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APRIL 05
ATV780C20Y~ATV780C71Y
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. 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:
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:
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.
1
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
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
2
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.
AC choke
Fibr
24V
for A
ATV
Figure 1. Parts included in delivery: AC choke and power module with integrated control unit and the
required cables for ATV780C56Y to ATV780C71Y
FR10: 123 kg
FR11: 210 kg
FR12: 2*123 kg
NOTE! The power module can temporarily rest on the cooling fan assembly, but shocks or non-
vertical forces may cause damage to the fans.
Choke Weight
CHK0261 53 kg
CHK0400 84 kg
CHK0520 115 kg
3
8• INSTALLING AC CHOKEs
4. INSTALLING AC CHOKES
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.
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
A A E
F
C
G
D
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.
5
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
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
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.
Grounding
cable
PE rail
5
12 • CONNECTING THE INTERNAL POWER CABLES
Power board
L1 L2 L3 B- B+/R+ R- U V W
BR
(option)
L1* L2* L3
M
3~
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
CONNECTING THE INTERNAL POWER CABLES • 13
L3
L2
L1
L1 L2 L3
L1 L2 L3
Voltage / Frequency
500V/50Hz
525V/50Hz
575V/60Hz
690V/50Hz
L1 L2 L3
L1 L2 L3
L1 L2 L3
Figure 9. Connecting the power cables between the AC choke and the power unit
Table 8. Required cable sizes for the internal power cables (90oC rating recommended)
14 • CONNECTING THE INTERNAL POWER CABLES
L3 L3
L2 L2
L1 L1
L1 L2 L3 L1 L2 L3
Fuses
L1 L2 L3 L1 L2 L3
Figure 10. Connecting the DC links together when the brake chopper of ATV780C56Y to A TV780C71Yis used
Power module 1
ASIC board
X10
FB board
X2
Power module 2
ASIC board
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.
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16 • PREPARING FOR EXTERNAL POWER CONNECTIONS
L1 L2 L3
7
PREPARING FOR EXTERNAL POWER CONNECTIONS 17
EMC grounding
7
18 • PREPARING FOR EXTERNAL POWER CONNECTIONS
Note!
Min cable
length 5m
M M M
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.
WARNING 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.
7
PREPARING FOR EXTERNAL POWER CONNECTIONS 19
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.
No of No of
IL Fuse In Mains and motor cable1)
Frame Type Bussmann fuse type supply motor
[A] [A] [mm2]
cables cables
Cu: 1*(3*185+95) Even/Odd Even/Odd
ATV780C20Y 261 170M5813 (3 pcs) 700
Al: 2*(3*120Al+41 Cu)
Cu: 1*(3*240+120) Even/Odd Even/Odd
FR10 ATV780C25Y 325 170M5813 (3 pcs) 700
Al: 2*(3*150Al+41Cu)
Cu: 2*(3*120+70) Even/Odd Even/Odd
ATV780C31Y 385 170M5813 (3 pcs) 700
Al: 2*(3*185Al+57Cu)
Cu: 2*(3*150+70) Even/Odd Even/Odd
ATV780C35Y 460 170M8547 (3 pcs) 1250
Al: 2*(3*240Al+72Cu)
Cu: 2*(3*185+95) Even/Odd Even/Odd
FR11
ATV780C45Y 502 170M8547 (3 pcs) 1250
Al: 2*(3*300Al+88 Cu)
Cu: 2*(3*240+120) Even Even/Odd
ATV780C50Y 590 170M5813 (6 pcs) 700
Al: 4*(3*120Al+41Cu)
Cu: 4*(3*95+50) Even Even
ATV780C56Y 650 170M5813 (6 pcs) 700
Al: 4*(3*150Al+41Cu)
Cu: 4*(3*120+70) Even Even
FR12
ATV780C63Y 750 170M5813 (6 pcs) 700
Al: 4*(3*150Al+41Cu)
Cu: 4*(3*150+70) Even Even
ATV780C71Y 820 170M5813 (6 pcs) 700
Al: 4*(3*185Al+57Cu)
Table 12. Cable recommendations
7
20 • 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.
Figure 15 Ventilation
arrangements on the cabinet
7
Control of main air flow 21
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.
A B
Air duct
Sheet metal
Shields
Touch protection
cover
Choke
upper
support
Mesh type
touch protection
Figure 17. Arrangements for steering hot air to the outlet at the top of the cabinet
7
22 • Control of main air flow
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.
The following table shows the heat dissipation from the AC choke.
7
10. APPENDICES
10.1 Dimensional drawings, Power
modules
225 225 67
506
7
APPENDICES 25
10.2 Dimensional drawings, AC chokes
CHK 520
497 204
43
1 1 1
40
20
3 3 3
2 2 2
200 145
0
244
165 165
CHK 400
350
238 39
1 1 1
30
15
3 3 3
2 2 2
140
150
275 262
120 120
7
26 • APPENDICES
CHK 261
206
39
1 1 1
30
15
3 3 3
2 2 2
120 120
354
7
APPENDICES 27
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.
Star coupler board on control unit Terminals on ASIC board of power module 1
H 22
H 21