Altivar 78 Variable Speed Drive

APRIL 05

ATV78 variable speed drives ip00 module installation

ATV780C20Y~ATV780C71Y

Installation Manual

2 •

INDEX 1. GENERAL 3 2. REQUIREMENTS 4

2.1 Environmental requirements 4 2.2 Cabinet 4 2.3 Accessories 5

3. PRODUCT HANDLING 6 3.1 Product type designation codes 6 3.2 Receipt of delivery 6 3.3 Receiving, unpacking and storing the product 6 3.4 Lifting the power module 7 3.5 Lifting AC chokes 7

4. INSTALLING AC CHOKEs 8 5. INSTALLING THE POWER MODULE 9

5.1 Preparing the enclosure 9 5.2 Mounting the power module 10 5.3 Grounding the power module 11

6. CONNECTING THE INTERNAL POWER CABLES 12 7. INSTALLING THE CONTROL UNIT 15

7.1 Connecting power supply and internal control cables 15 7.1.1 ATV 780C56Y to ATV780C71Y 15

8. PREPARING FOR EXTERNAL POWER CONNECTIONS 16 8.1 Installing mounting plate and input terminals 16 8.2 Installing fuses 17 8.3 Installing EMC grounding 17 8.4 Understanding the power unit topology 18 8.5 Connecting input and output power 18

8.5.1 Mains and motor cables 18 9. Control of main air flow 20

9.1 Arranging ventilation of the enclosure 20 9.2 Steering the internal air flow 21 9.3 Heat dissipation 22 9.4 Temperatures measured during test run 22

10. APPENDICES 23 10.1 Dimensional drawings, Power modules 23 10.2 Dimensional drawings, AC chokes 25 10.3 Optic fibre cables, signal lists and connections 27

10.3.1 ATV780C56Y to ATV780C71Y 27

GENERAL • 3

1

1. GENERAL

This manual provides instructions for the installation of ATV780C20Y …. C71Y (frames FR10 to FR12) variable speed drives in a cabinet, switchgear, or any other enclosure.

ATV780C20Y …. C71Y of frames FR10 to FR12 have 1 (FR10 and FR11) or 2 (FR12) power modules. Therefore for frame FR12, you will need twice the number of drive accessories (such as cables, terminals, chokes etc.) unless otherwise stated. Also note that ATV780C50Y requires two chokes mounted in parallel. See Figure 14

The ATV78 C20 …. C71Y product series comprise the following variable speed drives:

Table 1. ATV78 C20 …. C71Y variable speed drives, frames FR10…FR12

The variable speed drives can be installed in any enclosure that fulfils the requirements specified in chapter 2. In the illustrations in this manual, Rittal TS8 is used as an example enclosure.

Installing ATV780C20Y …. C71Y variable speed drives in an enclosure involves the following steps:

• Installing the AC choke(s) (chapter 4) • Installing and grounding of power module(s) (chapter 5) • Connecting internal power cables between the AC choke and the power module (chapter 6) • Preparing for input and output power connections (chapter 8) • Arranging air-cooling and ventilation (chapter 9).

General instructions for product handling are given in chapter 3. Dimensional drawings are found in chapter 10.

NOTE: The installation of the variable speed drives must be done by certified electricians. Safety regulations for electrical work must be followed during the installation work.

NOTE: Safe operation and full service lifetime of the product can be guaranteed only if the

installation instructions in this manual are followed. NOTE: The product warranty is not valid if the product is handled in a way that does not comply

with the instructions in this manual and the User's Manual.

Type code (partial)

Frame size Nominal current Choke type

Voltage range 525–690V ATV780C20Y FR10 261A CHK 261 ATV780C25Y FR10 325A CHK 400 ATV780C31Y FR10 385A CHK 400 ATV780C35Y FR11 460A CHK 520 ATV780C45Y FR11 502A CHK 520 ATV780C50Y FR11 590A 2*CHK 400 ATV780C56Y FR12 650A 2*CHK 400 ATV780C63Y FR12 750A 2*CHK 400 ATV780C71Y FR12 820A 2*CHK 400

4 • REQUIREMENTS

2. REQUIREMENTS

2.1 Environmental requirements

Refer to ATV78 User's Manual for information on required operating temperature, humidity, etc. Leave sufficient free space around the enclosure so the air flow is not obstructed. Air is generally sucked in from the front and exhausted upwards – leave at least 500 mm free space in front of the enclosure and 200 mm above the enclosure – also see section 9.3. NOTE! EN60439-1 specifies the ambient temperature for enclosed products at 35°C (24h

average)/40°C (maximum). The ventilation and cooling of the installation room must be sufficient to keep the temperature below this level.

For information on the heat dissipation of the product and the required cooling air, refer to section 9.3 and the User's Manual. 2.2 Cabinet

Width: Min. 600 mm Depth: Min. 600 mm Height: Min. 1800 mm if the AC choke is installed beneath the power

module, otherwise min. 1500 mm Mechanical requirements: The cabinet must be able to support a total equipment weight

of 275 kg (if the power module and the AC choke are installed in the same cabinet).

Protection class: This manual applies to IP21. Construction: According to EN60439-1 Ventilation openings: Refer to section 9.1. Table 2. Cabinet data for FR10

Width: Min. 800 mm Depth: See Table 2. Height: See Table 2. Mechanical requirements: The cabinet must be able to support a total equipment weight

of 350 kg (if the power module and the AC choke are installed in the same cabinet).

Protection class: This manual applies to IP21. Construction: According to EN60439-1 Ventilation openings: Refer to section 9.1. Table 3. Cabinet data for FR11

Width: Min. 1200 mm Depth: See Table 2. Height: See Table 2. Mechanical requirements: See Table 2. Protection class: This manual applies to IP21. Construction: According to EN60439-1 Ventilation openings: Refer to section 9.1. Table 4. Cabinet data for FR12

REQUIREMENTS • 5

2

2.3 Accessories

Accessory Specification Input terminals (optional) See Table 10. Input power cables See User’s manual. Internal power cables See Table 8 Output power cables See User’s manual. Grounding cable Cu grounding cable, min. 35mm2/power

module. The cable must fulfill the local regulations.

Mounting plates Module mounting rails Must be able to carry a weight of the

power module (see Figure 2). Fuse switch (optional) See Table 11. EMC grounding Clamp size according to the output cable

diameter, see section 8.3. PE rail See section 5.3 Table 5. Accessories data for FR10

6 • PRODUCT HANDLING

3. PRODUCT HANDLING

3.1 Product type designation codes

Product type designation codes are found on the power module and the control unit. For an explanation of the type designation codes, refer to the User's Manual. 3.2 Receipt of delivery

The standard delivery includes:

• Power module(s) with fixing frame(s) and with one integrated control unit • AC choke(s) • ATV780C56Y to ATV780C71Y units only: optical cable set for internal control connections

between power modules • IP00 Module Installation manual • User's manual. The following optional equipment is delivered on request:

• Door installation kit VW3A78102 or VW3A78103 for installing the control panel on the enclosure door.

3

TIc

Figure 1. Parts included in delivery: AC choke and power module with integrated control unit and the required cables for ATV780C56Y to ATV780C71Y

.3 Receiving, unpacking and storing the product

he product is delivered packed in a plywood case, which can be recycled or destroyed by burning. nstructions for receiving, handling and storing the product, as well as the general warranty terms an be found in the User’s manual.

AC chokeFibr24Vfor AATV

PRODUCT HANDLING • 7

3

3.4 Lifting the power module

The power module can be lifted by the holes on top of the module. Place the lifting hooks symmetri-cally in at least two holes. The lifting equipment must be able to carry the weight of the power module. See Figure 2.

Figure 2. Lifting the power module

NOTE! The power module can temporarily rest on the cooling fan assembly, but shocks or non-vertical forces may cause damage to the fans.

3.5 Lifting AC chokes

The AC choke can be lifted by the two eyebolts on top of the unit. The weight of the AC choke is 53 kg, 84 kg or 115 kg depending on the type (see Figure 3).

Figure 3. Lifting the AC choke

Choke WeightCHK0261 53 kgCHK0400 84 kgCHK0520 115 kg

FR10: 123 kgFR11: 210 kgFR12: 2*123 kg

8 • INSTALLING AC CHOKEs

4. INSTALLING AC CHOKES

Type code (partial)

Frame size Choke type

Voltage range 525–690V ATV780C20Y FR10 CHK 261 ATV780C25Y FR10 CHK 400 ATV780C31Y FR10 CHK 400 ATV780C35Y FR11 CHK 520 ATV780C45Y FR11 CHK 520 ATV780C50Y FR11 2*CHK 400 ATV780C56Y FR12 2*CHK 400 ATV780C63Y FR12 2*CHK 400 ATV780C71Y FR12 2*CHK 400

Table 6. Choke types

The recommended location for the AC choke is the bottom part of the enclosure, where it should be installed close to the rear wall. For a possible later installation of a fuse switch, it may be practical to install the AC choke somewhat to the left.

Fasten the choke on an assembly plate or using mounting rails.

Figure 4. Installing the AC choke

NOTE! An upper support plate must be installed above the choke if the cabinet is transported in a horizontal position. A possible fixed support plate must be equipped with air circulation holes. See Figure 17 on page 21.

INSTALLING THE POWER MODULE • 9

5

5. INSTALLING THE POWER MODULE

5.1 Preparing the enclosure

To facilitate a possible future replacement of boards as well as other service work, it is recom-mended that the power module be mounted on rails. Fasten mounting rails to the sides of the cabi-net at distances given under F (from the top) and G (from the bottom) in the table below. Leave a space (A) between the module and the walls on both sides for the internal cooling air circulation.

Figure 5. Preparing the enclosure for the power module

The power module should be fastened to the rear side of the enclosure as shown in Figure 6. For this purpose, install two fixing bars on the rear wall of the cabinet at appropriate levels.

Note the following dimensions that are essential for placing the power module. All dimensions in mm:

A B C D E F G 50* 100 1120 550 (290) 116 918 850 (590)

Table 7.

A = Minimum distance to the side walls or adjacent components. * = Note that the two cabinets, in which the modules of ATV780C56Y to ATV 780C71Y are installed, require no clearance between them.

B = Minimum distance from the top of the cabinet; This space is needed for the power cables (see Figure 9).

C = Module height

A E

B

C

D

A

F

G

10 • INSTALLING THE POWER MODULE

D = Minimum distance from the bottom of the enclosure if the AC choke is installed at the bottom of the enclosure. If the choke is installed in another location, the distance must not, however, be smaller than what is given in parentheses

E = Minimum distance from the cabinet door. F = Minimum distance from the mounting rails to top of the cabinet. G = Minimum distance from the mounting rails to the bottom of the cabinet. If the choke is

installed in another location, the distance must not, however, be smaller than what is given in parentheses

See also the dimensional drawings in chapter 10. 5.2 Mounting the power module

NOTE! If the space around the power module is narrow, lead the internal power cables along the wall and fasten them in brackets before mounting the power module. See chapter 6.

Fasten the power module to the rear wall of the enclosure utilising the fixing holes in the frame. Figure 6. Mounting the power module

NOTE! If the power module is installed before the AC choke, the centre of gravity is very high at

this stage. Make certain that the enclosure does not fall over during the assembly.

INSTALLING THE POWER MODULE • 11

5

5.3 Grounding the power module

Install a PE rail, for instance at the bottom front of the enclosure. Connect a grounding cable from the grounding connector at the lower right hand side of the power module frame to the PE rail of the enclosure. Use a copper grounding cable with a cross-sectional area of at least 35 mm2 per power module, which obeys the local regulations for grounding cables. See Figure 7 on page 11. NOTE! The PE rail must be connected to external ground at the installation site according to

local regulations.

Figure 7. Grounding the power module

PE rail

Groundingcable

12 • CONNECTING THE INTERNAL POWER CABLES

6. CONNECTING THE INTERNAL POWER CABLES

Figure 8. Connecting the power cables to ATV780C20Y to ATV780C50Y. For ATV780C56Y to ATV780C71Y the connection is to both the units.

Connect three power cables according to Figure 9 to the output terminals of the AC choke and the input terminals of the power module. It is recommended to use cables designed for 90°C. Connect the L1 cable from the L1 terminal of the AC choke to the L1 input terminal of the power module, the L2 cable to the L2 terminal, and the L3 cable to the L3 terminal.

NOTE! The choke has two sets of output terminals designed for different voltages/frequencies. Use the upper set for 500V/50Hz, 525V/50Hz, 600V/60Hz, and 690V/50Hz

NOTE! The connections for the external brake resistor are located at the top of the unit, beside the L1-L3 power input terminals

U V W

L1* L2* L3

L1 L2 L3

M3~

B- B+/R+ R-

Power board

BR(option)

CONNECTING THE INTERNAL POWER CABLES • 13

L1 L2 L3

L1L2

L3

L1L2L3

L1 L2 L3

L1 L2 L3

L1 L2 L3

Voltage / Frequency500V/50Hz

575V/60Hz690V/50Hz

525V/50Hz

Figure 9. Connecting the power cables between the AC choke and the power unit

Cu cables Product Temp. rating Cable size,

mm2 per phase Specification

90°C 2*70 GENELEC HD 21.7 H07V2-K ATV780C20Y ATV780C25Y ATV780C31Y 70°C 2*95 Standard

90°C 2*95 GENELEC HD 21.7 H07V2-K ATV780C35Y ATV780C45Y 70°C 2*120 Standard

90°C 2*2*70 GENELEC HD 21.7 H07V2-K ATV780C50Y ATV780C56Y ATV780C63Y ATV780C71Y 70°C 2*2*95 Standard

Table 8. Required cable sizes for the internal power cables (90oC rating recommended)

14 • CONNECTING THE INTERNAL POWER CABLES

L1 L2 L3

L1L2

L3

L1L2L3

L1 L2 L3

L1 L2 L3

L1L2

L3

L1L2L3

L1 L2 L3

R-DC- DC+ R-DC- DC+

Fuses

Figure 10. Connecting the DC links together when the brake chopper of ATV780C56Y to A TV780C71Yis used

Fuse ratings Product Current [A] Voltage

Recomm. fuse types (or equivalent)

ATV780C56Y 500 690V Bussmann 170M6202 (2 pcs) ATV780C63Y 500 690V Bussmann 170M6202 (2 pcs) ATV780C71Y 500 690V Bussmann 170M6202 (2 pcs)

Table 9. Fuse recommendations The cable used to connect the DC bus must be at least 90 mm2.

INSTALLING THE CONTROL UNIT • 15

7

7. INSTALLING THE CONTROL UNIT

NOTE! The ATV78 variable speed drive is delivered with the control unit mounted on the power unit

7.1 Connecting power supply and internal control cables

NOTE! Only ATV780C56Y to ATV780C71Y require connecting of cables by the customer. 7.1.1 ATV 780C56Y to ATV780C71Y

The control unit uses 24 VDC supplied from the ASIC board, which is located on the left side of the power unit 1. To access the board, remove the protective cover in front of the power module. Connect the power supply cable to the X10 connector on the ASIC board and to the X2 connector on the rear side of the control unit.

Figure 11. Connecting the power supply and control cables to the control unit, ATV 780C56Y to ATV780C71Y

Each fibre optic cable has a number 1...8 and 11…18 marked on the cable shield at both cable ends. Connect each cable to the connectors marked with the same number on the ASIC board and on the rear side of the control unit. Additionally, you may have to connect the 4 fibre cables from the field-bus board to the star coupler board. The list of the optic signals can be found in chapter 10.3.

X10

Power module 1ASIC board

Power module 2ASIC board

FB board

X2

Min bending radius 50 mm

Star coupler board

16 • PREPARING FOR EXTERNAL POWER CONNECTIONS

7

8. PREPARING FOR EXTERNAL POWER CONNECTIONS

8.1 Installing mounting plate and input terminals

For further installation of other devices (breakers, fuses, EMC grounding), it is recommended that an installation plate be mounted in front of the AC choke, leaving the bottom part open for air circu-lation. Install input terminals on the plate and connect them to the input terminals (the uppermost terminals) of the AC choke using busbars or flexible busbars according to Table 10.

Voltage range 525–690V Product Cu busbar, size ATV780C20Y.... ATV780C31Y 30*6 mm ATV780C35Y....ATV780C50Y 40*6 mm ATV780C56Y....ATV780C71Y 2 pcs 30*6 mm Table 10. Copper busbars

Figure 12. Power input terminals

L1 L2 L3

PREPARING FOR EXTERNAL POWER CONNECTIONS 17

7

8.2 Installing fuses

The power module contains no internal fuses. To protect the device and allow the installation of a main switch in the enclosure, it is recommended that a fuse switch be installed. Use aR type fuses according to Table 11, and install them in the same enclosure as the frequency converter, or in another enclosure in the immediate vicinity.

Fuse ratings Product Current [A] Voltage I2t at Un Size

Recomm. fuse types (or equivalent)

ATV780C20Y 700 690V 425000 2 Bussmann 170M5813 (3 pcs) ATV780C25Y 700 690V 425000 2 Bussmann 170M5813 (3 pcs) ATV780C31Y 700 690V 425000 2 Bussmann 170M5813 (3 pcs) ATV780C35Y 1250 690V 1350000 3 Bussmann 170M8547 (3 pcs) ATV780C45Y 1250 690V 1950000 3 Bussmann 170M8547 (3 pcs) ATV780C50Y 700 690V 425000 2 Bussmann 170M5813 (6 pcs) ATV780C56Y 700 690V 425000 2 Bussmann 170M5813 (6 pcs) ATV780C63Y 700 690V 425000 2 Bussmann 170M5813 (6 pcs) ATV780C71Y 700 690V 425000 2 Bussmann 170M5813 (6 pcs)

Table 11. Fuse recommendations

8.3 Installing EMC grounding

The output cables to the motor must be 360o EMC earthed. The EMC grounding clamps can, for instance, be installed on the mounting plate in front of the AC choke as shown in the figure below. The EMC grounding clamps must be suited to the output cable diameter to give a 360o contact with the cables. Refer to the User's Manual for output cable diameters.

Figure 13. Installing EMC grounding

PE rail

EMC grounding

Cable fixing clamps

18 • PREPARING FOR EXTERNAL POWER CONNECTIONS

7

8.4 Understanding the power unit topology

Figure 14 shows the principles for mains and motor connections of ATV780C20 to ATV780C71. ATV78C50 has double input devices and requires an even number of supply cables but an uneven number of motor cables can be used. ATV780C56 to ATV780C71 consist of two power modules and require an even number of supply and motor cables. See Figure 14 and Table 12.

Figure 14. Topology of mechanical sizes FR10 – FR12

8.5 Connecting input and output power

8.5.1 Mains and motor cables

The mains cables are connected to terminals L1, L2 and L3 and the motor cables to terminals marked with U, V and W, see Figure 8.

In ATV780C50Y to ATV780C71Y an even number of input cables is required. In converters consisting of double power modules (FR12) an even number of input cables and an even number of motor cables is needed.

In types with double inputs (ATV780C50Y to ATV780C71Y) or outputs (ATV780C56Y to ATV780C71Y) is it very important that the same cable dimensions, type and routing is used for all cables. In case the cabling between the converter modules is not symmetrical, unequal load inside converter might reduce loadability or even damage the converter.

In units with double motor outputs the motor cables must not be connected together in the converter end. Always connect the parallel motor cables together in the motor end only. The minimum motor cable length is 5m.

The output cables to the motor must be 360o EMC earthed. The EMC grounding clamps can, for instance, be installed on the mounting plate in front of the AC choke as shown in the figure below. The EMC grounding clamps must be suited to the output cable diameter to give a 360o contact with the cables.

WARNING

WARNING

M M M

ATV780C20Y toATV780C45YSingle inputSingle output

ATV780C50YDouble input*Single output

ATV780C56Y toATV780C71YDouble inputDouble output

Note!Min cablelength 5m

PREPARING FOR EXTERNAL POWER CONNECTIONS 19

7

As a rule of thumb, cables and the fuses can be dimensioned according to the frequency converter nominal OUTPUT current which you can find on the rating plate. Dimensioning according to the output current is recommended because the frequency converter input current never significantly exceeds the output current.

Table 12 shows the minimum dimensions of Cu- and Al-cables and the recommended aR fuse sizes.

If the motor temperature protection of the drive (see the Programming Manual, on the CD) is used as an overload protection, the cable should be chosen accordingly. If three or more cables are used in parallel (per block) in bigger units each cable requires a separate overload protection.

Frame Type IL

[A] Bussmann fuse type Fuse In

[A] Mains and motor cable1)

[mm2]

No of supply cables

No of motor cables

ATV780C20Y 261 170M5813 (3 pcs) 700 Cu: 1*(3*185+95) Al: 2*(3*120Al+41 Cu)

Even/Odd Even/Odd

ATV780C25Y 325 170M5813 (3 pcs) 700 Cu: 1*(3*240+120) Al: 2*(3*150Al+41Cu)

Even/Odd Even/Odd FR10

ATV780C31Y 385 170M5813 (3 pcs) 700 Cu: 2*(3*120+70) Al: 2*(3*185Al+57Cu)

Even/Odd Even/Odd

ATV780C35Y 460 170M8547 (3 pcs) 1250 Cu: 2*(3*150+70) Al: 2*(3*240Al+72Cu)

Even/Odd Even/Odd

ATV780C45Y 502 170M8547 (3 pcs) 1250 Cu: 2*(3*185+95) Al: 2*(3*300Al+88 Cu)

Even/Odd Even/Odd FR11

ATV780C50Y 590 170M5813 (6 pcs) 700 Cu: 2*(3*240+120) Al: 4*(3*120Al+41Cu)

Even Even/Odd

ATV780C56Y 650 170M5813 (6 pcs) 700 Cu: 4*(3*95+50) Al: 4*(3*150Al+41Cu)

Even Even

ATV780C63Y 750 170M5813 (6 pcs) 700 Cu: 4*(3*120+70) Al: 4*(3*150Al+41Cu)

Even Even FR12

ATV780C71Y 820 170M5813 (6 pcs) 700 Cu: 4*(3*150+70) Al: 4*(3*185Al+57Cu)

Even Even

Table 12. Cable recommendations

20 • Control of main air flow

7

2

1

9. CONTROL OF MAIN AIR FLOW

CAUTION! It is of utmost importance for the operation and lifetime of the frequency converter

that the enclosure is well ventilated to keep the temperature below the maximum operating temperature. Repeated overheating will shorten the lifetime of the converter.

9.1 Arranging ventilation of the enclosure

The enclosure door must be provided with air gaps for air intake. To achieve sufficient cooling inside the cabinet, the dimensions for the total area of free openings for incoming air given in Table 9 must be followed. For instance, there could be two screened gaps as presented in Figure 0 (Manufacturer’s recommendation). This layout ensures a sufficient air flow to the module fans as well as cooling of the additional components. Air outlet gaps must be situated on top of the cabinet. The minimum effective air outlet area per converter frame is given in Table 9.The cooling arrangements inside the cabinet must be such that they prevent hot output air from mixing with the incoming fresh air (see page 21 below). The ventilation gaps must fulfil the requirements set by the selected IP class. The examples in this manual apply to protection class IP21. During operation, air is sucked in and circulated by a fan blower at the bottom of the power unit. If the power unit is placed in the upper part of the cabinet, the fan blower will be in the mid of the cabinet, at the height of the upper ventilation grid.

FR10 FR11 FR12 1 2x13 dm2 2x20 dm2 2x26 dm2 2 7 dm2 11 dm2 14 dm2

Table 13. Ventilation requirements

Figure 15 Ventilation arrangements on the cabinet

Control of main air flow 21

7

9.2 Steering the internal air flow

Cooling air must be sucked in through the ventilation gaps on the door and blown out at the top of the enclosure. To steer the hot air from the power unit to the outlet at the top of the enclosure and prevent it from circulating back to the fan blower, use either of the following arrangements:

A. Install a closed air duct from the power unit to the outlet on top of the enclosure (A in the figure below).

B. Install shields in the gaps between the power unit and the cabinet walls (B in the

figure below). Place the shields above the air outlet gaps at the sides of the module. In ATV780C56Y to ATV780C71Y, close the opposing gaps in the upper part of the

cabinets with a sheet metal plate to ensure proper cooling.

Figure 17. Arrangements for steering hot air to the outlet at the top of the cabinet

A BAir duct

Touch protectioncover

Mesh typetouch protection

Shields

Chokeuppersupport

Sheet metal

22 • Control of main air flow

7

NOTE! To allow free air circulation, the touch cover at the bottom of the cabinet must be of type meshed sheet metal screen. For the same reason, the busbar touch protection cover and the choke upper support must be equipped with holes. See Figure 17.

NOTE! If a flat roof is used, mount a V-shaped air guide on the underside of the roof to direct the

air flow horizontally. See Figure 18.

Figure 18. Roof structure seen from the side

9.3 Heat dissipation

The efficiency of the frequency converter is a function of switching frequency, operating frequency and load (see User’s manual). Based on this information, heat dissipation can be calculated at a certain operating point. For most cases the following general formula based on frequency converter load can be used to estimate the heat dissipation of the power module:

[ ] [ ] 0.025*kW PkWP mot loss = The following table shows the heat dissipation from the AC choke.

Choke Heat dissipation CHK 261 460 W CHK 400 570 W CHK 520 810 W

Table 9-14. Heat dissipation from the AC choke

9.4 Temperatures measured during test run

The following table shows the temperatures measured during a test run of a 520A/400V unit with nominal load @50Hz. The test unit was installed in a Rittal TS8 enclosure following the guidelines described in this manual.

Measurement Temperature [°C] Note Ambient air 30 Outside enclosure Fan intake air 36 Module input terminal 59 L2-phase Output terminal 65 V-phase AC choke 92 L2 winding surface

Table 9-15. Temperatures measured during an accepted test run

10. APPENDICES

10.1 Dimensional drawings, Power modules

Figure 19. Power module dimensions, ATV780C20Y to ATV780C31Y

24 • APPENDICES

7

709Without terminal cover:

225 225 67

225 225 67

506

With integrated control unit

1L11L21L3R-DC- DC+ 2L12L2 2L3

Figure 20. Power module dimensions, ATV780C35Y to ATV780C50Y

ATV780C56 to ATV780C71 (frame FR12) is built of two FR10 modules.

APPENDICES 25

7

10.2 Dimensional drawings, AC chokes

CHK 520

Figure 21. Dimensions of AC choke CHK 520

CHK 400

Figure 22. Dimensions of AC choke CHK 400

497

4020

1 1 1

3 3 3

2 2 2

200

165 165

20443

0145

244

350

3015

150275

1 1 1

3 3 3

2 2 2

238 39

140262

120 120

26 • APPENDICES

7

CHK 261

Figure 23. Dimensions of AC choke CHK 261

1530

150275

1 1 1

2 2 2

3 3 3

20639

230108

min. 19mm

120 120354

APPENDICES 27

7

10.3 Optic fibre cables, signal lists and connections

In frame ATV780C56Y to ATV780C71Y, which consist of two power modules, you will have to connect the fibre cables from the star coupler board to the other power module. See chapter 3.2. Connect the cables according to the figures below. 10.3.1 ATV780C56Y to ATV780C71Y

Figure 24. Internal fibre cable connections, ATV780C56Y to ATV780C71Y

Star coupler board on control unit

H18 Trip signal from power module 2H17 VaconBus data from ASIC 2 to control boardH16 VaconBus data from control board to ASIC 2H15 ADC synchronization, power module 2H14 Phase W control, power module 2H13 Phase V control, power module 2H12 Phase U control, power module 2H11 Gate control enable, power module 2

H23 Feedback phase WH22 Feedback phase VH21 Feedback phase U

Terminals on ASIC board of power module 1

H1 Gate control enableH2 Phase U controlH3 Phase V controlH4 Phase W controlH5 ADC synchronizationH6 VaconBus data from control board to ASICH7 VaconBus data from ASIC to control boardT Trip signal

Terminals on ASIC board of power module 2

H1 Gate control enableH2 Phase U controlH3 Phase V controlH4 Phase W controlH5 ADC synchronizationH6 VaconBus data from control board to ASICH7 VaconBus data from ASIC to control boardU Feedback phase UV Feedback phase VW Feedback phase WT Trip signal

H8 Trip signal from power module 1H7 VaconBus data from ASIC 1 to control boardH6 VaconBus data from control board to ASIC 1H5 ADC synchronization, power module 1H4 Phase W control, power module 1H3 Phase V control, power module 1H2 Phase U control, power module 1H1 Gate control enable, power module 1

H12

H13

H14

H15

H16

H17

H18

H11

H23

H22

H21

H2

H3

H4

H5

H6

H7

H8

H1

H7

H6

H5

H4

H3

H2

H1

H8

H7

H6

H5

H4

H3

H2

H1

T

W

V

U