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User`s Manual for ALTIVAR 66 AC Drives

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1. Dimension amp Weights for Wall or Panel Mounting January 1999 Conduit Entries Bottom View Mounting 0 242 356 494 632 752 945 p 0 39 10 4x REF 54 90 5 125 5 160 5 191 240 s 2 01 14 29 o I Xp 27 9 Oz a L 2x9 1 46 37 S Lisa em z 8 a 21 85 47 H1 amp 2 H2 E amp S M o Outline 4 MEZ w2 0 REF 3 62 5 32 677 823 1 9 92 18 54 wi 92 135 172 209 252 344 2x 01 14 29 o gt o DOE ES 2x 02 01 51 e S gt CL Ae s z a a EL F za amp 64 T a iz gt gt c c D kn c c D N E T S 5 e c gt c c gt Dimensions CL in mm Outline 5 Door Drive Drive i Swing Controller Controller 1 a Outline 033 046 240 D54 079 11 Door hinges left hand side of drive controller Figure 8 Mounting Information for ATV66D33N4 to D79N4 and ATV66D33M2 to D46M2 16 1994 Square D All Rights Reserved
2. O ON o OODA OODV QOCOCCO OOOCO OOOO pessssssspwssssss Sp L1 L2 L3 aAA Daa 9 9191919165990 m lol o eq s 515 6 5 o0 9 9 o o o s 111213 5 5 F5 eue F6 Eu c ns PA Al V66D16N4 to D 9N4 and ATV66C10N4 to C19N4 ATV66D12M2 to D46M2 Figure 37 Location of PA and Terminals ATV66U41N4 to C19N4 and ATV66U41M2 to D46M2 1994 Square D All Rights Reserved 79 Chapter 4 Diagnostics Bulletin No VD0CO6S304E Procedure 1 Bus Voltage Measurement January 1999 Figure 38 Location of PA and Terminals ATV66C23N41 to C31N41 80 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 4 Diagnostics January 1999 Procedure 2 Input Line Voltage Measurement PROCEDURE 2 INPUT LINE VOLTAGE MEASUREMENT To measure the input line voltage 1 2 3 4 5 Perform Bus Voltage Measurement procedure see page 78 Set voltmeter to the 600 VAC scale Attach meter leads to L1 and L2 Reapply power and check for correct line voltage per drive controller nameplate rating Remove power and repeat procedure for L2 and L3 and L1 and L3 When all phases have been measured remove power Remove meter leads and reinstall covers PROCE
3. Insulated Shield Ferrite Core sias Select larger of Wo c RS iius the pore NOTE The Wobei ae Connect this wire to the shield drive controller for EN motor power wiring m ee terminations cable ground conductor Keep drain wire short shown here may be used instead of the methods shown in Insulated Shield Terminator VVDED296034 Consult cable or terminator manufacturer for proper shield termination techniques and hardware Motor Cable SHIELDED JACKETED CABLE Shield and drain wire short circuit current withstand rating must equal or exceed the cable ground conductor short circuit current withstand rating Use OLFLEX 110CY cable or equivalent Figure 20 Typical Diagram of Motor Power Wiring at Drive Controller 1994 Square D All Rights Reserved 51 Chapter 2 Wiring Bulletin No 00 065304 Using The Logic Inputs J12 January 1999 USING THE LOGIC INPUTS J12 The logic inputs may be operated from either the internal supply or an external supply Figure 21 shows the connections for operating the logic inputs from the internal power supply Customer supplied Figure 21 Operating the Logic Inputs from Internal Power Supply Figure 22 shows the connections for operating the logic inputs from an external power supply 12 30 VDC Supply
4. 6 50 Ole s a m 134 3 11 4 17 1 77 45 1 77 45 2 28 68 2 28 58 Li 8 94 100 4 61 117 Outline 1 Outline 2 5 x 01 14 29 2 28 58 Mounting S 6 89 245 175 5 79 147 2 28 58 2 28 58 EI 4 61 117 RI Outline 3 Mounting Dimensions Door Swing Een RRA 8 ATV66 N4 ATV66 M2 in mm in mm in mm in mm in mm kg mas os ao vs au ss vs wzz 55 s ar 2 U90 D12 U72 U90 12 8 325 12 2 310 234 3 D16 D23 400 234 I1 Door hinges on left hand side of drive controller Figure 7 Mounting Information for ATV66U41N4 to D23N4 and ATV66U41M2 to D16M2 NOTE When metallic conduit is used with drive controllers of outlines 1 3 install a metal conduit entry plate kit VY1A66201 separately ordered Kit mounts in place of the existing plastic plate and has a conduit hole pattern identical to those shown for outlines 1 3 1994 Square D All Rights Reserved 15 Chapter 1 Receiving and Installation Bulletin No VD0OCO6S304E
5. Supplied Customer Supplied Voltage Figure 27 Relay Outputs 1994 Square D All Rights Reserved 55 Chapter 2 Wiring Bulletin No 00 065304 Removal of CL1 CL2 Jumpers January 1999 Contact state is shown with drive controller deenergized You may assign relay contact outputs to functions other than those set at the factory Table 27 on page 67 lists factory settings For information on other functions refer to the Level 1 amp 2 Configuration Manual Maximum recommended fuse type and rating is Bussmann FNQ 2 or equivalent REMOVAL OF CL1 CL2 JUMPERS Jumpers CL1 and CL2 are factory installed If separate control power is required these jumpers must be removed To remove jumpers use the following procedure ATV66U41N4 to D12N4 and ATV66U41M2 to U90M2 drive controllers Loosen the CL1 and CL2 screws and the L1 and L2 screws Remove captive jumper wire assembly ATV66D16N4 to D79N4 and ATV66D12M2 to D46M2 drive controllers 1 Loosen the front screws only see Figure 28 Figure 28 CL1 CL2 Jumper Removal 2 Using a pair of needle nose pliers grasp the jumpers and pull straight out The sleeve on the bottom terminal should remain 3 Connect separate control power to the top terminals DO NOT make connections to the bottom terminals which contain the sleeves 4 Tighten the front screws to secure the connections ATV66C10N4 to C3
6. 66 16 2 s pce set REPRE CA Eo dd pe ERR AANA GE Y 4 Locating Nameplate on ATV66D33N4 to D79N4 and ATV66D23M2 to D46M2 4 Locating Nameplate on ATV66C10N4 to 19 4 5 Locating Nameplate on ATV66C23N41 to 1 41 5 Mounting Information for ATV66U41N4 to D23N4 and ATV66U41M2 to D16M2 15 Mounting Information for ATV66D33N4 to D79N4 and ATV66D33M2 to D46M2 16 Mounting Information for ATV66C10N4 to 19 4 17 Mounting Information for ATV66C23N41 to 1 41 18 Hoisting ATV66D54N4 to C31N41 and ATV66D46M2 19 Clearances for Drive Controllers 21 Ventilation for ATV66U41N4 to C31N41 and ATV66U41M2 to D46M2 23 Grounding Multiple Drive 40 Terminal Strip Locations ATV66U41N4 to D79N4 and ATV66U41M2 to D46M2 41 Terminal Strip Locations ATV66C10N4 to C19N4 42 Terminal Strip Locations ATV66C23N41 to C31N41 43 Terminal Strip Connections for Control 46 Typical Diagram of Control Wiring at Drive 50 Typical Diagram of Motor Power Wiring at Drive Controller 51 Operating the Logic Inputs from Internal Power 52 Operating the L
7. ATV66C23N4 to C31N4 VY1ADC614 Line Filter Board 460 V ATV66D16N4 D23N4 VX4A66103 ATV66D33N4 D46N4 VX4A66104 Board only ATV66D54N4 to D79N4 VX4A66105 ATV66C10N4 to C31N4 VX4A66106 Assembly with board and capacitors Line Filter Board 208 230 V ATV66D12M2 D16M2 VX4A66103 ATV66D23M2 D33M2 VX4A66104 Board only ATV66D46M2 VX4A66105 Line Rectifier Diode 460 V ATV66D16N4 D23N4 VZ3DM6075M1601 6 pack diode block ATV66D33N4 VZ3DM2080M1606 ATV66D46N4 VZ3DM2100M1601 ATV66D54N4 to D79N4 VZ3DM2160M1606 ATV66C10N4 C13N4 VZ3DM2170M1602 1 dual diode block ATV66C15N4 VZ3DM2260M1602 ATV66C19N4 VZ3DM2350M1602 ATV66C23N4 to C31N4 VZ3DM2600M1602 Line Rectifier Diode 208 230 V ATV66D12M2 D16M2 VZ3DM6075M1601 6 pack diode block ATV66D23M2 VZ3DM2080M1606 ATV66D33M2 VZ3DM2100M1601 1 dual diode block ATV66D46M2 VZ3DM2160M1606 DC Bus Capacitor 460 V ATV66D16N4 D23N4 VY1ADC152V450 i G pacitor ATV66D33N4 D46N4 VY1ADC472V450 ATV66D54N4 VY1ADC605 1 x Assembly with capacitors and stirring fan ATV66D64N4 D79N4 VY1ADC606 ATV66C10N4 to C19N4 VY1ADC615 Assembly with capacitors ATV66C23N4 to C31N4 VY1ADC608 DC Bus Capacitor 208 230 V ATV66D12M2 D16M2 VY1ADC152V450 ATV66D23M2 D33M2 VY1ADC472V450 ATV66D46M2 VY1ADC605 Assembly with capacitors and stirring fan 2002 Schneider Electric All Rights Reserved Bulletin No 30072 450 73 May 2002 Repair Parts List Continued Addendum to VD0C06S304E ATV66 Repair Pa
8. 250 ATV66C23N41 379 295 276 200 300 443 352 328 220 350 6 2 506 410 383 250 400 SING 571 467 438 11 10 000 AIC denoted by asterisk 2 18 000 AIC denoted by t 1994 Square D All Rights Reserved 35 Chapter 2 Wiring Bulletin No VD0CO6S304E Wiring January 1999 Table 14 Input Line Currents for Selecting Branch Circuit Conductors 460 V VTLN Note The input conductor ampacity rating should not be less than the ampacity rating selected based on the rated controller output current Input Line Current Motor AIC With Li Power Output 5 000 ith Line Drive Current 0 141 mH 22 000 AIC 65 000 AIC Impedance of Controller 10 000 0 032 mH 0 011 mH kW hp asp ZH 396 596 400V 460V 5 50 Hz 60 Hz A A A A A A 075 2 0 4 0 1 1 8 2 7 3 2 1 5 1 5 37 6 5 EE BCLS 3 4 47 5 7 2 7 22 5 3 9 0 3 48 6 5 8 0 3 9 3 ATV66U54N4 74 12 0 4 9 5 15 0 5 eens 7 6 9 8 11 9 13 2 6 7 6 2 55 11 8 20 0 11 0 13 9 16 7 18 5 10 0 9 2 7 5 16 0 ES 26 0 40 ATV66DI2N4 17 6 214 3 0 12 0 11 z 22 35 0 Zie cig e OTE 21 24 8 29 9 33 6 9 4 17 9 6 0 22 ATV66D33N4 ph T 00 30 40 44 0 52 4 59 7 37 0 34 2 30
9. 0 75 2 0 7 8 90 0 1 1 8 5 3 90 0 1 5 3 7 7 8 110 ATV66U41N4 2 3 4 5 8 110 2 2 5 3 7 8 130 1 3 4 8 5 3 130 3 0 74 7 8 150 4 0 9 5 10 5 ATV66U54N4 AA 5 76 8 4 180 5 5 11 8 13 0 ATV66U72N4 T 75 110 124 205 7 5 16 0 17 6 ATV66U90N4 ya 10 14 0 154 265 11 0 22 0 24 2 ATV66D12N4 i 15 210 23 1 350 15 0 30 0 33 0 ATV66D16N4 DS 20 27 0 29 7 480 18 5 37 0 40 7 ATV66D23N4 ra 25 34 0 37 4 560 30 0 60 0 66 0 800 i Bees 40 52 0 57 2 800 37 0 72 0 79 2 ATV66D46N4 AE 50 65 0 715 910 45 0 85 0 93 5 ATV66D54N4 Xr 60 770 84 7 960 55 0 105 115 5 ATV66D64N4 oe 75 96 0 105 1150 75 0 143 151 ATV66D79N4 e 100 124 136 1400 8 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 1 Receiving and Installation January 1999 Technical Characteristics Table 2 Variable Torque Drive Controller Ratings 460 V Continued 400 V 15 and 460 V 15 50 60 Hz 5 Switching Frequency ATV66U41N4 to D46N4 4 kHz ATV66D54N4 to C31N41 2 kHz Motor Power Max Total Output fi PH Drive Controller 400 V 460 V Current Transient Dissipated Part No 50 Hz 60 Hz Current 60 s Power kW hp A A 90 0 170 187 ATV66C10N4 125 156 171 2271 110 205 226 6 ATV66C13N4 150 180 198 2596 132 245 270 ATV66C15N4 n 200 240 264 3246 ATV66C19 111 160 300 330 200 370 407 ATV66C23N41 300 360 39
10. 150 ATVOGCISNA 180 191 217 246 182 170 132 270 275 200 PUCCIO 240 242 277 314 238 223 160 330 326 250 pices 300 318t 333 379 295 276 200 407 399 300 360 366 379 441 352 328 220 449 421 a 350 ATMOSESTNAT 420 419t 431 506 410 383 1 10 000 AIC denoted by asterisk 2 18 000 AIC denoted by t 1994 Square D All Rights Reserved 33 Chapter 2 Wiring Wiring Bulletin No VD0CO6S304E January 1999 Table 13 Input Line Currents for Selecting Branch Circuit Conductors 460 V VT Note The input conductor ampacity rating should not be less than the ampacity rating selected based on the rated controller output current Input Line Current Motor Power 5 000 AIC With Line Output 0 141 mH Impedance of Drive Current 10000 AIC 1 22 000AIC 65 000 AIC kW hp Controller 0 070 mH 0 032 mH 0 011 mH 3 5 2 o o 400V 460V 18 000 AIC 121 50 Hz 60 Hz 0 039 mH A A A A A A 0 75 2 0 4 0 1 1 8 2 7 3 2 3 5 1 6 1 5 1 5 3 7 6 5 2 ATV66U41N4 3 4 4 7 5 7 6 4 3 0 2 7 2 2 5 3 9 0 3 4 8 6 5 8 0 8 8 4 2 3 9 7 1 12 0 4 9 5 16 0 ATVOBUSANS 7 6 9 8 11 9 13 2 6 7 6 2 5 5 11 8 20 0 EE m bio Cdi 11 0 14 0 17 0 18 4 10 0 9 2 tae 16 0 25 0 _ PLN ESUBONT 14 0 1
11. Motor Power Max Total Output i es Drive Controller 208 230 V Current Transient Dissipated RR Part No 50 60 Hz Current 60 s Power kW hp A A w 75 1 4 0 15 9 120 1 ATV66U41M2 1 5 2 7 5 15 9 140 2 2 3 10 6 15 9 170 ATV66U72M2 4 5 16 7 25 1 239 2 ATV66U90M2 5 5 7 5 24 2 36 3 354 ATV66D12M2 7 5 10 30 8 46 2 437 3 ATV66D16M2 11 15 46 2 69 3 589 4 ATV66D23M2 15 20 59 4 89 1 728 ATV66D33M2 22 30 88 0 132 1052 5 ATV66D46M2 30 40 114 171 1439 Table 6 Variable Torque Drive Controller Ratings 208 V 230 V 208 V 10 and 230 V 15 50 60 Hz 5 Switching Frequency ATV66U41M2 to D33M2 4 kHz ATV66D46M2 2 kHz Motor Power Output Max Total Outli Drive Controller 208 230 V te Transient Dissipated Part 50 60 Hz Current 60 s Power kW hp A A w 75 1 4 0 15 4 120 1 ATV66U41M2 1 5 2 7 5 15 4 140 2 2 3 10 6 15 4 170 ATV66U72M2 5 5 7 5 24 2 26 6 302 2 ATV66U90M2 7 5 10 30 8 33 9 414 3 ATV66D12M2 11 0 15 46 2 50 8 559 TA 20 59 4 65 3 770 ATV66D23M2 4 25 74 8 82 3 831 ATV66D33M2 40 114 125 1260 5 ATV66D46M2 37 0 50 143 157 1528 1994 Square D All Rights Reserved 11 Chapter 1 Receiving and Installation Technical Characteristics Bulletin No VD0OCO6S304E January 1999 Table 7 Variable Torque Low Noise Drive Controller Ratings 208 V 230 V 208 V 10 and 230 V 15 50 60 Hz 5 Switching Freq
12. 54 USING THE ANALOG OUTPUTS J13 55 USING THE RELAY OUTPUTS J1 0 0 eect tees 55 REMOVAL OF CL1 CL2 JUMPERS ssesssseeee ee 56 CONTROL CIRCUIT DIAGRAMS 00 00 eee 57 3 Wite Gonttol oe ec ae ae Re ie dt ae a ees Ry RP ee 57 2 Wire Gonttol use ener d eR RE oC Need E WERL Bed 57 2 Wire Control with Isolation Contactor on Line Side coast to stop 58 EQUIPMENT 59 Mounting and Replacing Line Power Fuses ATV66C10N4 to C19N4 Drive Gontrollers 3 os oL crea ce voe prex eer oe he RU ORI TUNE t 64 Replacing Line Power Fuses in ATV66C23N41 to C31N41 Drive Controllers 64 1994 Schneider S A All Rights Reserved i ALTIVAR 66 Receiving Installation Start Up VDO0CO06S304E Contents January 1999 CHAPTER 3 3 5 63 INTRODUCTION iri tamen aee rero SUR Perte sna ma ed tae 66 FACTORY SETTINGS secu ve rr RI v em dux oh RUE dL m X PER EROR 67 CONTROL TY PES retten eh ne eo DAE e UE I ee aa 68 Normal 2242 2h p ces E Ra RA UR E tek Sled PR sca 68 High Torque reae here ee ob tas et n E Re EROR Ted 69 Special eoe pas eet Eaque oe p tp dele 69 NOELD No Load sees exa ee presen ree ene en 69 M
13. 115 5 157 5 ATV66D79N4 75 96 0 1440 1270 6 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 1 Receiving and Installation January 1999 Technical Characteristics Table 1 Constant Torque Drive Controller Ratings 460 V Continued 400 V 15 and 460 V 15 50 60 Hz 5 Switching Frequency ATV66U41N4 to D46N4 4 kHz ATV66D54N4 to C31N41 2 kHz Motor Power Max Total Drive C i 400 V 460 V Output Transient Dissipated Outline rive 00 Current Current p Part No 50 Hz 60 Hz Power 60 s kW hp A A 75 152 207 ATV66C10N4 MH 100 194 186 1605 90 190 258 ATV66C13N4 ie ie did 1952 6 110 226 307 ATV66C15N4 A 150 180 270 2251 132 270 367 ATV66C19N4 os 200 240 360 3067 160 330 450 ATV66C23N41 s 250 300 450 4483 200 407 555 7 ATV66C28N41 Wy 300 360 540 5246 220 449 612 ATV66C31N41 350 420 630 5966 1994 Square D All Rights Reserved 7 Chapter 1 Receiving and Installation Bulletin No VD0OCO6S304E Technical Characteristics January 1999 Table 2 Variable Torque Drive Controller Ratings 460 V 400 V 15 and 460 V 15 50 60 Hz 5 Switching Frequency ATV66U41N4 to D46N4 4 kHz ATV66D54N4 to C31N41 2 kHz Motor Power Max Total Output Ax Goiak Drive Controller 400 V 460 V Current Transient Dissipated Part No 50 Hz 60 Hz Current 60 s Power kW hp A A
14. ATV66D46N4 60 F2 780 40 52 57 1 67 6 45 6 24 7 1 3 1 z 76 6 49 0 as RS E go Aves 0 bu Ms eie aes X 75 ATV6GDZ9NA pn 106 e 133 90 1 83 5 11 10 000 AIC denoted by asterisk 36 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 2 Wiring Wiring Table 15 Input Line Currents for Selecting Branch Circuit Conductors 208 230 V CT Note The input conductor ampacity rating should not be less than the ampacity rating selected based on the rated controller output current Input Line Current Motor With Line Impedance of Power Output 230V 208 230 V Drive Current 208 V 208 V 230 V Controller 8 800 AIC 50 60 Hz 5 000 AIC 22 000 AIC 3 5 3 5 0 036 mH 0 070 mH 0 016 mH kW hp A A A A A A A A 0 75 1 4 0 5 7 4 8 5 7 3 5 3 3 3 5 3 0 1 5 2 ATV66U41M2 7 5 10 1 8 6 10 2 6 4 6 2 6 0 5 6 22 3 10 6 14 1 11 9 141 9 2 8 9 8 5 8 1 4 5 ATV66U72M2 16 7 214 18 0 21 5 147 143 140 12 9 5 5 7 5 ATV66U90M2 242 30 4 25 6 30 5 220 21 3 20 1 19 3 7 5 10 ATV66D12M2 30 8 38 6 32 6 38 7 29 0 278 265 252 11 15 ATV66D16M2 46 2 54 7 46 2 54 8 43 0 41 1 38 7 372 15 20 ATV66D23M2 59 4 69 4 58 8 69 5 57 0 54 1 50 4 49 0 20 30 ATV66D33M2 88 0 97 6 81 1 97 6 83 0 79 8 74 0 72 0 30 40 ATV66D46M2 114 124 2 102 1 125 4
15. Chapter 1 Receiving and Installation Bulletin No 00 065304 Dimension amp Weights for Wall or Panel Mounting January 1999 Conduit Entries Bottom View 0 REF 6 88 10 6 15 0 gt 19 1 21 8 175 269 382 DB amp 485 553 INPUT 1 INPUT 12 PARALLEL OUTPUT L1 L2 L3 L1 L2 L3 PA PB T1 T2 T3 CONTROL l 160 2 2 34 40 5 2 14 59 5 a b SW 2 54 2 8 8 3 33 E M8 M8 84 5 Cy aie M87 M87 LILILILILILILI Depth 14 76 875 Outline 6 Mounting KNOCKOUTS wwe M4 2 x 1 00 25 4 dia M8 2 50 63 5 dia M87 3 00 76 2 dia w 2 50 63 5 dia NOTES 11 Use 2 in 50 8 mm knockout for parallel cable runs B589 21 Use single in 76 2 mm knockout for single ESES cable run H1 Leave an area extending 12 in H2 843 mm below controller free of obstructions to allow access to ventilation fan Label Dimensions in mm Lx V OG IP rar res 12 305 Y Mounting Dimensions Door Swing Drive H1 H2 Wi w2 Weight Controller ATV66 N4 in mm in mm in mn in mm in mm lb kg in mm C10 280 127 6 C13 C15 C
16. DC bus LED 41 43 78 84 88 DC bus voltage 44 78 DC injection braking 68 70 DC BUS OVERVOL 89 deceleration 13 68 derating 72 dimensions clearances 21 controller 15 18 recess mounting 26 disconnect switch 22 driving torque 73 dynamic braking 44 73 91 enclosures NEMA Type 1 IP30 23 24 NEMA Type 12 IP54 24 26 sizing 24 environment 14 22 equipment requirements 59 63 F factor 13 fan 23 also see ventilation 23 26 flow rates 23 fault LED 41 43 88 1994 Square D All Rights Reserved 101 ALTIVAR 66 Receiving Installation Start Up Index faults control board 90 DB Resistor 91 dynamic braking 91 fault relay 47 ground 90 input phase loss 89 internal connection 90 LEDs 24 41 88 memory failure 90 messages 88 92 overcurrent 30 89 overheating 67 70 89 overload 89 overspeed 90 overtemperature 89 overvoltage 89 precharge fail 90 relay 47 serial link 91 short circuit 90 signal 90 tachogenerator 92 undervoltage 89 user defined 92 FEEDBACK LOSS 92 flux vector 69 frequency output 67 range 13 specifications 13 switching 6 12 fuses control 59 63 line power 59 64 power 57 58 transformer 59 62 G GND terminals 44 45 GROUND FAULT 90 grounding 40 43 H handling 19 heat sink 26 High Torque control 66 69 72 73 hoisting 19 inductors 39 IN PHASE LOSS 89 inputs disconnect switch 22 fuses 64 logic 47 52 phase fault 89 speed re
17. ENT to continue Figure 39 Drive Identification Screen A DANGER HAZARDOUS VOLTAGE Read understand and perform Procedure 1 Bus Voltage Measurement on page 78 before identifying the firmware version Measurement of DC bus capacitor voltage must be performed by qualified personnel The DC bus LED is not an accurate indication of absence of DC bus voltage DO NOT short across capacitors or touch unshielded components or terminal strip screw connections with voltage present Many parts in this drive controller including printed wiring boards operate at line voltage DO NOT TOUCH Use only electrically insulated tools Failure to follow these instructions will result in death or serious injury Alternate Procedure 1 Disconnect and verify that all power is removed from the drive controller including any power present on J22 J23 amp J24 terminals of the I O extension module if installed 2 Wait 1 minute to allow the DC bus to discharge 3 Perform the Bus Voltage Measurement Procedure listed above in this chapter 4 Insert a small electrically insulated screw driver in the notch of the firmware chip cover Apply slight upward pressure and pull out to remove the cover See Figure 40 NOTE If the drive controller is equipped with an I O extension module or communication carrier module first remove the module by loosening the 82 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapt
18. ATV66U41M2 to D16M2 6 25 1 159 FZ 76 76 E 12 305 Outline 6 ATV66C10N4 to C19N4 8 200 Outlines 4 5 ATV66D33N4 to D79N4 and ATV66D23M2 to D46M2 12 1 304 8 v eee 66 E Outline 7 ATV66C23N41 to C31N41 Figure 12 Clearances for Drive Controllers Mount drive controller vertically Do not locate drive controller near heat radiating elements When installation surface is uneven put a spacer behind the drive controller mounting pads to eliminate gaps The drive controller exterior may be damaged if fastened to an uneven surface 1994 Square D All Rights Reserved 21 Chapter 1 Receiving and Installation Bulletin No VD0C06S304E Installation Precautions January 1999 Drive controllers are Type 1 enclosed devices and must be installed in a suitable environment The environment around drive controller must not exceed Pollution Degree 3 requirements as defined in NEMA ICS 1 or IEC664 Verify that the voltage and frequency characteristics of the input line match the drive controller nameplate rating Installation of a disconnect switch between the input line and drive controller is recommended Follow national and local codes Overcurrent protection is required Install line power fuses F1 F3 recommended in Tables 21 throu
19. CT VT Littelfuse Soner Class T or CC ntactor Suppressor 3 Fuses kw hp low aes 208v 230v 2 noise 5 5 8 ea LC1 9070 FNQ R 3 FNQ R 6 T60100 1C12 p401085 LA4PA2G kzsp2o 4 10 3 ea LC1 9070 FNQ R 3 FNQ R 6 1321720 T60200 1C 2 potice L DA G K75p20 4 10 3 ea LC1 9070 FNQ R 3 FNQ R 6 18 5 25 T60200 10 2 Daot1G6 A4 DA 8 NORI 4 10 3 ea LC1 9070 FNQ R 3 FNQ R 6 221030 T 0200 1C 2 11 A4 DA 4 10 3 ea LC1 9070 FNQ R 2 FNQ R 1 FNQ R 1 30 40 T o200 1C 2 F115G6 L 9 980 Kooop20 14 6H0 60 8 ea 1 1 9070 FNQ R 2 FNQ R 1 FNQ R 1 37 250 T o400 1C 2 Ft15G6 L 97980 2 14 6H0 60 1 For F10 and F11 use Bussmann control fuse KTK R 3 The recommended control fuse carrier is 9080 FB2611CC 2 Bussmann part numbers 3 T1 has been dimensioned to supply KM1 coil inrush and sealed VA requirements only Any user control pilot device additions may require re dimensioning of T1 VA capacity 4 Square D Class CC Fuse Block numbers 5 Manufacturer specific fuse selection DO NOT SUBSTITUTE Table 25 Maximum Allowable Line Fuse F1 to F3 for 208 230 V Drive Controllers Controller ATV66 M2 Class CC Fast Acting Class T Littelfuse JLS 1 Gould Shawmut A4J 1 U41 600 V 25A 600 V 45A 600V 35A 600V 35A U72 U90 600 V 100A 60
20. Customer supplied Figure 22 Operating the Logic Inputs from External Power Supply You may assign the logic inputs to functions other than those set at the factory Table 27 on page 67 lists factory settings For information on other functions refer to the Level 1 amp 2 Configuration Manual 52 1994 Square D All Rights Reserved Bulletin No VD0CO6S304E Chapter 2 Wiring January 1999 Using The Logic Outputs J12 USING THE LOGIC OUTPUTS J12 The logic outputs can be operated from either the internal supply or an external supply You must use an external supply if logic outputs drive a load at a voltage other than 24 V or if the current required is greater than the available current as calculated in Note 5 in Table 20 on page 47 NOTE If you use the internal supply you must connect the LOP to 24 Figure 23 Operating the Logic Outputs from Internal Power Supply Figure 24 shows the connection of an external supply for operating the logic outputs 24 Customer 12 30 VDC supplied _ Supply Figure 24 Operating the Logic Outputs from External Power Supply 1994 Square D All Rights Reserved 53 Chapter 2 Wiring Bulletin No 00 065304 Using The Speed Reference Inputs J13 January 1999 USING THE SPEED REFERENCE INPUTS J13 The ALTIVAR 66 drive controller has two analog inputs for the sp
21. Space for isolation COM Speed reference common 0v Input 1 Speed ref voltage 0 10 V Z 30kQ J13 21 10 Reference supply 10 V Is 10 mA max Al2 Input 2 Speed ref current 4 20 mA 6 Z 250 Q AO1 Analog output 1 0 20 mA 12 V max programmable as 4 20 mA w keypad display AO2 Analog output 2 0 20 mA 12 V max programmable as 4 20 mA w keypad display COM Analog common 0v 2 3 4 5 6 See circuit diagrams on page 57 and 58 14 AWG 2 5 mm Tightening torque 3 5 Ib in 0 4 Nem Max wire size for all terminals Relay coil deenergizes on fault Contact state with drive contro ler deenergized Total current of 24 V internal supply is 210 mA Available current of the two logic outputs can be calculated as follows each logic input requires 10 mA each analog output requires 20 mA and the typical quiescent current of LOP is 15 mA For example in an application where three logic inputs and one analog output are used the total available current is 210 mA 3 x 10 mA 1x 20 mA 15 mA 145 mA to drive the logic output loads If more current is required an external supply must be used 0 20 mA x 20 mA 20 4 mA programmable with keypad display 0 5 V Z 2 30 kQ selectable with switch on control board 1994 Square D All Rights Reserved 47 Chapter 2 Wiring Bulletin No 00 065304 Electromagnetic Compatibility EMC January 1999 ELECTROMAGNETIC COMPATIBILITY E
22. Torque decreases linearly to 50 at 0 1 Hz Transient overtorque typical 41096 ATV66U41N4 to D12N4 and ATV66U41M2 to D12M2 170 torque for 60 s constant torque 11096 torque for 60 s variable torque 1994 Square D All Rights Reserved 73 Chapter 3 Start Up Bulletin No VD0CO6S304E Motor Considerations January 1999 ATV66D16N4 to C31N41 and ATV66D16M2 D46M2 150 torque for 60 s constant torque 11096 torque for 60 s variable torque Special constant torque and NOLD variable torque control types 100 torque typical at 50 of nominal frequency over 2 1 speed range Torque decreases linearly to 50 at 1096 of nominal frequency Transient overtorque typical 41096 ATV66U41N4 to C31N41 and ATV66U41M2 to D46M2 150 torque for 60 s constant torque 110 torque for 60 s variable torque T Tn 1 5 3 1 Continuous useful torque self ventilated motor 1 2 2 Continuous useful torque force cooled motor 1 0 95 1 3 Transient overtorque Fn nominal frequency 0 5 0 f 0 1 Fn 0 5 Fn Fn Figure 33 Typical Constant Torque Curves T Tn NS 1 Continuous useful torque 2 2 Transient overtorque Oy 3 Transient overtorque during acceleration 0 5 1 Fn nominal frequency 0 3 0 f 0 1 Fn Fn Fmax Figure 34 Typical Variable Torque Curves MOTOR CONSIDERATIONS Many factors must be considered when controlling a motor with a drive controller The following sections describe se
23. VDOCO6S304E January 1999 Printed USA FP Replaces Bulletin No VD0C06S304D dated 02 98 1994 1998 1999 Schneider S A All Rights Reserved Addendum ALTIVAR 66 Addendum to VD0C06S304E ATV66 Repair Parts Retain for future use INTRODUCTION SELECTING REPAIR PARTS FOR ATV66C10N4 TO ATV66C19N4 DRIVE CONTROLLERS 2002 Schneider Electric All Rights Reserved Bulletin No 30072 450 73 May 2002 Raleigh NC USA This Addendum replaces Appendix A of instruction bulletin VDOCO6S304E ALTIVAR 66 Adjustable Speed Drive Controllers for Asynchronous Motors User s Manual Constant and Variable Torque 1 to 400 hp 460 V and 1 to 50 hp 230 V Receiving Installation and Start up This addendum contains revised repair parts information Replacement of repair parts requires the use of special tools and installation procedures not included with the repair parts kits Before replacing any repair part consult the ALTIVAR 66 Drive Controller Service and Troubleshooting Manual bulletin number 00 065701 1 75 hp 100 hp VT or VD0C06S702 100 350 hp 125 400 hp VT These manuals can be ordered from your local Square D distributor Repair parts must be replaced only by qualified electrical personnel familiar with the service and troubleshooting manual When ordering repair parts for the ATV66C10N4 to ATV66C19N4 drive controllers check the drive controller serial number and follow these guidelines Refer to pages 3 5 of bu
24. whether from the same drive or other drives Do not run in the same conduit this separation reduces the possibility of coupling electrical noise between circuits When wiring ALTIVAR 66 drive controllers follow the wiring practices required by national and local electrical codes in addition to the following When using metallic conduit with ATV66U41N4 to D23N4 and ATV66U41M2 to D16M2 drive controllers you must also use a metal conduit entry plate kit VY 1466201 This kit mounts in place of the existing plastic plate and is held in place with two screws A bond wire which must be connected to ground GND on the J2 terminal strip is included Use metallic conduit for all drive controller wiring Do not run control and power wiring in the same conduit Separate metallic conduits carrying power wiring or low level control wiring by at least 3 in 8 cm Separate non metallic conduits or cable trays used to carry power wiring from metallic conduit carrying low level control wiring by at least 12 in 30 5 cm Cross the metallic conduits and non metallic conduits at right angles whenever power and control wiring cross Attenuate conducted emissions to the line from the drive controller in some installations to prevent interference with telecommunication radio and sensitive electronic equipment Such instances may require attenuating filters Consult catalog for selection and application of these filters Branch Circuit Conn
25. 1 to 2 inches Use of a cable shield is recommended The shield must be terminated to ground at one end only It is recommended that the shield be terminated at the drive controller Shield connection terminals are provided on the ALTIVAR 66 drive controller for this purpose Make sure that the coils of all relays and solenoids connected to the output contacts of the drive controller are equipped with appropriate transient suppressors For proper control wiring route conductors to avoid contact with other voltage potentials in the drive controller Wire insulation must have the appropriate voltage rating for the voltage present The ATV66C10N4 to C31N41 drive controllers are equipped with control wiring channels to 38 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Wiring allow routing of control conductors away from power circuit conductors The channels are located on the right side of ATV66C10N4 to C19N4 controllers and on the left side of ATV66C23N41 to C31N41 controllers Output Wiring Precautions A WARNING DRIVE CONTROLLER DAMAGE Drive controller will be damaged if input line voltage is applied to output terminals U T1 V T2 W T3 Check power connections before energizing drive controller Failure to follow these instructions can result in death serious injury or equipment damage The drive controller is sensitive to the amount of capacitance either phas
26. 109 1 105 4 98 7 95 6 Table 16 Input Line Currents for Selecting Branch Circuit Conductors 208 230 V VT Note The input conductor ampacity rating should not be less than the ampacity rating selected based on the rated controller output current Input Line Current Motor With Line Impedance of Power i Output 230 V 208 220 V Drive Current 208V 208 V 230 V Controller 8 800 AIC 50 60 Hz 5 000 22 000 AIC 3 5 3 5 0 036 mH 0 070mH 0 016 mH kW hp A A A A A A A A 0 75 1 4 0 5 7 4 9 5 8 3 5 3 3 3 5 3 0 15 2 ATVeeU41M2 7 5 10 2 8 6 10 2 64 62 60 56 22 3 10 6 14 0 11 8 14 0 92 89 85 81 5 5 7 5 ATV66U72M2 24 2 30 6 25 8 30 6 220 21 3 20 1 19 3 7 5 10 ATV66U90M2 30 8 38 8 32 7 38 8 29 0 278 26 5 252 11 15 ATVe6D12M2 46 2 54 7 46 2 54 8 43 0 41 1 387 372 15 20 59 4 69 3 58 7 69 4 57 0 54 1 50 4 49 0 18 5 25 ATV66D23M2 748 84 4 71 5 84 4 69 2 67 2 64 0 60 9 30 40 ATVeeDa3M2 114 124 9 102 7 125 9 109 1 105 4 98 7 95 6 37 50 ATV66D46M2 143 149 3 122 6 151 1 1340 129 6 121 0 117 4 1994 Square D All Rights Reserved 37 Chapter 2 Wiring Wiring Bulletin No VD0C06S304E January 1999 Table 17 Input Line Currents for Selecting Branch Circuit Conductors 208 230 V VTLN Note The input conductor ampacity rating should not be less than the ampacity rating selected based on the ra
27. 125A 110 191 60200 1013 L DA26 10 1 For F10 and F11 use Bussmann control fuse KTK R 3 The recommended control fuse carrier is 9080 FB2611CC 2 Square D Class CC Fuse Block numbers 3 Bussmann part numbers 4 Gould Shawmut part numbers 5 Ferraz part numbers 6 Fuse mounted inside drive controller 7 The power circuit configuration of the ATV66C23N4 to ATV66C31N4 drive controllers does not support the use of an input isolation contactor 8 T1 has been dimensioned to supply KM1 coil inrush and sealed VA requirements only Any user control pilot device additions may require re dimensioning of T1 VA capacity 9 Manufacturer specific fuse selection DO NOT SUBSTITUTE 10 125 A rating allowable for ATV66D54N4 controller 1994 Square D All Rights Reserved 59 Chapter 2 Wiring Bulletin No 00 065304 Equipment Recommendations January 1999 Table 21 Recommended Equipment for 1 to 400 hp 460 V Drive Controllers Continued M1 A1 F1 F3 Input F7 F8 F9 Controller i 2 Motor Line Power Fuses Ratings Fuse Class ATV66 N4 9 Primary Sec CT Gould Fuse Carriers Line Transient Xfmr Xfmr ww no CCFast uua Shawmut Class T or CC Contactor Suppressor Fuses Fuses tow Acting 9 A4J 3 3 noise 9 600 V 600 V 600V 3ea 9070 FNQ R 1 1 A8 360 3 D64 54 175 1
28. 39 Chapter 2 Wiring Bulletin No 00 065304 Wiring January 1999 Grounding For safe dependable operation drive controllers must be grounded according to all national and local codes To ground the drive controller Connect a copper wire from the grounding terminal to the power system ground conductor Wire size is determined by the drive controller size and by national and local codes Verify that resistance to ground is one ohm or less Improper grounding causes intermittent and unreliable operation A DANGER HAZARDOUS VOLTAGE INADEQUATE GROUNDING Ground equipment using screw provided Drive controller must be properly grounded before applying power Do not use metallic conduits or shields as a ground conductor Failure to follow these instructions will result in death or serious injury Multiple drive controllers must be grounded shown in Figure 14 Do not loop or series the ground cables Drive Controller Drive Controller Drive Controller Figure 14 Grounding Multiple Drive Controllers Drive Controller Drive Controller When using the metal conduit entry plate kit VY1A66201 with ATV66U41N4 to D23N4 and ATV66U41M2 D16M2 drive controllers the bond wire must be connected to ground GND as shown in Figure 15 on page 41 and Figure 16 on page 42 40 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 2 Wi
29. 6 ATV66C23N41 to C31N41 1994 Square D All Rights Reserved Chapter 1 Receiving and Installation Bulletin No VD0OCO6S304E Technical Characteristics January 1999 TECHNICAL CHARACTERISTICS 460 V Controllers The following tables show power and current ratings for 460 V drive controllers when set for constant torque Table 1 variable torque Table 2 and variable torque low noise Table 3 Table 4 on page 10 lists recommended braking resistance values Table 1 Constant Torque Drive Controller Ratings 460 V 400 V 15 and 460 V 15 50 60 Hz 5 Switching Frequency ATV66U41N4 to D46N4 4 kHz ATV66D54N4 to C31N41 2 kHz Motor Power Max Total 400 V 460 V Output Transient Dissipated Outline Drive Controller 00 60 Current Current Part No 50 Hz 60 Hz Power 60 s kW hp A A 0 75 2 3 8 0 95 0 1 1 8 7 2 95 0 1 5 4 1 8 0 117 ATV66U41N4 5 p de 2 2 5 8 8 0 140 3 4 8 7 2 140 ATV66U54N4 3 0 7 8 10 7 165 4 0 10 5 14 2 ATV66U72N4 b 5 76 a 185 5 5 13 17 7 ATV66U90N4 75 165 225 2 7 5 17 6 24 0 ATV66D12N4 10 140 210 290 11 0 24 2 33 0 ATV66D16N4 5 15 210 315 380 3 15 0 33 0 45 0 ATV66D23N4 8 20 270 405 530 22 0 48 4 66 0 ATV66D33N4 E 30 40 0 60 0 655 30 0 66 0 90 0 ATV66D46N4 E 40 52 0 780 880 37 0 79 2 108 ATV66D54N4 50 65 0 975 885 45 0 93 5 127 5 5 ATV66D64N4 VS 60 770 1155 1055 z 55 0
30. C19N4 VZ3IM2400M1202 driver boards 1 clamp module ATV66C23N4 C28N4 VZ31M1400M1207 4 IGBT blocks 2 snubber boards 2 gate ATV66C31N4 VZ31M1500M1207 driver boards 2002 Schneider Electric All Rights Reserved 3 Addendum to VD0C06S304E ATV66 Repair Parts Repair Parts List Continued Description Drive Controller Part No Bulletin No 30072 450 73 May 2002 Note Inverter IGBT 208 230 V ATV66D12M2 VZ3IM2075M0601 ATV66D16M2 VZ3lM2100M0601 ATV66D23M2 VZ3IM2150M0601 1 dual IGBT block ATV66D33M2 VZ3IM2200M0601 ATV66D46M2 VZ3IM2300M0601 Inverter IGBT Clamp Capacitor ATV66C23N4 to C31N4_ VY1ADC610 1 capacitor Dynamic Braking IGBT 460 V ATV66D16N4 D23N4 VZ3IM1025M1001 ATV66D33N4 D46N4 VZ3IM2050M1201 1 IGBT Block ATV66D54N4 VZ3IM2100M1201 ATV66D64N4 D79N4 VZ3IM2150M1201 ATV66C10N4 to C19N4 VZ3IM1300M1202 ATV66C23N4 VZ3IM1400M1208 1 IGBT block 1 diode block 1 snubber board 1 gate driver board ATV66C28N4 C31N4 VZ3IM1300M1208 2 IGBT blocks 2 diode blocks 2 snubber boards 1 gate driver board Dynamic Braking IGBT 208 230 V ATV66D12Me2 D16M2 VZ3IM1060M0601 ATV66D23M2 VZ31M2075M0601 1 IGBT block ATV66D33M2 VZ3IM2100M0601 ATV66D46M2 VZ3lM2150M0601 Dynamic Braking Clamp Capacitor ATV66C10N4 to C19N4_ VY1ADC616
31. C31N41 drive controllers contain the following resettable or renewable parts Refer to pages 79 and 80 for their location Resettable Parts Protective Switch GV2 for precharge resistor Note ATV66C23N41 to ATV66C31N41 drive controllers have two protective switches A tripped switch is displayed as a Precharge fault Perform Bus Voltage Measurement procedure on page 78 before resetting switch If switch trips operations of the KM1 contactor or disconnect means may have exceeded one per every two minutes as recommended on page 58 Prior to resetting the switch check number of operations of the KM1 contactor A tripped switch may also be caused by a short circuit on the DC bus In this case drive controller may require servicing Renewable Parts Line power fuses F1 F3 Refer to page 64 for information on mounting and replacing these fuses See Appendix A Spare Parts List for replacement fuses Control fuses F5 F6 Perform Bus Voltage Measurement procedure on page 78 The control fuses are contained in a removable clip To access fuses pull clip out of the fuse holder Replace with KTK R 5 fuses or use DF3CF00501 control fuse kit DC bus fuses F4A F4B and F4C on ATV66C10N4 to C31N41 drive controllers Before checking fuse perform the following Bus Fuse Test Procedures A DANGER HAZARDOUS VOLTAGE This equipment contains energy storage devices Read and understand the F4A F4B amp FAC bus fuse test procedure
32. CURRENT 000000000 000000000 7 ZZ29858 9 lt lt 44 COM ui LI2 LI3 LI4 24 LOP LO1 LO2 COM Figure 18 Terminal Strip Connections for Control Board 46 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 2 Wiring Control Wiring Table 20 Control Terminal Strip Characteristics Connector Terminal Function Characteristics R1A B contact 14 Fault relay Minimum 10 mA 24 VDC R1B N C contact output Maximum inductive load of R1C Common 2 0 A 120 VAC max 0 10 J operation 80 operations minute J1 21 R2A N O contact 4 Programmable 1 0 A 220 VAC max 0 25 J operation 25 operations minute R2B N C contact relay output 2 0 A 24 VDC max 0 10 J operation 80 operations minute R2C Common Arc suppression provided by varistors in parallel with relay contacts LH Logic input 1 24 V 10 mA State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V LI2 Logic input 2 24 V 10 mA State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V LI3 Logic input 3 24 V 10 mA State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V Ll4 Logic input 4 24 V 10 mA State 0 V lt 5 V State 1 V gt 12 V Vmax 30 V J12 121 24 Control supply Is 210 mA max 1 LOP LO supply input Minimum 12 V Maximum 30 V quiescent current typical 15 mA LO1 Logic output 1 24 V 200 mA max 5 LO2 Logic output 2 24 V 200 mA max 5 COM Logic common 5 Shield Ground
33. Drive Controller ATV66 u4ina U90N4 D16N4 D33N4 D54N4 Terminals U54N4 D12N4 D23N4 D46N4 D64N4 C23N41 U72N4 U72M2U D12M2 D23M2 D79N4 C1ON4 C15N4 C28N41 U41M2 90M2 D16M2 D33M2 D46M2 1 4 C19N4 C31N41 1 1 1 2 2 2 2 2 Max Wire AWG 10 6 12 12 12 8 8 8 CL21 Size mm 2 5 10 2 5 2 5 2 5 8 8 8 er Terminal Ib in 673 854 673 673 673 20 20 20 Torque Nem 0 76 4 076 0 76 0 76 23 23 23 Max Wire AWG 10 6 4 2 0 4 0 350 2x 300 L1 Size mm 2 5 10 10 35 70 120 185 S500 12 L3 Terminal Ib in 673 354 177 88 1704 325 375 375 Torque Nem 0 76 4 2 10 19 36 7 42 4 Max Wire AWG 10 6 4 2 0 4 0 350 350 MCM UTi Size mm 25 10 10 35 70 120 185 QOO MOM W T3 Terminal 673 354 177 88 1704 325 325 m Torque Nem 0 76 4 2 10 19 36 7 36 7 Max Wire AWG 10 6 4 2 0 4 0 350 350MCM Size mm 25 10 10 85 70 120 185 3X300 MOM Terminal b in 673 354 177 88 170141 325 325 uvm Torque Nem 0 76 4 2 10 19 36 7 36 7 Max Wire AWG 10 6 8 4 2 2 0 2 0 Size mm 2 5 10 6 16 35 35 35 2500 MEM Terminal Ib in 673 354 106 177 265 120181 120181 m Torque N m 0 76 4 12 2 3 13 6 13 6 Max Wire AWG 6 6 4 4 2 350 350 MCM cNp Size mm 6 10 10 16 35 70 95 eee MCM Terminal Ib in 17 7 854 177 265 26 5 325 325 Kr Torque Nem 2 4 2 3 3 36 7 36 7 Max Wire AWG 6 6 4 4 2 350 350 M
34. Dynamic Braking User s Manual 81 1 Resolution limited to processor resolution 2 Drive Controller at operating 3 Refer to page 73 oad and temperature 1994 Square D All Rights Reserved 13 Chapter 1 Receiving and Installation Technical Characteristics Bulletin No VDOCO6S304E January 1999 Table 9 Drive controller protection Specifications Continued Against short circuits between output phases between output phases and ground on the outputs of internal supplies on the logic and analog outputs Against input line supply under overvoltage Against overheating by thermal sensor Motor protection Incorporated electronic thermal protection page 70 Keypad display Self diagnostics with full fault messages in six languages Also refer to Level 1 amp 2 Configuration manual Communication Complete programming by keypad Optional multidrop serial link Modbus Plus Modbus Uni Telway Temperature Operation 32 to 104 F 0 to 40 C Storage 13 to 158 F 25 to 70 C Humidity 95 maximum without condensation or dripping water Altitude ATV66U41N4 M2 through ATV66C19N4 x 3 300 ft 1 000 m above this de rate by 1 296 for every 300 ft 100 m max 6 600 ft 2 000 m e ATV66C23N41 through ATV66C31NA41 lt 3 300 ft 1 000 m Enclosure NEMA Type 1 IP30 Pollution Degree Pollution Degree 3 per NEMA ICS 1 and IEC 664 1 Resist
35. LA4 DA2G FNQ R 1 2 T60060 3CRI3I 600V 600V 600 V d 9070 zt 611 21 t R 3 4 u54 UM Soa 20A 20 A LA4 DA2G FNQ R 1 2 T60060 3CRI3I 600V 600V 600 V 20805 9070 611 21 R 4 5 u72 054 Soa 20 A LA4 DA2G 50020 FNQ R 1 2 T60060 3CRI3 600V 600V 600 V 9070 T FB3611CC 2I R 55 7 5 PEN LA4 DA2G 50020 FNQ R 1 2 T60060 3CRI3I 600 V 600 V 600 V 9070 55 75 090 AN 20A 30A 160060 3CRISI LA4 DA2G FNQ R 1 2 600 V 600 V 600 V 7 9070 75 10 012 U90 35A 35A 160060 3CRISI LA4 DA2G FNQ R 1 2 600 V 600 V 600 V LC1 9070 Z 2 3CRI3I R 11 15 D12 45A 160060 3CR 1 LA4DA2G 50020 FNQ R 1 2 600 V 600 V 600 V LC1 9070 11 15 D16 60 60 A 60A 160060 3CRISI pesi0ce 1 40 29 50020 FNQ R 1 2 600 V 600 V 600 V LC1 9070 3C13 R 15 20 D23 D16 A 70 79A 760100 30 1096 1 40 29 50020 FNQ R 1 2 600 V 600 V 600 V LC1 9070 FNQ R 6 5 2 30131 7 18 57429 p23 90 A 90 A goa 150100 30 potige L DA26 5 20 10 600 V 600 V 600 V LC1 9070 FNQ R 6 z 3C13 4 227 30 2038 90A 90A goa 16010030 501166 L DA28 10 600 V 600 V 600V 3 ea LC1 9070 FNQ R 6 3044071 D484 D33 125A 125A 110A 60200 1 181 11 L DA28 10 600 V 600 V 600V LC1 FNQ R 6 BPP Soi Dos fy DAS 9i 125A
36. Line Power Fuses in ATV66C23N41 to C31N41 Drive Controllers Line power fuses for the ATV66C23N41 to ATV66C31N41 drive controllers can be mounted internally within the cabinet enclosure To replace internal fuses to the drive controller 1 Perform Bus Voltage Measurement Procedure on page 78 2 Locate the line fuses F1 F3 as shown in Figure 38 on page 80 These fuses are directly beneath the main disconnect switch 3 Remove the old fuses Save the mounting hardware 4 Using the hardware from step 3 mount the replacement fuses Screws M12 x 1 75 x 35 mm Recommended torque 486 608 Ib in 54 9 68 6 Nem 5 Close drive controller door 64 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 3 Start Up January 1999 CHAPTER 3 START UP INTRODUCTION ics ccv RR ek m Ee um XE Sed a eae Spes 66 FACTORY SETPINGS 2 Race ede en x ce ere E SUE Tic qm don 67 CONTROEUTYBES incertae Salem ee vae e SC c oer ake ree UR 68 X xri A a ep E REC ZEE 68 High Torque 2S Axe Re ce rh e redo boi 69 Special MM 69 NOED No Load orar ER ht o te eee I e DE onte ree RU RU 69 MOTOR THERMAL OVERLOAD PROTECTION 70 ADJUSTMENT OF MOTOR 71 AVAILABLE MOTOR TORQUE 0 00000 cece sh 72 Continuous Duty isses n 72 Overtorque Capabi
37. Matched keypad and control basket ATV66D23M2S264U VX4A66CK1S260 with latest firmware Keypad display for drive controllers with ATV66 all sizes VW3A66206U For drive controllers with firmware firmware level 3 0 and later see Chapter earlier than 3 0 order the control kit 4 section Identifying the Firmware isted above Version Removable Control Terminal Strips ATV66 all sizes VZ3N006 J1 J12 and J13 on control basket Power Board 460 V ATV66U41N4 VX5A66U41N4 ncludes IGBT block rectifier diode Serial number ends in code A21 heatsink and fan and earlier see Chapter 1 section Nameplates and Serial Numbers ATV66U41N4 VX5A663U41N4 ncludes IGBT block and rectifier Serial number ends in code A22 diode and later see Chapter 1 section Nameplates and Serial Numbers ATV66U54N4 VX5A662U54N4 ncludes IGBT block and rectifier diode ATV66U72N4 VX5A662U72N4 ncludes IGBT block and rectifier diode ATV66U90N4 VX5A662U90N4 ncludes IGBT block and rectifier diode ATV66D12N4 VX5A662D12N4 ncludes IGBT block and rectifier diode ATV66D16N4 VX5A66D16N4 ATV66D23N4 VX5A66D23N4 ATV66D33N4 VX5A66D33N4 ATV66D46N4 VX5A66D46N4 ATV66D54N4 VX5A66D54N4 ATV66D64N4 VX5A66D64N4 ATV66D79N4 VX5A66D79N4 ATV66C10N4 VX5A661C10N4 ATV66C13N4 VX5A661C13N4 ATV66C15N4 VX5A661C15N4 ATV66C19N4 VX5A661C19N4 ATV66C23N41 VX5A661C23N4 ATV66C28N41 VX5A661C28N4 ATV66C31N41 VX5A661C31N4 94 1994 Square D All Rights Reserved Bul
38. X 15 21 23 1 350 15 30 33 0 ATV66D23N4 AMA 20 27 29 7 480 22 44 48 4 ATV66D33N4 x 30 40 44 0 600 30 60 66 0 ATV66D46N4 Eii 40 52 572 800 E 37 72 79 2 ATV66D54N4 50 65 715 910 45 85 93 5 5 ATV66D64N4 coy 60 77 84 7 960 m 55 105 115 ATV66D79N4 NE 75 96 105 1150 Table 4 Recommended Braking Resistance Values 460 V Drive Controller PAPE Minimum 460 V Drive Controller PAPE Minimum Resistance Resistance Part No Part No Q Q ATV66U41N4 120 ATV66D64N4 5 0 ATV66U54N4 120 ATV66D79N4 5 0 ATV66U72N4 120 ATV66C10N4B 1 2 5 ATV66U90N4 56 ATV66C13N4B 1 2 5 ATV66D12N4 56 ATV66C15N4B 1 2 5 ATV66D16N4 28 ATV66C19N4B 1 2 5 ATV66D23N4 28 ATV66C23N41 2 0 ATV66D33N4 14 ATV66C28N41 1 25 ATV66D46N4 14 ATV66C31N41 1 25 ATV66D54N4 10 1 Refer to page 73 for more information 10 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 1 Receiving and Installation Technical Characteristics 208 V and 230 V Controllers Tables 5 through 7 show the power and current ratings for 208 V and 230 V drive controllers when set for constant torque Table 5 variable torque Table 6 and variable torque low noise Table 7 Table 8 lists recommended braking resistance values Table 5 Constant Torque Drive Controller Ratings 208 V 230 V 208 V 10 and 230 V 15 50 60 Hz 5 Switching Frequency ATV66U41M2 to D33M2 4 kHz ATV66D46M2 2 kHz
39. before performing this procedure Measurement of DC bus capacitor voltage must be performed by qualified personnel DC bus LED is not an accurate indication of absence of DC bus voltage DO NOT short across capacitors or touch unshielded components or terminal strip screw connections with voltage present Many parts in this drive controller including printed wiring boards operate at line voltage DO NOT TOUCH Use only electrically insulated tools Failure to follow these instructions will result in death or serious injury 84 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 4 Diagnostics January 1999 Resettable Renewable Parts F4A F4B and F4C Bus Fuse Test Procedure ATV66C10N4 to ATV66C31N41 Be sure to check the serial number on your drive controller to determine if this procedure applies to the model you are testing If the seventh digit of the serial number is not a 1 do not follow this procedure Instead consult the receiving and installation manual that was shipped with the drive controller or the ALTIVAR 66 Drive Controller Service and Troubleshooting Manual bulletin number VD0C06S701 The PA and terminals are located inside the drive controller see Figures 41 and 42 To measure the bus capacitor voltage and voltage at the fuse oO ct Disconnect and verify all power is removed from the drive controller Wait one minute to allow the DC bus to discharge Open the f
40. dee ng es 88 1994 Square D All Rights Reserved 7T Chapter 4 Diagnostics Bulletin No 00 065304 Precautions January 1999 PRECAUTIONS Read the safety statement below before proceeding with any maintenance or troubleshooting procedures Tables 30 and 31 on pages 88 92 list fault messages displayed on the keypad display probable causes or faults and associated corrective action Before taking corrective action remove all power and check the bus voltage Procedure 1 input line voltage Procedure 2 on page 81 and peripheral equipment Procedure 3 on page 81 A DANGER HAZARDOUS VOLTAGE Read and understand these procedures before servicing ALTIVAR 66 drive controllers Installation adjustment repair and maintenance of these drive controllers must be performed by qualified personnel Failure to follow these instructions will result in death or serious injury PROCEDURE 1 BUS VOLTAGE MEASUREMENT A DANGER HAZARDOUS VOLTAGE This equipment contains energy storage devices Read and understand Bus Voltage Measurement Procedure before performing procedure Measurement of DC bus capacitor voltage must be performed by qualified personnel DC bus LED is not an accurate indication of absence of DC bus voltage DO NOT short across capacitors or touch unshielded components or terminal strip screw connections with voltage present Many parts in this drive controller including printed wiring boards operate a
41. drive controller line terminals L1 L2 and L3 does not affect the motor rotation direction If the ALTIVAR 66 drive controller is supplied as part of a larger system also refer to the documentation supplied with the system for applicable configuration settings The drive controller is equipped with a number of control algorithms and features for flexibility in application Self tuning is incorporated into several of the control algorithms to allow optimal control of the motor The factory default control type Normal control incorporates such a feature Observe the following precautions when using Normal or High Torque control types The adjustment range of the Nominal Current parameter is 4596 to 10596 of the drive controller rated output current allowing the use of motors with horsepower equal to or one horsepower size less than the drive controller horsepower To adjust the Nominal Current parameter see the Level 1 amp 2 Configuration Manual Before powering up for the first time compare motor nameplate current rating with output current in Table 1 2 3 5 6 or 7 depending on drive controller configuration If the motor rating is not within 45 to 105 of the value in the table it is necessary to use a different drive controller For the ATV66U41N4 use the output current corresponding to motor horsepower and set Motor Power parameter for that value See the Level 1 amp 2 Configuration Manual 66 1994 Square D Al
42. in parallel Disable Disable 1 Special Additional motor Enable Disable 1 Special Synchronous permanent magnet Disable Disable 1 Special Synchronous wound field Disable Disable 1 Special Synchronous reluctance Disable Enable Special An external thermal overload relay is required if the drive controller protection is disabled 76 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 4 Diagnostics January 1999 CHAPTER 4 DIAGNOSTICS PRECAUTIONS ws cass ace nece Ne ROUX Bh C T ey AG Gs 78 PROCEDURE 1 BUS VOLTAGE MEASUREMENT 78 PROCEDURE 2 INPUT LINE VOLTAGE 81 PROCEDURE 3 CHECKING PERIPHERAL 81 PROCEDURE 4 IDENTIFYING THE FIRMWARE VERSION 82 Power OmProcedure vcre eR Rs e er eR 82 Alternate Procedure 82 PREVENTIVE MAINTENANCE 0 0000000 cece hrs 83 RESETTABLE RENEWABLE PARTS 84 Hesettable Parts xis le wees dise ewe RU uo Eua tee degen 84 Renewable Paris sc eee o poenae dera mo ges ese rides 84 F4A F4B amp F4C Bus Fuse Test Procedure ATV66C23N44 to ATV66C31N41 85 LEDS ite ee ste ete arte Xu ue EU o E ib RE ee e ra ete sis 88 FAUETAMESSAGES x em YR Oz RICE E EEUU EA ne
43. motor 76 synchronous reluctance motor 69 T T1 T2 T3 terminals 44 45 tachogenerator 92 terminals 44 45 79 80 10 47 54 24 52 53 analog outputs 55 control 47 logic inputs 52 logic outputs 53 power 44 45 terminal strips 41 47 thermal limit 24 thermal overload 70 89 thermal protection 24 68 three wire control 57 timing sequence 75 torque constant 6 11 68 73 72 driving 73 motor 68 72 overtorque 72 regenerative 73 tightening 45 64 variable 8 9 11 12 68 69 73 74 transformer fuses 59 transient suppressors 38 59 62 troubleshooting 88 92 two wire control 57 U U V W terminals 44 45 undervoltage 89 V variable torque 8 9 11 12 68 69 73 74 ventilation 23 26 72 vibration resistance 14 voltage 10 V supply 47 54 24 V supply 47 53 bus capacitor 78 control 44 DC bus 44 input line 13 44 logic inputs 52 output 67 Volts Frequency 67 weight 15 18 wiring 30 40 64 control 38 57 general practices 28 output 39 power terminals 45 precautions 38 wire size 45 wound field motor 69 71 76 VDOC06S304E January 1999 Symbols terminals 44 45 79 80 10 terminal 47 54 24 terminal 47 53 Numerics 2 wire control 57 3 wire control 57 104 1994 Square D All Rights Reserved ATV66 VDOC06S304 1078590192041 86 92041 GROUPE SCHNEIDER B6 Merlin Gerin W SquareD BI Telemecanique
44. relays connected to drive controller output overload relay must be capable of operation over the expected range of drive controller output frequencies including direct current When DC injection braking is used Overload relay must be suitable for operation with direct current flowing to the motor Do not use overload relays equipped with current transformers for sensing the motor current Failure to follow these instructions can result in equipment damage A CAUTION MOTOR OVERHEATING This drive controller does not provide direct thermal protection for the motor Use of a thermal sensor in the motor may be required for protection at all speeds and loading conditions Consult motor manufacturer for thermal capability of motor when operated over desired speed range Failure to follow this instruction can result in injury or equipment damage ALTIVAR 66 drive controllers provide indirect motor thermal protection by continuously calculating the theoretical thermal state of the motor The drive controller will trip if this state reaches 10996 of nominal current The microprocessor calculates the theoretical thermal state of the motor from Motor thermal time constant based on assumed motor power Operating frequency Current absorbed by the motor Running time Assumed maximum ambient temperature of 40 C around the motor 70 1994 Square D All Rights Reserved Bulletin No 00 065304 Cha
45. this instruction will result in death or serious injury Installing the Control Cable Ferrite Core For the control wiring use the smaller ferrite core supplied with the kit or drive controller All conductors except the shield drain wire must pass through the ferrite core see Figure 19 The ferrite core must be installed around a non shielded portion of the control cable as close as possible to the terminal strips on the control board and the 24 VDC I O Extension Module if installed Route control wiring and any exposed portions of the cable shield to avoid contact with other energized parts in the drive controller Wire insulation must have appropriate voltage rating for the voltages present If the voltages and signals present on the conductors terminated on J1 amp J24 warrant a separate control cable this cable must also be equipped with its own ferrite core installed as shown in Figure 19 The quantity of conductors and the connection points made to the terminal strips illustrated are typical The quantity and connection points depend on the application and control method selected for the drive controller See bulletin VDOCOGT306 and page 41 of this bulletin for terminal strip definitions DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow Procedure 1 Bus Voltage Measurement in Chapter 4 of this bulletin Failure to observe this instruction will result in death or serious inju
46. 0 INSTALLATION PRECAUTIONS 00 00000 e cece rn 20 MOUNTING IN GENERAL PURPOSE METAL 23 Ventilation si mai etree ADI BRA SEE SOLAN eR LIU 23 MOUNTING IN TYPE 12 IP54 METAL ENCLOSURE 24 Calculating Non Ventilated Enclosure Size 24 Ventilati n Ae EE OR ie ia e puc eoe Pe 26 Recess Mounting eene rae her ah eR EU e RR RE nra 26 1994 Square D All Rights Reserved 1 Chapter 1 Receiving and Installation Bulletin No VD0C06S304E Introduction January 1999 INTRODUCTION Scope ALTIVAR 66 is a family of 1 to 400 hp 2 2 to 250 kW 460 V and 1 to 50 hp 2 2 to 37 kW 230 V adjustable frequency AC drive controllers The 460 V line consists of 19 devices in 7 outlines the 230 V line consists of 8 devices in 5 outlines Capable of controlling either constant or variable torque loads and designed to handle simple or complex applications ALTIVAR 66 drive controllers may function as stand alone drive controllers or as part of complex drive systems The ALTIVAR 66 family also includes optional peripherals Consult catalog for descriptions This manual covers receiving installation and startup of the 460 V and 230 V lines of ALTIVAR 66 drive controllers It also includes information on diagnostics For configuration and adjustment of the drive controller parameters refer to the Level 1 am
47. 0 V 100A 600 V 80A D12 D16 600 V 125A 600 V 125A 600 V 100A D23 D33 600 V 225A 600 V 225A 600 V 225A D46 600 V 250A 600 V 250A 600 V 250A 1 Manufacturer specific fuse selection DO NOT SUBSTITUTE Table 26 Recommended Equipment for all Drive Controllers R1 Potentiometer 9001 K2106 Push buttons 9001 KR1UH13 Control station enclosure accepts R1 and two push buttons 9001 KYAF3 1994 Square D All Rights Reserved 63 Chapter 2 Wiring Bulletin No 00 065304 Equipment Recommendations January 1999 Mounting and Replacing Line Power Fuses in ATV66C10N4 to C19N4 Drive Controllers Line power fuses for ATV66C10N4 to C19N4 drive controllers be mounted either externally or internally To mount or replace fuses internal to the drive controller 1 Perform Bus Voltage Measurement Procedure on page 78 2 Open inside door by loosening the two knurled screws located to the left of the control board 3 Remove plastic terminal shield 4 When initially installing fuses remove the three shorting bars located at terminals 1 2 and 3 Otherwise remove the old fuses Save the screws 5 Using the screws from step 4 mount the fuses in place of the shorting bars Screws M8 x 1 25 x 16 mm Recommended torque 131 164 Ib in 14 8 18 5 Nem 6 Replace plastic terminal shield 7 Close inside door and tighten screws 8 Close drive controller door Replacing
48. 0 c10 LC1 F150G6 LA9 F980 907 ENQ R 1 1 4 FNO R 1 6 10 x 50 400141 1133 K200D20 id MENU FWHA400AISI 6 ea 9070 90 125 C13 C10 ABOPA00l41 BH 1133 LC1 F265G7 LA9 F980 K350D20 FNQ R 1 6 10 FNQ R 2 8 10 FWHSO0ABI 6 ea 9070 110 150 C15 ABOPSOOI BH 3245 LC1 F265G7 LA9 F980 K350D20 FNQ R 1 6 10 FNQ R 2 8 10 FWHA400AI3I 6 ea 9070 110 150 C13 AS0P400l4 BH 1133 LC1 F265G7 LA9 F980 K350D20 FNQ R 1 6 10 FNQ R 2 8 10 FWH600AI3I 6 ea 9070 132 200 C19 A50P600 l4 BH 3245 LC1 F330G7 LA9 F980 K250D20 FNQ R 1 1 4 FNQ R 2 FWH500AISI 6 ea 9070 132 200 C15 ABOPSOOI BH 3245 LC1 F330G7 LA9 F980 K250D20 FNQ R 1 1 4 FNQ R 2 FWH700AI3I 160 250 C23 170 6711181 6 7 7 7 7 7 N30023115 FWH800A 3 200 300 C28 C23 170 6712181 6 7 7 7 7 7 P300232 5 1 For F10 and F11 use Bussmann control fuse KTK R 3 The recommended control fuse carrier is 9080 FB2611CC 2 Square D Class CC Fuse Block numbers 3 Bussmann part numbers 4 Gould Shawmut part numbers 5 Ferraz part numbers 6 Fuse mounted inside drive controller 7 The power circuit configuration of the ATV66C23N4 to ATV66C31N4 drive controllers does not support the use of an input isolation contactor 8 T1 has been dimensioned to supply KM1 coil inrush and sealed VA requirements only Any user control pilot device additions may require re dimensioning of T1 VA capacit
49. 009 Netus i ri ad power Power Terminal Plexiglass Shield ATV66C10N4 to C19N4 VY1ADV612 Dynamic Braking Flexible Bus ATV66C23N4 to C31N4 VZ3N626 Connects capacitor bank to PA terminal and DB IGBT module Flex Cables 460 V ATV66U41N4 to D12N4 VZ3NO601 Control Board J3 J4 and J5 ATV66D16N4 D23N4 VZ3N613 ATV66D33N4 to 07934 VZ3N615 ATV66C10N4 to C31N4_ VZ3N616 3 flat ribbon cables Flex Cables 208 230 V ATV66U41M2 to U90M2 VZ3N601 Control Board J3 J4 and J5 ATV66D12M2 D16M2 VZ3N613 ATV66D23M2 to D46M2 VZ3N615 2002 Schneider Electric All Rights Reserved Bulletin No 30072 450 73 May 2002 Repair Parts List Continued Addendum to VD0C06S304E ATV66 Repair Parts Description Drive Controller Part No Note Internal Hardware Kit 460 V ATV66U41N4 to U72N4 VY1ADV601 ATV66U90N4 D12N4 VY1ADV602 ATV66D16N4 D23N4 VY1ADV603 ATV66D33N4 D46N4 VY1ADV604 ATV66D54N4 to D79N4 VY1ADV605 ATV66C10N4 to C19N4 VY1ADV613 Specialty hardware mounting posts etc ATV66C23N4 to C31N4 VY1ADV614 Internal Hardware Kit 230 V ATV66U41M2 VY1ADV601 ATV66U72M2 U90M2 VY1ADV602 ATV66D12M2 D16M2 VY1ADV603 ATV66D23M2 D33M2 VY1ADV604 ATV66D46M2 VY1ADV605 Packaging Kits 208 230 460 V ATV66U41N4 to U72N4 VY1A66101 Order this kit if the control basket is not mounted to ATV66U90N4 D12N4 VY1A66102 ground plane within the drive ATV6
50. 1 Check feedback feedback 2 Machine overload 2 Check load base speed and power rating compare with operating speed and drive controller motor power rating 3 No tachometer signal 3 Check tachometer connection 4 Tachometer polarity incorrect 4 Check tachometer polarity CUSTOM FAULT 1 User defined 1 Dependent on user setting FEEDBACK LOSS 1 No tachometer feedback signal 1 Check tachometer wiring Other faults may be displayed depending on how the drive controller is programmed For more information on faults and self diagnostics refer to Level 1 amp 2 Configuration Manual For controllers like this use the manual shipped with the controller or VD0C06S701 Service and Troubleshooting Manual Units prior to June 1 1998 Figure 44 ATV66C10N4 to ATV66C19N4 92 1994 Square D All Rights Reserved Bulletin No 00 065304 Appendix A Spare Parts List January 1999 APPENDIX A SPARE PARTS LIST Replacement of spare parts requires the use of special tools and installation procedures not included with the spare parts kits Before replacing any spare part consult the ALTIVAR 66 Drive Controller Service and Troubleshooting Manual bulletin number VD0C06S701 This manual can be ordered from your local Square D distributor Spare parts must be removed and installed only by qualified electrical personnel familiar with the Service and Troubleshooting manual When ordering spare parts
51. 15 ATV66 N4 units 4 D Snos 208 V 10 230 V 15 ATV66 M units PPY 47 to 63 Hz CL2114 CL22 Tap for CL1 and CL2 ATV66C10N4 to C31N41 drive controllers only For power terminal strip locations refer to Figures 15 to 17 on pages 41 to 43 Drive controllers ATV66C23N41 to C31N41 do not have a J2 terminal block See Figure 17 for the location of each individual terminal Pl Seecircuit diagrams on page 57 and 58 Bl TheCL1 and CL2 terminals are connected with jumpers to L1 and L2 power supply When using a line contactor the jumpers must be removed and CL1 and CL2 supplied separately to maintain control power See circuit diagrams on page 57 and page 58 CL1 and CL2 must be connected to the same feeder conductors that supply L1 L2 and L3 of the drive controller 4 Terminals are located on TB1 for ATV66C10N4 to C31N41 44 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Power Wiring Table 19 Power Terminal Wire Range NOTE All wire entries in AWG or Thousand Circular Mills MCM represent the maximum allowable conductor size for the referenced field wiring terminal All wire entries in square mm represent the recommended size of conductor based on IEC 364 conductor dimensioning criteria Do not use the IEC 364 conductor selections for installations requiring dimensioning per NFPA 70 or CSA C22
52. 19 38 6 980 37 7 960 23 0 585 20 8 528 375 9 5 300 136 23 584 1 Door hinges on left hand side of drive controller Clearance 1 Outline Figure 9 Mounting Information for ATV66C10N4 to C19N4 1994 Square D All Rights Reserved 17 Chapter 1 Receiving and Installation Dimension amp Weights for Wall or Panel Mounting Bulletin No VD0CO6S304E January 1999 37 94 963 7 Oi 7 555 Outline 7 T Conor supone e patem 7 i knockouts provided 39 98 1015 5 2000 _ _ 1 90 508 0 889 36 18 48 3 919 0 Hesso Removable 35 0 s d Dia 2 places 3 00 Telemecanique ALTIVAR 66 g some 76 20 T T zn 140 6 3 i p t 94 65 2404 1 m 2577 T 227 Label 71 59 1818 3 i 20 25 514 3 i i T ri Front View E Right Side View 38 1 6 17 40 86 156 7 1037 9 2000 35 46 508 0 900 7 1 00 Dimensions 55 35 90 25 4 in mm 1405 9 Both Sides Dia 2 places WEIGHT 1 400 LB 635 KG 11 15 0 P 381 0 17 5 Bottom View Figure 10 Mounting Information for ATV66C23N41 to C31N41 18
53. 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 1 Receiving and Installation January 1999 Handling Drive Controllers HANDLING DRIVE CONTROLLERS It is recommended that the drive controller be kept in its factory carton during storage and transport to the installation site The carton protects the drive controller and prevents damage to its exterior Handle the drive controller carefully to avoid damage to the internal components frame or exterior When handling a drive controller balance it carefully to keep it from tipping ATV66U41N4 through D46N4 and ATV66U41M2 through D33M2 drive controllers can be removed from their packing and installed manually After being removed from the carton or shipping wrap ATV66D54N4 through C31N41 and ATV66D46M2 drive controllers require some type of mechanical lifting Handle drive controllers With a hoist attaching a spreader bar to the two lifting rings on top of the drive controller see Figure 11 or For ATV66D54N4 through C19N4 and ATV66D46M2 in a horizontal position with back of drive controller resting on a pallet WARNING HANDLING AND LIFTING HAZARD Keep area below any equipment being lifted clear of all personnel and property Use lifting method shown below in Figure 11 Failure to follow these instructions can result in death serious injury or equipment damage To hoist the drive controller attach a spreader bar to the two lifting rings on
54. 1N41 drive controllers Loosen the CL1 and CL2 screws and the CL21 and CL22 screws Remove jumpers See Figures 16 and 17 on pages 42 and 43 56 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Control Circuit Diagrams CONTROL CIRCUIT DIAGRAMS This section contains wiring diagrams for 2 and 3 wire control circuits The Level 1 amp 2 Configuration Manual Operation explains 2 and 3 wire control 3 Wire Control Internal L3 12 See ontrol ca B Power REDE come LA 0 20 4 20 mA Equipment 1 5 F1 F3 1 R1 i Pn Hro cle cli 13 L2 L1 pe 424 LH 14 AI2 10 COM C 2 cli L3 L2 L1 F6 i i Keypad Connector i 1 Wi 1 102 101 COM A92 AO1 COM R2C R2A R2B de R1B PB PA i c Q 9o 0 0 9 9 0 6 1 F10 and F11 fuses if tap conductor protection is required The CL1 and CL2 inputs of all ATV66 drive controllers are internally protected and require no external fusing 2 F5 and F6 fuses are present only on ATV66C10N4 to ATV66C31N41 drive controllers Figure 29 Recommended 3 Wire Control Circuit Diagram Dynamic Braking Resistor Figure 29 is the recommended 3 wire control circuit diagram It shows how to connect a branch circuit disconnect device and protective fusing to the drive controller Additio
55. 230 V ATV66D23M2 to D46M2 VY1ADA614 Control Power Fuses ATV66C10N4 to C31N41 DF3CF00501 Two fuses DC Bus Fuse ATV66C10N4 C13N4 VY1ADF250V700 One fuse per kit ATV66C15N4 C19N4 VY1ADF350V700 ATV66C23N41 to C31N41 VY1ADF400V700 AC Line Fuse ATV66C23N41 VY1ALF700V700 One fuse per kit ATV66C28N41 VY1ALF800V700 ATV66C31N41 VY1ALF900V700 Power Terminal Blocks 460 V ATV66D16N4 D23N4 VZ3N603 ATV66D33N4 D46N4 VZ3N604 ATV66D54N4 to D79N4 VZ3N605 Power Terminal Blocks 208 230 V ATV66D12M2 D16M2 VZ3N603 ATV66D23M2 D33M2 VZ3N604 ATV66D46M2 VZ3N605 Box Lug Power Terminal ATV66C10N4 to C19N4 VZ3N008 C10 C19 L1 3 T1 3 GND C15 19 T1 3 GND Clam Shell Power Terminal ATV66C10N4 to C19N4 VZ3N009 C15 19 L1 3 Power Terminal Plexiglass Shield ATV66C10N4 to C19N4 VY1ADV612 Internal Power Cables 460 V ATV66D16N4 D23N4 VZ3N623 ATV66D33N4 D46N4 VZ3N624 ATV66D54N4 to D79N4 VZ3N625 Internal Power Cables 208 230 V ATV66D12M2 D16M2 VZ3N627 ATV66D23M2 D33M2 VZ3N628 ATV66D46M2 VZ3N625 Dynamic Braking Flexible Bus ATV66C23N41 to C31N41 VZ3N626 Connects capacitor bank to PA terminal and DB IGBT module Flex Cables 460 V ATV66U41N4 to D12N4 VZ3N601 Control Board 48 4 ands ATV66D16N4 D23N4 VZ3N613 ATV66D33N4 to D79N4 VZ3N615 ATV66C10N4 to C31N41 VZ3N616 Flex Cables 208 230 V ATV66U41M2 to U90M2 VZ3N601 Contra Board 35 endis ATV66D12M2 D16M2 VZ3N613 ATV66D23M2 to D46M2 VZ3N615 1994 Square D All
56. 30 3CRI2 D2510G6 LAADA K50D20 2 2 2 90805 C1 9070 FNQ R 1 FNQ R 1 FNQ R 1 FB3611CCl4l LCt R R R T60030 3CRU I D2510G6 LA4 DA2G K50D20 2 2 2 pin C1 9070 FNQ R 1 FNQ R 1 FNQ R 1 FB3611CCl4 LCt 1 R R R 3 T60030 3CRU2I D2510G6 LA4 DA2G K50D20 2 2 2 LC1 9070 FNQ R 1 FNQ R 1 FNQ R 1 3 2 T60060 3Cf7l D2510G6 LAEDAPG K50D20 2 2 2 LC1 9070 FNQ R 1 FNQ R 1 FNQ R 1 3 121 3 5 5 T60060 3Cl D2510G6 LA4 DA2G K50D20 2 2 2 LC1 9070 FNQ R 1 FNQ R 1 FNQ R 1 3 2 4 7 5 T60060 3CI2 D3210G6 LA4 DA2G K50D20 2 2 2 1 For F10 and F11 use Bussmann control fuse KTK R 3 The recommended control fuse carrier is 9080 2611 2 Bussmann part numbers 3 T1 has been dimensioned to supply KM 1 coil inrush and sealed VA requirements only Any user control pilot device additions may require re dimensioning of T1 VA capacity 4 Square D Class CC Fuse Block numbers 5 Manufacturer specific fuse selection DO NOT SUBSTITUTE 62 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Equipment Recommendations Table 24 Recommended Equipment for 1 to 50 hp 208 230 V Drive Controllers Continued M1 A1 F1 F3 TS Ti F6 F7 F8 Controller Line Power Fuses Primary Xfmr Motor Ratings Fuses ALO Me Fuse Class 1 2 Sec Fuse Carriers Transient Xfmr Xfmr
57. 4N4 LC1D4011P7 ATV66D79N4 LC1D6511P7 ATV66C10N4 C13N4 VY1A661C1010 ATV66C15N4 C19N4 VY1A661C1510 ATV66C23N41 to C31N41 VY1A66102310 Precharge Contactor 208 230 V ATV66D12M2 D16M2 LP4D2500BW3 ATV66D23M2 LC1D3201P7 ATV66D33M2 LC1D5011P7 ATV66D46M2 LC1D4011P7 1994 Square D All Rights Reserved 97 Appendix A Spare Parts List Bulletin No VDOCO6S304E January 1999 Table 32 Spare Parts List Continued Description Drive Controller Reference No Note Precharge Contactor Auxiliary Contact ATV66C10N4 to C31N41 LA1DN04 Block Precharge Circuit Protector ATV66C10N4 to C31N41 GV2M10 Heatsink Fan 460 V ATV66U41N4 U54N4 VZ3V661 ATV66U72N4 VZ3V662 ATV66U90N4 D12N4 VZ3V663 ATV66D16N4 D23N4 VZ3V664 ATV66D33N4 to D79N4 VZ3V665 ATV66C10N4 to C19N4 VZ3V670 ATV66C23N41 to C31N41 VZ3V666 Heatsink Fan 208 230 V ATV66U41M2 VZ3V662 ATV66U72M2 U90M2 VZ3V663 ATV66D12M2 D16M2 VZ3V664 ATV66D23M2 to D46M2 VZ3V665 Stirring Fan 460 V ATV66D33N4 to D79N4 VZ3V6654 Power board fan ATV66D54N4 to D79N4 VZ3V6655 Capacitor bank fan ATV66C10N4 to C19N4 VZ3V671 ATV66C23N41 to C31N41 VZ3V669 Stirring Fan 208 230 V ATV66D23M2 to D46M2 VZ3V6654 Power board fan ATV66D46M2 VZ3V6655 Capacitor bank fan Fan Failure Detection Assembly ATV66C23N41 to C31N41 VY1ADR100 Resistor and temperature switch Power Supply for Overtemperature AT
58. 5 W from Table 1 Maximum internal temperature T 40 C Area resistivity for painted metal K 300 Maximum allowable thermal resistance Rip calculated by formula 40 25 Rth 188W 0 081 C W Minimum useful heat exchange surface area S calculated by formula 300 2 S 0 081 3700 in 1994 Square D All Rights Reserved 25 Chapter 1 Receiving and Installation Bulletin No VD0C06S304E Mounting in Type 12 IP54 Metal Enclosure January 1999 Ventilation Useful heat exchange surface area S of the proposed wall mounted enclosure Height 40 in 1016 mm Width 40 in 1016 mm Depth 20 in 508 mm front area top area side area S 40x40 20x 40 2 40 x 20 4000 in If the selected enclosure does not provide the required surface area or does not meet application needs consider the following Use larger enclosure Use one of the recess mounting kits ATV66U41N4 to D23N4 and ATV66U41M2 to D16M2 drive controllers Refer to Table 11 on page 27 Add a passive heat exchanger to the enclosure Add an air conditioning unit to the enclosure Consult enclosure manufacturer When the drive controller is mounted inside a Type 12 or IP54 enclosure observe the following ventilation precautions Observe minimum clearance distances shown in Figure 12 on page 21 Follow the installation precautions on pages 20 through 22 Use stirring fan if necessary to
59. 6 5246 220 408 449 7 ATV66C28N41 A 350 420 462 5966 250 460 506 ATV66C31N41 p 400 477 525 6624 1 Unit available for 400 V 50 Hz supply voltage only Table 3 Variable Torque Low Noise Drive Controller Ratings 460 V 400 V 15 and 460 V 15 50 60 Hz 5 Switching Frequency ATV66U41N4 to D46N4 10 kHz ATV66D54N4 to D79N4 4 kHz Motor Power Total Output Max Transient Dissipated Outline Drive Controller 400 460 Current Current 60 s 50 Hz 60 Hz Power kW hp A A 0 75 2 0 5 8 90 0 1 1 8 5 3 90 0 1 5 3 7 5 8 110 ATV66U41N4 u 2 34 53 110 1 2 2 5 3 5 8 130 3 4 8 5 8 130 ATV66U54N4 3 0 7 1 7 8 150 4 0 9 5 10 5 ATV66U72N4 d 5 76 84 180 5 5 11 8 13 0 ATV66U90N4 E 75 110 124 205 7 5 16 0 17 6 ATV66D12N4 kb 10 140 154 265 1994 Square D All Rights Reserved 9 Chapter 1 Receiving and Installation Bulletin No VD0OCO6S304E Technical Characteristics January 1999 Table 3 Variable Torque Low Noise Drive Controller Ratings 460 V Continued 400 V 15 and 460 V 15 50 60 Hz 5 Switching Frequency ATV66U41N4 to D46N4 10 kHz ATV66D54N4 to D79N4 4 kHz Motor Power Total Output Max Transient Dissipated Outline Drive Controller 400 V 460 Current Current 60 s Part No 50 Hz 60 Hz Power kW hp A A E 11 22 24 2 3 ATV66D16N4
60. 67 Table 28 Factory Settings Inputs and 68 Table 29 Operating Non Standard Motors 76 Table 30 Fault MBSSRUSS Loo ove aang ea oA OLN TON 88 Table 31 Fault Messages from Option 92 Table 32 Spare Pars Vistek beh ERR e E res bused 94 iv 1994 Schneider S A All Rights Reserved Bulletin No 00 065304 Chapter 1 Receiving and Installation January 1999 CHAPTER 1 RECEIVING AND INSTALLATION INTRODUCTION cd nee AE bad Baa aor REX CE de esa Shaken eR SI pU 2 SCODO Ute d acute elite rea dg 2 Documentationl ist Ree Re dre bea a og ERR 2 Revision 2 HAZARD LABELING bcs RR DUREE ERE t REUS 3 NAMEPLATES AND SERIAL 3 TECHNICAL 5 1 5 2 2 es 6 460 V GControllers re ee Re Ra Ree Ae len eae REFS ENERO 6 208 V and 230 V Controllers 0 0 0 0 ee 11 Controller lt 13 DIMENSIONS amp WEIGHTS FOR WALL OR PANEL MOUNTING 15 HANDLING DRIVE CONTROLLERS 0 00 0000 0c cee eee eee 19 PRELIMINARY INSPECTION 0 000000 sers 2
61. 6D16N4 D23N4 VY1A66103 ATV66U41M2 VY1A66101 ATV66U72M2 U90M2 VY1A66102 ATV66D12M2 D16M2 VY1A66103 T All plastic sides covers and front door Packaging Kits 208 230 460 V ATV66U41N4 to U72N4 VY1A661 11 Order this kit if the control basket is mounted toa ATV66U90N4 D12N4 VY1A66112 rasa ground plane within the drive ATV66D16N4 D23N4 VY1A66113 ATV66U41M2 VY1A66111 ATV66U72M2 U90M2 VY1A66112 ATV66D12M2 D16M2 VY1A66113 Clip Pliers ATV66U41N4 to D23N4 Use when replacing power board all IGBTs Tool for removing voltage regulator VY1ADV608 filter board precharge components bus heatsink clips 2002 Schneider Electric All Rights Reserved ATV66U41M2 to D16M2 capacitors and line rectifier diodes ALTIVAR 66 Addendum to VD0C06S304E ATV66 Repair Parts Bulletin No 30072 450 73 Instruction Bulletin May 2002 Square D Company 8001 Hwy 64 East Knightdale NC 27545 Electrical equipment should be serviced only by qualified personnel No responsibility is assumed 1 888 SquareD 1 888 778 2733 by Schneider Electric for any consequences arising out of the use of this material This document www SquareD com is not intended as an instruction manual for untrained persons 8 2002 Schneider Electric All Rights Reserved D SQUARE D
62. 7 7 21 4 23 4 13 0 12 0 11 22 0 36 0 21 0 25 1 30 6 35 3 19 4 17 9 15 30 0 45 0 izg PCD IEE 27 0 31 8 38 3 42 9 26 0 23 6 18 5 37 0 57 0 25 ATV66D23N4 340 38 7 47 0 54 6 31 1 30 1 30 60 0 79 0 2a ag di aa 52 0 57 1 67 6 76 6 49 0 45 6 37 72 0 94 0 _ 50 ATV66D46N4 65 0 68 6 81 2 91 9 61 2 56 3 45 85 0 112 eo ATV66D54N4 770 86 4 94 6 108 71 6 66 7 55 105 130 75 ATV66D64N4 96 0 106 116 133 90 1 83 5 75 143 176 124 138 150 171 121 113 90 190 199 125 abis 156 165 185 210 153 143 11 10 000 AIC denoted by asterisk 2 18 000 AIC denoted by t 34 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Wiring Table 13 Input Line Currents for Selecting Branch Circuit Conductors 460 V VT Note The input conductor ampacity rating should not be less than the ampacity rating selected based on the rated controller output current Input Line Current Motor Power 5 000 AIC With Line Output 0 141 mH Impedance of Drive Current 10 000 AIC 11 22 000AIC 65 000 AIC kW hp Controller 0 070 mH 0 032 mH 0 011 mH 3 5 2 o o 400V 460V 18 000 AIC PI 50 Hz 60 Hz 0 039 mH A A A 110 150 246 182 170 132 200 AT VERE TONS 314 238 223 160 ATV66C19 160
63. 75A 175A 60200 1 131 LC1 F115G6 LA9 F980 1 4 6 10 600 V 600 V 600V 3 ea 9070 FNQ R 1 FNQ R 1 95 D64 T 200 A 200 A 200A T60200 1CI3l LC1 F115G6 LA9 F980 6 10 600 V 600 V 600V 3 ea 9070 FNQ R 1 FNQ R 1 fo OO pia a 225A 225A 225A T60400 1Cl3 LC1 F150G6 LA9 F980 koooD20 1 4 6 10 1 For F10 and F11 use Bussmann control fuse KTK R 3 The recommended control fuse carrier is 9080 FB2611CC 2 Square D Class CC Fuse Block numbers 3 Bussmann part numbers 4 Gould Shawmut part numbers 5 Ferraz part numbers 6 Fuse mounted inside drive controller 7 The power circuit configuration of the ATV66C23N4 to ATV66C31N4 drive controllers does not support the use of an input isolation contactor 8 T1 has been dimensioned to supply KM1 coil inrush and sealed VA requirements only Any user control pilot device additions may require re dimensioning of T1 VA capacity 9 Manufacturer specific fuse selection DO NOT SUBSTITUTE 10 125 A rating allowable for ATV66D54N4 controller Table 22 Recommended Semiconductor Fuses for 1 400 460 V Controllers M1 Al F1 F3 Input KM1 TS 1 F7 F8 F9 Motor Controller ATV66 N4 Line Power Fuse Primary Sec Xfmr Fuses Carriers Line Transient Xfmr Xfmr Fuses Fuses kw np VT Semiconductor 3 Contactor Suppressor 8 3 Fuse Class 3 3 3 75 10
64. ADC614 Line Filter Board 460 V ATV66D16N4 D23N4 VX4A66103 ATV66D33N4 D46N4 VX4A66104 ATV66D54N4 to D79N4 VX4A66105 ATV66C10N4 to C31N41 VX4A66106 Line Filter Board 208 230 V ATV66D12M2 D16M2 VX4A66103 ATV66D23M2 D33M2 VX4A66104 ATV66D46M2 VX4A66105 Line Rectifier Diode 460 V ATV66D16N4 D23N4 VZ3DM6075M 1601 6 pack diode block ATV66D33N4 VZ3DM2080M 1606 1 dual diode block ATV66D46N4 VZ3DM2100M1601 1 dual diode block ATV66D54N4 to D79N4 VZ3DM2160M 1606 1 dual diode block ATV66C10N4 C13N4 VZ3DM2170M 1602 1 dual diode block ATV66C15N4 VZ3DM2260M 1602 1 dual diode block ATV66C19N4 VZ3DM2350M 1602 1 dual diode block ATV66C23N41 to C31N41 VZ3DM2600M 1602 1 dual diode block Line Rectifier Diode 208 230 V ATV66D12M2 D16M2 VZ3DM6075M 1601 6 pack diode block ATV66D23M2 VZ3DM2080M 1606 1 dual diode block ATV66D33M2 VZ3DM2100M1601 1 dual diode block ATV66D46M2 VZ3DM2160M1606 1 dual diode block 96 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Appendix A Spare Parts List Table 32 Spare Parts List Continued Description Drive Controller Reference No Note DC Bus Capacitor 460 V ATV66U41N4 U54N4 VY1ADC601 Assembly with capacitors ATV66U72N4 VY1ADC602 Assembly with capacitors ATV66U90N4 VY1ADC603 Assembly with capacitors ATV66D12N4 VY1ADC604 As
65. CM eno Sue mm 6 io 10 46 35 70 95 OUT Terminal 17 7 854 177 265 26 5 325 325 dos Torque Nem 2 4 2 3 3 36 7 36 7 60 75 C copper 21 75 copper I3 For 10 14 AWG 2 5 5 mm conductors use 35 4 Ib in 4 Nem torque and for 8 AWG 8 mm conductors use 40 Ib in 4 5 Nem torque 4 For 2 0 AWG 35 mm and smaller conductors use 88 Ib in 10 Nem torque NOTE The LI L2 and L3 terminals on the ATV66C15N4 and C19N4 drive controllers are equipped with metric hex head bolts requiring a 13 mm socket The other terminals except PA amp PB require a 3 8 inch hex wrench supplied with the drive controller Terminals PA and PB require a 3 16 inch hex wrench supplied with the drive controller 1994 Square D All Rights Reserved 45 Chapter 2 Wiring Bulletin No 00 065304 Control Wiring January 1999 CONTROL WIRING NOTE The logic inputs and outputs and analog inputs and outputs are all referenced to Common COM on J12 and J13 This Common is isolated from the input line and from ground S on J13 RMS voltage rating of the isolation barrier between Common and ground is 250 V If Common is elevated with respect to earth by external user connections then all devices connected to Common must be rated for the applied voltage J1 is located on the power board
66. D All Rights Reserved Bulletin No 00 065304 Chapter 3 Start Up January 1999 Control Types with the High Torque control type the process requires less tuning When using Normal control the motor horsepower must be equal to or one horsepower size less than the drive controller horsepower When Normal control type is used on a constant torque configuration self tuning is active When the drive controller is powered up a pulse of direct current equal to motor rated current is injected into the motor allowing the drive controller to determine the resistance of the motor to set the motor parameters High Torque High Torque control is also sensorless flux vector control available when the drive controller is configured for constant torque In order to create high torque atlow speeds the drive controller maintains a 90 phase relationship between the rotor and stator electromagnetic fields by continuously calculating the position of the rotor in relation to the electrical position of the stator High Torque provides more flexible setup and optimized parameters than the Normal control type therefore offering better torque performance Select this control type when controlling only one motor in constant torque configuration When using High Torque control the motor horsepower must be equal to or one horsepower size less than the drive controller horsepower When High Torque control type is used self tuning is active When the driv
67. DURE 3 CHECKING PERIPHERAL EQUIPMENT You may need to check the following equipment If you do please follow the manufacturer s procedures 1 2 3 A protective device such as a fuse or circuit breaker may have opened A switching device such as a contactor may not be closing at the correct time Conductors may require repair or replacement Connection of cables to the motor or connections to ground may need to be checked Follow NEMA standard procedure WC 53 Motor insulation may need to be checked Follow NEMA standard procedure MG 1 Do not apply high voltage to drive controller output terminals U T1 V T2 or W T3 Do not connect high potential dielectric test equipment or insulation resistance tester to the drive controller since the test voltages utilized may damage the drive controller Always disconnect the drive controller from the conductors or motor while performing such tests 1994 Square D All Rights Reserved 81 Chapter 4 Diagnostics Bulletin No VD0CO6S304E Procedure 3 Checking Peripheral Equipment January 1999 PROCEDURE 4 IDENTIFYING THE FIRMWARE VERSION Power On Procedure 1 With the drive controller powered up press the ESC key one or more times to access the Drive Identification screen 2 Read the firmware version from the upper right corner of the Drive Identification screen DRIVE IDENTIFICATION ATV66U41N4 C POWER 2 2kW 3HP firmware version In 5 8A Imax 1 5In SUPPLY 400 415V
68. E FIRMWARE VERSION 82 PREVENTIVE MAINTENANCE ssssssssssl eee eee eee 83 RESETTABLE RENEWABLE 84 Resettable Parts eee ee e uk LEY 84 Renewable Parts E ey Anes Ss 84 F4B F4C Bus Fuse Test Procedure ATV66C10N41 to ATV66C31N41 eee a REM EUR LET cae PER EAS 85 ies iste SU SEHE 88 FAUET MESSAGES eR ER SR Moe Ses s qa P E E ead 88 APPENDIX A SPARE PARTS 93 INDEX qc 99 ii 1994 Schneider S A All Rights Reserved VDO0CO6S304E January 1999 LIST OF FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 ALTIVAR 66 Receiving Installation Start Up List of Figures and Tables Hazard Labeling zs cete ee a seed ok ly b ed ao ice uera e xut kee ERE E 3 Sample Nameplate SU hee Dew CEN DES 3 Locating Nameplate on ATV66U41N4 to D23N4 and ATV66U41M2 to
69. INARY INSPECTION ssssssseee eR 20 INSTALLATION PRECAUTIONS sssssesseee eee n 20 MOUNTING IN GENERAL PURPOSE METAL 23 Ventilation o kn Ye Wee ee hee ee iene tale e Ep 23 MOUNTING IN TYPE 12 IP54 METAL ENCLOSURE 24 Calculating Non Ventilated Enclosure 24 MentllatiOnsos s de t e bo te eam msn vit n pe BE Settee anera RATE pus 26 Recess Mountlng 2 2 RI RES EUR deeem ee re eda 26 CHAPTER 2 WIRING 2 ADR EE e ee E ER Ed eds 29 23er iet tree dear ibn dtp dh E eed ee eod 30 General Wiring 30 Branch Circuit Connections l i 30 Control Wiring 5 38 Output Wiring Precautions 39 Grounding erias redes ca ep cb exrxiqendeir acepten 4 EAE Rd 40 TERMINAL STRIP m 41 POWER WIRING ra ECUS os GUAEGU RA eens 44 CONTROL WIRING rer ne on e ERR eR REC RUD E etg 46 ELECTROMAGNETIC COMPATIBILITY 48 Installing the Ferrite Cores 49 USING THE LOGIC INPUTS J12 isses 52 USING THE LOGIC OUTPUTS J12 53 USING THE SPEED REFERENCE INPUTS 13
70. Instruction Bulletin VDOC06S304E January 1999 Price 30 00 Replaces VD0C06S304D 02 98 ALTIVAR 66 Adjustable Speed Drive Controllers For Asynchronous Motors User s Manual Constant and Variable Torque 1 to 400 hp 460 V and 1 to 50 hp 230 V Receiving Installation and Start Up EJ telemecanique B SQUARE D A DANGER HAZARDOUS VOLTAGE Read and understand this bulletin in its entirety before installing or operating ALTIVAR 66 drive controllers Installation adjustment repair and maintenance of these drive controllers must be performed by qualified personnel Disconnect all power before servicing drive controller WAIT ONE MINUTE until DC bus capacitors discharge then measure DC bus capacitor voltage between PA and terminals to verify DC voltage is less than 45 V see pages 78 through 80 The DC bus LED is not an accurate indication of the absence of DC bus voltage DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw connections with voltage present Install all covers and close door before applying power or starting and stopping the drive controller User is responsible for conforming to all applicable code requirements with respect to grounding all equipment For drive controller grounding points refer to the terminal connection drawings on pages 41 42 and 43 Many parts in this drive controller including printed wiring boards operate at line voltage D
71. MC For ATV66U41N4 to ATV66D79N4 and ATV66U41M2 to ATV66D46M2 This section provides information to integrators and end users who are including the drive controller as part of a machine being exported to Europe When addressing EMC the ATV66 drive controller must be considered as a component It is neither a machine nor a device ready for use in accordance with European standards EN 60201 1 on the safety of machines EN 50081 amp 50082 on electromagnetic compatibility and IEC 1800 3 Adjustable Speed Electrical Power Drive Systems Part 3 EMC Product Standard Including Specific Test Methods The ATV66 drive controller must be installed and implemented in compliance with applicable international and national standards in the location where the controller will be used It is the responsibility of the integrator end user to ensure that this machine conforms to these standards To aid the integrator end user in meeting the requirements of the Electromagnetic Compatibility EMC directive in regards to ATV66 products publication VVDED296034 ATV66 Electromagnetic Compatibility Catalog has been prepared This publication which recommends specific mitigation devices and installation methods can be ordered from your local Square D Representative NOTICE Wiring recommendations found in publication VVDED296034 apply to European power systems ONLY and do not apply to North American installations In order for a machine containi
72. N4 VX5A66D79N4 Power board only ATV66C10N4 VX5A661C10N4 ATV66C13N4 VX5A661C13N4 ATV66C15N4 VX5A661C15N4 ATV66C19N4 VX5A661C19N4 ATV66C23N4 VX5A661C23N4 ATV66C28N4 VX5A661C28N4 ATV66C31N4 VX5A661C31N4 Power Board 208 230 V ATV66U41M2 VX5A662U41M2 ATV66U72M2 VX5A662U72M2 Includes IGBT block and rectifier diode ATV66U90M2 VX5A662U90M2 ATV66D12M2 VX5A66D12M2 Power board only ATV66D16M2 VX5A66D16M2 Power Board and Gate Driver Board 208 230 V ATV66D23M2 VX5A66D234M2 ATV66D33M2 VX5A66D335M2 Matched set ATV66D46M2 VX5A66D466M2 Gate Driver Board 460 V ATV66D16N4 VX5A66103 ATV66D23N4 VX5A66104 ATV66D33N4 VX5A66105 ATV66D46N4 VX5A66106 ATV66D54N4 VX5A66107 Gate driver board only ATV66D64N4 VX5A66108 ATV66D79N4 VX5A66109 Gate Driver Board 208 230 V ATV66D12M2 VX5A661 12 ATV66D16M2 VX5A66113 Inverter IGBT 460 V ATV66D16N4 VZ3IM2050M1201 1 For units with a serial number starting with 6W ATV66D23N4 VZ3IM2075M1201 or for units with a serial number starting with ATV66D33N4 VZ3IM2100M1201 86 and a date code of 0216 or earlier ATV66D46N4 D54N4 VZ3IM2150M1201 1 dual IGBT block 2 For units with a serial number starting with 86 ATV66D64N4 VZ3IM2200M1201 and a date code of 0217 or later ATV66D79NA 11 VZ31M2300M1201 Refer to pages 3 5 of bulletin VDOCO6S304E ATV66D79N4 2 VZ31M2200M1202 in finding the serial number ArygeC10NA4 VZ31M2300M1202 2 IGBT blocks 2 snubber boards 2 gate ATV66C13N4 to
73. O NOT TOUCH Use only electrically insulated tools Before servicing drive controller Disconnect all power e Place a DO NOT TURN ON label on drive controller disconnect Lock disconnect in open position Failure to follow these instructions will result in death or serious injury Square D and D are registered trademarks of Square D Company ALTIVAR is a registered trademark of Schneider Electric S A 1994 1998 1999 Schneider S A All rights reserved This document may not be copied in whole or in part or transferred to any other media without the written permission of Schneider S A Electrical equipment should be serviced only by qualified electrical maintenance personnel No responsibility is assumed by Schneider S A for any consequences arising out of the use of this material VDOCO6S304E ALTIVAR 66 Receiving Installation Start Up January 1999 Contents CHAPTER 1 RECEIVING AND 1 INTRODUCTION Scho cee Rem men recte eet edere De n egies 2 SCOPE dude as es ee ae ee EU EUR oe 2 Docurrientatton List cus xut x ce Rb e SOR Re ies 2 Revision Level greit miee eng un peer Eg 2 HAZARD LABELING ssssssseeee e mn 3 TECHNICAL CHARACTERISTICS 00 0 cece cette eee eae 6 DIMENSIONS amp WEIGHTS FOR WALL OR PANEL MOUNTING 15 HANDLING DRIVE CONTROLLERS sssssesee ne 19 PRELIM
74. OTOR THERMAL OVERLOAD PROTECTION 70 ADJUSTMENT OF MOTOR OVERLOAD 71 AVAILABLE MOTOR TORQUE ssssssssesess s eee 72 Contirious Duly Corm rne ne OPI ale eee repa pes 72 Overtorque Capability and Speed 72 Overspeed Operation f gt 50 60 2 73 Regenerative Operation 73 Driving Torque Production 73 MOTOR CONSIDERATIONS ni ccena a rn 74 Motor Insulation EEE me eure Rd rede e ER 75 Motors in Parallel 2 2 2 22 22 22 kmiocie iio 75 Output Contactor Between Motor and Drive 75 Additional Motor Connected Downstream of the Drive Controller 75 Using a Synchronous Permanent Magnet or Wound Field Motor 76 Using a Synchronous Reluctance 76 CHAPTER 4 DIAGNOSTICS 75 PREGAUTIONS vpn iA Se aha E ua ea oy eot ba d Yet P dus 78 PROCEDURE 1 BUS VOLTAGE 78 PROCEDURE 2 INPUT LINE VOLTAGE MEASUREMENT 81 PROCEDURE 3 CHECKING PERIPHERAL 81 PROCEDURE 4 IDENTIFYING TH
75. Reserved 41 Chapter 2 Wiring Bulletin No 00 065304 Terminal Strip Locations January 1999 Outline 7 DC Bus LED a Caution LED E Power LED Outline 6 Figure 16 Terminal Strip Locations ATV66C10N4 to C19N4 42 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Terminal Strip Locations DB TERMINALS L _ a OUT L2 19 13 99 D Figure 17 Terminal Strip Locations ATV66C23N41 to C31N41 1994 Square D All Rights Reserved 43 Chapter 2 Wiring Power Wiring Bulletin No VD0C06S304E January 1999 POWER WIRING Table 18 Power Terminal Strip Characteristics 11 Connector Terminal 21 Function Characteristics Pa 400 460 VAC 15 ATV66 N4 units i Ma P 208 V 10 230 V 15 ATV66 M2 units Pply 47 to 63 Hz L3 Filtered 550 to 850 VDC ATV66 NA4 units DC voltage 275 to 425 VDC ATV66 M2 units U T1 V T2 Output connections 0 to 400 VAC 0 to 460 VAC J2 W T3 to motor to 208 VAC 0 to 230 VAC GND PA Dynamic braking 550 to 850 VDC ATV66 NA4 units PB resistor 275 to 425 VDC ATV66 M2 units 7 400 460 VAC
76. Rights Reserved 99 Appendix A Spare Parts List Bulletin No VDOCO6S304E January 1999 Table 32 Spare Parts List Continued Description Drive Controller Reference No Note Internal Hardware Kit 460 V ATV66U41N4 to U72N4 VY1ADV601 ATV66U90N4 D12N4 VY1ADV602 ATV66D16N4 D23N4 VY1ADV603 ATV66D33N4 D46N4 VY1ADV604 ATV66D54N4 to D79N4 VY1ADV605 ATV66C10N4 to C19N4 VY1ADV613 ATV66C23N41 to C31N41 VY1ADV614 Internal Hardware Kit 230 V ATV66U41M2 VY1ADV601 ATV66U72M2 U90M2 VY1ADV602 ATV66D12M2 D16M2 VY1ADV603 ATV66D23M2 D33M2 VY1ADV604 ATV66D46M2 VY1ADV605 Packaging Kits 208 230 460 V ATV66U41N4 to U72N4 VY1A66101 All plastic sides covers and front k s NOT res wwe within the drive ATV66D16N4 D23N4 VY1A66103 ATV66U41M2 VY1A66101 ATV66U72M2 U90M2 VY1A66102 ATV66D12M2 D16M2 VY1A66103 Packaging Kits 208 230 460 V ATV66U41N4 to U72N4 VY1A66111 All plastic sides covers and front aes ions a drive ATV66D16N4 D23N4 VY1A66113 ATV66U41M2 VY1A66111 ATV66U72M2 U90M2 VY1A66112 ATV66D12M2 D16M2 VY1A66113 Clip Pliers ATV66U41N4 to D23N4 VY1ADV608 Use when replacing power board all Tool for removing voltage regulator ATV6GUA1M2 to D16M2 VY1ADV6OB IGBTs filter board precharge heatsink clips components bus capacitors diode bridge temperature sensor and ground fault sens
77. V663 ATV66D16N4 D23N4 VZ3V664 ATV66D33N4 to 07934 VZ3V665 1 fan ATV66C10N4 to C19N4 VZ3V670 Fan assembly and capacitor ATV66C23N4 to C31N4 VZ3V666 1 fan and capacitor Heatsink Fan 208 230 V ATV66U41M2 VZ3V662 ATV66U72M2 U90M2 VZ3V663 Fan s and mounting bracket ATV66D12M2 D16M2 VZ3V664 ATV66D23M2 to D46M2 VZ3V665 1 fan Stirring Fan 460 V ATV66D33N4 to 07934 VZ3V6654 Power board fan ATV66D54N4 to 07934 VZ3V6655 Capacitor bank fan ATV66C10N4 to C19N4 VZ3V671 Power board fan ATV66C23N4 to C31N4 VZ3V669 IGBT fan Stirring Fan 208 230 V ATV66D23M2 to D46M2 VZ3V6654 Power board fan ATV66D46M2 VZ3V6655 Capacitor bank fan Fan Failure Detection Assembly ATV66C23N4 to C31N4 VY1ADR100 Resistor and temperature switch Fan Failure Relay Assembly ATV66C23N4 to C31N4_ VZ3SA66012 Relay and retaining clip Power Supply for Overtemperature Detection Circuit ATV66C23N4 to C31N4 VY1A66200 Power supply only Heatsink Temperature Sensor ATV66C10N4 to C31N4 VZ3GNO005 NTC thermistor and cable 2002 Schneider Electric All Rights Reserved Addendum to VD0C06S304E ATV66 Repair Parts Repair Parts List Continued Bulletin No 30072 450 73 May 2002 Description Drive Controller Part No Note Temperature Switch ATV66C10N4 to C19N4 VZ3G007 1 switch mounted on fuse bar ATV66C10N4 to C19N4 VZ3G008 2 switches mo
78. V66C23N41 to C31N41 VY1A66200 Detection Circuit Heatsink Temperature Sensor ATV66D16N4 to D79N4 VZ3GN006 ATV66C10N4 to C31N41 VZ3GN005 ATV66D12M2 to D46M2 VZ3GN006 Temperature Switch ATV66C10N4 to C19N4 VZ3G007 Switch mounted on fuse bar ATV66C10N4 to C19N4 VZ3G008 Switch mounted on heatsink and motor current sensor ATV66C23N41 to C31N41 VZ3G004 One 68C switch one 85C switch heatsink mounted Motor Current Sensor 460 V ATV66D33N4 D46N4 VY1A66104 2 sensors ATV66D54N4 to D79N4 VY1A66105 2 sensors ATV66C10N4 C13N4 VY1A66106 ATV66C15N4 C19N4 VY1A66107 ATV66C23N41 to C31N41 VY1A66108 Motor Current Sensor 208 230 V ATV66D23M2 VY1A66104 2 sensors ATV66D33M2 D46M2 VY1A66105 2 sensors Ground Fault Sensor 460 V ATV66D16N4 D23N4 VY1A66114 ATV66D33N4 D46N4 VY1A66115 ATV66D54N4 to D79N4 VY1A66116 ATV66C10N4 to C19N4 VY1A66109 ATV66C23N41 to C31N41 VY1A66110 98 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Appendix A Spare Parts List Table 32 Spare Parts List Continued Description Drive Controller Reference No Note Ground Fault Sensor 208 230 V ATV66D12M2 D16M2 VY1A66114 ATV66D23M2 D33M2 VY1A66115 ATV66D46M2 VY1A66116 Control Power Transformer 460 V ATV66D33N4 to D79N4 VY1ADA604 ATV66C10N4 to C19N4 VY1ADA606 ATV66C23N41 to C31N41 VY1ADA607 Control Power Transformer
79. ance to vibration Conforming to IEC 68 2 6 ATV66U41N4 to D46N4 and ATV66U41M2 to D33M2 1 mm peak to peak from 5 to 22 3 Hz and 2 g peak from 22 3 to 150 Hz ATV66D54N4 to C31N41 and ATV66D46M2 0 15 mm peak to peak from 10 to 58 Hz and 1 g peak from 58 to 150 Hz Resistance to shock Conforming to IEC 68 2 27 15g peak for 11 ms Codes and standards UL Listed per UL 508C as incorporating electronic overload protection ATV66U41N4 to D79N4 UL File E164874 and ATV66U41M2 to D46M2 CCN NMMS ATV66C10N4 to C31N41 ATV66U41M2 to D46M2 UL File E138755 CCN NMMS CSA certified ATV66U41N4 to D79N4 CSA File LR96921 Class 3211 06 CSA File LR 60905 Class 3211 06 ATV66C10N4 to C31N41 CE marked Conforms to applicable NEMA ICS NFPA IEC and ISO 9001 standards 1 Resolution limited to processor resolution 2 Drive Controller at operating 3 Refer to page 73 and temperature 14 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 1 Receiving and Installation January 1999 Dimension amp Weights for Wall or Panel Mounting DIMENSION amp WEIGHTS FOR WALL OR PANEL MOUNTING Conduit Entries Bottom View 5x 91 14 29 2 28 58 2x 01 14 29 c 3 x 00 87 22 P WD
80. and Troubleshooting Manual ATV66 100 hp CT 125 400 hp VD0C06S702 ATV66U41N4 to D79N4 VX4A66CK1 Control Kit ATV66C10N4 to C31N4 VX4A66CK2 ATV66U41M2 to D46M2 Matched keypad display and control basket except VX4A66CK1 with latest firmware ATV66D23M2S264U VX4A66CK1S260 Keypad Display Refer to the section Identifying the Firmware Version in Chapter 4 of bulletin VDOCO6S304E and determine the firmware version of your drive controller For drive controllers with firmware level 3 0 and ATV66 all sizes VW3A66206U later For drive controllers with firmware version earlier than 3 0 Order the control kit listed above that is appropriate for your drive controller Removable Control Terminal Strips ATV66 all sizes VZ3N006 J1 J12 and J13 on control basket 2002 Schneider Electric All Rights Reserved Bulletin No 30072 450 73 Addendum to VD0C06S304E May 2002 ATV66 Repair Parts Repair Parts List Continued Description Drive Controller Part No Note Power Board 460 V ATV66U41N4 VX5A66U41N4 ATV66U54N4 VX5A66U54N4 e f ATV66U72N4 VX5A66U72N4 hen n rectifier diode ATV66U90N4 VX5A66U90N4 ATV66D12N4 VX5A66D12N4 ATV66D16N4 VX5A66D16N4 ATV66D23N4 VX5A66D23N4 ATV66D33N4 VX5A66D33N4 ATV66D46N4 VX5A66D46N4 ATV66D54N4 VX5A66D54N4 ATV66D64N4 VX5A66D64N4 ATV66D79
81. appears on the keypad display The ventilation system continues operating if control supply is maintained enabling the drive controller to cool rapidly For ATV66D16N4 to C31N41 and ATV66D12M2 to D46M2 drive controllers the yellow pre alarm LED flashes when the drive controller approaches the thermal limit When the drive controller is running at rated load and the thermal limit is reached the drive controller will fault after a minimum one minute pre alarm warning Additional thermal protection of ATV66C10N4 C31N41 drive controllers is provided High temperature switches are attached to the heat sink and other key components When one of the switches opens an immediate protective trip occurs MOUNTING IN TYPE 12 IP54 METAL ENCLOSURE Although the ALTIVAR 66 drive controller is a Type 1 IP30 enclosed product certain applications may require Type 12 or IP54 protection Two types of recess mounting kits are available for mounting drive controller with the heat sink outside the enclosure see page 26 Calculating Non Ventilated Enclosure Size Use the following equation to calculate Rth C W the maximum allowable thermal resistance of the enclosure 1994 Square D All Rights Reserved Bulletin No VDOC06S304E Chapter 1 Receiving and Installation January 1999 Mounting in Type 12 IP54 Metal Enclosure Max internal ambient temp C around drive controller 40 C T To Max external ambi
82. bly into the enclosure This process aids in installation and maintenance of the drive controller Table 11 Recess Mounting Kits Gasket Kit VW3 A66801T Mounting Adaptor Plate Kit VW3 A66806 Drive Controller ATV66U41N4 ATV66U54N4 ATV66U72N4 ATV66U41M2 W 70 VW3 A66802T VW3 A66807 ATV66U90N4 ATV66D12N4 ATV66U72M2 ATV66U90M2 75 VW3 A66803T 11 Pi power dissipated in the enclosure by a recess mounted drive control VW3 A66808 ATV66D16N4 ATV66D23N4 ATV66D12M2 ATV66D16M2 er 110 130 110 130 1994 Square D All Rights Reserved 27 Chapter 1 Receiving and Installation Bulletin No VD0OCO6S304E Mounting in Type 12 IP54 Metal Enclosure January 1999 28 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 CHAPTER 2 WIRING WIRING cease oy dt doe bee a doa debian vay Mex EIE Ee 30 General Wiring Practices 30 Branch Circuit Connections 30 Control Wiring lt 38 Output Wiring Precautions 39 Gro hdifig cree Sean pooh ak ah pach Mo eese tiers of dtes 40 TERMINAL STRIP 5 2 n 41 POWER WIRING i 6 ev EE Ys ooh x RIXA XU tee hey rx a Yl 44 CONTROEWIRING attente ror bete
83. by asterisk 2 18 000 AIC denoted by t 32 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 2 Wiring Wiring Table 12 Input Line Currents for Selecting Branch Circuit Conductors 460 V CT Continued Note The input conductor ampacity rating should not be less than the ampacity rating selected based on the rated controller output current Input Line Current Motor Power 5 000 AIC With Line Output 0 141 mH Impedance of Drive Current 10 000 AIC 22 000 AIC 65 000 AIC kW hp Controller 0 070 mH 0 032 mH 0 011 mH 3 5 2 o 400V 460V 18 000 AIC 121 50Hz 60 Hz 0 039 mH A A A A A A 11 24 2 35 0 m 15 ATVOODTON 21 0 24 8 29 9 33 6 19 4 17 9 15 33 0 45 0 20 ATVOGBSSNA 27 0 31 9 38 7 44 8 26 0 23 6 22 48 4 x 60 0 ES 30 RIORDSSNA 40 0 44 0 52 4 59 7 37 0 34 2 30 66 0 78 0 40 GODAIS 52 0 574 67 6 76 6 49 0 45 6 37 79 2 94 0 t 50 65 0 68 3 80 8 91 9 61 2 56 3 45 93 5 110 60 IVOODRMIS 77 0 86 4 94 6 108 71 6 66 7 55 115 5 130 75 bcn 96 0 106 116 133 90 1 83 5 75 157 171 100 ATVGOCTONS 124 138 151 173 121 113 90 190 198 125 ATVOBCISNA 156 166 186 211 153 143 110 226 237
84. circulate the air inside the enclosure prevent hot spots in the drive controller and distribute the heat uniformly to convection cooled surfaces fthereis a possibility of condensation keep the control supply switched on during periods when the motor is not running or install thermostatically controlled strip heaters Recess Mounting To reduce power dissipated in an enclosure ATV66U41N4 to D23N4 and ATV66U41M2 to D16M2 drive controllers may be recess mounted in a wall of the enclosure with the heat sink on the outside Recess mounting requires a cutout in the enclosure and a recess mounting kit Using this kit dissipates the majority of the drive controller heat load outside the enclosure The power dissipated in the enclosure P must be dissipated by the available surface area of the enclosure The heat sink assembly which is mounted 26 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 1 Receiving and Installation Mounting in Type 12 IP54 Metal Enclosure outside the enclosure is rated for Type 12 IP54 protection when used with this kit There are two types of recess mounting kits the Gasket Kit which contains only the gasket necessary for recess mounting and the Mounting Adaptor Plate Kit which provides mounting plates along with gaskets The gaskets in the Mounting Adaptor Plate Kit allow you to assemble the drive controller to the plates before bolting the assem
85. controller not the motor full load current The input current of the controller depends on impedance of the power distribution system and available fault current at the drive input terminals The controller input current is stamped on the nameplate see Figures 3 6 for nameplate location Select the input current corresponding to the available fault current capability or the line impedance present If the branch circuit available fault current capability is limited by fuses or circuit breakers not system impedance use the available fault current capability on the line side of the fuses or circuit breakers to select the drive controller input current Tables 12 17 provide input current information to optimally size branch circuit conductors Line reactors can be used to add reactance to the branch circuit Line reactors are not recommended if the branch circuit inductance as shown in the heading of Tables 12 17 for each AIC rating exceeds 100 of the inductance value calculated for a 3 line impedance or exceeds 20 of the inductance value calculated for a 5 line impedance Excessive impedance may shift input voltage out of the tolerance of the drive controller rating Line reactors can be used to minimize drive controller input line current and reduce controller nuisance tripping due to transient overvoltage If line reactors are used the input conductor ampacity rating should not be less than the ampacity rating selected based o
86. culate the minimum line reactance of a nominal 396 reactor VL 460 V utilization voltage 2 3 rated line reactor Iruna 11 controller rated output 60 Hz fundamental line frequency 460 V x 3x 10 L 1 9213 mH 11A x V3 x 2n x 60 Hz Select a line reactor that has a minimum inductance rating per phase greater than or equal to 1 9213 mH None of the branch circuit inductance values of Tables 12 14 exceed 1 9 mH Table 12 Input Line Currents for Selecting Branch Circuit Conductors 460 V CT Note The input conductor ampacity rating should not be less than the ampacity rating selected based on the rated controller output current Input Line Current Motor 3 2 Power 5 000 AIC With Line Output 0 141 mH Impedance of Drive Current 10 000 11 22 000 AIC 65 000 AIC Controller 0 070 mH 0 032 mH 0 011 mH kw np 18 000 AIC 2 3 5 400V 460V 50 Hz 60 Hz 0 039 mH A A A A A A 0 75 2 3 4 0 1 8 2 7 3 2 3 5 1 6 1 5 15 4 1 3 5 a sor THERE 3 4 4 7 5 7 6 4 3 0 2 7 2 2 5 8 9 0 3 4 8 6 5 8 0 8 8 4 2 3 9 3 ATV66U54N4 7 8 12 4 10 5 15 0 5 7 6 9 8 11 9 13 2 6 7 6 2 5 5 13 20 0 75 11 13 9 16 7 18 5 10 0 9 2 7 5 17 6 26 0 10 TENE 14 0 17 6 21 4 24 7 13 0 12 0 11 10 000 AIC denoted
87. de sufficient free air flow an enclosure ventilation fan is required to exhaust the heat to the enclosure outside ambient The enclosure fan should have a greater fan flow rate than the drive controller fan flow rate listed in Table 10 on page 24 Ifthere is a possibility of condensation keep the control supply switched on during periods when the motor is not running or install thermostatically controlled strip heaters Side view shown t V oe gt AX IK ATV66U41N4 to D23N4 ATV66D33N4 to C19N4 ATV66C23N41 to C31N41 and U41M2 to D16M2 and D23M2 to D46M2 Figure 13 Ventilation for ATV66U41N4 to C31N41 and ATV66U41M2 to D46M2 1994 Square D All Rights Reserved 23 Chapter 1 Receiving and Installation Mounting in Type 12 IP54 Metal Enclosure Bulletin No VD0C06S304E January 1999 Table 10 Flow Rates for ALTIVAR 66 Drive Controller Fans Fan Flow Rate 1 Drive Controller CFM dm3 s ATV66U41N4 ATV66U54N4 10 5 ATV66U72N4 ATV66U41M2 20 10 ATV66U90N4 ATV66D12N4 ATV66U72M2 ATV66U90M2 44 22 ATV66D16N4 ATV66D23N4 ATV66D12M2 ATV66D16M2 94 47 ATV66D33N4 ATV66D46N4 ATV66D54N4 ATV66D64N4 ATV66D79N4 200 100 ATV66D23M2 ATV66D33M2 ATV66D46M2 ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 500 250 ATV66C23N41 ATV66C28N41 ATV66C31N41 1000 500 11 Free air flow rates If an overtemperature condition occurs The fault LED illuminates and a fault message
88. e controller is powered up a pulse of direct current equal to motor rated current is injected into the motor allowing the drive controller to determine the resistance of the motor to set the motor parameters Special The Special control type available when the drive controller is configured for constant torque maintains a constant volts frequency ratio throughout the speed range For example if the voltage to the motor is 460 V at 60 Hz it will be 230 V at 30 Hz functioning as a current limited power supply Use Special control when controlling synchronous permanent magnet motors synchronous wound field motors and synchronous reluctance motors NOLD No Load NOLD control is only available when the drive controller is configured for variable torque This function maintains a constant volts frequency ratio during acceleration Once the motor is stable however voltage to the motor is automatically reduced as a function of load At light load the motor voltage is minimized even at motor base speed This reduces audible motor noise without reducing motor RPM NOLD control should not be used with motors in parallel For more information see the Level 1 amp 2 Configuration Manual 1994 Square D All Rights Reserved 69 Chapter 3 Start Up Bulletin No VD0CO6S304E Motor Thermal Overload Protection January 1999 MOTOR THERMAL OVERLOAD PROTECTION A CAUTION LOSS OF MOTOR OVERLOAD PROTECTION When using external overload
89. e to phase or phase to ground present on the output power conductors If excessive capacitance is present the drive controller may trip Follow the guidelines below when selecting output cable Cable type the cable selected must have a low capacitance phase to phase and to ground Do not use mineral impregnated cable because it has a very high capacitance Immersion of cables in water increases capacitance Cable length the longer the cable the greater the capacitance Cable lengths greater than 320 ft 100 m may require analysis to determine if mitigation is required Contact your local ALTIVAR representative Proximity to output cables from other drive controllers because of the high frequency switching and increased capacitance the drive may fault under some conditions Do not use lightning arrestors or power factor correction capacitors on output of drive controller For installation where cable capacitances may be a problem an inductor can be installed between the drive controller and the motor See catalog or consult factory for additional information A CAUTION DRIVE CONTROLLER SWITCH FAILURE For proper drive controller electronic short circuit protection inductance is required in the output power wiring Provide at least 48 in 122 cm of cable at the drive controller output U T1 V T2 W T3 Failure to follow these instructions can result in equipment damage 1994 Square D All Rights Reserved
90. ections A WARNING OVERCURRENT PROTECTIVE DEVICES MUST BE PROPERLY COORDINATED Toachieve published fault withstand current ratings install the specified fuses listed on the drive controller nameplate and in Tables 21 through 25 Do connect drive controller to power feeder whose short circuit capacity exceeds drive controller withstand fault rating listed on drive controller nameplate Failure to follow these instructions can result in death serious injury or equipment damage All ALTIVAR 66 drive controllers require fuse protection ATV66U41N4 to D79N4 and ATV66U41M2 to D46M2 drive controllers require user supplied external fuses as indicated on the nameplate in Table 21 on page 59 and in 30 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Wiring Table 24 on page 62 ATV66C10N4 to C19N4 drive controllers have provisions for mounting the user supplied fuses internally refer to the controller nameplate or Table 22 on page 60 for recommended fuses ATV66C23N41 to C31N41 drive controllers are shipped with fuses See page 64 for information on mounting and replacing fuses in ATV66C10N4 to ATV66C31NA44 drive controllers Refer to NEC Article 430 for sizing branch circuit conductors All branch circuit components and equipment such as transformers feeder cables disconnect devices and protective devices must be rated for the input current of the ALTIVAR 66 drive
91. ee STON Ra ee ED 27 Table 12 Input Line Currents for Selecting Branch Circuit Conductors 460 VCT 32 Table 13 Input Line Currents for Selecting Branch Circuit Conductors 460 V VT 34 Table 14 Input Line Currents for Selecting Branch Circuit Conductors 460 V VTLN 36 Table 15 Input Line Currents for Selecting Branch Circuit Conductors 208 230 V CT 37 Table 16 Input Line Currents for Selecting Branch Circuit Conductors 208 230 V VT 37 Table 17 Input Line Currents for Selecting Branch Circuit Conductors 208 230 V 38 Table 18 Power Terminal Strip Characteristics 1 44 Table 19 Power Terminal Wire Range 45 Table 20 Control Terminal Strip 5 47 Table 21 Recommended Equipment for 1 to 400 hp 460 V Drive Controllers 1 59 Table 22 Recommended Semiconductor Fuses for 1 400 hp 460 V Controllers 60 Table 23 Maximum Allowable Line Fuse F1 to for 460 V Drive Controllers 62 Table 24 Recommended Equipment for 1 to 50 hp 208 230 V Drive Controllers 1 62 Table 25 Maximum Allowable Line Fuse F1 to for 208 230 V Drive Controllers 63 Table 26 Recommended Equipment for all Drive 63 Table 27 Factory Settings Functions ao iens esee x teen
92. eed reference Al1 and Al2 Al1 is a 0 10 V voltage input A speed potentiometer between 1 and 10 can be connected at COM Al1 and 10 V as shown in Figure 25 AI2 is factory set as a 4 20 mA current input It can be programmed to 0 20 mA x 20 mA or 20 4 mA with the keypad display It can also be set for 0 5 V with a switch on the control board The speed reference controls the frequency of applied power to the motor The actual shaft speed remains dependent on the acceleration and deceleration ramps the torque capabilities of the motor drive controller combination the control type selected see page 68 and the number of poles on the motor The speed range is limited by Low Speed and High Speed settings Factory settings are zero and nominal or base frequency The speed reference inputs share the same common and are isolated from the input line and from ground The 10 V internal supply terminals 10 COM has a 10 mA supply capability and is protected against short circuits If signals are present on both inputs the values are summed for the speed reference With the keypad display they can be configured to be independent For more information on configuration of the analog inputs refer to the Level 1 amp 2 Configuration Manual Figure 25 shows how the speed reference inputs may be connected The speed reference inputs are isolated from the input line 0v 10V 1kQ lt R lt 10kQ Default setting Al1 A
93. ein a 46 ELECTROMAGNETIC COMPATIBILITY 48 Installing the Ferrite 49 USING THE LOGIC INPUTS J12 lsssesssese e eee 52 USING THE LOGIC OUTPUTS 312 53 USING THE SPEED REFERENCE INPUTS 013 54 USING THE ANALOG OUTPUTS 13 55 USING THE RELAY OUTPUTS J1 0 0 c eee I e 55 REMOVAL OF CL1 CL2 JUMPERS 0 000 c eee eee 56 CONTROL CIRCUIT 57 3 Wire Controls cs nie ee Ba EE REEL M sd eee 57 2 Wire Gonlrol eoe nut n Page dae Malate ER uta 57 2 Wire Control with Isolation Contactor on Line Side coast to stop 58 EQUIPMENT 59 Mounting and Replacing Line Power Fuses ATV66C10N4 to C19N4 Drive Controllers e a atte Resto ES coe Ro o RE e vga 64 Replacing Line Power Fuses in ATV66C23N41 to C31N41 Drive Controllers 64 1994 Square D All Rights Reserved 29 Chapter 2 Wiring Bulletin No 00 065304 Wiring January 1999 WIRING General Wiring Practices Good wiring practice requires the separation of control circuit wiring from all power line and load wiring Power wiring to the motor must have the maximum possible separation from all other power wiring
94. ent temp C around enclosure P Total power dissipated in enclosure W For the power dissipated by the drive controllers at rated load see Table 1 on page 6 Table 2 on page 8 Table 3 on page 9 Tables 5 and 6 on page 11 and Table 7 on page 12 Useful heat exchange surface area S ir of a wall mounted enclosure generally consists of the sides top and front Use the following equation to calculate the minimum surface area required for a drive controller enclosure ases Rth S Rth Thermal resistance of the enclosure calculated previously K Area restivity of enclosure material consult enclosure manufacturer Consider these points when sizing the enclosure Use only metallic enclosures because they have good thermal conduction Do not install enclosures where external heat sources such as direct sunlight can add to enclosure heat load This procedure does not consider radiant or convected heat load from external sources Consider the heat load of additional devices present inside the enclosure Use a mounting method that allows air to move freely over all surfaces that are convection cooled The actual useful area for convection cooling of the enclosure will vary depending upon the method of mounting The following example calculates enclosure size for an ATV66U72N4 5 hp CT drive controller mounted in a Type 12 enclosure Maximum external temperature T 25 C Power dissipated inside enclosure P 18
95. er 4 Diagnostics January 1999 Preventive Maintenance two mounting screws On the I O extension module also unplug the separable connectors J22 J23 amp J24 from the bottom of the module Record the firmware revision number from the chip Replace the plastic cover over the firmware chip Reinstall the module as required see note in Step 4 Close the drive controller cover Figure 40 Main Control Board Location of Chip Cover PREVENTIVE MAINTENANCE Before performing preventive maintenance remove all power and check the bus voltage Procedure 1 on page 78 The following preventive maintenance procedures are recommended at regular intervals Check the condition and tightness of the connections Make sure the ventilation is effective and temperature around the drive controller remains at an acceptable level Remove dust and debris from the drive controller if necessary If anything unusual occurs when putting the drive controller into service or during operation be sure all recommendations relating to the environment mounting and connection of the drive controller have been followed 1994 Square D All Rights Reserved 83 Chapter 4 Diagnostics Bulletin No 00 065304 Resettable Renewable Parts January 1999 RESETTABLE RENEWABLE PARTS The ATV66U41N4 to D79N4 and ATV66U41M 2 to D46M2 drive controllers contain no resettable or renewable parts The ATV66C10N4 to
96. ference 13 47 54 supply 47 terminal strips 41 inspection 20 installation 20 26 interference 30 INTERNAL FAULT 90 isolation contactor 58 J J1 terminals 47 55 J12 terminals 46 47 52 J13 terminals 46 47 54 55 VDOC06S304E January 1999 J2 terminal 46 jog 68 L L1 L2 L3 terminals 44 45 LEDs 24 41 43 78 82 88 fault LED 24 LIt LI2 LIS LIA4 terminals 47 52 lightning arrestors 39 line contactor 59 62 logic inputs 47 52 logic outputs 53 LOP LO1 LO2 terminals 47 53 LOSS FOLLOWER 90 M maintenance 83 MEMORY FAILURE 90 MOT OVERLOAD 89 motors continuous duty 72 multiple 71 75 noise 69 overload fault 89 overload protection 76 overspeed 73 overtorque 72 parallel 75 permanent magnet 71 76 self ventilating 72 speed range 72 synchronous 69 76 timing sequence 75 torque 68 72 wound field 71 102 1994 Square D All Rights Reserved VDOCO06S304E ALTIVAR 66 Receiving Installation Start Up January 1999 Index mounting fault 89 ratings 4 dimensions 15 18 protection 76 230 V 11 12 NEMA Type 1 IP30 23 24 relay 70 71 460 V 6 10 NEMA Type 12 IP54 24 26 recess 26 multiple controllers 40 nameplate 3 5 NOLD control 69 72 72 Nominal Current 67 nominal output frequency 67 nominal output voltage 67 Normal control 66 68 69 72 73 options compression lug kit 45 conduit entry plate 30 recess mounting kit 26 outputs ana
97. for 460 V Drive Controllers Littelfuse Controller ATV66 NA4 Class CC Fast Acting Class T JLS AAJ Semiconductor 4 4 4 U41 U54 U72 600 V 25 A 600 V 35 A 600 V 30 A U90 D12 600 V 60A 600 V 45A 600V 45A D16 D23 600 V 100A 600 V 100A 600 V 80A D33 D46 600 V 125A 600 V 125A 600 V 110A 054 064 079 600 V 225A 600 V 225A 600V 225A FWH500A 11 x A50P500 121 FWH6OQA 11 C13 C15 C19 E TE A50P600 2 FWH900A 11 C23 C28 C31 170M6713 121 Q300233 3 1 Bussmann part numbers 2 Gould Shawmut part numbers 3 Ferraz part numbers 4 Manufacturer specific fuse selection DO NOT SUBSTITUTE Table 24 Recommended Equipment for 1 to 50 hp 208 230 V Drive Controllers M1 A1 F1 F3 TS T1 F6 F7 F8 Controller Line Power Fuses Primary Xfmr Motor Mj Ratings Fuses 2 Fuse Class 2 Fuse Carriers Transient Xfmr Xfmr CT VT Littelfuse eerie Class T or CC Contactor Suppressor 3 Fuses kw low AS UMS 208V 230v 2 noise 5 5 9080 C1 9070 FNQ R 1 FNQ R 1 FNQ R 1 FB3611CC I LCt R R R ME T60030 3CRUAI D2510G6 LMSDA2G K50D20 2 2 2 9080 C1 9070 FNQ R 1 FNQ R 1 FNQ R 1 FB3611CCl4l LCt 1 R R R T60030 3CRU I D2510G6 LA4DA2G K50D20 2 2 2 200 C1 9070 FNQ R 1 FNQ R 1 FNQ R 1 83611 000 LCt R R R t T600
98. for the ATV66C10N4 to ATV66C19N4 drive controllers follow this guideline Ifthe drive controller serial number has a 1 as the seventh digit this table can be used to select spare parts All controllers shipped after May 1998 should have a 1 as the seventh digit Ifthe drive controller serial number does not have a 1 as the seventh digit consult the Receiving and Installation manual that was shipped with the drive controller or the ALTIVAR 66 Drive Controller Service and Troubleshooting Manual bulletin number VD0C06S701 SeeFigures 44 and 45 Use the spare parts list in this appendix for all other drive controller models ATV66U41N4 to D79N4 ATV66U41M2 to D46M2 and ATV66C23N41 to C31N41 For controllers like these use the Units after May 31 1998 following spare parts list Figure 45 ATV66C10N4 to ATV66C19N4 1994 Square D All Rights Reserved 93 Appendix A Spare Parts List Bulletin No VDOCO6S304E January 1999 Table 32 Spare Parts List Description Drive Controller Reference No Note ALTIVAR 66 Adjustable Frequency Drive ATV66 all sizes VDOC06S701_ Controller Service and Troubleshooting Manual Control Kit 460 V ATV66U41N4 to D79N4 VX4A66CK1 Matched keypad and control basket ATV66C10N4 to C31N41 VX4A66CK2 with latest firmware Control Kit 208 230 V ATV66U41M2 to D46M2 VX4A66CK1
99. ge 70 Jog Function Speed limited to 5 Hz Ramp time 0 1 s Time between two pulses 0 5 s Control Scheme Two wire control Table 28 Factory Settings Inputs and Outputs Inputs and Outputs Terminal Factory Setting Programmable Li Run Enable No LI2 Run Forward No Logic Inputs LI3 Run Reverse Yes LI4 Jog Yes Alt Speed Reference 1 Yes Analog Inputs Al2 Speed Reference 2 Yes LO1 At Speed Yes LO2 Current Limit Yes Logic Outputs R1 Fault No R2 Running State Yes AO1 Motor Speed Yes Analog Outputs AO2 Motor Current Yes CONTROL TYPES Normal The control type affects the amount of available motor torque The control type setting is dependent on the type of motor used and the application The following paragraphs describe control types For information on changing the control type see the Level 1 amp 2 Configuration Manual The Normal control type is the factory setting for both constant and variable torque configurations Normal is a sensorless flux vector control In order to create high torque at low speeds the drive controller maintains a 90 phase relationship between the rotor and stator electromagnetic fields by continuously calculating the position of the rotor in relation to the electrical position of the stator It is generally applicable on asynchronous motors and provides good torque performance Because there are fewer parameters than 68 1994 Square
100. gh 24 starting on page 59 Turn off all power before installing the drive controller Place a DO NOT TURN ON label on the drive controller disconnect Before proceeding with installation lock the disconnect in the open position The ATV66U41N4 to ATV66C19N4 and ATV66U41M2 to ATV66D46M2 drive controllers may be mounted inside another enclosure to increase the degree of protection or size of the enclosure See Mounting in General Purpose Metal Enclosure on page 23 or Mounting in Type 12 IP54 Metal Enclosure on page 24 To improve ventilation remove the front cover when mounting the drive controller in an enclosure For ATV66U41N4 to D23N4 and ATV66U41M2 to ATV66D16Me drive controllers remove the front cover by first opening the cover then separating the retaining clips on the cover from the side panel For ATV66D33N4 to D79N4 and ATV66D23M2 to ATV66D46M2 drive controllers remove the front cover by first opening the cover then lifting it vertically For ATV66C10N4 to C19N4 drive controllers remove the front cover by removing the 3 hinge fastening bolts For ATV66C23N41 to C31N41 drive controllers there are no removable covers With the front cover removed the ATV66U41N4 to D79N4 and ATV66U41M2 to ATV66D46M2 drive controllers have an IP20 enclosure rating and the ATV66C10N4 to C19N4 drive controllers have an IPOO enclosure rating For ATV66C10N4 to C31N41 drive controllers the protective switch see Figure 41 on page 86 and Figu
101. hardware drive controller for control wiring Figure 19 Typical Diagram of Control Wiring at Drive Controller 50 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Electromagnetic Compatibility EMC Installing the Motor Cable Ferrite Core DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow Procedure 1 Bus Voltage Measurement in Chapter 4 of this bulletin Failure to observe this instruction will result in death or serious injury DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on the control board power board and I O extension module if installed connectors Verify that all power has been removed from J1 J2 and J13 connectors If I O extension module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to observe this instruction will result in death or serious injury GND This terminal not included on ATV66U41N4 U72N4 and ATV66U41M2 On these models connect motor cable ground conductor and shield drain wire to GND terminal on U V W other end of J2 For location GND CL1 CL2 LI L2 L3 PA PB T2 T3 GND of ground terminals see page 45 of this bulletin O O CD Gb J2 Power Terminal Strip in Drive Controller For terminal strip location see page 45 of this bulletin
102. ing user supply oras shown Wr Internal Control Power F1 F3 Det OO PE 24 Li4 L2 1 2 10 d m 1 1 1 1 1 1 B 1 i 5 3 im D 1 0 PRED ls 1 1 Keypad i 1 1 Connector 1 1 i LOP 102 101 COM oo ADR SOM Pi pen Ric m B PB PA 1 9 e 2 9 COOL OO Ti 1 r3 External Isolation Isolation Dynamic Closed I Open Braking o o olo Resistor M1 1 Add F10 and 11 fuses if tap conductor protection is required The internally protected CL1 and CL2 inputs of all ATV66 drive controllers require no external fusing 2 F5 and F6 fuses are present only on ATV66C10N4 to ATV66C31N41 drive controllers 3 The power circuit configuration of the ATV66C23N41 to ATV66C31N41 drive controllers does not support the use of an input isolation contactor Figure 31 2 Wire Control Circuit Diagram with Isolation Contactor see Table 21 Figure 31 is a 2 wire control circuit diagram with an isolation contactor on the line side It shows how to connect a branch circuit disconnect device and protective fusing to the drive controller Additional sequencing logic may be required Refer to Tables 21 to 26 on pages 59 63 for additional equipment required NOTE External fusing is recommended for the ATV66C 10N4 to ATV66C 19N4 drive controllers when used with an isolation contactor on the line side If the internal fuse installation
103. ion check circuit continuity between W T3 terminal to terminal Continuity should be present for either polarity of the measurement Lack of continuity in one direction is an indication that fuse FAC is open 1994 Square D All Rights Reserved 85 Chapter 4 Diagnostics Bulletin No 00 065304 Resettable Renewable Parts January 1999 10 If any of the fuses are open this indicates that other components may be damaged Do not attempt replacement Contact your local representative 11 Reconnect the motor leads to the U T1 V T2 and W T3 terminals of the drive controller oN Ol F4A EI DC Bus LED E o F4B cavon Leo OS Power LED HO U T1 PE W T3 PB Ke CL 21 CL 22 CL 1 ooo CL2 Protective Switch Fuses GV2 F5 and F6 pA Figure 41 F4C Bus Fuse Test Procedure ATV66C10N4 to C19N4 86 1994 Square D All Rights Reserved Bulletin No VD0C06S304E Chapter 4 Diagnostics January 1999 Resettable Renewable Parts PA Figure 42 Bus Fuse Test Procedure ATV66C23N41 to C31N41 1994 Square D All Rights Reser
104. is used the short circuit current rating of the isolation contactor must be coordinated with the overcurrent protective device protecting the drive controller feeder The maximum number of operations of the KM1 contactor or controller disconnect should not exceed one per minute for the ATV66U41N4 to ATV66D79N4 and ATV66U41M2 to ATV66D46M2 drive controllers and one per every two minutes for the ATV66C10N4 to ATV66C31N41 drive controllers 58 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 2 Wiring Equipment Recommendations EQUIPMENT RECOMMENDATIONS Equipment listings in Tables 21 though 26 are valid for all versions of the circuit diagrams Table 21 Recommended Equipment for 1 to 400 hp 460 V Drive Controllers M1 A1 F1 F3 Input F7 F8 F9 Controller Motor Line Power Fuses Ratings Fuse Class ATV66 N4 9 Primary Sec CT t Gould Fuse Carriers Line Transient Xfmr Xfmr TM VT CCFast Shawmut ClassT or Contactor Suppressor Fuses Fuses P tow Acting on A4J 3 3 9 600V 600V 600 V hang 9070 z FB3611CC 2I T d R 075 1 U41 Ud LM DA2G 50020 FNQ R 1 2 T60060 3CRI3 600V 600V 600 V ee 9070 FB3611CC 2 E R 15 2 un Utt Yoa 10 TOA LA4 DA2G FNQ R 1 2 T60060 3CRI3I 600V 600V 600 V 208 9070 2 61100 21 T R 22 3 Ut UM ic 45 aa
105. l IGBT blocks snubber boards gate driver boards ATV66C31N41 VZ31M1500M1207 4 dual IGBT blocks snubber boards gate driver boards Inverter IGBT 208 230 V ATV66D12M2 VZ31M2075M0601 1 dual IGBT block ATV66D16M2 VZ31M2100M0601 1 dual IGBT block ATV66D23M2 VZ31M2150M0601 1 dual IGBT block ATV66D33M2 VZ31M2200M0601 1 dual IGBT block ATV66D46M2 VZ31M2300M0601 1 dual IGBT block Inverter IGBT Clamp Capacitor ATV66C23N41 to C31N41 VY1ADC610 1994 Square D All Rights Reserved 95 Appendix A Spare Parts List Bulletin No 00 065304 January 1999 Table 32 Spare Parts List Continued Description Drive Controller Reference No Note Dynamic Braking IGBT 460 V ATV66D14N4 D23N4 VZ31M1025M1001 ATV66D33N4 D46N4 VZ31M2050M 1201 ATV66D54N4 VZ31M2100M1201 ATV66D64N4 D79N4 VZ31M2150M1201 ATV66C10N4 to C19N4 VZ31M1300M1202 1 dual IGBT block 1 dual diode block 1 snubber board 1 gate driver board ATV66C23N41 VZ31M1400M1208 1 dual IGBT block 1 dual diode block 1 snubber board 1 gate driver board ATV66C28N41 C31N41 VZ31M1300M1208 2 dual IGBT blocks 2 dual diode blocks 2 snubber boards 1 gate driver board Dynamic Braking IGBT 208 230 V ATV66D12M2 D16M2 VZ31M1060M0601 ATV66D23M2 VZ31M2075M0601 ATV66D33M2 VZ31M2100M0601 ATV66D46M2 VZ31M2150M0601 Dynamic Braking Clamp Capacitor ATV66C10N4 to C19N4 VY1ADC616 ATV66C23N41 to C31N41 VY1
106. l Rights Reserved Bulletin No 00 065304 Chapter 3 Start Up January 1999 Factory Settings A CAUTION MOTOR OVERHEATING Each time the drive controller is powered up with Normal or High Torque control type selected direct current equal to the drive controller rated current is injected into the motor Do not use motors with a full load current rating that is not within the adjustment range of the drive controller Nominal Current parameter Failure to follow this instruction can result in injury or equipment damage When the drive controller is powered up direct current equal to the motor rated current is injected into the motor allowing the drive controller to determine the resistance of the motor and set the motor parameters For optimal torque performance operate the drive controller and motor under no load at 50 60 Hz during initial commissioning or any time the motor is changed This allows the drive controller to measure key motor parameters The Nominal Current parameter must be set on the drive controller keypad display to match the motor full load current rating If the Nominal Current parameter cannot be adjusted to the motor full load current Normal and High Torque control types cannot be used for the application For multiple motor applications contact your local representative FACTORY SETTINGS The ALTIVAR 66 drive controller is factory set to meet most applications If the following values are c
107. l2 supplied Customer 4 Figure 25 Using Speed Reference Inputs 54 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Using The Analog Outputs J13 USING THE ANALOG OUTPUTS J13 The ALTIVAR 66 drive controller has two 0 20 mA analog outputs AO1 and AO2 They are both 0 20 mA current inputs 1 is factory set as proportional to motor frequency with 20 mA corresponding to High Speed AO2 is factory set as proportional to motor current with 20 mA corresponding to twice the rated output current of the drive controller see Tables 1 to 7 on pages 6 12 Maximum driving voltage is 12 V with an internal impedance of 100 Q Theanalog outputs can be assigned to other functions than those set at the factory For information on other functions refer to the Level 1 amp 2 Configuration Manual Customer supplied Figure 26 Analog Outputs USING THE RELAY OUTPUTS J1 The ALTIVAR 66 drive controller has two voltage free Form C relay output contacts see Figure 27 The contacts have the following characteristics Minimum voltage 24 VDC minimum current 10 mA Maximum voltage 30 VDC maximum current 2 A 120 VAC maximum current 2 A 220 VAC maximum current 1 A R1 is the drive controller fault relay It is not programmable 2 1 6 pf R1 R1 R2 R2 6 1 hH ete XD RO Mae
108. letin No 00 065304 Appendix A Spare Parts List January 1999 Table 32 Spare Parts List Continued Description Drive Controller Reference No Note Power Board 208 230 V ATV66U41M2 VX5A662U41M2 Includes IGBT block and rectifier diode ATV66U72M2 VX5A662U72M2 Includes IGBT block and rectifier diode ATV66U90M2 VX5A662U90M2 Includes IGBT block and rectifier diode ATV66D12M2 VX5A66D12M2 ATV66D16M2 VX5A66D16M2 Power Board and Gate Driver Board ATV66D23M2 VX5A66D234M2 Matched set 55209290 ATV66D33M2 VX5A66D335M2 Matched set ATV66D46M2 VX5A66D466M2 Matched set Gate Driver Board 460 V ATV66D16N4 VX5A66103 ATV66D23N4 VX5A66104 ATV66D33N4 VX5A66105 ATV66D46N4 VX5A66106 ATV66D54N4 VX5A66107 ATV66D64N4 VX5A66108 ATV66D79N4 VX5A66109 Gate Driver Board 208 230 V ATV66D12M2 VX5A66112 ATV66D16M2 VX5A66113 Inverter IGBT 460 V ATV66D16N4 VZ3IM2050M1201 1 dual IGBT block ATV66D23N4 VZ31M2075M 1201 1 dual IGBT block ATV66D33N4 VZ3M2100M 1201 1 dual IGBT block ATV66D46N4 D54N4 VZ31M2150M 1201 1 dual IGBT block ATV66D64N4 VZ3IM2200M1201 1 dual IGBT block ATV66D79N4 VZ3IM2300M 1201 1 dual IGBT block ATV66C10N4 VZ31M2300M 1202 2 dual IGBT blocks snubber boards gate driver boards 1 clamp module ATV66C13N4 to C19N4 VZ31M2400M 1202 2 dual IGBT blocks snubber boards gate driver boards 1 clamp module ATV66C23N41 C28N41 VZ31M1400M1207 4 dua
109. lity and Speed 72 Overspeed Operation f gt 50 60 2 73 Regenerative Operation 73 Driving Torque Production Envelope 73 MOTOR CONSIDERATIONS 00000 0 ce cece teens 74 Motor lrisulatiOni s 6 mi ear diet oka an carlo sehr e eek cue en RS fio es 75 Motors in Parallel Geo oe a Sek Ga SERI 75 Output Contactor Between Motor and Drive Controller 75 Additional Motor Connected Downstream of the Drive Controller 75 Using a Synchronous Permanent Magnet or Wound Field Motor 76 Using a Synchronous Reluctance 76 1994 Square D All Rights Reserved 65 Chapter 3 Start Up Bulletin No VD0C06S304E Introduction January 1999 INTRODUCTION The ALTIVAR 66 drive controller is software driven The factory default settings may require reconfiguration If the factory settings do not match the requirements of your application or if you must reconfigure the drive controller for a new application refer to the Level 1 amp 2 Configuration Manual Generally at least four key parameters should be checked and adjusted if necessary prior to motor operation Nominal Current Motor Overload Control Type Rotation Normalization Note Changing the wiring of
110. lletin VDOCO6S304E for assistance in finding the drive controller serial number Ifthe serial number has a 1 as the seventh digit select repair parts from the repair parts list beginning on page 2 of this addendum All drive controllers shipped on or after June 1 1998 have a 1 as the seventh digit of the serial number See Figure 2 on page 2 for illustrations of these controllers If the serial number does not have 1 as the seventh digit consult bulletin VDOC06S702 for repair parts These are drive controllers that shipped on or before May 31 1998 They are illustrated in Figure 1 Use the repair parts list beginning on page 2 of this addendum for all other drive controller models ATV66U41N4 to ATV66D79N4 ATV66U41M2 to ATV66D46M2 and ATV66C23N4 to ATV66C31N4 For controllers like this select repair parts from bulletin VD0C06S702 Service and Troubleshooting Manual 100 350 hp 125 400 hp VT Figure 1 ATV66C10N4 C19N4 Shipped On or Before May 31 1998 D SQUARE D Addendum to VD0C06S304E ATV66 Repair Parts Repair Parts List Bulletin No 30072 450 73 May 2002 For controllers like these select repair parts from the following Repair Parts List Figure 2 ATV66C10N4 C19N4 Shipped On or After June 1 1998 Description Drive Controller Part No Note ATVG6 TB 701 ALTIVAR 66 Adjustable Speed Drive Controllers 100 hp VT Service
111. log 47 55 contactor 75 customer supply 47 dynamic braking 44 logic 47 53 motor 44 91 power 44 relay 47 55 terminal strips 41 wiring 39 overcurrent 30 89 overheating 67 70 overload overspeed 73 90 OVERTEMP DRIVE 89 overtemperature 89 overtorque 72 overvoltage 89 P PA PB terminals 44 45 79 80 parallel motors 75 parts list 27 59 63 94 permanent magnet motor 69 71 76 phase fault 89 power 13 control 88 fuses 57 58 input line 81 LED 41 43 88 ratings 6 12 supplies control 44 input line 44 logic inputs 52 logic outputs 53 PRECHARGE FAIL 90 preventive maintenance 83 programmable relay 47 R R1A R1B R1C terminals 47 R2A R2B R2C terminals 47 ramp time 68 recess mounting 26 reference inputs 47 regenerative torque 73 relays capacitor charge 90 fault 47 55 outputs 55 overload 70 71 precautions 38 programmable 47 terminals 47 S S terminal 47 safety label 3 sensorless flux vector 69 sensors thermal 24 SERIAL LINK 90 serial link fault 90 service factor 72 shielding 38 shock resistance 14 SHORT CIRCUIT 90 short circuit protection 39 slip compensation 67 solenoids 38 spare parts 94 Special control 69 72 74 76 specifications 6 18 speed range 54 72 speed reference inputs 13 47 54 1994 Square D All Rights Reserved 103 ALTIVAR 66 Receiving Installation Start Up Index supply control 89 input external 52 input line 81 synchronous
112. n the rated controller output current in systems that use bypass contactors the line reactor should always be connected between the L1 L2 and L3 terminals on the controller and the line fuses A line reactor in a bypass motor starting circuit will reduce the ability of the motor to produce starting torque the voltage tolerance at input of the reactor will be different from that of the drive controller due to the voltage drop across the line reactor Voltage tolerance measured at input terminals of the drive controller will be as specified in this manual the line reactor can also improve a phase to phase voltage imbalance The input line current ratings listed in Tables 12 17 for 3 and 5 line reactance are based on coordinated ratings To calculate the necessary 1994 Square D All Rights Reserved 31 Chapter 2 Wiring Bulletin No VD0CO6S304E Wiring January 1999 minimum line reactance use the following formula to verify the selection of the minimum reactor impedance needed for installation E inductance in millihenries mH S VL input voltage measured line to line utilization voltage VL L X Z x 10 Z desired input impedance rating in percent Ind X V3 x 27 x f drive controller output current rating T Pi constant 3 14 f fundamental line frequency 50 or 60 Hz Example User has a 7 5 hp 11 A at 460 V 60 Hz motor in combination with ATV66U90NAU 7 5 hp 460 V 11 FLA drive controller Cal
113. nal sequencing logic may be required Refer to Tables 21 to 26 on pages 59 63 for additional equipment required The drive controller is factory set for 2 wire control To set for 3 wire control refer to the Level 1 amp 2 Configuration Manual 2 Wire Control Control Internal 3 t2 L1 ontrol po oa E Control Power Ft 4 NX RUN RUN 0 20 mA Power _ siphon JOG ENABLE 4 20 mA Equipment 1 F1 F3 R1 e de Oe ee em ea 4 14 L2 LH Al2 10 Ai Keypad Connector 2i LOP 102 101 COM AO2 AO R2C R2A R2B R1C R1A R1B PB PA 1 09 6 Joe External Dynamic Braking Resistor 1 Add F10 and F11 fuses if tap conductor protection is required The internally protected CL1 and CL2 inputs of all ATV66 drive controllers require no external fusing 2 F5 and F6 fuses are present only on ATV66C10N4 to ATV66C31N41 drive controllers Figure 30 2 Wire Control Circuit Diagram 1994 Square D All Rights Reserved 57 Chapter 2 Wiring Bulletin No 00 065304 Control Circuit Diagrams January 1999 Figure 30 is a 2 wire control circuit diagram It shows how to connect a branch circuit disconnect device and protective fusing to the drive controller Additional sequencing logic may be required See Tables 21 to 26 on pages 59 63 for additional equipment required 2 Wire Control with Isolation Contactor on Line Side Coast to Stop Exist
114. nd on the bottom right corner of the right side of the controller The exceptions are the ATV66C23N41 through C31N44 where the plate is located on the inside of the front door Serial numbers are usually found next to the nameplate except on ATV66D33N4 to D46N4 and ATV66D23M2 to D33M2 where the serial number is in two separate locations For ATV66C10N4 to C19N4 controllers covered by this manual there is always a 1 as the seventh digit of the serial number Catalog number A4 Date code Figure 2 Sample Nameplate 1994 Square D All Rights Reserved 3 Chapter 1 Receiving and Installation Bulletin No 00 065304 Nameplates and Serial Numbers January 1999 The following four figures show the location of nameplates and serial numbers Side View a Ii Serial number Nameplate Figure 3 ATV66U41N4 to D23N4 and ATV66U41M2 to ATV66D16M2 Bottom View lt Serial nurfiler open door above keypad ome Side View Nameplate Serial number Figure 4 ATV66D33N4 to D79N4 and ATV66D23M2 to D46M2 4 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 1 Receiving and Installation Nameplates and Serial Numbers January 1999 Side View Top rU zmd x Serial number Nameplate Figure 5 ATV66C10N4 to C19N4 Catalog number Serial Nameplate number Figure
115. ng current of the motor at nameplate speed maximum transient output current of the drive controller and the applied V Hz at reduced speed Maximum transient overtorque capability is typically Normal constant torque and variable torque and High Torque constant torque control types ATV66U41N4 to D12N4 and ATV66U41M2 to D12M2 170 constant torque or 110 variable torque over 50 1 speed range ATV66D16N4 to C31N41 and ATV66D16M2 to D46M2 150 constant torque or 110 variable torque over 50 1 speed range Special constant torque and NOLD variable torque control types ATV66U41N4 to C31N41 and ATV66U41M2 to D46M2 150 constant torque or 110 variable torque over 10 1 speed range With Special and NOLD control the motor overtorque capability begins to decrease below 50 of motor nameplate speed To improve low speed overtorque performance adjust the Voltage Boost parameter See the Level 1 amp 2 Configuration Manual 72 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 3 Start Up January 1999 Available Motor Torque Overspeed Operation f gt 50 60 Hz With an adjustable frequency drive controller operation at speeds greater than motor nameplate speed may be possible The following must be considered A CAUTION MACHINERY OVERSPEED Some motors and or loads may not be suited for operation above nameplate motor speed and frequency Consult motor manufacturer bef
116. ng this drive controller to be exported to the European market an optional RFI filter may be required A listing of the available RFI Filters can be found in VVDED296034 referenced above NOTICE RFI filters available for the ATV66 drive controller and listed in instruction manual VVDED296034 are qualified for use on European power systems ONLY In addition for a machine containing this drive controller to be exported to the European Market a motor cable ferrite core and a control cable ferrite core may need to be installed After February 1997 the following ATV66 drive controllers may be shipped with a package that contains one motor cable ferrite core and one control cable ferrite core ATV66U41N4 ATV66D79N4 e ATV66U41M2 ATV66D46M2 48 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Electromagnetic Compatibility EMC Ferrite core kits containing one motor cable ferrite core and one control cable ferrite core are available from your Square D Distributor VW3 A66470 for ATV66U41N4 D46N4 and ATV66U41M2 D33M2 VW3 A66471 for ATV66D54N4 D79N4 and ATV66D46M2 Installing the Ferrite Cores DANGER HAZARDOUS VOLTAGE Read and understand these procedures before servicing ALTIVAR 66 drive controllers Installation adjustment repair and maintenance of these drive controllers must be performed by qualified personnel Failure to observe
117. ogic Inputs from External Power 52 Operating the Logic Outputs from Internal Power Supply 53 Operating the Logic Outputs from External Power 53 Using Speed Reference Inputs 54 Analog Outputs a es eee Sees AAE ale nus 55 Relay Outputs ennn a Ee E ete 55 GLT CL Jumper Removal of oc n EAE E DEEE oA Re ROR EA 56 Recommended 3 Wire Control Circuit 57 2 Wire Control Circuit Diagram 57 2 Wire Control Circuit Diagram with Isolation Contactor see Table 21 58 Thermal Curves Constant 71 Typical Constant Torque 74 Typical Variable Torque 74 Motors inParallel 5 29 5 olen Miata 75 Connecting an Additional 75 Location of PA and Terminals ATV66U41N4 to C19N4 and ATV66U41M2 to D46M2 tse S NO Rei er ato Aaah weak Te deos a RR 79 Location of PA and Terminals ATV66C23N41 to 1 41 80 Drive Identification Screen ora anair ena oneei sese 82 Main Control Board Location of Chip 83 F4A F4B F4C Bus Fu
118. ompatible with the application the drive controller can be started up If the values listed below do not match the requirements of your application change their settings with the keypad display For detailed use of the keypad display refer to the Level 1 amp 2 Configuration Manual Table 27 Factory Settings Functions Function Factory Setting Automatically set at first power up according to the input frequency 50 Hz input 400 V ATV66 N4 units 230 V ATV66 M2 units 60 Hz input 460 V ATV66 N4 units 230 V ATV66 M2 units Nominal Current 0 9 times permanent output current of drive controller Nominal Output Voltage and Frequency Normal linear law Law IR compensation preset at 100 Slip Compensation On and automatic 50 Hz input 0 1 to 50 Hz 60 Hz input 0 1 to 60 Hz Operating Frequency Range 1994 Square D All Rights Reserved 67 Chapter 3 Start Up Control Types Bulletin No VD0CO6S304E January 1999 Table 27 Function Ramp Times Braking To Standstill low speed Factory Settings Functions Continued Factory Setting Acceleration 3 s Deceleration 3 s Ramp time automatically adapted in case of overtorque Automatic by DC injection for 0 5 s when frequency drops below 0 1 Hz DC current level 0 7 times the permanent output current of drive controller Motor Thermal Protection 0 9 times continuous output current of drive controller see pa
119. or 100 1994 Square D All Rights Reserved VDOCO6S304E ALTIVAR 66 Receiving Installation Start Up January 1999 Index A logic inputs 52 CUSTOM FAULT 92 acceleration 12 68 AC LIN OVERVOL 89 additional controllers 40 additional motor 75 AIH AI2 terminals 46 47 54 analog inputs 47 analog outputs 47 55 AO1 AC terminals 47 55 attenuation 30 AUTO TEST FAIL 90 braking DC injection 68 70 dynamic 44 73 91 braking resistance values 460 V drives 10 208 230 V drives 12 branch circuit 30 38 57 58 bus capacitor voltage 78 bypass 75 C cable 38 39 cable trays 38 capacitance 39 capacitors charge relay fault 90 DC bus 78 power factor correction 39 caution LED 24 41 43 88 circuit diagrams control 57 58 logic outputs 53 CL1 CL2 terminals 44 45 CL21 CL22 terminals 44 45 COM terminal 47 53 compression lug kit 45 condensation 23 26 conduit entries 15 18 entry plate 30 38 wiring requirements 30 constant torque 6 11 32 37 68 73 74 contactors isolation 58 line 59 63 output 75 continuous duty 72 control board 46 circuit diagrams 57 58 terminals 47 three wire 57 two wire 57 types 68 69 72 73 76 voltage supply 44 wiring precautions 38 controllers handling 19 inspection 20 installation 20 26 part numbers 6 12 specifications 6 13 weight 15 18 wiring 30 40 64 current nominal 67 overcurrent 30 89 ratings 6 12 D DB Resistor 91
120. ore information on configuring the drive controller refer to the Level 1 amp 2 Configuration Manual 1994 Square D All Rights Reserved 71 Chapter 3 Start Up Bulletin No VD0OC06S304E Available Motor Torque January 1999 AVAILABLE MOTOR TORQUE Continuous Duty For continuous duty reduced speed applications motor torque de rating may be necessary This de rating is linked to two causes Although the current waveform is similar to a sine wave motor heating is slightly greater than when operating directly from the input line supply The resulting torque de rating is approximately 596 For 1 0 service factor motors de rating must be considered when choosing the continuous torque production capability of the motor at nameplate speed For 1 15 service factor motors de rating of motor continuous torque capability is not required at nameplate rated speed For self ventilating motors ventilation produced by the internal shaft fan decreases as speed is reduced therefore requiring de rating of the maximum continuous torque capability of the motor Generally the required de rating occurs at approximately 5096 of nameplate motor speed Since motor designs vary consult the motor manufacturer for the required de rating for a specific motor Overtorque Capability and Speed Range The driving overtorque capabilities of a given motor are determined by the motor NEMA design category Design B Design D etc no load magnetizi
121. ore operating motor above rated speed Failure to follow this instruction can result in injury or equipment damage The drive controller is incapable of producing additional output voltage when operating above the nominal output frequency generally 50 60 Hz When operating above the nominal output frequency the available continuous motor torque will begin to decrease along with the motor maximum overtorque capability Consult the motor manufacturer for continuous and overtorque torque capabilities of the particular motor Regenerative Operation A dynamic braking kit must be installed if regenerative torque is required Overtorque capability in the regenerative mode is similar to overtorque in the motoring mode For continuous regeneration applications consult the factory For C10 through C19 controllers a suffix is required for dynamic braking operation Driving Torque Production Envelope Figures 33 and 34 illustrate typical continuous torque and overtorque driving capability for a typical NEMA Design B 1 0 service factor motor with constant torque Figure 33 and variable torque Figure 34 loads For 1 15 service factor motors the continuous torque rating is 1 0 times the motor rated torque value from 50 to 10096 of motor nameplate rated speed Normal constant torque and variable torque and High Torque constant torque control types 100 torque typical at 50 of nominal frequency over 2 1 speed range
122. ower rating too low for 2 Verify motor and drive controller application selection is correct for application 3 For motors with continuous current rating 1 This fault always causes a freewheel stop 2 This occurs only on power up less than 50 of drive controller current rating see Level 1 amp 2 Configuration Manual 1994 Square D All Rights Reserved 89 Chapter 4 Diagnostics Fault Messages Bulletin No VD0OC06S304E January 1999 Table 30 Fault Message SHORT CIRCUIT 1 Screen showing Short Circuit with means LIC exceeded Fault Messages Continued Probable Cause Short circuit or grounding on drive controller output Short Circuits or Short Circuit Troubleshooting Procedure Remove all power With drive controller disconnected check connecting cables and motor insulation Internal drive fault 2 Usedrive controller self diagnostics See creen showing Short ircui Level 1 amp 2 Configuration Manual Circuit with no other symbol Short Circuit evel 1 8 2 means desaturation Motor improperly applied 3 See Motor Considerations on page 74 Short Circuite PRECHARGE FAILE I Capacitor charge relay closure 1 Check connections in drive controller control fault after following Bus Voltage Measurement Procedure see page 78 2 Reset switch after following Bus Voltage For ATV66C10N4 C31N41 tripped Measuremen
123. p 2 Configuration manual Many options are available for the ALTIVAR 66 drive controller Refer to the catalog for a description of these options A manual or instruction sheet is provided with each option Documentation List The following ALTIVAR 66 drive controller documents are available e Receiving Installation and Start Up VD0C06S304 Level 1 amp 2 Configuration VDOC06S305_ e Dynamic Braking VDOCO6S908 _ Catalog VD0C06S201 Additional documentation is provided with the optional peripherals Revision Level This document Revision E replaces VD0C06S304D dated February 1998 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 1 Receiving and Installation January 1999 Hazard Labeling HAZARD LABELING The ALTIVAR 66 drive controller is shipped with an English safety label applied to the control board If a Spanish German or French label is required affix it to the main control board above the English label see Figure 1 Do not obstruct the English label Spanish German or French English Figure 1 Hazard Labeling The ATV66C10N4 to ATV66C31N41 drive controllers also ship with a similar English safety label applied to the front door Affix a Spanish German or French label above the English label as required See Figure 9 and Figure 10 NAMEPLATES AND SERIAL NUMBERS For most of the drive controllers the nameplate is fou
124. pter 3 Start Up January 1999 Adjustment of Motor Overload 6 24 36 60Hz 15 20 30 50Hz Note for variable torque configuration use the same curves but limit 10 min overload to I In 1 1 4 min cold 2 min 1 min hot 07 08 09 1 11 12 13 14 1 5 Iin Figure 32 Thermal Curves Constant Torque External thermal overload relays are required when more than one motor is connected to the output or when the motor connected to the drive controller is less than half of the drive controller rating or with a permanent magnet or wound field motor See Table 29 on page 76 The thermal state of the drive controller is not automatically reset when power is removed ADJUSTMENT OF MOTOR OVERLOAD To adjust Motor Overload first select the type of protection in the 7 4 Fault Management menu Four types of protection are available from the Motor Overload screen Self Cooled Motor Forced Ventilation Motor Manual Tuning NoThermal Protection The drive controller is factory set for a self cooled motor Once the type of protection is selected the Motor Overload current can be set in either the 1 Parameter Setting menu or in the 7 4 Fault Management menu Motor Overload can be adjusted from 0 45 to 1 15 times the nominal drive controller current factory preset at 0 9 times the nominal drive controller current Adjust Motor Overload value to nominal motor current For m
125. r can store up to eight faults and display them as messages on the keypad display These fault messages listed in Table 30 allow access to Fault History Screens which display the drive controller run status atthe time of each fault For more information on Fault History Screens see the Level 1 amp 2 Configuration Manual For more information on troubleshooting see the ATV66 Service and Troubleshooting Manual instruction bulletin VD0C06S701 available through a Square D distributor Table 30 Fault Messages Fault Message Probable Cause Troubleshooting Procedure Display off or partial display 1 No control supply 1 Check input line voltage Procedure 2 on page 81 2 Control voltage too low 2 Check fuses and circuit breaker Procedure 3 on page 81 3 Check CL1 CL2 control terminal connections This fault always causes a freewheel stop 2 This occurs only on power up 88 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 4 Diagnostics Fault Messages Table 30 Fault Messages Continued Fault Message IN PHASE LOSS Input phase loss Probable Cause No supply to terminals L1 L2 L3 Troubleshooting Procedure Check input line voltage Procedure 2 on page 81 Power fuses open 2 Check fuses and circuit breaker Procedure 3 on page 81 Brief input line failure t gt 200 ms 3 Reset drive controller Internal connection
126. r more information refer to the Level 1 amp 2 Configuration manual Additional Motor Connected Downstream of the Drive Controller When connecting an additional motor comply with the recommendation for Motors in Parallel OL1 Drive Controller Figure 36 Connecting an Additional Motor If the motor will be connected to the drive controller while the drive controller is running the sum of the running motor current s plus the expected starting current of the switched motor must not exceed 90 of the drive controller s transient output current rating 1994 Square D All Rights Reserved 75 Chapter 3 Start Up Bulletin No VD0CO6S304E Motor Considerations January 1999 Using a Synchronous Permanent Magnet or Wound Field Motor It is possible to operate a synchronous permanent magnet or synchronous wound field motor as long as the following conditions are met Slip compensation is disabled Internal overload protection is disabled and external protection overload relay or thermal sensor is used Operation is only with Special control type with constant torque setting Appropriate field excitation and protection is provided for externally excited motors Using a Synchronous Reluctance Motor It is possible to operate a synchronous reluctance motor as long as slip compensation is disabled Table 29 Operating Non Standard Motors Description Slip Compensation Overload Control Type Motors
127. re 42 on page 87 may have tripped during transit Reset before applying power Breaker On Start Failure to validate may inhibit proper power up of the drive controller The solid state switches of the drive controller power circuit do not provide complete isolation from the line Leakage currents and voltages may be present at the U T1 V T2 W T3 terminals of the drive controller whenever power is present 22 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 1 Receiving and Installation January 1999 Mounting in General Purpose Metal Enclosure MOUNTING IN GENERAL PURPOSE METAL ENCLOSURE The ALTIVAR 66 drive controller is a Type 1 IP30 enclosed product However certain application considerations may require that the drive controller be installed inside a larger enclosure If so observe the following precautions Ventilation Forced air cooling is provided on all drive controllers A fan is located in the bottom of the drive controller see Figure 13 and is protected by a perforated cover The fan draws in ambient air from underneath or from the front of the enclosure over the heat sink fins and expels it vertically from the top of the enclosure When mounting the drive controller be sure the air inlets and outlets are not obstructed Follow the installation precautions on pages 20 through 22 Observe minimum clearance distances as indicated in Figure 12 Ifthe enclosure does not provi
128. rements Frequency accuracy 0 0075 Hz 0 00005 times High Speed Temperature drift 2 Drive controller Analog inputs 3 x 104 times High Speed C typical Keypad display 7 x 1077 times High Speed C maximum With option board Option board analog inputs 2 5 x 105 times High Speed C typical Serial link 7 x 10 times High Speed maximum Frequency range ATV66U41N4 to D79N4 0 1 to 400 Hz constant torque configuration ATV66C10N4 to C31N41 0 1 to 200 Hz constant torque configuration ATV66U41N4 to C31N41 0 1 to 75 90 Hz variable torque configuration ATV66U41M2 to D46M2 0 1 to 400 Hz constant torque configuration ATV66U41M2 to D46M2 0 1 to 75 90 Hz variable torque configuration Torque overtorque See page 72 Ali 0 10 V Al2 4 20 Speed reference 0 5 V with switch on control board 0 20 mA x 20 mA 20 4 mA with keypad display Speed regulation Volts Hertz control type determined by motor slip 3 typical for NEMA B motor Normal or high torque sensorless flux vector control type 1 096 without adjustments 0 596 with optional tachometer Efficiency Typically greater than 9696 Reference sample time 10 ms Ramps Acceleration 0 1 to 999 9 seconds Deceleration 0 1 to 999 9 seconds Braking to standstill By DC injection Automatic for 0 5 s if frequency drops below 1 Hz Manual by external signal Dynamic braking By optional resistor see
129. ring Terminal Strip Locations TERMINAL STRIP LOCATIONS TA 20006932 00000005 ara s X pessa es CL24 CL1 GND J1 L14 L3 Outlines 1 amp 2 ATV66U41N4 to D12N4 and ATV66U41M2 to U90M2 GND Outline 3 Pl I 00009 09009009 J13 J12 lee ss lee Ss ATV66D33N4 to D46N4 and ATV66D23M2 to D33M2 Figure 15 aq ojo ASH Outline 4 Outline 5 ATV66D54N4 to D79N4 and ATV66D46M2 W T3 viT2 ATV66D16N4 to D23N4 and ATV66D12M2 to D16M2 GND _W T3 VIT2 U T1 Terminal Strip Locations ATV66U41N4 to D79N4 and ATV66U41M2 to D46M2 1994 Square D All Rights
130. ront cover of the drive controller Set the voltmeter to the 1000 VDC scale Measure the bus capacitor voltage between the PA and terminals to verify the DC voltage is less than 10 V Do not short across capacitor terminals with voltage present If the bus capacitors are not fully discharged contact your local representative do not operate the drive controller Measure the voltage between the terminal and U T1 V T2 and W T3 terminals to verify the voltage is less than 10 V If the voltage is not less than 10 V contact your local representative do not operate the drive controller Disconnect the motor leads from the U T1 V T2 and W T3 terminals of the drive controller Mark leads to facilitate correct replacement to terminals Using a multimeter equipped with a diode junction test function Fluke Model 87 Multimeter or equivalent perform the following measurements to determine the condition of fuses F4A F4B and FAC a Using the diode test function check circuit continuity between U T1 terminal to terminal Continuity should be present for either polarity of the measurement Lack of continuity in one direction is an indication that fuse F4A is open b Using the diode test function check circuit continuity between V T2 terminal to terminal Continuity should be present for either polarity of the measurement Lack of continuity in one direction is an indication that fuse F4B is open c Using the diode test funct
131. rts Description Drive Controller Part No Note DC Bus Capacitor Bank Plexiglass Shield ATV66C10N4 to C19N4 VY1ADV611 Shield with mounting screws Discharge Resistor 460 V ATV66D33N4 to 07934 VZ3R5KOW040 1 resistor ATV66C10N4 to C19N4_ VZ3R2K5W600 2 resistors ATV66C23N4 to C31N4_ VZ3R1K2W480 Discharge Resistor 208 230 V ATV66D23M2 to 046 2 VZ3R5KOW040 Precharge Resistor 460 V ATV66D16N4 D23N4 VZ3R033W009 1 resistor ATV66D33N4 D46N4 VZ3R010W025 ATV66D54N4 to 07934 VZ3R010W481 ATV66C10N4 to C31N4_ VZ3R010W270 2 resistors Precharge Resistor 208 230 V ATV66D12M2 D16M2 VZ3R033J710 ATV66D23M2 D33M2 VZ3R010W025 1 resistor ATV66D46M2 VZ3R010W481 Precharge Contactor 460 V ATV66D16N4 D23N4 LP4D1801BW3 ATV66D33N4 LC1D1801P7 ATV66D46N4 LC1D2501P7 ATV66D54N4 D64N4 LC1D4011P7 ATV66D79N4 LC1D6511P7 ATV66C10N4 C13N4 VY1A661C1010 ATV66C15N4 C19N4 VY1A661C1510 icc ATV66C23N4 to C31N4_ VY1A661C2310 Precharge Contactor 208 230 V ATV66D12M2 D16M2 LP4D2500BW3 ATV66D23M2 LC1D3201P7 ATV66D33M2 LC1D5011P7 ATV66D46M2 LC1D4011P7 Precharge Contactor Auxiliary Contact Block ATV66C10N4 to C31N4_ LA1DNO4 1 contact block Precharge Circuit Protector ATV66C10N4 to C31N4 GV2M10 Heatsink Fan 460 V ATV66U41N4 U54N4 VZ3V661 ATV66U72N4 VZ3V662 Fan s and mounting bracket ATV66U90N4 D12N4 VZ3
132. ry 1994 Square D All Rights Reserved 49 Chapter 2 Wiring Bulletin No 00 065304 Electromagnetic Compatibility EMC January 1999 DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on the control board power board and I O extension module if installed connectors Verify that all power has been removed from J1 J2 and J13 connectors If I O extension module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to observe this instruction will result in death or serious injury oar ID M de Module d 4 if installed VW3 A66201T PALL LEY z 2002 S SSS 3 ff leooooooooo leooo F See page 41 for J13 Ppeecedea joog location of J1 in Insulated Shield Drain the drive Wire controller NOTE The Connect to terminal Son gt K shield connector J13 on control 000022 J1 terminations board See page 46 for shown here may terminal strip definitions WIHA Ferrite Core d Select smaller of t ti i Insulated Shield Terminator tend Ae ih VVDED296034 Consult cable or terminator manufacturer for proper shield termination techniques and
133. s 4 Check connections UNDERVOLTAGE 1 Supply too low 1 Check input line voltage Procedure 2 on V lt 380 V ATV66e N4 page 81 Check Nominal Motor Voltage V lt 170 V ATV66 eM2 parameter see Level 1 amp 2 Configuration Manual Temporary voltage drop t 2200 2 Reset drive controller ms Internal connections 3 Check connections AC LIN OVERVOL 11 Supply too high 1 Check input line voltage Procedure 2 on AC Line Overvoltage V2550V ATV66NA page 81 Check Nominal Motor Voltage V2270V ATV66 M2 parameter see Level 1 amp 2 Configuration Manual DC BUS OVERVOL 11 Overvoltage or overcurrent due to 1 Increase deceleration time Add braking DC Bus Overvoltage excessive braking or an overhauling option if necessary Reset is possible if load even with braking option line voltage lt 550 V OVERTEMP DRIVE Heat sink temperature too high 1 Check motor load fan and ambient Drive Overtemperature temperature around drive controller Wait for drive controller to cool down before resetting MOT OVERLOAD Motor If thermal trip setting is gt 118 of 1 Check setting of MOT OVERLOAD Overload normal thermal state 109 of parameter and compare with motor In nominal current thermal trip is due Check load and compare with operating to prolonged overload or output speed Check braking conditions phase failure possibility of single phase operation Wait approximately 7 minutes before resetting Motor p
134. se Test Procedure ATV66C10N4 to C19N4 86 F4A F4B F4C Bus Fuse Test Procedure ATV66C23N41 to C31N41 87 Drive Controller LEDS EFE veyed bie See eee eee REV bone 88 ATV66C10N4 to ATV66C19N4 92 ATV66C10N4 to ATV66C19N4 93 1994 Schneider S A All Rights Reserved jii ALTIVAR 66 Receiving Installation Start Up VDO0CO6S304E List of Figures and Tables January 1999 LIST OF TABLES Table 1 Constant Torque Drive Controller Ratings 460 6 Table 2 Variable Torque Drive Controller Ratings 460 8 Table 3 Variable Torque Low Noise Drive Controller Ratings 460 9 Table 4 Recommended Braking Resistance 10 Table 5 Constant Torque Drive Controller Ratings 208 V 230 11 Table 6 Variable Torque Drive Controller Ratings 208 V 230 11 Table 7 Variable Torque Low Noise Drive Controller Ratings 208 V 230V 12 Table 8 Recommended Braking Resistance 12 Table 9 Specifications ERR rU Wide Ge bea ee eet Ug 13 Table 10 Flow Rates for ALTIVAR 66 Drive Controller Fans 24 Table 11 Recess Mounting KiS cisco kcu pese cae Re e
135. sed adjustments 90 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 4 Diagnostics Fault Messages Table 30 Fault Message DYNAMIC BRAKE Fault Messages Continued Probable Cause DB transistor short circuit DB resistor short or open circuited Braking resistor thermal contact Troubleshooting Procedure Remove all power Check connecting cables and DB resistor with drive controller disconnected Use drive controller self diagnostics See Level 1 amp 2 Configuration Manual Check dynamic brake connections Change resistor if necessary tripped DB RESISTOR DB resistor overload Increase deceleration time Reset drive controller Increase DB resistor power rating LINK FAULT Internal fault Note LED sequence on drive controller Software execution stopped FAULT CAUTION POWER all illuminated or CAUTION POWER illuminated Cycle power If fault persists replace keypad or main control board SEQUENCE T OUT Sequence Time out Sequence input not received after Run command within programmed time Bypass function Check connection between user supplied contact and logic input ensuring it is connected to programmed input Verify operation of contact Verify operation of external control sequencing PROCESS TIME OUT Process input not received after Run command wi
136. sembly with capacitors ATV66D16N4 D23N4 VY1ADC152V450 One capacitor ATV66D33N4 D46N4 VY1ADC472V450 One capacitor ATV66D54N4 VY1ADC605 uH y with capacitors and stirring an ATV66D64N4 D79N4 VY1ADC606 oe y with capacitors and stirring an ATV66C10N4 to C19N4 VY1ADC615 Assembly with capacitors ATV66C23N41 to C28N41 VY1ADC608 Assembly with capacitors DC Bus Capacitor 208 230 V ATV66U41M2 VY1ADC611 Assembly with capacitors ATV66U72M2 VY1ADC612 Assembly with capacitors ATV66U90M2 VY1ADC613 Assembly with capacitors ATV66D12M2 D16M2 VY1ADC152V450 One capacitor ATV66D23M2 D33M2 VY1ADC472V450 One capacitor ATV66D46M2 VY1ADC605 Assembly with capacitors and stirring fan DC Bus Capacitor Bank Plexiglass Shield ATV66C10N4 to C19N4 VY1ADV611 Discharge Resistor 460 V ATV66D33N4 to D79N4 VZ3R5KOW040 One resistor ATV66C10N4 to C19N4 VZ3R2K5W600 Two resistors ATV66C23N41 to C31N41 VZ3R1K2W480 One resistor Discharge Resistor 208 230 V ATV66D23M2 to D46M2 VZ3R5KOW040 One resistor Precharge Resistor 460 V ATV66D16N4 D23N4 VZ3R033W009 One resistor ATV66D33N4 D46N4 VZ3R010W025 One resistor ATV66D54N4 to D79N4 VZ3R010W481 One resistor ATV66C10N4 to C31N41 VZ3R010W270 Two resistors Precharge Resistor 208 230 V ATV66D12M2 D16M2 VZ3R033W009 One resistor ATV66D23M2 D33M2 VZ3R010W025 One resistor ATV66D46M2 VZ3R010W481 One resistor Precharge Contactor 460 V ATV66D16N4 D23N4 LP4D1801BW3 ATV66D33N4 LC1D1801P7 ATV66D46N4 LC1D2501P7 ATV66D54N4 D6
137. t Procedure see page 84 protective switch GV2 SERIAL LINK Serial link communication fault 1 Check connections between drive controller and keypad computer and or programmable controller INTERNAL FAULT 11 Internal connection fault 1 Check internal connections after Missing connections on CL1 and following Bus Voltage Measurement CL2 procedure see page 78 LOSS FOLLOWER Loss of 4 20 mA signal on AI2 input 1 Verify signal connections 2 Check signal GROUND FAULT Short circuit of phase to earth or 1 Remove all power With drive controller grounding on the output of the drive disconnected check connecting cables controller and motor insulation 2 Use drive controller diagnostics See Level 1 amp 2 Configuration Manual MEMORY FAILURE 2 EEPROM memory storage fault 1 Recall factory or customer settings with keypad AUTO TEST Main control board failure 1 Remove all power Check control board connections with drive controller disconnected 2 Replace main control board CONTROL SUPPLY 121 CL1 CL2 not connected 1 Check connection of CL1 and CL2 OVERSPEED Output frequency is 2096 above 1 Check load base speed and power Maximum Frequency parameter rating compare with operating speed setting no tachometer present and drive controller motor power rating 2 Check setting of output and bandwidth if This fault always causes a freewheel stop 2 This occurs only on power up u
138. t line voltage DO NOT TOUCH Use only electrically insulated tools Failure to follow these instructions will result in death or serious injury The PA and terminals are located inside the drive controller see Figure 37 To measure the bus capacitor voltage 1 Disconnect and verify all power is removed from drive controller 2 Wait 1 minute to allow the DC bus to discharge 3 Open the front cover of the drive controller 4 Set the voltmeter to the 1000 VDC scale Measure the bus capacitor voltage between the PA and terminals to verify the DC voltage is less than 45 V Do not short across capacitor terminals with voltage present 78 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 4 Diagnostics January 1999 Procedure 1 Bus Voltage Measurement 5 f the bus capacitors are not fully discharged contact your local representative Do not operate the drive controller o UN U ATV66U41N4 to D12N4 and ATV66U41M2 to U90M2
139. ted controller output current Input Line Current Motor With Line Impedance of Power Output 230V 208 250 V Drive Current 208V 208 V 230V Controller 8 800 AIC 50 60 Hz 5 000 AIC 22 000 AIC 3 5 3 5 0 036 mH 0 070mH 0 016 mH kW hp A A A A A A A A 0 75 1 4 0 5 8 5 4 6 4 25 3 3 3 5 3 0 1 5 2 ATV66U41M2 7 5 10 4 8 8 10 4 64 62 60 56 22 3 10 6 14 3 12 0 14 3 92 89 85 84 4 5 ATV66U72M2 16 7 21 8 18 3 21 8 14 7 143 14 0 12 9 5 5 7 5 ATV66U90M2 24 2 30 6 25 8 30 7 22 0 21 3 20 1 19 3 7 5 10 ATV66D12M2 30 8 38 9 32 8 39 0 29 0 278 265 252 11 15 ATV66D16M2 462 55 1 46 5 55 2 43 0 41 1 38 7 372 15 20 ATV66D23M2 59 4 70 3 59 6 70 3 57 0 541 50 4 49 0 22 30 ATV66D33M2 88 0 97 2 80 8 97 2 83 0 79 8 740 72 0 30 40 ATV66D46M2 114 124 2 102 0 1254 109 1 105 4 98 7 95 6 Control Wiring Precautions Although all control inputs and outputs of the drive controller are isolated from the input lines you must follow certain control wiring precautions Keep control wiring conductor runs short and direct Follow the conduit and circuit separation requirements listed throughout this section Make sure that the control contacts used with the drive controller inputs are rated for operation at open circuit voltages of 24 VDC and closed circuit currents of 10 mADC Analog inputs and outputs require twisted cable with a pitch of
140. thin programmed time Bypass function Check connection between user supplied contact and logic input ensuring it is connected to programmed input Verify operation of contact Verify operation of process TRANS SHORT C OR GF Transistor Short Circuit Transistor is in short circuit Contact local service representative OPEN TRANSISTOR Transistor has failed open Contact local service representative OUT PHASE LOSS Motor power ratio too small for controller Output phase disconnected This fault always causes a freewheel stop 2 This occurs only on power up Motor power rating must be gt 45 of controller power rating Check output power conductors load disconnect or contactors for lack of continuity Check output contactor sequence 1994 Square D All Rights Reserved 91 Chapter 4 Diagnostics Bulletin No 00 065304 Fault Messages January 1999 The additional faults listed in Table 31 may be displayed if an option module is installed and a fault occurs Table 31 Fault Messages from Option Modules Fault Messages Probable Cause Troubleshooting Procedure Without tachometer OVERSPEED 1 Output frequency is 2096 above 1 Check load base speed and power rating Maximum Frequency parameter compare with operating speed and drive setting controller motor power rating With tachometer 1 Incorrect adjustment of tachometer
141. top of the drive controller as shown in Figure 11 Handle the drive controller carefully to avoid damage to the internal components frame or exterior Place the drive controller in an upright position S FORCE Figure 11 Hoisting ATV66D54N4 to C31N41 and ATV66D46M2 1994 Square D All Rights Reserved 19 Chapter 1 Receiving and Installation Bulletin No VD0C06S304E Preliminary Inspection January 1999 PRELIMINARY INSPECTION The drive controller must be thoroughly inspected before storing or installing Upon receipt 1 Remove the drive controller from its packaging and visually inspect exterior for shipping damage 2 Checkthatthe drive controller catalog number agrees with the packing slip and corresponding purchase order The catalog number appears on the drive controller nameplate and shipping package label Refer to page 3 for location of drive controller nameplate 3 If you find any shipping damage notify the carrier and your sales representative 4 If you will store drive controller after receipt replace it in original packing material and observe storage temperature specifications on page 14 Prior to installation 1 Open the drive controller door or remove access covers 2 Visually verify that all internal mounting hardware and terminal connection hardware is properly seated securely fastened and undamaged 3 Visually verify that the control board is properly seated securely fastened and
142. uency ATV66U41M2 to D33M2 10 kHz ATV66D46M2 4 kHz Motor Power Max Total Output P Outline Drive Controller 208 230 V Current Tansient Dissipated Part No 50 60 Hz Current 60 s Power kW hp A A 75 1 4 0 11 7 125 1 ATV66U41M2 1 5 2 75 11 7 150 2 2 3 10 6 11 7 181 ATV66U72M2 4 0 5 16 7 18 4 252 6 ATV66U90M2 5 5 7 5 24 2 26 6 375 ATV66D12M2 7 5 10 30 8 33 9 459 3 ATV66D16M2 11 0 15 46 2 50 8 619 1 ATV66D23M2 15 0 20 59 4 65 3 785 ATV66D33M2 22 0 30 88 0 96 8 1127 5 ATV66D46M2 30 0 40 114 125 1332 Table 8 Recommended Braking Resistance Values 208 230 V Drive Controller Part No Resistance ATV66U41M2 47 ATV66U72M2 18 ATV66U90M2 18 ATV66D12M2 12 ATV66D16M2 9 ATV66D23M2 6 ATV66D33M2 4 5 ATV66D46M2 3 12 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 1 Receiving and Installation Technical Characteristics Controller Specifications Table 9 Input voltage Specifications 400 V 15 and 460 V 15 or 208 V 10 and 230 V 15 Displacement power factor Approximately 0 96 Input frequency 47 5 to 63 Hz Output voltage Maximum voltage equal to input line voltage Frequency resolution Drive controller Input Al1 High Speed 1 024 Hz 11 Input Al2 High Speed 512 Hz 11 Keypad display 0 1 Hz increments Processor 0 015 Hz increments With Option Board Option board analog inputs High Speed 4096 Hz 11 Serial link 0 015 Hz inc
143. undamaged Verify that internal wiring connections are tight Inspect all connections for damage 4 Close and secure the drive controller door or replace access covers A CAUTION EQUIPMENT DAMAGE HAZARD Do not operate or install any drive controller that appears damaged Failure to follow this instruction can result in injury or equipment damage INSTALLATION PRECAUTIONS To avoid equipment damage follow these precautions when installing the drive controller Electrical current through drive controller will result in heat losses that must be dissipated into the ambient air immediately surrounding the drive controller To prevent thermal fault or equipment damage provide sufficient enclosure cooling and or ventilation to limit the ambient temperature around drive controller to a maximum of 40 For power dissipation refer to Tables 1 to 3 and Tables 5 to 7 on pages 6 12 Figure 12 on page 21 shows the minimum clearances required around the drive controller for 20 1994 Square D All Rights Reserved Bulletin No 00 065304 January 1999 Chapter 1 Receiving and Installation Installation Precautions unobstructed air flow For proper thermal dissipation do not base the minimum enclosure size on clearances alone Refer to section Mounting in General Purpose Metal Enclosure on page 23 for additional information Dimensions in mm Outlines 1 3 ATV66U41N4 to D23N4 and
144. unted on heatsink and motor current sensor ATV66C23N4 to C31N4 VZ3G004 p M and 1 85 C switch heatsink Motor Current Sensor 460 V ATV66D33N4 D46N4 VY1A66104 TRE ATV66D54N4 to D79N4 VY1A66105 ATV66C10N4 C13N4 VY1A66106 ATV66C15N4 C19N4 VY1A66107 1 sensor ATV66C23N4 to C31N4 VY1A66108 Motor Current Sensor 208 230 V ATV66D23M2 VY1A66104 T NDS ATV66D33M2 D46M2 VY1A66105 Ground Fault Sensor 460 V AT VASO ONIO AIINS 1 sensor ATV66C23N4 to C31N4 VY1A66110 Control Power Transformer 460 V ATV66D33N4 to D79N4 VY1ADA604 ATV66C10N4 to C19N4 VY1ADA606 Transformer only ATV66C23N4 to C31N4 VY1ADA607 Control Power Transformer 230 V ATV66D23M2 to D46M2 VY1ADA614 Control Power Fuses ATV66C10N4 to C31N4 DF3CF00501 2 fuses F5 and F6 DC Bus Fuse ATV66C10N4 C13N4 VY1ADF250V700 ATV66C15N4 C19N4 VY1ADF350V700 ATV66C23N4 to C31N4 VY1ADF400V700 hie AC Line Fuse ATV66C23N4 VY1ALF700V700 ATV66C28N4 VY1ALF800V700 ATV66C31N4 VY1ALF900V700 Power Terminal Blocks 460 V ATV66D16N4 D23N4 VZ3N603 ATV66D33N4 D46N4 VZ3N604 ATV66D54N4 to 07934 VZ3N605 All output terminals and DIN rail for Power Terminal Blocks 208 230 V ATV66D12M2 D16M2 VZ3N603 mounting ATV66D23M2 D33M2 VZ3N604 ATV66D46M2 VZ3N605 Box Lug Power Terminal Three terminals for replacing power or ground terminals ATV66C10N4 to C19N4 VZ3NO08 Ei bese le ATV66C15N4 C19N4 T1 T2 T3 GND Clam Shell Power Terminal ATV66C15N4 to C19N4 VZ3N
145. ved 87 Chapter 4 Diagnostics Bulletin No 00 065304 LEDs January 1999 LEDS The LEDs on the front of the drive controller indicate the following 2 FAULT 69 Illuminated Fault exists Red S CAUTION 69 Illuminated with Fault LED OFF Drive controller is running and in current limit or Yellow 47 ramp modification NOTE LED may appear to flash rapidly as drive controller regulates at current limit or ramp modification Slow Flashing with Fault LED OFF This Pre Alarm indicates either a Drive Overtemperature Fault ATV66D12M2 to D46M2 or ATV66D16N4 to C31N41 only or a Motor Overload Fault Consult Keypad Display for Motor Thermal State or Drive Thermal State ATV66D12M2 to D46M2 or ATV66D16N4 to C31N41 only to determine which condition is causing the Pre Alarm If either of these thermal states exceeds 100 the Caution LED will flash slowly Illuminated with Fault LED ON Drive controller fault exists on either Motor Overload or Drive Overtemperature and the cool down period has not yet expired Consult the fault display on the keypad or the fault history in Menu 3 to determine the most recent fault POWER wre Illuminated Drive controller is powered For locations of Green bus gt 50 V or voltage is present at CL1 CL2 LEDs see pages 41 42 and 43 DC BUS Illuminated DC bus gt 50 V RED A Figure 43 Drive Controller LEDs FAULT MESSAGES The ALTIVAR 66 drive controlle
146. veral drive controller characteristics as they relate to motor protection and performance 74 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 3 Start Up January 1999 Motor Considerations Motor Insulation ALTIVAR 66 drive controllers use pulse width modulation Verify that the motor insulation is designed for this modulation method Motors in Parallel Drive controller selection Drive controller In gt In1 In2 Inx Controler Drive controller Pn gt Pn1 2 Protect each motor with a thermal overload relay w In rated current Pn rated power Figure 35 Motors in Parallel To operate motors in parallel use the keypad display to set the Control Type to Normal When motors are in parallel slip compensation is not at the optimum level If the load is to be shared between the motors disable the slip compensation For information on adjusting and disabling parameters see the Level 1 amp 2 Configuration Manual If three or more motors are to be installed in parallel consult factory Output Contactor Between Motor and Drive Controller When using an output contactor between the drive controller and motor use of the Bypass application function is recommended In order to set the motor parameters for optimum performance the motor must be directly connected to the output of the drive controller at least one time during drive controller power up Fo
147. y 60 1994 Square D All Rights Reserved Bulletin No 00 065304 Chapter 2 Wiring January 1999 Equipment Recommendations Table 22 Recommended Semiconductor Fuses for 1 400 hp 460 V Controllers M1 Al F1 F3 Input KM1 TS T1 F7 F8 F9 Motor Controller ATV66 N4 Line Power Fuse r Primary Sec Xfmr Fuses Carriers Line Transient Xfmr Fuses Fuses kW hp CT VT low VT Semiconductor 3 Contactor Suppressor 8 BI 13 noise Fuse Class FWH900AI3I 220 350 C31 C28 170 6713 81 6 7 7 7 7 7 0300233 5 FWH900AI3I 250 400 C31 170M67133 6 7 7 7 7 7 0300233151 1 For F10 and F11 use Bussmann control fuse KTK R 3 The recommended control fuse carrier is 9080 FB2611CC 2 Square D Class CC Fuse Block numbers 3 Bussmann part numbers 4 Gould Shawmut part numbers 5 Ferraz part numbers 6 Fuse mounted inside drive controller 7 The power circuit configuration of the ATV66C23N4 to ATV66C31N4 drive controllers does not support the use of an input isolation contactor 8 T1 has been dimensioned to supply KM1 coil inrush and sealed VA requirements only Any user control pilot device additions may require re dimensioning of T1 VA capacity 1994 Square D All Rights Reserved 61 Bulletin No VD0C06S304E January 1999 Chapter 2 Wiring Equipment Recommendations Table 23 Maximum Allowable Line Fuse F1 to F3

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