Instruction Bulletin. ALTIVAR 58 Adjustable Speed Drive Controllers

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1 Instruction Bulletin August 1998 Raleigh, NC, USA ALTIVAR 58 Adjustable Speed Drive Controllers Installation Guide Type N Controllers

2 DANGER HAZARDOUS VOLTAGE Read and understand this bulletin in its entirety before installing or operating ALTIVAR 58 drive controllers. Installation, adjustment, repair, and maintenance of these drive controllers must be performed by qualified personnel. Disconnect all power before servicing the drive controller. WAIT THREE MINUTES until the DC bus capacitors discharge, then measure DC bus capacitor voltage between J2-4 (+) and J2-5 (-) for drive controllers ATV58NU09M2 and NU18M2, or between J2-5 (PA) and J18-7 for all other ALTIVAR 58 Type N drive controllers to verify that the DC voltage is less than 45 V. Refer to the bus voltage measurement procedure on page 11. DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw connections with voltage present. Close the door before applying power or starting and stopping the drive controller. The user is responsible for conforming to all applicable code requirements with respect to grounding all equipment. Many parts in this drive controller, including printed wiring boards, operate at line voltage. DO NOT TOUCH. Use only electrically insulated tools. Before servicing drive controller: Disconnect all power. Place a DO NOT TURN ON label on drive controller disconnect. Lock disconnect in open position. Electrical shock will result in death or serious injury.

3 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Table of Contents INTRODUCTION... 1 REVISION LEVEL... 1 RECEIVING AND PRELIMINARY INSPECTION... 1 STORING AND SHIPPING... 2 TECHNICAL CHARACTERISTICS... 2 SPECIFICATIONS... 5 Operation Above 40 C... 6 DIMENSIONS... 8 INSTALLATION PRECAUTIONS... 9 MOUNTING THE CONTROLLER WIRING Bus Voltage Measurement Procedure General Wiring Practices Conduit Connections Branch Circuit Connections Output Wiring Precautions Grounding Use On a Grounded Neutral Or Neutral Connected To An Impedance Power Terminals Control Terminals WIRING DIAGRAMS Single-Phase Input Three-Phase Input RECOMMENDED POWER FUSES USING A LINE CONTACTOR Output Contactor Wiring Diagram EXTERNAL 24 V SUPPLY FAULT RELAY AVAILABLE TORQUE FACTORY SETTINGS START UP SECURING THE DOOR LIGHT EMITTING DIODES (LEDS) KEYPAD DISPLAY Square D All Rights Reserved i

4 ALTIVAR 58 Type N Drive Controller Bulletin No Table of Contents August 1998 PREVENTIVE MAINTENANCE TROUBLESHOOTING AND MAINTENANCE Procedure 1: Checking Supply Voltage Procedure 2: Checking the Peripheral Equipment Fault Storage ii 1998 Square D All Rights Reserved

5 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Introduction INTRODUCTION REVISION LEVEL ALTIVAR 58 is a family of adjustable-frequency AC drive controllers for three-phase asynchronous motors. The Type N drive controller is a Type 4/4X device and is available from: 1 to 10 hp (0.75 to 7.5 kw), 460 V, three-phase input 0.5 to 3 hp (0.37 to 2.2 kw), 230 V, single-phase input 2 to 5 hp (1.5 to 4.0 kw), 230 V, three-phase input This instruction bulletin covers the technical characteristics, specifications, installation, and wiring of ALTIVAR 58 Type N drive controllers. For information on programming and maintenance of the drive controller, refer to the keypad display instruction bulletin, VVDED397047US. Many options are available for the ALTIVAR 58 drive controller. Refer to catalog 8806CT9801 for a description of the options. This is a new document. RECEIVING AND PRELIMINARY INSPECTION Before installing the drive controller, read this manual and follow all precautions. Before removing the drive controller from its packing material, verify that it is not damaged from shipping. Damage to the packing carton usually indicates improper handling. If any damage is found, notify the carrier and your Square D representative. After removing the drive controller from its packaging, inspect the exterior for shipping damage. If any shipping damage is found, notify the carrier and your sales representative. Verify that the drive controller nameplate and label conform to the packing slip and corresponding purchase order. 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 Square D All Rights Reserved 1

6 ALTIVAR 58 Type N Drive Controller Bulletin No Storing and Shipping August 1998 STORING AND SHIPPING TECHNICAL CHARACTERISTICS If the drive controller is not being immediately installed, store it in a clean, dry area where the ambient temperature is between -13 to +149 F (-25 to +65 C). If the drive controller must be shipped to another location, use the original shipping material and carton to protect the drive controller. Table 1 shows the technical characteristics of single-phase input, threephase output drive controllers, rated for 200 V -10% to 240 V +10%, for use at 50/60 Hz ±5%. Table 1: 200 to 240 V, Single-Phase Input, Three-Phase Output Drive Controllers Drive Controller Catalog Number [2] Input Line Current [3] Single Phase 200 V 240 V Motor Power [4] Rated Output Current (In) Transient Output Current [5] Total Dissipated Rated Load Short Circuit Rating A A kw hp A A W A rms sym. ATV58NU09M ATV58NU18M ATV58NU29M ATV58NU41M2 [1] [1] When these drive controllers are used with a single-phase input, a line inductor must be used. For inductor selection, see catalog 8806CT9801. [2] Complete the catalog number by entering KU for ALTIVAR 58 Type N controllers with factory-installed keypad, or ZU for controllers without a factory-installed keypad. For catalog numbers ending in ZU, an operator interface must be used to modify factory settings. Order separately. Refer to catalog 8806CT9801 for available interface options. [3] Values indicate the current absorbed by drive controllers supplied by mains with fault capacity equal to the short-circuit rating indicated in the table, and under nominal conditions of motor load and speed without additional inductance. Values are accurate for drive controllers operating at 40 C maximum. For operation at 50 C, see Table 5 on page 6. [4] Power indicated is for a switching frequency between 0.5 and 4 khz, and at steady state. For switching frequency between 8 and 16 khz, derate the drive controller by one horsepower size (for example, for 0.5 hp, order drive controller ATV58NU18M2). If the duty cycle (i.e., drive controller run time) does not exceed 60% (36 second maximum for a 60 second cycle), derating is not required for operation above 8 khz. [5] For 60 seconds Square D All Rights Reserved

7 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Technical Characteristics Table 2 shows the technical characteristics of three-phase input, threephase output drive controllers, rated for 200 V -10% to 240 V +10%, for use at 50/60 Hz ±5%. Table 2: 200 to 240 V, Three-Phase Input, Three-Phase Output Drive Controllers Drive Controller Catalog Number [1] Input Line Current [2] Three Phase 200 V 240 V Motor Power [3] Rated Output Current (In) Transient Output Current [4] Total Dissipated Rated Load Short Circuit Rating A A kw hp A A W A rms sym. ATV58NU29M ATV58NU41M ATV58NU54M ATV58NU72M [1] Complete the catalog number by entering KU for ALTIVAR 58 Type N controllers with factory-installed keypad, or ZU for controllers without a factory-installed keypad. For catalog numbers ending in ZU, an operator interface must be used to modify factory settings. Order separately. Refer to catalog 8806CT9801 for available interface options. [2] Values indicate the current absorbed by drive controllers supplied by mains with fault capacity equal to the short-circuit rating indicated in the table, and under nominal conditions of motor load and speed without additional inductance. Values are accurate for drive controllers operating at 40 C maximum. For operation at 50 C, see Table 5 on page 6. [3] Power indicated is for a switching frequency between 0.5 and 4 khz, and at steady state. For switching frequency between 8 and 16 khz, derate the drive controller by one horsepower size (for example, for 2 hp, order drive controller ATV58NU41M2). If the duty cycle (i.e., drive controller run time) does not exceed 60% (36 seconds maximum for a 60 seconds cycle), derating is not required for operation above 8 khz. [4] For 60 seconds Square D All Rights Reserved 3

8 ALTIVAR 58 Type N Drive Controller Bulletin No Technical Characteristics August 1998 Table 3 shows the technical characteristics of three-phase input, threephase output drive controllers, rated for 380 V -10% to 500 V +10%, for use at 50/60 Hz ±5%. Table 3: 380 to 500 V, Three-Phase Input, Three-Phase Output Drive Controllers Drive Controller Catalog Number [1] Input Line Current [2] Three Phase 380 V 500 V Motor Power [3] Rated Output Current (In) Transient Output Current [4] Total Dissipated Rated Load Short Circuit Rating A A kw hp A A W A rms sym. ATV58NU18N ATV58NU29N ATV58NU41N ATV58NU54N ATV58NU72N ATV58NU90N ATV58ND12N ,000 [1] Complete the catalog number by entering KU for ALTIVAR 58 Type N controllers with factory-installed keypad, or ZU for controllers without a factory-installed keypad. For catalog numbers ending in ZU, an operator interface must be used to modify factory settings. Order separately. Refer to catalog 8806CT9801 for available interface options. [2] Values indicate the current absorbed by drive controllers supplied by mains with fault capacity equal to the short-circuit rating indicated in the table, and under nominal conditions of motor load and speed without additional inductance. Values are accurate for drive controllers operating at 40 C maximum. For operation at 50 C, see Table 5 on page 6. [3] Power indicated is for a switching frequency between 0.5 and 4 khz, and at steady state. For switching frequency between 8 and 16 khz, derate the drive controller by one horsepower size (for example, for 1 hp, order drive controller ATV58HU29N4). If the duty cycle (i.e., drive controller run time) does not exceed 60% (36 seconds maximum for a 60 seconds cycle), derating is not required. [4] For 60 seconds Square D All Rights Reserved

9 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Specifications SPECIFICATIONS Table 4: Environmental Specifications Degree of protection Type 4/4X indoors. Type 4/4X outdoors with closing plate installed in door. Do not expose drive controller to direct sunlight or exceed the maximum ambient temperature. Resistance to vibrations According to IEC : 1.5 mm peak from 3 to 13 Hz 1 g from 13 to 200 Hz Resistance to shocks According to IEC : 15 g, 11 ms Pollution degree (drive controller w/out enclosure) Maximum relative humidity (drive controller w/out enclosure) Maximum ambient temperature Altitude Operational position Pollution degree 3 according to IEC 664-1, EN50718 and NEMA ICS-1. Protect the drive controller against dust, corrosive gas, and falling liquid. 100% maximum, non-condensing and without dripping according to IEC Provide heating system if there is condensation. Storage: -25 to +65 C (-13 to +149 F) Operation (see page 6 for maximum current capabilities): -10 to +40 C (+14 to 104 F) without derating -10 to +50 C (+14 to 122 F) with derating of the current. See Operation Above 40 C on page ft (1000 m) maximum without derating; derating of the current by 1% for each additional 330 ft (100 m) Vertical, ±10, with power terminals at the bottom Square D All Rights Reserved 5

10 ALTIVAR 58 Type N Drive Controller Bulletin No Specifications August 1998 Operation Above 40 C Some of the ALTIVAR 58 Type N drive controllers can be operated above 40 C without derating if the maximum input and output currents do not exceed the values in Table 5. To operate the drive controller between 40 and 50 C one of the following must be observed: 1. Derate the drive controller by one hp size 2. Measure the input current to ensure that it does not exceed the maximum value listed in Table 5. Table 5: Maximum Drive Controller Current Capabilities Line Voltage 200 to 240 VAC Input Single Phase Three Phase Motor ATV58N Max. Drive Controller Input Current with 3% LIne Reactor Power Current at 50 C Input Current Output Current kw hp Input Vmax U09M U18M2 [1] U29M U41M2 [1] U29M U41M U54M U72M2 [1] U18N U29N U41N4 [1] to Three 500 VAC Phase 3.00 U54N U72N U90N D12N4 [1] [1] Drive controller has been derated by one hp size for operation above 40 C. If the input current exceeds the levels in Table 5, ensure that the drive controller is operating within its thermal limits by: Reducing the load requirements Installing line reactors to reduce the input current Lowering the available short-circuit current by providing a supply line impedance which emulates a 3% line reactor Square D All Rights Reserved

11 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Specifications Table 6: Electrical Specifications Input voltage 200 V -10% to 240 V +10% single phase input, 0.5 to 3 hp 200 V -10% to 240 V +10% three phase input, 2 to 5 hp 380 V -10% to 500 V +10% three phase input, 1 to 10 hp Input frequency 50/60 Hz ±5% Output voltage Three-phase output, maximum voltage equal to input voltage Galvanic isolation Galvanic isolation between power and control (inputs, outputs, supplies) Output frequency 0.1 to 500 Hz Switching frequency Configurable: khz without derating khz with derating in steady state or without derating with reduced duty cycle Speed range 1:100 Braking torque 30% of nominal motor torque without dynamic braking (typical value). Up to 150% with dynamic braking option. Maximum transient current Drive controller protection Motor protection 136% of nominal drive controller current for 60 s. 150% of nominal motor current for a motor sized for 90% of the drive controller rating. Protection against short circuits: between output phases between output phases and ground on outputs on internal supplies Thermal protection against overheating and overcurrents. Undervoltage and overvoltage faults. Protection in the case of loss-of-input phase (avoid single-phase operation on the three-phase drive controllers). Thermal protection integrated in the drive controller by continuous calculation of I 2 t, taking speed into account. Saving of the motor thermal state at loss of power. Motor thermal protection function can be modified to correspond with the type of motor cooling. Protection against motor phase loss. Protection by motor thermal sensors with option card Square D All Rights Reserved 7

12 ALTIVAR 58 Type N Drive Controller Bulletin No Dimensions August 1998 DIMENSIONS F D I A G E Ø Recommended Screw Size H B Altivar 56 C See Table 8 on page 13 for conduit hole size. J Door Swing Bottom View Top View Figure 1: ATV58N Dimensions Catalog No. ATV58N U09M2, U18M2 U29M2, U41M2, U18N4, U29N4, U41N4 U72M2, U72N4, U90N4 D12N4 A in. (mm) 9.42 (239) (276) (298) (387) B in. (mm) (317) (356) (406) (508) C in. (mm) 7.88 (200) (256) (279) (375) D in. (mm) 0.29 (7) 0.31 (8) 0.38 (10) 0.50 (13) E in. (mm) 8.05 (204) 9.00 (229) (254) (337) F in. (mm) 0.40 (10) 0.62 (15.8) 0.50 (13) 0.50 (13) G in. (mm) 8.63 (219) 9.63 (245) (273) (362) H in. (mm) (279) (317) (362) (464) I in. (mm) 1.12 (28) 1.12 (28) 1.25 (32) 1.25 (32) J in. (mm) (389) (468) (517) (695) Ø in. (mm) 1/4-20 (M6) 1/4-20 (M6) 3/8-16 (M10) 3/8-16 (M10) Weight lb (kg) 18 (8.2) 28 (12.7) 42 (19.1) 67 (30.5) Square D All Rights Reserved

13 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Installation INSTALLATION PRECAUTIONS Turn off all power before installing the drive controller. Place a DO NOT TURN ON label on the drive controller disconnect. Before proceeding with the installation, lock the disconnect in the open position. DANGER HAZARDOUS VOLTAGE Before working on this equipment: Disconnect all power. Place a DO NOT TURN ON label on the drive controller disconnect. Lock the disconnect in open position. Electrical shock will result in death or serious injury. The ALTIVAR 58 drive controller must be installed in a suitable environment. The environment around the drive controller must not exceed Type 4/4X limitations. Install the drive controller vertically, +/- 10, with the power terminals at the bottom. Avoid placing the drive controller near any heat sources. Mount the drive controller on a flat, solid surface to achieve proper air flow. Leave enough room in front of the drive controller for door swing. See Dimensions on page 8. 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 the drive controller should be in accordance with national and local codes. Overcurrent protection is required. Install line power fuses recommended in Tables 13 to 15 on page Square D All Rights Reserved 9

14 ALTIVAR 58 Type N Drive Controller Bulletin No Wiring August 1998 MOUNTING THE CONTROLLER WIRING When mounting the ALTIVAR 58 Type N drive controller, note the following: Mount the drive controller on a solid, flat surface. Use bolts with washers to secure the controller. To maintain a minimum distance between drive controllers, do not overlap the mounting feet. Do not mount the drive controller directly above another controller or a heat generating source. Do not mount the drive controller in direct sunlight or exceed the maximum ambient temperature. In outdoor applications, the keypad must be mounted internally (on the drive controller, not the door). Before wiring the drive controller, first perform the bus voltage measurement procedure on page 11. Figure 2 shows the location of the terminal strips. Control Terminals Power Terminals Figure 2: Ground Terminal Wiring Terminals (Bottom of Controller, Door Open) Square D All Rights Reserved

15 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Wiring Bus Voltage Measurement Procedure DANGER HAZARDOUS VOLTAGE Read and understand the bus voltage measurement procedure before performing procedure. Measurement of bus capacitor voltage must be performed by qualified personnel. 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. Electrical shock will result in death or serious injury. Measure the voltage between the + and - terminals as shown in Table 7. Refer to Figure 3 for terminal location. Table 7: Drive Controller ATV58N DC Bus Measurement Terminals + Terminal - Terminal U09M2 and U18M2 J2-4 (+) J2-5 (-) All other ALTIVAR 58 Type N controllers J2-5 (PA) J18-7 J18-7 L1 L2 + - U V W L1 L2 L3 PA PB U V W J2 Terminal Block Figure 3: DC Bus Measurement Terminals 1998 Square D All Rights Reserved 11

16 ALTIVAR 58 Type N Drive Controller Bulletin No Wiring August 1998 General Wiring Practices To measure the bus capacitor voltage: 1. Disconnect all power from the drive controller. 2. Wait three minutes to allow the DC bus to discharge. 3. Unlatch and open the door. 4. Set the voltmeter to the 1000 Vdc scale. Measure the voltage between the + terminal and the - terminal to verify that the DC voltage is less than 45 V for each measurement. 5. If the bus capacitors are not fully discharged, contact your local Square D representative do not operate the drive controller. 6. Close and latch the door. Good wiring practice requires the separation of control circuit wiring from all power wiring. Power wiring to the motor must have the maximum possible separation from all other power wiring, whether from the same drive controller or other drive controllers. Do not run power and/or control or multiple power wiring in the same conduit. This separation reduces the possibility of coupling electrical transients from power circuits into control circuits or from motor power wiring into other power circuits. CAUTION EQUIPMENT DAMAGE HAZARD Follow wiring practices described in this document in addition to those already required by the National Electric Code and local electrical codes. Failure to follow this instruction can result in injury or equipment damage. Follow these practices when wiring enclosed ALTIVAR 58 drive controllers: 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. (76 mm). 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. (305 mm). Whenever power and control wiring cross, the metallic conduits and non-metallic conduits or trays must cross at right angles. Equip all inductive circuits near the drive (relays, contactors, solenoid valves) with noise suppressors or connect them to a separate circuit Square D All Rights Reserved

17 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Wiring Conduit Connections The ALTIVAR 58 Type N controller is furnished with four conduit openings at the bottom of the device. The conduit openings are closed with Type 4/4X-rated plugs. The holes are intended for input and output power wiring, control wiring, and connection to external components such as DB resistors or line reactors. To maintain the Type 4/4X rating, do not remove the plugs from unused conduit holes. Conduit holes are pre-drilled for the conduit recommended in Table 8. Table 8: Recommended Conduit Drive Controller Catalog No. ATV58NU09M2, ATV58NU18M2 All other ALTIVAR 58 Type N Drive Controllers Conduit Hole Size Recommended Conduit Hub Catalog No. 7/8 inch 1/2 inch /32 inch 3/4 inch Branch Circuit Connections All branch circuit components and equipment (such as transformers, feeder cables, disconnect devices, and protective devices) must be rated for the maximum input current of the ALTIVAR 58 drive controller, not the motor full load current. The drive controller input current is stamped on the nameplate. WARNING OVERCURRENT PROTECTIVE DEVICES MUST BE PROPERLY COORDINATED To achieve published fault-withstand current ratings, install the specified fuses which are listed on the drive controller nameplate and in Tables 13 to 15 (page 22) of this manual. Do not connect the drive controller to a power feeder whose short circuit capacity exceeds the drive controller withstand fault rating listed on drive controller nameplate. Failure to follow this instruction can result in death, serious injury or equipment damage Square D All Rights Reserved 13

18 ALTIVAR 58 Type N Drive Controller Bulletin No Wiring August 1998 Output Wiring Precautions WARNING DRIVE CONTROLLER DAMAGE The drive controller will be damaged if input line voltage is applied to output terminals (U, V, W). Check power connections before energizing the drive controller. Failure to follow this instruction can result in death, serious injury or equipment damage. The drive controller is sensitive to the amount of capacitance (either phase-to-phase or phase-to-ground) present on the output power conductors. If excessive capacitance is present, the drive controller may trip on overcurrent. Follow the guidelines below when selecting output cable: Cable type: the cable selected must have a low capacitance phaseto-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 100 ft (30.5 m) may affect controller and/or motor performance. Proximity to other output cables: because of high frequency switching and increased capacitance, the drive controller may fault under some conditions. Do not use lightning arrestors and/or power factor correction capacitors on the output of the drive controller. Wiring needs a minimum inductance to protect the drive controller output from short circuits. Provide at least 20 in. (500 mm) of cable at the drive controller output (U, V, W). CAUTION DRIVE CONTROLLER SWITCH FAILURE For proper drive controller short circuit protection, certain values of inductance may be required in the output power wiring. Inductance can be supplied by the power wiring or auxiliary inductors. Failure to follow this instruction can result in injury or equipment damage Square D All Rights Reserved

19 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Wiring Grounding For safe, dependable operation, ground the drive controller according to National Electrical Code and all local codes. To ground the drive controller: Connect the system ground conductor and the motor ground conductor to the ground bar located on the heat sink. See Figure 4 for ground connection locations. 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. L1 L2 + - U V W Drive GND L1 L2 L3 PA PB U V W J2 Terminal Block Housing GND System GND Motor GND Figure 4: Grounding DANGER HAZARDOUS VOLTAGE Ground equipment using the provided ground connecting point as shown in Figure 4. The drive controller panel must be properly grounded before power is applied. Do not use metallic conduit as a ground conductor. Electrical shock will result in death or serious injury Square D All Rights Reserved 15

20 ALTIVAR 58 Type N Drive Controller Bulletin No Wiring August 1998 Ground multiple drive controllers as shown in Figure 5. Use one grounding conductor per device. Do not loop ground conductors or install them in series. YES NO Drive Controller Drive Controller Drive Controller Drive Controller Drive Controller Drive Controller Drive Controller Drive Controller Drive Controller Figure 5: Grounding Multiple Drive Controllers Use On a Grounded Neutral Or Neutral Connected To An Impedance When the three-phase mains has a voltage greater than 480 V ±10% with a grounded neutral or a neutral connected to an impedance, the internal EMC filters wired to the heat sink must be disconnected. Call or fax the Square D AC Drives Technical Support Group for more information. Telephone: (919) Fax (919) Square D All Rights Reserved

21 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Wiring Power Terminals L1 L2 + - U V W ATV58NU09M2 and U18M2 (Single-phase input only) L1 L2 L3 PA PB U V W All other drive controllers Table 9: Function of Power Terminals Terminal Function For ATV58 L1 L2 L3 + - PA PB U V W Ground terminal Input power Connection for DB module Connection for DB resistor Output connections to motor Ground terminal All models All models All models except U09M2 and U18M2 U09M2 and U18M2 All models except U09M2 and U18M2 All models All models Table 10: Power Terminal Wire Size and Torque Drive Controller ATV58N Maximum Wire Size [1] AWG (mm 2 ) Torque lb-in (N m) U09M2, U18M2 14 (1.5) 5.0 (0.56) U29M2, U41M2, U18N4, U29N4, U41N4 8 (6) 7.5 (0.85) U54M2, U72M2, U54N4, U72N4, U90N4 8 (6) 7.5 (0.85) D12N4 6 (10) 20 (2.26) [1] 75 C copper Square D All Rights Reserved 17

22 ALTIVAR 58 Type N Drive Controller Bulletin No Wiring August 1998 Control Terminals The control terminal strip contains two pull-apart terminal blocks, one for the relay outputs and one for the low level inputs and outputs. The S terminal is used for the shield connection. Maximum wire size for all control terminals is 14 AWG (1.5 mm 2 ). Tightening torque is 3.5 lb-in (0.4 N m). Figure 6 shows the location of the control terminals. Control board R1A R1B R1C R2A R2C S COM AI AI 2 LI 1 LI 2 LI 3 LI Figure 6: Location of Control Terminals WARNING UNINTENDED EQUIPMENT OPERATION Logic input 1 has priority. If logic input 1 is closed while logic input 2 is active, the controller will respond to logic input 1. If logic input 1 is lost while logic input 2 is active, the controller will respond to logic input 2. The logic inputs must be programmed appropriately for the application to prevent the motor from spinning in an unintended direction. Failure to follow this instruction can result in death or serious injury. Table 11: Control Terminals Characteristics Terminal Function Characteristics R1A R1B R1C R2A R2C S R1A to R1C is a N.O. contact. When the drive controller is powered with no fault, the contact is closed. R1B to R1C is a N.C. contact. When the drive controller is powered with no fault, the contact is open. N.O. programmable relay R2 Shield connection Minimum: 10 ma, 24 VDC Maximum: inductive load of 1.5 A for 250 VAC and 30 VDC Square D All Rights Reserved

23 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Wiring Table 11: Control Terminals Characteristics (Continued) Terminal Function Characteristics COM Common for logic and analog inputs AI1 Analog input 1 (voltage) 0 to 10 VDC, Impedance = 30 kω +10 AI2 LI1 LI2 LI3 LI4 Supply for reference potentiometer (1 to 10 kω potentiometer) Analog input 2 (current) Logic inputs +24 Supply for inputs 10 V ± 1%, protected against short circuits and overloads 10 ma maximum X to Y ma, with X and Y being programmable from 4 to 20 ma; factory setting: 4 to 20 ma Impedance = 100 Ω Supplied by +24 VDC State 0 if < 5 V, state 1 if > 11 V Vmax = 30 V Impedance = 3.5 kω +24 V protected against short circuits and overloads Minimum 20 V, maximum 30 V 200 ma maximum Table 12: Factory Logic Input Settings Hdg: Material Handling GEn: General Use VT: Variable Torque Logic Input LI1 Forward Forward Forward Logic Input LI2 Reverse Reverse Reverse Logic Input LI3 2 Preset speeds Jog Reference switching Logic Input LI4 4 Preset speeds Freewheel stop DC injection braking WARNING UNINTENDED EQUIPMENT OPERATION If both logic inputs 1 and 2 are selected (high state) and logic input 1 reverts to zero state, the drive controller will reverse directions.the logic inputs must be programmed appropriately for the application to prevent the motor from spinning in an unintended direction. Failure to follow this instruction can result in death or serious injury Square D All Rights Reserved 19

24 ALTIVAR 58 Type N Drive Controller Bulletin No Wiring Diagrams August 1998 WIRING DIAGRAMS Single-Phase Input L1 L2 (1) F1 F2 (2) (3) (4) Type 4/4X Housing (6) A1 L1 U L2 V W R1A R1C R1B LI1 +10 LI2 AI1 LI3 COM (0 V) LI4 +24 AI2 R2A R2C ATV58 U09M2 and U18M2 + - ATV58 other models PA PB U1 V1 M 3 φ W1 Manual X - Y ma Speed Potentiometer (1-10 kω) (5) A2 + - PA PB Brake resistor if required Brake resistor if required (1) Line inductor if required. See catalog 8806CT9801 for recommendation. (2) Fault relay contacts for remote signalling of the drive controller state. Contact state shown with drive controller deenergized or faulted. (3) Internal +24 V. When using +24 V external supply, connect the 0 V to the COM terminal. Do not use the +24 terminal on the control board, but connect logic inputs to external +24 V. See Figure 10 on page 24. (4) Relay R2 for external brake coordination. Can be reassigned. (5) Use dynamic braking module (A2) VW3A58701 with drive controllers ATV58NU09M2 and NU18M2 if dynamic braking is required. See catalog 8806CT9801 for braking resistor. (6) Do not install additional components within the Type N controller. Figure 7: Single-Phase Wiring Diagram Square D All Rights Reserved

25 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Wiring Diagrams Three-Phase Input L1 L2 L3 (1) F1 F2 F3 Type 4/4X Housing (6) (2) (3) (4) A1 U V W PA PB +10 AI1 COM (0 V) L1 U1 V1 W1 L2 L3 R1A R1C R1B LI1 AI2 LI2 LI3 LI4 +24 R2A R2C M 3 φ Brake resistor if required (5) Manual X - Y ma Speed Potentiometer (1-10 kω) (1) Line inductor if required. See catalog 8806CT9801 for recommendations. (2) Fault relay contacts for remote signalling of the drive controller state. Contact state shown with drive controller deenergized or faulted. (3) Internal +24 V. When using +24 V external supply, connect the 0 V to the COM terminal. Do not use the +24 terminal on the control board, but connect logic inputs to external +24 V. See Figure 10 on page 24. (4) Relay R2 for coordination of external brake. Can be reassigned. (5) See catalog 8806CT9801 for braking resistor. (6) Do not install additional components within the Type N controller. Figure 8: Three-Phase Wiring Diagram 1998 Square D All Rights Reserved 21

26 ALTIVAR 58 Type N Drive Controller Bulletin No Recommended Power Fuses August 1998 RECOMMENDED POWER FUSES Table 13: 200/240 V Single-Phase Drive Controllers M A1 F1, F2 Motor [1] Drive Controller Line Power Fuses hp kw ATV58N Class J [2] U09M U18M U29M U41M2 40 Notes to Table 13: [1] Power shown for a switching frequency between 0.5 and 4 khz, and at steady state. For switching frequency between 8 and 16 khz, derate the controller by one hp size. For example, for 0.5 hp, order drive controller ATV58U18M2. [2] Fast-acting. Class CC fuse may be used if recommended fuse rating is 20 A or lower. Table 14: 200/240 V Three-Phase Drive Controllers M A1 F1, F2, F3 Motor [1] Drive Controller Line Power Fuses hp kw ATV58N Class J [2] U29M U41M U54M U72M2 35 Table 15: 380/500 V Three-Phase Drive Controllers M A1 F1, F2, F3 Motor [1] Drive Controller Line Power Fuses hp kw ATV58N Class J [2] U18N U29N U41N U54N U72N U90N D12N4 40 Notes to Table 14: [1] Power shown for a switching frequency between 0.5 and 4 khz, and at steady state. For switching frequency between 8 and 16 khz, derate the controller by one hp size. For example, for 2 hp, order drive controller ATV58U41M2. [2] Fast-acting. Class CC fuse may be used if recommended fuse rating is 20 A or lower. Notes to Table 15: [1] Power shown for a switching frequency between 0.5 and 4 khz, and at steady state. For switching frequency between 8 and 16 khz, derate the controller by one hp size. For example, for 1 hp, order drive controller ATV58U29N4. [2] Fast-acting.Class CC fuse may be used if recommended fuse rating is 20 A or lower Square D All Rights Reserved

27 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Using a Line Contactor USING A LINE CONTACTOR Output Contactor Wiring Diagram When controlling the power with an isolation line contactor, avoid frequently opening and closing the line contactor as this could cause premature failure of the filtering capacitors and precharge resistor. Use inputs LI1 to LI4 to start and stop the drive controller. Limit operations of the line contactor to less than once per minute. Use the function Output Contactor Command with relay R2, or logic output LO on the I/O extension card. Refer to keypad display instruction bulletin VVDED397047US for more information on this function. In the wiring diagram, the shaded portion is to be added to either the singlephase input wiring diagram (Figure 7 on page 20) or the three-phase input wiring diagram (Figure 8 on page 21). A1 U V W R2A R2C (1) KM2 KM2 TS 120 Vac U1 V1 W1 TS = Transient suppressor M 3 φ (1) See Table 11 on page 18. Figure 9: Output Contactor Wiring Diagram NOTE: Use transient suppression on all inductive circuits near the drive controller or connected on the same circuit, such as relays, contactors, and solenoids Square D All Rights Reserved 23

28 ALTIVAR 58 Type N Drive Controller Bulletin No External 24 V Supply August 1998 EXTERNAL 24 V SUPPLY Table 16: Recommended Output Contactors A1 KM2 A1 KM2 ATV58N LC1- ATV58N LC1- U09M2 D2510F7 U18N4 D2510 U18M2 D2510F7 U29N4 D2510 U29M2 D2510F7 U41N4 D2510 U41M2 D2510F7 U72N4 D2510 U72M2 D2510F7 U90N4 D2510 D12N4 D2510 Refer to the Square D Digest for other control voltages. An external 24 V power supply can be used for the logic inputs. In this case, the +24 terminal on the drive controller is not used. Figure 10 shows the wiring diagram when an external supply is used. A1 0 V + 24 V COM LI LI LI LI + 24 Figure 10: External Supply Wiring Diagram FAULT RELAY The fault relay is energized whenever there is power to the drive controller and there is no fault. Provides a normally-open and a normally-closed contact. Drive controller reset after a fault is accomplished either by cycling power, allowing the red LED to turn off; or automatically after certain faults, if automatic restart is selected. For further explanation of automatic restart, refer to the instruction bulletin for the keypad display, VVDED397047US Square D All Rights Reserved

29 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Available Torque AVAILABLE TORQUE Continuous duty: For self-ventilated motors, motor cooling depends on the speed. Continuous duty results in derating for speeds less than 50% of the nameplate motor speed. Operation in overspeed: In overspeed operation, the voltage no longer increases with the frequency, resulting in reduced induction in the motor which translates into a loss of torque. Consult the motor manufacturer to ensure that the motor can operate in overspeed. For a special motor, the nominal frequency and the maximum frequency can be adjusted between 40 and 500 Hz using the keypad display, handheld programmer, or commissioning software. CAUTION MACHINERY OVERSPEED Some motors and/or loads may not be suited for operation above the nameplate motor speed and frequency. Consult the motor manufacturer before operating the motor above the rated speed. Failure to follow this instruction can result in injury or equipment damage. The available overtorque depends on the transient current that the drive controller can deliver: 200% of the nominal motor torque for 2 seconds, and 170% for 60 seconds. Figure 11 on page 26 shows the typical torque characteristics of the ALTIVAR 58 drive controller Square D All Rights Reserved 25

30 ALTIVAR 58 Type N Drive Controller Bulletin No Factory Settings August 1998 T/Tn Self-ventilated motor, continuous duty 2 Force-ventilated motor, contiunous duty 3 Transient overtorque for 60 seconds maximum 4 Torque in overspeed at constant power Speed (Hz) FACTORY SETTINGS Figure 11: Typical Torque Characteristics The ALTIVAR 58 drive controller is preset for constant torque applications. Table 17 lists the factory settings. Table 17: Factory Settings Function Setting Display Reference frequency displayed if keypad present Base frequency 50/60 Hz [1] Motor voltage 230 V or 400/460 V, depending on model. See Figure 12 on page 28. Acceleration and deceleration 3 s ramps Low speed 0 Hz High speed 50/60 Hz [1] Maximum frequency 60/72 Hz [1] Motor thermal current 0.9 times rated drive controller output current DC braking current at stop 0.63 times rated drive controller output current for 0.5 s Operation Constant torque Macroconfiguration Material handling Control type 2-wire control 2 run directions LI1, LI2 Logic inputs 4 preset speeds LI3, LI4: LSP + reference, 10 Hz, 15 Hz, HSP [1] Depending on the position of the 50/60 Hz switch. Switch is factory-set to 60 Hz Square D All Rights Reserved

31 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Start Up Table 17: Factory Settings (Continued) Function Analog inputs Relay outputs Switching frequency Setting AI1: 0 to +10 V reference AI2: 4 to 20 ma reference Analog inputs set for reference summing R1: fault relay (cannot be reassigned) R2: brake command (can be reassigned) 4 khz START UP DANGER HAZARDOUS VOLTAGE Read and understand this bulletin in its entirety before installing or operating ALTIVAR 58 drive controllers. Installation, adjustment, repair, and maintenance of these drive controllers must be performed by qualified personnel. Disconnect all power before servicing the drive controller. WAIT THREE MINUTES until the DC bus capacitors discharge, then measure DC bus capacitor voltage between J2-4 (+) and J2-5 (-) for drive controllers ATV58NU09M2 and NU18M2, or between J2-5 (PA) and J18-7 for all other ALTIVAR 58 Type N drive controllers to verify that the DC voltage is less than 45 V. Refer to the bus voltage measurement procedure on page 11. DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw connections with voltage present. The user is responsible for conforming to all applicable code requirements with respect to grounding all equipment. Many parts in this drive controller, including printed wiring boards, operate at line voltage. DO NOT TOUCH. Use only electrically insulated tools. Electrical shock will result in death or serious injury. Before powering up the drive controller and using the keypad display, the 50/60 Hz switch must be set to correspond with the incoming power frequency. Unlatch and open the door to access the 50/60 Hz switch on the control board. If an option card is present, the switch will still be accessible through the card. Set the switch to the position corresponding to the mains frequency Square D All Rights Reserved 27

32 ALTIVAR 58 Type N Drive Controller Bulletin No Start Up August 1998 The pre-adjusted operating voltage corresponding to the switch position is: 50 Hz Position: 230 V, 50Hz for ATV58 M2 400 V, 50Hz for ATV58 N4 60 Hz Position (Factory Setting): 230 V, 60Hz for ATV58 M2 460 V, 60Hz for ATV58 N4 Green LED Red LED 50/60 Hz Switch or 50 Hz 60 Hz Figure 12: Setting the 50/60 Hz Switch Several tools are available to aid in starting up the ALTIVAR 58 drive controller: Keypad display, VW3A58101U. The drive controller can be ordered with or without the keypad display. Handheld programmer, VW3A58102U, ordered separately Commissioning software, VW3A58104, ordered separately Each of these tools is provided with its own documentation. If your ALTIVAR 58 drive controller has an I/O extension card or communication card, also consult the documentation provided with the option Square D All Rights Reserved

33 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Start Up SECURING THE DOOR To maintain the seal for the Type 4/4X rating, both latches on the door must be closed. Latch Closed Latch Open Altivar 56 Figure 13: Securing the Door 1998 Square D All Rights Reserved 29

34 ALTIVAR 58 Type N Drive Controller Bulletin No Troubleshooting and Maintenance August 1998 LIGHT EMITTING DIODES (LEDs) The LEDs on the front of the ALTIVAR 58 drive controller indicate several states as shown in Figure 14 on page 30. On the ALTIVAR 58 Type N controllers, the LEDs can be viewed with the door opened. POWER FAULT Other LEDs, displaying the state with option cards installed POWER FAULT Green POWER LED Red FAULT LED illuminated: drive controller powered illuminated: drive controller faulted KEYPAD DISPLAY Figure 14: LED States Part numbers for ALTIVAR 58 Type N drive controllers provided with a keypad display end with KU. A closing plate kit, catalog number VW3A58836, can be ordered separately to prevent access to the keypad if the keypad is to be removed from the controller, or if the controller is to be installed outdoors. If the controller is installed outdoors, the keypad must be removed and replaced with the closing plate. Part numbers for ALTIVAR 58 Type N controllers without a keypad display end with ZU. A keypad, catalog number VW3A58101U, can be ordered separately and installed directly on the drive controller, or on the door with a remote-mounting kit, catalog number VW3A PREVENTIVE MAINTENANCE At regular intervals: Check the condition and tightness of the connections. Ensure that the ventilation is effective and the temperature around the drive controller remains at an acceptable level. Remove dust and debris from the drive controller, heat sink, and fans. Check fan operation Square D All Rights Reserved

35 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Troubleshooting and Maintenance TROUBLESHOOTING AND MAINTENANCE If a fault is detected, the drive controller trips and the fault relay deenergizes. After verifying that there is no voltage present on the DC bus (see Bus Voltage Measurement Procedure on page 11), check the supply voltage (Procedure 1 on page 31) and the peripheral components (Procedure 2 on page 31). If no problem is found with the supply voltage and peripheral equipment, install a keypad display for additional fault information. The faults are identified in the keypad display manual, VVDED397047US. Procedure 1: Checking Supply Voltage To determine if the voltage is within the drive controller tolerance: 1. Perform the bus voltage measurement procedure on page Attach meter leads to L1 and L2. Set the voltmeter to the 600 Vac scale. 3. Reapply power and check for the correct line voltage, shown on the drive controller nameplate rating. 4. For three-phase drive controllers, remove power and repeat the procedure for L2 and L3, and L1 and L3. 5. When all phases have been measured, remove power and remove leads. Procedure 2: Checking the Peripheral Equipment The following equipment may need to be checked. Follow the manufacturers procedures when checking this equipment. 1. A protective device such as fuses or a circuit breaker may have opened or tripped. 2. A switching device such as a contactor may not be closing at the correct time. 3. Conductors may require repair or replacement. 4. Connection cables to the motor or high resistance connections to ground may need to be checked. Follow NEMA standard procedure WC Motor insulation may need to be checked. Follow NEMA standard procedure MG-1. Do not apply high voltage to U, V, or W. Do not connect the high potential dielectric test equipment or insulation resistance tester to the drive controller since the test voltages used 1998 Square D All Rights Reserved 31

36 ALTIVAR 58 Type N Drive Controller Bulletin No Troubleshooting and Maintenance August 1998 may damage the drive controller. Always disconnect the drive controller from the conductors or motor while performing such tests. CAUTION EQUIPMENT DAMAGE HAZARD Do not perform high-potential dielectric tests on circuits while the circuits are connected to the drive controller. Any circuit requiring high-potential dielectric tests must be disconnected from the drive controller prior to performing the test. Failure to follow this instruction can result in injury or equipment damage. Fault Storage The first fault detected is saved and displayed on the keypad if power is maintained. The drive controller trips and the fault relay opens. To reset the fault: 1. Remove power from the drive controller. 2. Before switching power back on, identify and correct the cause of the fault. 3. Restore power. This will reset the fault if it has been corrected. In certain cases, if automatic restart has been enabled, the drive can be automatically restarted after the cause of the fault has disappeared Square D All Rights Reserved

37 Bulletin No August 1998 ALTIVAR 58 Type N Drive Controller Index Numerics 50/60 Hz switch 26, 27 A acceleration ramp 26 altitude 5 analog inputs 19, 27 B bus voltage measurement 11 C cable length 14 cable type 14 capacitance 14 capacitors 23 commissioning software 25, 28 constant torque 26 control type 26 current braking 26 fault withstand. See current, short circuit input 13 maximum 6 maximum thermal 26 maximum transient 7 short circuit 2, 3, 4 transient 25 D deceleration ramp 26 dimensions 8 disconnect switch 9 dynamic braking connection 17 E external power supply 24 F factory settings 26 fault relay. See relays faults resetting 32 frequency input 7 maximum 26 output 7 reference 26 switching. See switching frequency fuses 13 line power 22 G grounding H handheld programmer 25, 28 humidity 5 I inductors 2 installation 9 K keypad display 25, 27, 28, 30 L LEDs 24, 30 line contactor 23 logic inputs 19, 23, 26 M maintenance 31 preventive 30 metallic conduit 12 motors self-ventilated 25 special 25 O operating position 5 options 1 output contactors 24 overspeed operation 25 P peripheral equipment checking 31 pollution degree 5, 9 potentiometer 19 precharge resistor 23 protection 9 drive controller 7 motor 7 thermal Square D All Rights Reserved 33

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