multiple systems ....................................................... 14 Fusing - Size 5 Regen system ................................................ 15 Fusing - Standard systems ..................................................... 14
T
Thermal overload ....................................................................38 Thermal overload sizing ..........................................................39 Trip codes ...............................................................................29
G
Ground leakage current .......................................................... 42
I
Important considerations ......................................................... 16 Inductor thermistors .................................................................. 9 Inductors ................................................................................. 10 Isolating transformer ............................................................... 33
V
Varistors ........................................................................... 13, 53 Ventilation ...............................................................................16 Voltage control mode ..............................................................29
K
Kits .......................................................................................... 43
W
Wiring guidelines ..................................................................... 21
L
Line to ground capacitors ........................................................ 41 Logic diagram ......................................................................... 27 Long cables ............................................................................. 41
M
Magnetic overload ................................................................... 38 Magnetic overload sizing ........................................................ 38
54

Control Techniques UNIDRIVE

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Part Number: 0460-0026-02 Issue Number: 2

Drive software version

October 2002 Control Techniques Drives Limited

Sizing of a Regen system .............................................................................................3 Power connections........................................................................................................4

Control circuit connections ..........................................................................................8

Unidrive Regen EMC information...............................................................................19

Commissioning and operation ...................................................................................28

Unidrive Regen Installation Issue Number: 2

Appendix A Unidrive Regen as a Brake Resistor Replacement ............................................. 30

Appendix B Component sizing calculations ............................................................................ 36

Appendix C Long cables ............................................................................................................ 41 Appendix D Regen kits ............................................................................................................... 43

Appendix E Unidrive Regen specifications ............................................................................. 44 Appendix F Physical dimensions ............................................................................................. 45

Unidrive Regen Installation Guide Issue Number: 2

Power flow from supply

Power flow back to supply

Unidrive Regen Installation Guide Issue Number: 2

Advantages of Unidrive operating in Regen mode

Unidrive Regen Installation Guide Issue Number: 2

Sizing of a Regen system

The motoring drive can supply power

The motoring drive max. power is

Unidrive Regen Installation Guide Issue Number: 2

Overall system layout

Unidrive Regen Installation Guide Issue Number: 2

Standard single Regen, single/multiple motoring system

Figure 3-1 Power connections: Single Regen

Unidrive Regen Installation Guide Issue Number: 2

Standard multiple Regen, multiple motoring system

Unidrive Size 5 Regen Drive 1

Unidrive Size 5 Regen Drive 1

Unidrive Regen Installation Guide Issue Number: 2

Non standard configurations

Switching frequency filter

Unidrive Regen Installation Guide Issue Number: 2

Control circuit connections

Unidrive Regen Installation Guide Issue Number: 2

Regen inductor thermistors

(Set Pr 8.25 to Pr 15.14)

Drive Healthy aux2 User enable aux 1x

Speed/Torque Ref 4 - 20mA Current Loop

At Zero Speed O/P Reset

Unidrive Regen Installation Guide Issue Number: 2

The following parts are required to assemble a Unidrive Regen system:

4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 160

Unidrive Regen Installation Guide Issue Number: 2

Drive size 1&2 3 4&5

Contactors, MCBs and overload

Contactors and MCBs are required as follows:

Unidrive Regen Installation Guide Issue Number: 2

Switching frequency filter

X = number of size 5 drives

Unidrive Regen Installation Guide Issue Number: 2

Configuration Line to line Line to ground

Switching Frequency Filter

B 550Vac varistors 680Vac varistors E

Unidrive Regen Installation Guide Issue Number: 2

Multiple size 1 to 4 motoring drives

+DC AC Supply Fusing -DC

Main Contactor Additional Circuitry