Altivar 61
Contents
1. ATV61HC16N4 Front view View from above 80 3 13 56 2 19 58 2 28 D ST La N x I 1 Z si M12 so MM fi q a n o GER Y Uh PO PA PC gt Fan terminals 1 plana View from below SPEC LI q I D E O O O sa al a N sl sai T daag eea T ee 8 epa 5 Vo voy Y Y A N 3 18 0 71 E lum vr2 wrs 43 1 68 __ 75 2 94 80 3 13 75 2 94 R L1 S L2 T L3 PA PB RI L 257 10 07 n 38 1 49 Maximum terminal wire size tightening torque Drive terminals L1 R L2 S L3 T U T1 V T2 W T3 PC PO PA PA PB RO SO TO 1 2 x 120 mm 24 Nm 2x 120 mm2 41 Nm 120 mm 24 Nm 5 5 mm 1 4 Nm 2 x 250 MCM 212 bin 2 x 250 MCM 360 lb in 250 MCM 212 Ib in AWG 10 12 Ib in 1 Power supply for the fans compulsory if the drive is only powered by the DC bus Do not use i2. View from above L S O Ig y Ke LL LI D M12 db db Ab PO PAM PC View from below Z Fan terminals 1 a an na l o He ei oe E y Ji lei le rt Edir OJ JO fo faite mo o As 3 M10 8 3 1 S 8 S SI DI M10 JE 5 E 11040 2 ry E yy ris ln N mn 2000 38 1 49 dE ER 55 5 2 17 60 2 35 O R L1 S L2 T L3 PA PB D r ra 217 8 50 pt La Maximum terminal wire size tightening torque Drive terminals L1 R L2 S L3 T U T1 V T2 W T3 PC PO PA PA PB RO SO TO 1 2 x 100 mm 24Nm 2 x 150 mm 41 Nm 60 mm 12 Nm 5 5 mm 1 4 Nm 2 x 250 MCM 212 lb in 2 x 250 MCM 360 Ib in 250 MCM 106 bin AWG 10 12 lb in 1 Power supply for the fans compulsory if the drive is only powered by the DC bus Do not use if the drive is powered with a 3 phase supply by L1 R L2 S L3 T 28 Power terminals
3. ATV61H C40N4 Normal Le IT system filter connected MK filter disconnected o Ges CAUTION When the filters are disconnected the drive switching frequency must not exceed 4 kHz Refer to the programming manual for the corresponding parameter setting Failure to follow this instruction can result in equipment damage 59 Operation on an IT system ATV61H C50N4 Le IT system YX filter disconnected Normal filter connected Ol loro O o o o o o o ef ie oe o o ATV61H C63N4 E KIT system a filter disconnected filter connected
4. Terminals RO SO TO Modification for fans powered externally by RO SO TO 55 Connection diagrams ATV61H C40N4 C50N4 HG 5 LI T OD Bs SS OD a d lt 5 8 Ke gt Y 0 o o 2 x Pi ws e S x CI o a S DO a XE OOC ke E Factory wiring fans powered internally by R L1 S L2 T L3 Terminals RO SO TO i Terminals RO SO TO Modification for fans powered externally by RO SO TO 56 Connection diagrams ATV61H C63N4 RO SO TO Terminals Ecg LX yndu LX
5. CAUTION When the filters are disconnected the drive switching frequency must not exceed 4 kHz Refer to the programming manual for the corresponding parameter setting Failure to follow this instruction can result in equipment damage 60 Electromagnetic compatibility wiring Electromagnetic compatibility Principle Grounds between drive motor and cable shielding must have high frequency equipotentiality Use of shielded cables with shielding connected to ground at both ends for the motor cables braking resistor if used and control signal wiring Metal ducting or conduit can be used for part of the shielding length provided that there is no break in continuity Ensure maximum separation between the power supply cable line supply and the motor cable Installation diagram ATV61H D55M3X to D90M3X and ATV61H D90N4 to C63N4 W I 1 Altivar 61 1 e 2 Sheet steel earthed plate 3 Metal clamps e 2 4 Shielded cable for motor connection with shielding connected to e ground at both ends The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes ee ef eos 3 E 5 Shielded cable for connecting
6. a i 670 26 37 x 1 eda esa T pd E O o o e 1 4 O SE 8x01 e ls e Le 377 mm 392 mm G al 540 mm 21 26 in 14 77 in 15 43 in E 102 5 mm 27 5 mm 4 03 in 1 08 in ATV61H a b G H K K1 K2 For weight mm mm mm mm mm mm mm mm screws kg in in in in in in in in Ib D55M3X D90N4 60 320 920 250 650 150 75 30 11 5 M10 132 D75M3X C11N4 12 60 36 22 9 84 2559 5 91 2 95 1 18 0 45 CR 163 C13N4 D90M3X 360 1022 298 758 150 72 30 11 5 M10 80 14 17 40 23 11 73 29 84 5 91 2 83 1 18 0 45 176 C16N4 340 1190 285 920 150 75 30 11 5 M10 110 13 39 46 62 11 22 36 22 5 91 2 95 1 18 0 45 242 C22N4 440 1190 350 920 150 75 30 11 5 M10 140 17 32 46 62 13 78 36 22 5 91 2 95 1 18 0 45 309 C25N4 140 595 1190 540 920 150 75 30 11 5 M10 309 C31N4 23 43 46 62 21 26 36 22 5 91 2 95 1 18 0 45 215 474 With O or 1 option card 1 2 option cards 1 ATV61H C40N4 to C50N4 ATV61H C63N4 a a e J J Ja A Ji J Ji E TT R TT ii e DS a I I x II A TIE ee ZI L ho L AS A a 2 S 139 14x els E i 377 mm 392 mm i G qd G Al G sli G BI 14 77 in 15 43 in ATV61H a b G J Ji H K K
7. strip I 79 Aa DI o o oo Ho lO o o Ollo 0 0 o O LE E LE E E i PO 1 PA PO 2 Example 2 ATV61HC22N4 C31N4 Example 4 ATV61HC50N4 C63N4 D KA li d Grounding strip Derating as a function of the temperature and switching frequency Derating curves for the drive current In as a function of the temperature and switching frequency ATV61HD55M3X HD75M3X HD90M3X Ye 120 In 100 90 80 70 60 40 C 104 F 50 C 122 F 60 C 140 F ew ev Switching frequency 50 40 2 5 kHz 30 t 4 kHz ATV61HC11N4 120 106 In 100 88 80 40 C 104 F ol s1 L 50 C 122 F 40 60 C 140 F 20 0 kHz EU Switching frequency 2 5 kHz 4 kHz ATV61HC16N4 Ye 120 104 In 100 92 RI 40 C 104 F 50 C 122 F 60 60 C 140 F 40 20 6 kHz out Switching frequency 2 5 kHz 4 kHz ATV61HD90N4 120 110 In 100 80 67 60 40 20 0 2 5 kHz 4 kHz 6 kH
8. 20 2 5kHz 4kHz 6 kHz 8 kHz Switching frequency ATV61HC50N4 Yo 120 1041 In 100 93 80 78 40 C 104 F 60 50 C 122 F 60 C 140 F 40 20 25kHz 4kHz 6 kHz 8 kHz Switching frequency For intermediate temperatures e g 55 C 131 F interpolate between 2 curves 15 Mounting in a wall mounted or floor standing enclosure Install the drive vertically at 10 Do not place it close to heating elements Figure 1 Td ATV61 En Cooling duct for power components IP54 protection ATV61 Kit for IP31 or UL Type 1 conformity Mounting with the heatsink inside the enclosure The power dissipated by the drive power components is given in the table below Dissipated power These levels of power dissipation are given for operation at nominal load and for a switching frequency of 2 5 Hz ATV61H Dissipated power ATV61H Dissipated power W W D55M3X 1715 C22N4 5482 D75M3X 2233 C25N4 6379 D90M3X 2694 C31N4 7867 D90N4 2403 C40N4 9598 C11N4 3056 C50N4 12055 C13N4 3583 C63N4 15007 C16N4 4036 The drive has a fan for cooling the power components The air is circulated from the bottom to the top of the unit via a duct the duct is shown shaded gray on the diagram opposite This duct is isolated from the control section by IP54 protecti
9. 48 Connection diagrams Control connection diagrams Control card connection diagram Reference potentiometer Logic input switch SW1 The logic input switch SW1 is used to adapt the operation of the logic inputs to the technology of the programmable controller outputs Setthe switch to Source factory setting if using PLC outputs with PNP transistors e Set the switch to Sink Int or Sink Ext if using PLC outputs with NPN transistors e SWI switch set to Source position e SWI1 switch set to Source position and use of an external power supply for the Lis Source ATV61Heeeee Source swi swi nt Sink Ext i Int Sink i Ext susa I Il Ext e SWI switch set to Sink Int position e SWI switch set to Sink Ext position aa He ie n q IST rm 4 Ss Source ATV61Heeeee Source ATV61Heeeee Sink m E si Sink Int 1 Ext A WARNING Unintended Equipment Operation When the SW1 switch is set to Sink Int or Sink Ext the common must never be connected to ground or the protective ground as there is then a risk of unintended equipment operation on the first insulation fault Failure to follow this instruction can result in death or serious injury 49 Connection diagrams Bipolar speed reference Dc TR ATV61Heeeee I I l E lt lt 8 10 V source Speed reference using a
10. Bunued YX H bunueg YX Modification for fans Factory wiring fans powered internally by R L1 S L2 T L3 powered externally by RO S0 TO 57 Operation on an IT system IT system Isolated or impedance grounded neutral Use a permanent insulation monitor compatible with non linear loads such as a Merlin Gerin type XM200 or equivalent Altivar 61 drives feature built in RFI filters These filters can be isolated from ground for operation on an IT system as follows Disconnection of RFI filters ATV61H D55M3X to D90M3X and ATV61H D90N4 to C13N4 Normal filter connected IT system filter disconnected ATV61H C16N4 to C22N4 Normal IT system filter connected x filter disconnected CAUTION When the filters are disconnected the drive switching frequency must not exceed 4 kHz Refer to the programming manual for the corresponding parameter setting Failure to follow this instruction can result in equipment damage 58 Operation on an IT system ATV61H C25N4 to C31N4 Normal Le IT system filter connected E filter disconnected
11. There is a special slot on the drive for adding an encoder interface card E First remove the empty option card support if present as indicated on the previous page so you can access the slot for the encoder feedback card e If an I O or communication option card or a Controller Inside programmable card has already been installed remove it so you can access the slot for the encoder feedback card After mounting the encoder interface card replace the empty card support or any option cards Installing an I O extension card a communication card a Controller Inside programmable card or a multi pump card O Position the option card on the clasps O Pivot the card until it clicks into place Replace the control front panel on the option card same procedure as for installing the option card see 1 and 2 23 Wiring recommendations Power The drive must be connected to the protective ground To comply with current regulations concerning high leakage currents above 3 5 mA use at least a 10 mm AWG 6 protective conductor or 2 protective conductors with the same cross section as the power supply conductors A DANGER HAZARDOUS VOLTAGE Ground equipment using the provided ground connecting point as shown in the figure below The drive panel must be properly grounded before power is applied Failure to follow these instructions will res
12. 11 73 29 84 0 47 0 45 176 C16N4D 330 950 285 920 15 11 5 M10 110 12 99 37 4 11 22 36 22 0 59 0 45 242 C22N4D 430 950 350 920 15 11 5 M10 140 16 33 37 4 13 78 36 22 0 59 0 45 309 C25N4D 140 585 950 540 920 15 11 5 309 C3iN4D 23 03 37 4 21 26 36 22 0 59 0 45 MO ag 474 With O or 1 option card 1 2 option cards 1 ATV61H C40N4D to C50N4D ATV61H C63N4D Ka o O y o 377 mm 392 mm 14 84 in 15 43 in ATV61H a b G H F For weight mm mm mm mm mm mm screws kg Ib in in in in in in C40N4D 225 880 1150 417 5 1120 415 11 5 M10 496 C50N4D 35 65 54 72 16 44 44 09 16 34 0 45 300 661 C63N4D 1110 1150 532 5 1120 532 5 11 5 M10 300 43 49 54 72 20 96 44 09 20 0 45 661 1 For the addition of I O extension cards communication cards the multi pump card or the Controller Inside programmable card 11 Installing the DC choke This should be performed after mounting the drive and before wiring it If a VW3 A7 101 braking module is being used install the module on the drive before mounting the DC choke During installation ensure that no liquid dust or conductive objects fall into the drive Example of installing DC chokes on an ATV61HC22N4 Mountthe DC choke chassis O on the wall on top of the drive Ensure that the chassis is tightly secured to the drive to maintain the IP54 seal of the ventilation
13. C11N4 View from above 320 12 54 PO PA View from below Front view 70 2 74 60 2 35 La Si pa da Ad Al Jel O CS SS o A A 3 y CEA O JO a s MMMM g Oe ao as sao eg Le _ RD Sn T TO p Oli nl UM V T2 W T3 pere E pa u82 125 BIL S L2 LE PA PB 105 4 11 I SE Maximum terminal wire size tightening torque Drive terminals L1 R L2 S L3 T U T1 V T2 W T3 PC PO PA PA PB 2 x 100 mm2 41Nm 60 mm 12 Nm 2 x 100 mm2 24 Nm 2 x 250 MCM 212 bin 2 x 250 MCM 360 lb in 250 MCM 106 Ib in 27 Power terminals ATV61H D90M3X C13N4 Front view 149 5 84 67 2 62 5 0 2 E
14. T3 R L1 1 S L2 1 7134 R L1 2 S L2 2 T L3 2 D a d Lo win 36 141 7 i i N d o o o o o al o o o 7 illo ole ote ollo o ette o o o e 4 IR l J T D og o_o o_o o_o 4 n T eLo l ei l AO o o o o Bal 58 d 433 433 2 23 GC 17 05 SS 17 05 200 50 96 96 241 96 96 7 73 8 76 3 76 T 9 44 Te 8 76 138 50 272 L 297 q 6 4 CM 10 65 10 65 36 Power terminals ATV61HC63N4 View from above 313 50 12 34 BU PO 1 BU PA PC PO 2 View from below um mist sus 131 wm R2 st22 32 WTS Maximum terminal wire size tightening torque Drive terminals R L1 1 R L1 2 S L2 1 U T1 V T2 W T3 PC PA RO SO TO 1 S L2 2 T L3 1 T L3 2 4 x 185 mm 41 Nm 6 x 185 mm 41 Nm 8 x 185 mm 41 Nm 5 5 mm 1 4 Nm 3 x 500 MCM 360 Ib in 5 x 500 MCM 360 Ib in 5 x 500 MCM 360 Ib in AWG 10 12 Ib in 1 Power supply for the fans compulsory if the drive is only powered by the DC bus Do not use if the drive is powered with a 3 phase supply by L1 R L2 S L3 T 37 Control terminals Access to the control terminals To access the control terminals open the cover on the control front panel To make it easier to wire the drive control section the control terminal card can be removed Undo the screw until the spring is fu
15. above table Figure 2 It is advisable to use a kit for IP31 UL Type 1 conformity to be ordered as an option for attaching the power cables The design of the IP31 kit is based on the same principle as the DC choke and has an IP54 duct to help guide the incoming air Note If the air in the power circuit is totally evacuated to the outside very little power is dissipated inside the enclosure In this case use the dissipated power table for dust and damp proof flange mounting see the next page Connect all the additional metal parts to ground Mounting in a wall mounted or floor standing enclosure ATV61 Mounting the heatsink inside the enclosure continued IP54 mounting standard operating conditions The drive must be mounted in an IP54 enclosure in certain environmental conditions dust corrosive gases high humidity with risk of condensation and dripping water splashing liquid etc The simplest way of obtaining an enclosure with IP54 protection is to follow the mounting recommendations for IP23 protection with the following 5 additional points 1 Do not make an air outlet hole for the control section Do not make an air inlet hole in the enclosure door In the power section the air will enter through the bottom of the enclosure via a plinth added for this purpose 2 Add the IP31 or UL Type 1 conformity kit in accordance with the mounting instruction
16. duct Then install the DC choke 2 on the chassis 1 using the nuts provided Connect the choke between the PO and PA terminals on the drive see note and next page Connect the grounding strip between the DC choke chassis 1 and the drive Then mount the cover 3 on the chassis and secure it with the nuts 4 provided Then mount panels and 6 using the screws provided Once the choke has been installed the degree of protection of the top the drive is IP31 Note The number of DC chokes supplied with the drive varies according to the drive rating Connecting the DC choke Between 1 and 4 chokes can be connected in parallel as described in the following examples Table of drive choke combinations Drive Number of chokes in parallel Choke model ATV61HD55M3X D75M3X 1 DC CHOKE 5 ATV61HD90M3X 1 DC CHOKE 6 ATV61HD90N4 C11N4 1 DC CHOKE 1 ATV61HC13N4 1 DC CHOKE 2 ATV61HC16N4 1 DC CHOKE 4 ATV61HC22N4 2 DC CHOKE 1 ATV61HC25N4 2 DC CHOKE 3 ATV61HC31N4 2 DC CHOKE 4 ATV61HC40N4 3 DC CHOKE 3 ATV61HC50N4 4 DC CHOKE 2 ATV61HC63N4 4 DC CHOKE 7 Example 1 Example 3 ATV61HD55M3X D9OM3X ATV61HC40N4 ATV61HD90N4 C16N4 NI o Grounding Qu o
17. lt gt GI Up sL2 ts PA PB EH ie Ta OO p 357 13 99 38 1 49 Maximum terminal wire size tightening torque Drive terminals L1 R L2 S L3 T U T1 V T2 W T3 PC PO PA PA PB RO SO TO 1 2 x 150 mm 41 Nm 120 mm 24 Nm 5 5 mm 1 4 Nm 2x 150 mm 41 Nm 2 x 350 MCM 360 lb in 2 x 350 MCM 360 Ib in 250 MCM 212 Ib in AWG 10 12 Ib in 1 Power supply for the fans compulsory if the drive is only powered by the DC bus Do not use if the drive is powered with a 3 phase supply by L1 R L2 S L3 T 30 Power terminals ATV61H C25N4 C31N4 View from above 8 pa Front view 7 3 41 100 3 92 112 4 39 gt lt T j 9 amp A S I I ol Ss ci 2 S 2 bi ka D D We NW ai To oe LH 2 DI DI DI PO PA PC Fan terminals 1 View from below Dm aa ur A ET Ata EE in E as 3 3 ala 2 ail al ga 8 AE 2 E DEA WI A o fi ii 1 Y voy 36 1 41 7 UT V T2 wr 3 113 5 4 45 175 6 85 pat gt R L1 S
18. page 26 for the arrangement of the power terminals lfthe DC bus capacitors have not discharged completely contact your local Schneider Electric representative do not repair or operate the drive A 21 Installing option cards These should ideally be installed once the drive is mounted and before wiring it Check that the red capacitor charging LED has gone out Measure the DC bus voltage in accordance with the procedure indicated on page 21 The option cards are installed under the drive control front panel Remove the graphic display terminal then take off the control front panel as indicated below Removing the control front panel O l YP A Using a screwdriver press down on the Do the same on the e Pivot the control front panel catch and pull to release the left hand right hand side and remove it part of the control front panel Removing the empty option card support E ATV61H D55M3X to D90M3X and ATV61H D90N4 to C63N4 drives are supplied with an empty option card support H adding an I O or communication option card the multi pump card or a Controller Inside programmable card remove the support using the procedure described below This card support serves no purpose when at least one option card is used O Open the empty option card support 2 Unhook the support from its clasps and remove it 22 Installing option cards Installing an encoder interface card
19. this operation Failure to follow this instruction can result in death or serious injury A WARNING DAMAGED EQUIPMENT Do not operate or install any drive that appears damaged Failure to follow this instruction can result in death or serious injury Unpacking handling The drive and the DC choke are mounted on a pallet with screws figure 1 When the DC choke is present it is supplied already assembled to make it easier to transport The unit should be unpacked in the following order 1 Dissassemble the components of the DC choke figure 2 for installation later and remove the choke by means of a hoist figure 3 2 Remove the fixing screws figure 3 from the choke support on the pallet A WARNING RISK OF CUTS The fixing screws that hold the choke support on the pallet are difficult to access leading to a risk of cutting oneself Take all possible measures to avoid this risk and use protective gloves Failure to follow this instruction can result in serious injury 3 Remove the screws holding the drive on the pallet and lift off the drive by means of a hoist It is fitted with handling lugs for this purpose figure 4 A WARNING RISK OF TOPPLING Never stand the drive upright figure 5 without keeping hold of it or it willtopple over Failure to follow this instruction can result in death or serious injury as well as equipment damage Preliminary recommenda
20. 0 Option terminals Extended I O option card terminals VW3 A3 202 Logic input switch SW4 UD Ara o ARA n Ei ci 5 Ei n Source Factory setting Source n Sink Ex q pl Int A Sw4 PETTO Dov le CLO DL Lo4 7 4 Los e RE 79 II DI TH2 leed SS I ILL aa Maximum wire size ninni 1 5 mm AWG 16 Il 222 Max tightening torgue TSS d B sgg odds een 025NM 221 bin Characteristics and functions of the terminals Terminals Function Electrical characteristics R4A Common point C O contact R4C of Minimum switching capacity 3mA for 24 V R4B programmable relay R4 Maximum switching capacity on resistive load R4C 5 A for 250 V or 30 V e Maximum switching capacity on inductive load cos q 0 4 L R 7 ms 1 5 A for 250 V or 30 V Reaction time 10 ms 1ms Service life 100 000 operations 10 10 V power supply for reference 10 V 10 5 V 0 5V potentiometer 1 to 10 kQ 10 mA max Al3 polarity of the current differential Analog input X Y mA X and Y can be programmed from 0 to 20 mA analog input AI3 impedance 250 Q Al3 polarity of the current differe
21. 0 75 mm AWG 18 984 ft 200 mA 1 5 mm AWG 15 44 Connection diagrams Connection diagrams conforming to standards EN 954 1 category 1 and IEC EN 61508 capacity SIL1 stopping category O in accordance with standard IEC EN 60204 1 Diagram with line contactor Diagram with switch disconnect d y A lt ol af lt o ct ala A ci ele cl a cc o ou T1 owrTa T L3 l 1 Line choke if used 2 Fault relay contacts for remote signaling of drive status 3 For the wiring of the power section AC supply for ATV61HC50N4 and ATV61HC63N4 drives please refer to page 48 Note Fit interference suppressors to all inductive circuits near the drive or coupled to the same circuit relays contactors solenoid valves etc Choice of associated components Please refer to the catalog 45 Connection diagrams Connection diagrams conforming to standards EN 954 1 category 3 and IEC EN 61508 capacity SIL2 stopping category O in accordance with standard IEC EN 60204 1 This connection diagram is suitable for use with machines with a short freewheel stop time with low inertia or high resistive torque When the emergency stop is activated the drive power supply is turned off immediately and the motor stops in accordance w
22. 1 K2 Q For weight mm mm mm mm mm mm mm mm mm mm screws kg in in in in in in in in in in Ib C40N4 225 890 1390 417 5 70 380 1120 150 75 30 11 5 M10 496 C5ON4 35 04 54 72 16 44 2 76 14 96 4409 5 91 2 95 1 18 0 45 390 661 C63N4 1120 1390 532 5 70 495 1120 150 75 30 11 5 M10 300 44 09 54 72 20 96 2 76 1949 4409 5 91 2 95 1 18 0 45 661 1 For the addition of I O extension cards communication cards the multi pump card or the Controller Inside programmable card Dimensions and weights e e c ATV61H D55M3XD to D9OM3XD With O or 1 option card 1 2 option cards 1 ATV61H D90N4D to C28N4D vith R INERTI 4x9 4x9 ei S o o A4 ry t 1 o M o I al X I o q o EEE e 392 G dis 97 5 mm 540 mm 21 17 in 22 5 mm Lazem 545 in 7 SE 3 82 in 660 mm 25 87 in 1 0 88 in ATV61H a b G H H For weight mm mm mm mm mm mm screws kg in in in in in in Ib D55M3XD D90N4D 60 310 680 250 650 15 11 5 132 D75M3XD C11N4D 12 20 26 77 9 84 25 59 0 59 0 45 M10 74 163 C13N4D D90M3XD 350 782 298 758 12 115 M10 80 13 78 30 79
23. 2 Max Apparent Max available Max transient Catalog number 3 indicated on prospective power nominal current 1 for plate 1 line Isc 4 current In 1 60s at 380 V at 480 V kW A A kA kVA A A 90 166 143 35 109 179 215 ATV61HD90N4 110 202 168 35 133 215 236 ATV61HC11N4 132 239 224 35 157 259 285 ATV61HC13N4 160 289 275 50 190 314 345 ATV61HC16N4 200 357 331 50 235 427 470 ATV61HC22N4 220 396 383 50 261 250 444 435 50 292 481 529 ATV61HC25N4 280 494 494 50 365 616 678 ATV61HC31N4 315 555 544 50 365 355 637 597 50 419 759 835 ATV61HC40N4 400 709 644 50 467 500 876 760 50 577 941 1035 ATV61HC50N4 560 978 858 50 644 1188 1307 ATV61HC63N4 630 1091 964 50 718 1 These power ratings and currents are given for an ambient temperature of 45 C 122 F and at the factory set switching frequency of 2 5 kHz used in continuous operation Above 2 5 kHz the drive will reduce the switching frequency automatically in the event of excessive temperature rise For continuous operation above 2 5 kHz derating must be applied to the drive nominal current in accordance with the curves on pages 14 and 15 2 Typical value for the indicated motor power with a standard 4 pole motor on a line supply with the indicated prospective line Isc 3 The drives are supplied as standard with a DC choke which must be used for connecting the drive on a 3 phase line supply For connections on the DC bus the drive can be controlled without a choke Add the letter
24. 22 Asl 350 Es 200 40 4 78 13 78 7 83 1 57 34 Power terminals ATV61HC50N4 View from above Hem 313 50 12 34 BU PO 1 BU PA PC PO 2 View from below UTI Riti stat mai wm R12 S z T L3 2 wm Maximum terminal wire size tightening torque Drive terminals R L1 1 R L1 2 S L2 1 U T1 V T2 W T3 PC PA RO SO TO 1 S L2 2 T L3 1 T L3 2 2 x 185 mm 41 Nm 2 x 500 MCM 360 Ib in 4 x 500 MCM 360 lb in 4 x 500 MCM 360 lb in AWG10 12 Ib in 1 Power supply for the fans compulsory if the drive is only powered by the DC bus Do not use if the drive is powered with a 3 phase supply by L1 R L2 S L3 T 4 x 185 mm 41 Nm 8 x 185 mm 41 Nm 5 5 mm 1 4 Nm 35 Power terminals ATV61HC63N4 155 50 _ 95 85 BR 40 40 40 80 40 40 40 90 6 09 ea Tes ASIA 8 19 US UGT UE 8 53 TE z lt SE z gea E A 3 j IIIe na DI 518 i v Q Q a lo N EE Ee arik Si LU ALI Io verrete NI re fe OTT RNR SA SD BU PO 1 BU PC PO 2 o o Fan terminals 1 Besari U T1 V T2 W
25. 365 308 375 298 250 35 35 11 5 M10 14 37 12 13 14 76 11 73 9 84 1 38 1 38 0 45 A9 211 345 323 375 285 240 35 55 11 5 M10 13 58 12 72 14 76 11 22 9 40 1 37 2 15 0 45 A9 212 445 383 429 350 250 65 75 11 5 M10 17 52 15 08 16 89 13 78 S E 9 84 2 56 2 95 0 45 A9 213 600 383 475 540 S E 250 65 75 11 5 M10 23 62 15 08 18 70 21 26 x S E 9 84 2 56 2 95 0 45 A9 214 670 383 475 540 1025 27 5 a 250 65 75 11 5 M10 23 43 15 08 18 70 21 26 4 03 1 08 S 9 84 2 56 2 95 0 45 20 Position of the charging LED Before working on the drive turn it off wait until the red capacitor charging LED has gone out then measure the DC bus voltage Position of the capacitor charging LED Red LED indicating that the DC bus is turned on Ok Procedure for measuring the DC voltage A DANGER HAZARDOUS VOLTAGE Read and understand the instructions on page 4 before performing this procedure Failure to follow this instruction will result in death or serious injury The DC bus voltage can exceed 1 000 V Use a properly rated voltage sensing device when performing this procedure To measure the DC bus voltage 1 Disconnect the drive power supply 2 Wait for the capacitor charging LED to go off 3 Measure the voltage of the DC bus between the PA and PC terminals to check whether the voltage is less than 45 V See
26. 7 in and connecting the shielding to ground at each end If using conduit do not lay the motor power supply and control cables in the same conduit Keep the metal conduit containing the power supply cables at least 8 cm 3 in away from the metal conduit containing the control cables Keep the non metal conduits or cable ducts containing the power supply cables at least 31 cm 12 in away from the metal conduits containing the control cables If it is necessary for control and power cables to cross each other be sure they cross at right angles Length of motor cables 0 50m 50 100m 100 200m 200 300m 300 400m 1400 600 m 0 164 ft 164 328 ft 328 656 ft 656 984 ft 984 1312 ft 1312 1968 ft Shielded Motor choke 2 motor chokes in series ATV61HeeeM3X cable ATV61HD90N4 N4 i 61HD90N4 to C63 SS Motor choke 2 motor chokes in series Note On old generation motors or those with poor insulation we recommend using a motor choke where the cable is more than 5 m 16 4 ft long Choice of associated components Please refer to the catalog 25 Power terminals Access to the power terminals To access the power terminals unscrew the front panel and remove the protective cover Terminals for D DC choke C bus power supply Fan power supply Power section line supply Output to t
27. 835 ATV61HC40N4 600 644 50 467 700 760 50 577 941 1035 ATV61HC50N4 800 858 50 644 1188 1307 ATV61HC63N4 900 964 50 718 1 These power ratings and currents are given for an ambient temperature of 45 C 122 F and at the factory set switching frequency of 2 5 kHz used in continuous operation Above 2 5 kHz the drive will reduce the switching frequency automatically in the event of excessive temperature rise For continuous operation above 2 5 kHz derating must be applied to the drive nominal current in accordance with the curves on pages 14 and 15 2 Typical value for the indicated motor power with a standard 4 pole motor on a line supply with the indicated prospective line Isc 3 The drives are supplied as standard with a DC choke which must be used for connecting the drive on a 3 phase line supply For connections on the DC bus the drive can be controlled without a choke Add the letter D at the end of the reference Example ATV 61HD90N4 becomes ATV 61HD90N4D 4 If the drive is installed on a line supply with a prospective short circuit current that is higher than the value given in this column use line chokes please refer to the catalog Dimensions and weights With O or 1 option card 1 2 option cards 1 ATV61H D55M3X to D9OM3X ATV61H D90N4 to C31N4 ATV61H C25N4 to C31N4 with braking unit
28. Altivar 61 Variable speed drives Installation Manual for asynchronous motors Retain for future use 55 kW 75 HP 90 kW 125 HP 200 240V 90 kW 125 HP 630 kW 900 HP 380 480V a brand of io Telemecanique Contents Contents Before you begin Steps for setting up the drive Preliminary recommendations Drive ratings Dimensions and weights Installing the DC choke Connecting the DC choke Derating as a function of the temperature and switching frequency Mounting in a wall mounted or floor standing enclosure Installing the kit for IP31 UL Type 1 conformity Position of the charging LED Installing option cards Wiring recommendations Power terminals Control terminals Option terminals Connection diagrams Operation on an IT system Electromagnetic compatibility wiring Before you begin Read and understand these instructions before performing any procedure on this drive A DANGER HAZARDOUS VOLTAGE Read and understand this manual before installing or operating the Altivar 61 drive Installation adjustment repair and maintenance must be performed by qualified personnel The user is responsible for compliance with all international and national electrical standards in force concerning protective grounding of all equipment Many paris of this variable speed drive including the printed circuit boa
29. D at the end of the reference Example ATV 61HD90N4 becomes ATV 61HD90N4D 4 If the drive is installed on a line supply with a prospective short circuit current that is higher than the value given in this column use line chokes please refer to the catalog Drive ratings Powers in HP 3 phase supply voltage 200 240 V 50 60 Hz 3 phase motor 200 240 V Motor Line supply input Drive output Altivar 61 Power Line current 2 Max Apparent Max available Max transient Catalog number 3 indicated on prospective power nominal current 1 for plate 1 line Isc 4 current In 1 60s at 200 V at 240 V HP A A kA kVA A A 75 200 173 35 72 221 265 ATV61HD55M3X 100 271 232 35 96 285 313 ATV61HD75M3X 125 336 288 35 120 359 395 ATV61HD90M3X 3 phase supply voltage 460 480 V 50 60 Hz 3 phase motor 480 V Motor Line supply input Drive output Altivar 61 Power Line current 2 Max prospective Apparent power Max available Max transient Catalog number 3 indicated on line Isc 4 nominal current 1 for plate 1 current In 1 60s at 480 V HP A kA kvA A A 125 143 35 109 179 215 ATV61HD90N4 150 168 35 133 215 236 ATV61HC11N4 200 224 35 157 259 285 ATV61HC13N4 250 275 50 190 314 345 ATV61HC16N4 300 331 50 235 427 470 ATV61HC22N4 350 383 50 261 400 435 50 292 481 529 ATV61HC25N4 450 494 50 365 616 678 ATV61HC31N4 500 544 50 365 597 50 419 759
30. Function Electrical characteristics R3A Common point C O contact R3C of Minimum switching capacity 3mA for 24 V R3B programmable relay R3 Maximum switching capacity on resistive load R3C 5 Afor250V or 30 V Maximum switching capacity on inductive load cos q 0 4 L R 7 ms 2 A for 250 V or 30 V Reaction time 7 ms 0 5 ms Service life 100 000 operations 10 10 V power supply for reference 10 V 10 5 V 0 5V potentiometer 1 to 10 kQ 10 mA max 24 Logic input power supply SW3 switch in Source or Sink Int position 24 V power supply min 21 V max 27 V protected against short circuits and overloads Max current available for customers 200 mA This current corresponds to the total consumption on the control card 24 and the option cards 24 SW3 switch in Sink Ext position Input for external 24 V power supply for the logic inputs LI7 Programmable logic inputs e 24 V power supply max 30 V LI9 Reaction time 2 ms 0 5 ms Source factory setting lt 5 V gt 11V EO Sink Int or Sink Ext gt 16V lt 10V 0 V OV 0 V TH1 PTC probe input Trip threshold 3 kQ reset threshold 1 8 kQ TH1 Short circuit detection threshold lt 50 92 LO1 Open collector programmable logic 24 V max 30 V LO2 outputs e Max current 200 mA for internal power supply and 200 mA for external power supply Reaction time 2 ms 0 5 ms CLO Logic output common ON 0 V 0 V 4
31. L2 T L3 43 1 67 p 173 5 68 01 L 176 5 69 19 D D 190 5 09 eL 175 6 85 ol 175 6 85 Maximum terminal wire size tightening torque Drive terminals L1 R L2 S L3 T U T1 V T2 W T3 PC PO PA RO SO TO 1 4 x 185 mm 41 Nm 4 x 185 mm 41 Nm 5 5 mm 1 4 Nm 3 x 350 MCM 360 bin 3 x 350 MCM 360 bin AWG 10 12 Ib in 1 Power supply for the fans compulsory if the drive is only powered by the DC bus Do not use if the drive is powered with a 3 phase supply by L1 R L2 S L3 T 31 Power terminals ATV61H C40N4 122 50 70 70 45 40 40 40 65 1 40 40 40 75 M12 4 80 2 74 2 74 179 1 59 1 57 1 57 2 55 1 57 1 57 1 57 2 94 o o o la o 9 o o o o o Oo oo oo o O o e e BU PO 1 BU PA PC PO 2 o o o ek ee o o o P o o Fan terminals 1 a o U T1 V T2 W T3 R L1 S L2 T L3 M12 e o o o o o o o o o o o o o E Me E ZE d bd ads Jl E X Ho Pag o O o g Q N e o l al o sl o N LR 57 19 285 li 285 2 23 40 11 16 11 16 167 1 57 285 a 285 a 6 54 mm 11 16 11 16 254 50 1 57 285 162 50 a 9 97 an 11 16 Ex 6 36 32 Power terminals ATV61H C40N4 View from above il UT Vi
32. The 7 encoder interface cards available as options with the ATV61 enable three different encoder technologies to be used Optical incremental encoder with differential outputs compatible with the RS422 standard Optical incremental encoder with open collector outputs e Optical incremental encoder with push pull outputs The encoder must comply with the following two limits Maximum encoder frequency 300 kHz Maximum resolution 5 000 points revolution Choose the max standard resolution within these two limits to obtain optimum accuracy Wiring the encoder Use a shielded cable containing 3 twisted pairs with a pitch of between 25 and 50 mm 0 98 in and 1 97 in Connect the shielding to ground at both ends The minimum cross section of the conductors must comply with the table below to limit line voltage drop Max length of VW3 A3 401 0 402 VW3 A3 403 407 encoder cable Max consumption Minimum cross section of Max consumption Minimum cross section of current of encoder conductors current of encoder conductors 10m 100 mA 0 2 mm AWG 24 100 mA 0 2 mm AWG 24 32 8 ft 200 mA 0 2 mm AWG 24 200 mA 0 2 mm AWG 24 50m 100 mA 0 5 mm AWG 20 100 mA 0 5 mm AWG 20 164 ft 200 MA 0 75 mm AWG 18 200 mA 0 75 mm AWG 18 100m 100 mA 0 75 mm AWG 18 100 mA 0 75 mm AWG 18 328 ft 200 mA 1 5 mm AWG 15 200 mA 1 5 mm AWG 16 200 m 100 mA 0 5 mm AWG 20 656 ft 200 mA 1 5 mm AWG 15 300 m 100 mA
33. W3 a b c G G1 G2 G3 H1 H2 H3 For mm mm mm mm mm mm mm mm mm mm mm screws in in in in in in in in in in in A9 109 325 228 375 250 E E 95 73 75 11 5 M10 12 80 8 98 14 76 9 84 3 lt 3 74 2 87 2 95 0 45 A9 110 365 308 375 298 2 250 35 35 11 5 M10 14 37 12 13 14 76 11 73 9 84 1 38 1 38 0 45 A9 111 345 323 362 285 240 35 55 11 5 M10 13 58 12 72 14 25 11 22 9 40 1 38 2 15 0 45 A9 112 445 383 362 350 250 65 75 11 5 M10 17 52 15 08 14 25 13 78 9 84 2 56 2 95 0 45 A9 113 600 383 362 540 E 250 65 75 11 5 M10 23 62 15 08 14 25 21 26 S 9 84 2 56 2 95 0 45 A9 114 670 383 362 540 102 5 27 5 a 250 65 75 11 5 M10 23 43 15 08 14 25 21 26 4 03 1 08 9 84 2 56 2 95 0 45 A9 115 895 483 462 835 350 65 75 11 5 M10 35 04 19 02 18 19 32 87 3 13 78 2 56 2 95 0 45 A9 116 1125 483 462 495 75 350 65 75 11 5 M10 44 29 19 02 18 19 19 49 S 2 95 13 78 2 56 2 95 0 45 VW3 A9 209 216 VW3 A9 209 213 215 VW3A9 214 VW3 A9 216 4x0 o 40 o np L 8x0 Ta o I 3 H H rd bls oil G Je La a Si VW3 a b G G G1 G2 G3 Hi H2 H3 For mm mm mm mm mm mm mm mm mm mm mm screws in in in in in in in in in in in A9 209 325 228 375 250 95 73 75 11 5 M10 12 80 8 98 14 76 9 84 3 74 2 87 2 95 0 45 A9 210
34. curacy 0 6 for A0 60 C 140 F linearity 0 15 of max value COM Analog I O common OV Al2 Depending on software configuration Analog voltage input or Analog current input Analog input Oto 10 V max safe voltage 24 V impedance 30 kQ or analog input X Y mA X and Y can be programmed from 0 to 20 mA impedance 250 Q Reaction time 2 ms 0 5 ms e 11 bit resolution accuracy 0 6 for A0 60 C 140 F linearity 0 15 of max value COM Analog I O common OV AO Depending on software configuration Analog voltage output Analog output O to 10 V load impedance greater than 50 kQ or or Analog current output analog output X Y mA X and Y can be programmed from 0 to 20 mA max load impedance 500 Q e 10 bit resolution reaction time 2 ms 0 5 ms e Accuracy 1 for AO 60 C 140 F linearity 0 2 of max value P24 Input for external 24 V control e 24 V min 19 V max 30 V power supply Logic input common and OV of P24 external power supply e Power 30 Watts Programmable logic inputs Depending on the position of the SW2 switch Programmable logic input or Input for PTC probes ON e 24 V max 30 V i Impedance 3 5 kQ SW1 switch State 0 State 1 e Reaction time 2 ms 0 5ms Source factory setting 5 V gt 11V Sink Int or Sink Ext gt 16V lt 10V SW2 switch on LI factory setting Same charac
35. drive mounted in this way becomes IP54 To fit the kit to the drive please refer to the manual supplied with the kit Check that the back of the enclosure is strong enough to support the weight of the drive Use the dissipated power table above to calculate the enclosure dimensions In this case the DC choke can be installed directly on the back of the enclosure 17 Mounting in a wall mounted or floor standing enclosure If the hot air exiting the drive is not ducted and evacuated to the outside it risks being sucked back in making the ventilation totally ineffective In order to avoid this it is important to leave enough free space around the drive as indicated below The enclosure must be cooled in order to get rid of the dissipated heat x ATV61H hi h2 mm in mm in D55M3X D75M3X D90M3X D90N4 C11N4 100 3 94 100 3 94 C13N4 C16N4 C22N4 150 5 90 150 5 90 C25N4 C31N4 200 7 87 150 5 90 C40N4 C50N4 300 11 81 250 9 84 C63N4 400 15 75 250 9 84 Free space in front of the drive 10 mm 0 39 in minimum Installing the kit for IP31 UL Type 1 conformity On ATV61H D55M3X to D90M3X and D90N4 to C31N4 drives the cable shielding can be attached and connected to ground using one of the following two kits Kit for IP31 conformity VW3 A9 109 114 e Kit for UL Type 1 conformity VW3 A9 209 214 On ATV61H C40N4 to C63N4 drives the cable shielding can be attached and connected to g
36. e properly coordinated The Canadian Electricity Code and the National Electrical Code require branch circuit protection Use the fuses recommended on the drive nameplate to achieve published short circuit current ratings Do not connect the drive to a power feeder whose short circuit capacity exceeds the drive short circuit current rating listed in the tables on pages 8 and 9 Failure to follow these instructions can result in death or serious injury 24 Wiring recommendations Keep the power cables away from low level signal circuits in the installation detectors PLCs measuring apparatus video telephone The motor cables must be at least 0 5 m 20 in long Do not immerse the motor cables in water Do not use surge arresters or power factor correction capacitors on the variable speed drive output CAUTION IMPROPER USE OF A BRAKING RESISTOR Only use the braking resistance values recommended in our catalogs Wire a thermal overload relay in the sequence or configure the braking resistor protection please refer to the Programming Manual so that the drive power section AC supply is disconnected in the event of a fault Failure to follow these instructions can result in equipment damage Control Keep the control circuits away from the power circuits For control and speed reference circuits we recommend using shielded twisted cables with a pitch of between 25 and 50 mm 0 98 and 1 9
37. ended equipment operation on the first insulation fault Failure to follow this instruction can result in death or serious injury 52 Connection diagrams Connection of several drives in parallel on the DC bus Connection on DC bus between drives with equivalent ratings Each drive uses its own charging circuit 3u Ia e sl e E 0 0 0 2 O bei N l 3 a l oo D DO l Il Il ATV61Heeeee 3 PA O Il Il l 1 I I Drives O 2 and 3 must not be more than one size apart when they are connected in this way F1 F2 F3 fast acting semiconductor fuses for protection on the DC bus side Connection on DC bus between drives with different ratings F2 F3 3x p eeM pm PC PA PC D e lt x a I ATV61HeeeeeD 2 i i I 1 Drives 2 and 3 powered only by their DC bus do not necessarily have a DC choke catalog number ATVE1eeeeD F1 F2 F3 fast acting semiconductor fuses for protection on the DC bus side CAUTION Drive 1 must be large enough to supply all the motors capable of operating simultaneously When power ratings D9OM3X and C13N4 to C63N4 drive 3 in the above diagram are powered only by their DC bus and not by their R L1 S L2 T L3 terminals it is essential to power the fans separately with a 3 phase supply 380 480 V 50 60 Hz RO SO TO te
38. equipment damage Steps for setting up the drive INSTALLATION E 1 Take delivery of the drive O Check that the catalog number printed on the label is the same as that on the purchase order O Remove the Altivar from its packaging and check that it has not been damaged in transit E 2 Check the line voltage O Check that the line voltage is compatible with the voltage range of the drive see pages 8 and 9 Steps 1 to 4 must be performed with the power off E 3 Mount the drive O Mount the drive in accordance with the instructions in this document O Install and connect the DC choke see page 12 O Install any internal and external options E 4 Wire the drive O Connect the motor ensuring that its connections correspond to the voltage O Connect the line supply after making sure that itis turned off O Connect the control O Connect the speed reference Preliminary recommendations DC choke Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Acceptance The packaging contains two items The drive DC choke except for ATV61eeeD Handling storage To protect the drive prior to installation handle and store the device in its packaging Ensure that the ambient conditions are acceptable A WARNING DAMAGED PACKAGING If the packaging appears damaged it can be dangerous to open it or handle it Take precautions against all risks when performing
39. ew from below wm ms VII S L2 U T1 R L1 Maximum terminal wire size tightening torque 1 TO so 5 5 mm 1 4 Nm RO PA 8 x 185 mm 41 Nm PC L3 T U T1 V T2 W T3 L2 S 4 x 185 mm 41 Nm L1 R Drive terminals AWG 10 12 lb in 4 x 500 MCM 360 Ib in 1 Power supply for the fans compulsory if the drive is only powered by the DC bus Do not use if the drive is powered with a 3 phase 4 x 500 MCM 360 Din supply by L1 R L2 S L3 T 33 Power terminals ATV61HC50N4 122 50 70 11 70 1 45 40 40 40 65 40 40 40 75 M12 480 2 74 2 74 01 70 0 570 571 59 2 55 052015710571 2 94 ag RESA E GE SN ESP GN ENI RON A DE ae IP o o o o do o o i 8 i i e Em tm WW p 7 L CC CH e L YT CD ATA S N HE de 9 Le ay eI toa po UM 2 US vi BU PO 1 BU PA PO 2 o o o o o o lb Fan terminals 1 lte um v T2 R L1 1 S L2 1 T L3 1 R L1 2 S L22 T L3 2 2 51 187 70 1 70 180 70 70 7 32 49 2 74 2 74 7 05 2 74 2 74 57 057 340 a 340 20 2 23 40 13 39 13 39 1 57 cai 1
40. f the drive is powered with a 3 phase supply by L1 R L2 S L3 T 29 Power terminals ATV61HC22N4 Front view View from above 47 1 84 100 3 92 150 5 88 gt a gt 1 A D E A N a I 8 E a a M12 jo D m s el 5 5 in m C a e rs Sa d 2 2 8 UI UU DN E Y Y MAA 24 Y g PO PA PC LC O O o O gt Fan terminals 1 paag eleele View from below A ch CO T T ry i ES VH VEH KH d lal EA EA O O O el ei a 8 O Ol O Sl g JPEE lt pera Hora 8 nl El S SS d E Lady AH g ka kal is 5 S ES E T T ID EN C S AJ ala E 218 M12 Mie S a Li I Li I M12 M8 i l uu ES N f 114 4 47 102 4 00 ra na Lasi um VIT2 uma 21 0 82 104 4 07 102 4 00 gt
41. he motor Connections to ground Output to braking resistor up to ATV61HC16N4 rating only Characteristics and functions of the power terminals Terminals Function Altivar 3x Protective ground connection terminals All ratings R L1 S L2 T L3 1 Power section line supply All ratings PO Connection of the DC choke o GE PO 1 PO 2 Connection of the DC chokes ATV61H C40N4 to C63N4 PA DC bus polarity and connection of the DC choke All ratings PC DC bus polarity All ratings PA Output to braking resistor ATV61H D55M3X to D9OM3X PB Output to braking resistor ATV61H D9ON4 to C22N4 2 U T1 V T2 W T3 Output to the motor All ratings RO SO TO Separate fan supply when the drive is only powered by ATV61H D75M3X D90M3X the DC bus ATV61H C13N4 to C63N4 BU BU and polarities to be connected to the braking unit ATV61H C25N4 to C63N4 X20 X92 X3 Connection of the braking unit control cable Refer to the User s Manual for the braking unit 1 ATV61H C50N4 to C63N4 drives have two input bridges The power section line supply is connected on terminals R L1 1 R L1 2 S L2 1 S L2 2 and T L3 1 T L3 2 2 From the ATV61HC25N4 upwards there are no braking resistor connection terminals on the drive as the braking unit is optional please refer to the catalog The braking resistor is then connected on the braking unit 26 Power terminals ATV61H D55M3X D75M3X D90N4
42. ith category O of standard IEC EN 60204 1 NG L1 1 Line choke if used 2 Fault relay contacts for remote signaling of drive status 3 It is essential to connect the shielding on the cable connected to the Power Removal input to ground 4 For the wiring of the power section AC supply for ATV61HC50N4 and ATV61HC63N4 drives please refer to page 48 Standard EN 954 1 category 3 requires the use of a stop button with double contact S1 S1 is used to activate the Power Removal safety function S2 is used to initialize the Preventa module when powering up or after an emergency stop ESC enables the use of other initialization conditions for the module One Preventa module can be used for the Power Removal safety function on several ATV61 drives A logic input on the Preventa module can be used to indicate safely that the drive is operating in safe conditions Note For preventive maintenance the Power Removal function must be activated at least once a year The drive power supply must be turned off and then on again before carrying out this preventive maintenance The drive logic output signals cannot be considered as safety type signals Fit interference suppressors to all inductive circuits near the drive or coupled to the same circuit relays contactors solenoid valves etc Choice of associated components Please refer to the catalog 46 Connection diagrams Connec
43. lly extended Remove the card by sliding it downwards CAUTION IMPROPERLY SECURED TERMINAL CARD When replacing the control terminal card it is essential to fully tighten the captive screw Failure to follow this instruction can result in eguipment damage Logic input switch Source gr Factory setting Source Sink Ext LI6 input switch Factory setting LI PTC Li Maximum wire size 2 5 mm AWG 14 x e025 5 2a 4 Max tightening torque 0000000000 RJ45 connector 0 6 Nm 5 3 Ib in Note The ATV61 is supplied with a link between the PWR and 24 terminals 38 Control terminals Characteristics and functions of the control terminals Terminals Function Common point C O contact R1C of Electrical characteristics Minimum switching capacity 3 mA for 24 V R1B programmable relay R1 Maximum switching capacity on resistive load RIC 5 A for 250 V or30V R2A N O contact of programmable relay R2 Maximum switching current on inductive load cos q 0 4 L R 7 ms R2C 2 A for 250 V or 30 V Reaction time 7 ms 0 5 ms Service life 100 000 operations at max switching power 10 10 V power supply for reference 10 V 10 5 V 0 5V potentiometer 1 to 10 kQ 10 mA max Al1 Differential analog input Al1 e 10 to 10 V max safe voltage 24 V AH Reaction time 2 ms 0 5 ms 11 bit resolution 1 sign bit e Ac
44. nded operation Do not forget to reactivate the Power Removal input to start the motor Before turning on or on exiting the configuration menus check that the inputs assigned to the run command are deactivated at state 0 since they can cause the motor to start immediately Failure to follow these instructions will result in death or serious injury Ce If the safety of personnel requires the prohibition of unwanted or unintended starts electronic locking is performed by the Altivar 61 s Power Removal function This function requires the use of connection diagrams conforming to category 3 of standard EN954 1 and safety integrity level 2 according to IEC EN61508 The Power Removal function takes priority over any run command Drive ratings Powers in kW 3 phase supply voltage 200 240 V 50 60 Hz 3 phase motor 200 240 V Motor Line supply input Drive output Altivar 61 Power Line current 2 Max Apparent Max available Max transient Catalog number 3 indicated on prospective power nominal current 1 for plate 1 line Isc 4 current In 1 60s at 200 V at 240 V kW A A kA kVA A A 55 200 173 35 72 221 265 ATV61HD55M3X 75 271 232 35 96 285 313 ATV61HD75M3X 90 336 288 35 120 359 395 ATV61HD90M3X 3 phase supply voltage 380 480 V 50 60 Hz 3 phase motor 380 480 V Motor Line supply input Drive output Altivar 61 Power Line current
45. ntial Reaction time 5 ms 1 ms io Ver AIS 11 bit resolution 1 sign bit accuracy 0 6 for A8 60 C 140 F Linearity 0 15 of max value Al4 Depending on software configuration Analog current input Analog input Oto 10 V max safe voltage 24 V impedance 30 kQ or or Analog voltage input Analog input X Y mA X and Y can be programmed from 0 to 20 mA impedance 250 Q Reaction time 5 ms 1 ms e 11 bit resolution accuracy 0 6 for A9 60 C 140 F linearity 0 15 of max value COM Analog I O common OV AO2 Depending on software configuration AOS Analog voltage outputs e 0 10 V or 10 10 V bipolar analog output depending on software or Analog current outputs configuration load impedance greater than 50 kQ or Analog current output X Y mA X and Y can be programmed from 0 to 20 ma max load impedance 500 2 10 bit resolution e Reaction time 5 ms 1 ms accuracy 1 for A0 60 C 140 F linearity 0 2 41 Option terminals Terminals Function Electrical characteristics 24 Logic input power supply SW4 switch in Source or Sink Int position e 24 V output min 21 V max 27 V protected against short circuits and overloads Max current available for customers 200 mA This current corresponds to the total consumption on the control card 24 and the option cards 24 SW4 switch in Sink Ext position Input fo
46. on The DC choke extends this duct while maintaining IP54 protection The drive dissipates a great deal of power which must be evacuated to the outside of the enclosure Air inlets and outlets must be provided to ensure that the flow of air in the enclosure is at least equal to the value given in the table below for each drive ATV61H Flow rate m hour f min D55M3X D75M3X D90N4 C11N4 402 236 D90M3X C13N4 774 455 C16N4 745 438 C22N4 860 506 C25N4 C31N4 1260 742 C40N4 C50N4 2100 1236 C63N4 2400 1412 Several methods of evacuation are possible The following is a proposed method for IP23 and IP54 mounting IP23 mounting standard operating conditions Figure 1 Install the drive on an enclosure baseplate Install the DC choke in accordance with the mounting recommendations The simplest mounting is to extend the IP54 duct between the upper outlet of the DC choke and the top of the enclosure D Fixing points are provided for this purpose on the top of the DC choke The hot air is thus evacuated to the outside and does not contribute towards increasing the internal temperature of the enclosure It is advisable to add a plate approximately 150 mm from the top of the enclosure over the air outlet opening to prevent foreign bodies falling into the drive cooling duct The air inlet can be via a grille on the bottom front panel of the enclosure door in accordance with the required flow rates given in the
47. r external 24 V power supply for the logic inputs LI11 Programmable logic inputs e 24 V max 30 V _ LI12 Impedance 3 5 kQ SW4 switch State O State 1 LI13 e Reaction time 5 ms 1 ms Source factory setting lt 5 V gt 11V GU Sink Int or Sink Ext gt 16V lt 10V OV Logic input common oV TH2 PTC probe input Trip threshold 3 KQ reset threshold 1 8 KQ TH2 Short circuit detection threshold 50 2 RP Freguency input Frequency range 0 30 kHz e Cyclic ratio 50 10 e Maximum sampling time 5 ms 1 ms Maximum input voltage 30 V 15 mA Add a resistor if the input voltage is greater than 5 V 510 Q for 12 V 910 Q for 15 V 1 3 kQ for 24 V e State 0 if lt 1 2 V state 1 if gt 3 5 V LO3 Open collector programmable logic 24 V max 30 V LO4 outputs e Max current 20 mA for internal power supply and 200 mA for external power supply e Reaction time 5 ms 1ms CLO Logic output common ON 0 V OV 42 Option terminals Encoder interface card terminals VW3 A3 401 407 O gt Pl uvuz 2 Y Maximum wire size 1 5 mm AWG 16 Max tightening torque 0 25 Nm 2 21 Ib in Characteristics and functions of the terminals Encoder interface cards with RS422 compatible differential outputs Terminals Function Electrical characteristics VW3 A3 401 VW3 A3 402 Vs Encoder power 5V max 5 5V protected against shor
48. rds operate at the line voltage DO NOT TOUCH Use only electrically insulated tools DO NOT touch unshielded components or terminal strip screw connections with voltage present DO NOT short across terminals PA and PC or across the DC bus capacitors Install and close all the covers before applying power or starting and stopping the drive Before servicing the variable speed drive Disconnect all power Place a DO NOT TURN ON label on the variable speed drive disconnect Lock the disconnect in the open position Disconnect all power including external control power that may be present before servicing the drive Wait for the charging LED to go off Then follow the DC bus voltage measurement procedure on page 21 to verify that the DC voltage is less than 45 V The drive LEDs are not accurate indicators of the absence of DC bus voltage Electric shock will result in death or serious injury CAUTION IMPROPER DRIVE OPERATION e If the drive is not turned on for a long period the performance of its electrolytic capacitors will be reduced Ifitis stopped for a prolonged period turn the drive on every two years for at least 5 hours to restore the performance of the capacitors then check its operation It is recommended that the drive is not connected directly to the line voltage The voltage should be increased gradually using an adjustable AC source Failure to follow this instruction can result in
49. rminals protected with fuses or motor disconnect Power and connection are detailed on the following page Failure to follow these instructions can result in equipment damage 53 Connection diagrams Power consumed by the fans ATV61H drive Power consumed by the fans D90M3X C13N4 C16N4 C22N4 550 VA C25N4 C31N4 1145 VA C40N4 C50N4 2200 VA C63N4 2750 VA Connecting fans for a separate power supply In order to remove the link between the fans and power supply terminals R L1 S L2 T L3 and take it to terminals RO SO TO connectors X1 and X4 must be crossed as indicated on the diagrams below ATV61H D90M3X C13N4 Factory wiring fans powered internally by R L1 S L2 T L3 a INPUT X1 U E d Terminals RO SO TO E OTT Nee Lea 9 al Of fe Modification for fans powered externally by RO SO TO Terminals RO SO TO Gabe Ta TE I SFERE 54 Connection diagrams ATV61H C16N4 C22N4 C25N4 C31N4 Factory wiring fans powered internally by R L1 S L2 T L3 EXT INT AT PED X4 1 X1 a g Parking Input PEG eee E i o Terminals RO SO TO
50. round using the kit for IP31 conformity VW3 A9 115 116 This kit is not supplied with the drive It must be ordered separately please refer to the catalog It is mounted under the drive as shown below EMC clamp for holding the cables in place and connecting the shielding to ground Mount the chassis O on the wall or the back of the enclosure under the drive Ensure that the chassis is tightly secured to the drive to maintain the IP54 seal of the ventilation duct To do this use the 2 locking flanges that are attached in the drive transport holes 5 s Mount the EMC plate 2 on the kit chassis using the screws provided Mount the bridge to ensure equipotentiality of the grounds between the drive and the EMC plate Then mount the IP31 or UL Type 1 cover 4 on the EMC plate using the screws provided Note This kit can be used to simplify guiding the inlet air It is supplied with a seal to provide IP54 sealing for the duct to the drive Close the drive transport holes 6 with the plastic plugs provided 19 Installing the kit for IP31 UL Type 1 conformity VW3 A9 109 116 VW3 A9 109 113 115 VW3 A9 114 VW3 A9 116 40 o o h 71 8x0 E a 1 T Je Le ag LT V
51. s 3 Add an enclosure baseplate designed to provide IP54 protection around the power cables 4 Add an air evacuation duct between the baseplate and the duct of the IP31 or UL Type 1 conformity kit The IP31 or UL Type 1 conformity kit enables an extension duct to be mounted Drill a hole in the base of the enclosure to allow air to enter Place seals around the duct that has been added to maintain IP54 protection 5 Add a 200 mm plinth at the bottom of the enclosure with grilles to allow air to enter 6 Use the dissipated power table below to calculate the enclosure dimensions Note Connect all the additional metal parts to ground Power dissipated by the control section inside the enclosure for calculating the enclosure dimensions These power ratings are given for operation at nominal load and for the factory set switching frequency ATV61H Dissipated power 1 ATV61H Dissipated power 1 W W Ge 154 C25N4 606 D90N4 237 C31N4 769 C11N4 269 C40N4 C13N4 304 C50N4 C16N4 362 C63N4 C22N4 452 1 Add 7W to this value for each option card added Dust and damp proof flange mounting heatsink outside the enclosure This mounting is used to reduce the power dissipated in the enclosure by locating the power section outside the enclosure This requires the use of the dust and damp proof flange mounting kit VW3A9509 517 please refer to the catalog The degree of protection for the
52. t circuits 15 V max 16 V protected against short circuits OVS supply and overloads and overloads Max current 200 mA Max current 175 mA A A Incremental Max resolution 5 000 points rev B B logic inputs Max frequency 300 kHz Encoder interface cards wi th open collector outputs Terminals Function Electrical characteristics VW3 A3 403 VW3 A3 404 Vs Encoder power 12 V max 13 V protected against short circuits 15 V max 16 V protected against short circuits OVs supply and overloads and overloads Max current 175 mA Max current 175 mA A A Incremental Max resolution 5 000 points rev B B logic inputs Max frequency 300 kHz Encoder interface cards wi th push pull outputs Terminals Function Electrical characteristics VW3 A3 405 VW3 A3 406 VW3 A3 407 Vs Encoder power 12 V max 13 V protected e 15 V max 16 V protected e 24V min 20V max 30V OVs supply against short circuits and against short circuits and protected against short circuits overloads e Max current 175 mA overloads e Max current 175 mA and overloads Max current 100 mA State 0 If lt 1 5 V State 1 If gt 7 7Vand lt 13V If gt 7 7Vand lt 16V If 511 5 Vand lt 25 V A A Incremental Max resolution 5 000 points rev B B logic inputs Max frequency 300 kHz 43 Option terminals Selecting the encoder
53. teristics as logic inputs LI1 to LI5 or SW2 switch on PTC Trip threshold 3 kQ reset threshold 1 8 kQ Short circuit detection threshold lt 50 Q 24 PWR Logic input power supply Power Removal safety function input When PWR is not connected to the 24V the motor cannot be started compliance with functional safety standard EN 954 1 and IEC EN 61508 SW1 switch in Source or Sink Int position e 24 V power supply min 21 V max 27 V protected against short circuits and overloads e Max current available for customers 200 mA SW1 switch in Sink Ext position Input for external 24 V power supply for the logic inputs e 24 V power supply max 30 V Impedance 1 5 kQ State 0 if lt 2V state 1 if gt 17V e Reaction time 10ms 39 Option terminals Logic I O option card terminals VW3 A3 201 de AAA O LV Err O U O E ne Gi ER 200 SS EE o Ll di o DOSA Fe nd Source Logic input switch SW3 Factory setting Source Maximum wire size 1 5 mm AWG 16 Max tightening torque 0 25 Nm 2 21 Ib in CLO ov Er GE IIS ERES R3A R3B R3C 10 24 LIZ Lig Lg LHO ov Lo2 Characteristics and functions of the terminals Terminals
54. the braking resistor if used e la The shielding must be continuous and intermediate terminals must 10 4 be in EMC shielded metal boxes Ju 2 6 Shielded cables for connecting the control signal cables For applications reguiring several conductors use cables with a small cross section 0 5 mm 7 Shielded cables for connecting the Power Removal safety function input The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes 8 Shielded cables for connecting the encoder The shielding must be continuous and intermediate terminals must be in EMC shielded metal boxes 9 Non shielded wires for relay contact output 10 Unshielded drive power supply cables Note If using an additional input filter it should be connected directly to the line supply via an unshielded cable Link 10 on the drive is then via the filter output cable The HF eguipotential ground connection between the drive motor and cable shielding does not remove the need to connect the PE protective conductors green yellow to the appropriate terminals on each unit 61 atv6le installation manual en vi 2005 07
55. tion diagram conforming to standards EN 954 1 category 3 and IEC EN 61508 capacity SIL2 stopping category 1 in accordance with standard IEC EN 60204 1 This connection diagram is suitable for use with machines with a long freewheel stop time machines with high inertia or low resistive torque When the emergency stop is activated deceleration of the motor controlled by the drive is requested first Then after a time delay corresponding to the deceleration time the Power Removal safety function is activated Example 2 wire control LI assigned to forward LI2 assigned to reverse ve vafvafvs 14 24 34 42 58 68 gt D m al L s s2 i ESC o 1 Line choke if used 2 Fault relay contacts for remote signaling of drive status 3 In this example the logic inputs Lix are wired as Source but can be wired as Sink Int or Sink Ext please refer to page 49 4 It is essential to connect the shielding on the cable connected to the Power Removal input to ground 5 For the wiring of the power section AC supply for ATV61HC50N4 and ATV61HC63N4 drives please refer to page 48 Standard EN 954 1 category 3 requires the use of an emergency stop with double contact S1 S1 is used to activate the Power Removal safety function S2 is used to initialize the Preventa module when powering up or after an emergency s
56. tions Installing the drive Mount the drive on a wall or the back of the enclosure in accordance with the recommendations described in this document before installing the DC choke Installing the DC choke ATV61H D55M3XD to D90M3XD and ATV61H D90N4D to C63N4D drives are supplied without a DC choke ATV61H D55M3X to D9OM3X and ATV61H D90N4 to C63N4 drives are supplied with a DC choke that must be installed on top of the drive and wired in accordance with the recommendations described in this document This choke must be used for connecting drives to the 3 phase line supply Mount the DC choke on the back of the enclosure or on the wall above the drive and connect it up The instructions for installing and connecting the choke are given on page 12 Make sure that the seal between the drive and the choke chassis is doing its job properly Precautions Read and understand the instructions in the Programming Manual CAUTION INCOMPATIBLE LINE VOLTAGE Before turning on and configuring the drive ensure that the line voltage is compatible with the supply voltage range shown on the drive nameplate The drive may be damaged if the line voltage is not compatible Failure to follow this instruction can result in equipment damage A DANGER UNINTENDED EQUIPMENT OPERATION Before turning on and configuring the Altivar 61 check that the PWR POWER REMOVAL input is deactivated at state 0 in order to prevent uninte
57. top ESC enables the use of other initialization conditions for the module One Preventa module can be used for the Power Removal safety function on several ATV61 drives In this case the time delay must be set to the longest stopping time A logic input on the Preventa module can be used to indicate safely that the drive is operating in safe conditions Note For preventive maintenance the Power Removal function must be activated at least once a year The drive power supply must be switched off and then on again before carrying out this preventive maintenance The drive logic output signals cannot be considered as safety type signals Install interference suppressors on all inductive circuits near the drive or coupled to the same circuit relays contactors solenoid valves etc Choice of associated components Please refer to the catalog 47 Connection diagrams Power terminal connection diagram for ATV61HC50N4 and ATV61HC63N4 drives To disconnect 1 Line chokes if used Braking resistor connection diagram ATV61H D55M3X D75M3X D90M3X ATV61H D90N4 to C22N4 Up to 220 kW power ATV61HC22N4 braking resistors are connected directly to the terminals at the base of the drive terminals PA and PB braking resistor 1 Thermal overload relay ATV61H C25N4 to C63N4 From 250 kW upwards ATV61HC25N4 the braking resistor is connected on the external braking unit Refer to the braking unit User s Manual
58. ult in death or serious injury Drive Check whether the resistance of the protective ground is one ohm or less If several drives need to be connected to protective ground each one must be connected directly to this ground as indicated opposite A WARNING IMPROPER WIRING PRACTICES The ATV61 drive will be damaged if input line voltage is applied to the output terminals U T1 V T2 W T3 e Check the power connections before energizing the ATV61 drive If replacing another drive verify that all wiring connections to the ATV61 drive comply with all wiring instructions in this manual Failure to follow these instructions can result in death or serious injury When upstream protection by means of a residual current device is required by the installation standards a type A device should be used for single phase drives and type B for 3 phase drives Choose a suitable model integrating HF current filtering A time delay which prevents tripping caused by the load from stray capacitance on power up The time delay is not possible for 30 mA devices In this case choose devices with immunity against nuisance tripping for example residual current devices with reinforced immunity from the s i range Merlin Gerin brand If the installation includes several drives provide one residual current device per drive A WARNING INADEQUATE OVERCURRENT PROTECTION Overcurrent protective devices must b
59. xis control Axis control 10 V reference SW2 switch The LI6 logic input switch SW2 makes it possible to use the LI6 input either as a logic input by setting the switch to LI factory setting or for motor protection via PTC probes by setting the switch to PTC Motor Control power supply via an external source The control card can be supplied via an external 24V source ATV61Heeeee 50 Connection diagrams I O extension card connection diagrams Connection diagram for extended I O option card VW3A3202 Al3 Motor or X Y mA Connection diagram for logic I O option card VW3A3201 51 Connection diagrams SW3 SW4 logic UO switch Switch in Source position Switch in Source position and use of an external 24 V source SW3 or SW4 SW3 or SW4 me va di ima ee r a 7 Source Sec Lo Sa Ge VW3 A3 206 sink Mt Sink Int Ext il ig a 3 8 2 LRR ao 24V source T Ree 24V ov O lle etna 4 Switch in Sink Int position Switch in Sink Ext position SW3 or SW4 SW3 or SW4 ni Source Source i Sink Int S Sink ing Ext Ext 1 I 24V source A WARNING Unintended Equipment Operation e When the SW3 or SW4 switches are set to Sink Int or Sink Ext the common must never be connected to ground or the protective ground as there is then a risk of unint
60. z 40 C 104 F 50 C 122 F 60 C 140 F 8 kHz Switching frequency ATV61HC13N4 Yo 120 104 In 100 91 80 ZL K 60 O ee 40 20 2 5 kHz 4 kHz 6 kHz 40 C 104 F 50 C 122 F 60 C 140 F 8 kHz Switching frequency ATV61HC22N4 120 105 In 100 90 80 67 60 I p 40 20 0 2 5 kHz 4 kHz 6 kHz 40 C 104 F 50 C 122 F 60 C 140 F 8 kHz Switching frequency For intermediate temperatures e g 55 C 131 F interpolate between 2 curves Derating as a function of the temperature and switching frequency ATV61HC25N4 Yo 120 105 4 In 100 90 0 40 C 104 F 69 60 50 C 122 F 60 C 140 F 40 20 2 5kHz 4 kHz 6 kHz 8 kHz Switching frequency ATV61HC40N4 Ye 120 1051 In 100 90 80 697 60 40 C 104 F 50 C 122 F 40 60 C 140 F 20 0 25kHz 4kHz 6 kHz 8 kHz Switching frequency ATV61HC63N4 Yo 120 104 In 100 934 80 TIT 40 C 104 F 60 50 C 122 F 60 C 140 F 40 20 2 5 kHz 4 kHz 6kHz 8 kHz Switching freguency ATV61HC31N4 Yo 120 104 In 100 927 Es 40 C 104 F 70 E SSS eu 122 F 60 C 140 F 40
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