PACKAGED PRODUCTS

Technical Manual Supplement to Standard Drive Product Manual

Converteam Ltd. Kidsgrove, Stoke-on-Trent, Staffordshire, ST7 1TW ENGLAND Telephone: Stoke-on-Trent +44 (0) 1782 781000 Fax: Stoke-on-Trent +44 (0) 1782 781001

Packaged Products ACKNOWLEDGEMENTS

MODBUS is a registered trademark of Modicon Electronics Limited.

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Packaged Products SAFETY INSTRUCTIONS

1. GENERAL

Electrical equipment represents a risk to life. Safety instructions are given on the product, in this supplement and other relevant manuals referred to in this supplement. Reference must be made to the instructions in this manual for any action taken when transporting, commissioning, operating, maintaining and disposing of the product. Dangerous voltages appear on the circuitry. There can be moving parts and hot surfaces. Death, severe physical injury and extensive material damage can result if the instructions given in this manual are not observed. Local safety regulations must be observed during erection, commissioning and maintenance of the product. Persons performing this work must be suitably skilled and should have been trained in that work for these products. Electrostatic sensitive components are used within this product. Static handling precautions in accordance with Protection of Electrostatic Sensitive Devices, Part 1, General Requirements, EN 100015 Pt.1:1992 (CECC 00015:1992) must be observed. All products weighing in excess of 20kg (44lbs.) should be moved by mechanical handling equipment using the lifting points provided. Radio transmitters (e.g. walkie-talkies, mobile telephones) can cause incorrect operation. Transmitters with an output of more than 2 watts must not be used in the vicinity of the product. Transmitters with output power of 2 watts or less must not be used less than 2 metres (6 feet) from the product. 2. INTENDED USE

These products are components designed for incorporation in installations, apparatus and machines. In the European Union, a machine should not be taken into service until the machine has been proven to conform with the provisions of the Machinery (Safety) Directive, 89/392/EEC as amended. In the European Union, the requirements of the EMC Directive, 89/336/EEC, and any amendments to that Directive should be established before any installation, apparatus or machine which incorporates the product is taken into service. The product complies with the requirements of the Low Voltage Directive, 73/23/EEC as amended. The product complies with the safety and EMC standards listed in the Specifications section of the manual. The technical data and the information concerning the supply conditions should be taken from the rating plate and this manual, and must be strictly observed.

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3. TRANSPORTATION AND STORAGE

The instructions for storage and transport specified on the packaging and in this manual must be followed. The climatic conditions should be within the limits specified in this manual. 4. ERECTION AND COMMISSIONING

Erection and commissioning of, and cooling medium flow to, the product should be in accordance with the specifications given in the manual. Erection and commissioning of the product must be carried out in line with any local electrical installation and wiring standards and IEC 364 or (in the United Kingdom) BS 7671. The earth terminal must be connected to earth (safety ground) in accordance with local safety regulations and IEC 364-5-54. The products must be protected against excessive strains. In particular, no component must be bent or isolation distances altered during the transportation, handling, installation or maintenance of the product. The degree of protection provided by the covers is for indoor use only. Compliance with the requirements of EMC laws is the responsibility of the installer or the manufacturer of the machine. Instructions for erection and commissioning the product in accordance with the EMC requirements of the European Union are given in the manual and must be complied with. These instructions contain information on screening (shielding), earthing (grounding), wiring and relative positioning of electrical equipment. Shrouds may be modified only as described in the manual. 5. ELECTRICAL CONNECTION

When working on the product, the local health and safety legislation must be observed. Conductors, protective devices etc. should be provided in accordance with the requirements stated in the manual. 6. OPERATION

The product must not be used as a single item safety system. It may be used as a component in a voting safety system. Additional control and protective devices must be provided in accordance with the safety requirements of the installation. Changes by means of the application software are admissible. Rotating motors are a source of energy and can apply high voltages to the circuitry. Capacitors can retain voltages and must be allowed to discharge. A minimum period of 5 minutes must be observed after the input supply is disconnected and the rotating machinery has stopped before access to live connections is permitted. In this respect warning labels must be observed.

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When the product is configured for "auto restarts" (where relevant), it is possible that the motor may turn without an operator command. Precautions must be taken to prevent injury to personnel. During operation all shrouds and covers and doors must be closed. If shrouds and covers are removed and not replaced before power is reapplied there is danger of serious personal injury and damage to property. Your attention is also drawn to the electromagnetic emission and susceptibility screening provided by the enclosure. These may be compromised when shrouds and covers are removed or enclosure doors are open. 7. MAINTENANCE AND SERVICE

The information given in the documentation for maintaining and servicing the product must be followed. 8. DISPOSAL

Local regulations must be followed when disposing of the product. This technical manual should be regarded as part of the product. It should be stored with the product and passed on to any subsequent owner or user of the product.

Any question or doubt should be referred to Converteam Ltd.

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Packaged Products CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH

1. GENERAL

Care has been taken with selection of all components, interconnections, housing and packaging and in the design and manufacture of this equipment to minimise the risk to the health and safety of all personnel who are in contact with this equipment during its life, when the equipment is properly handled and used. Modern high technology materials have been used in the manufacture of the equipment to ensure optimum performance. Some of these materials are toxic under certain conditions. Mechanical or electrical damage is unlikely to give rise to any direct hazard, but toxic vapours may be generated if the materials are heated to destruction and it is important that the recommendations given below are observed. Care should be taken to ensure that all personnel who may handle, use or dispose of this equipment are aware of the necessary precautions. 2. DISPOSAL

This equipment or any part of the equipment should be disposed of in accordance with the relevant legislation; in the United Kingdom, disposal should therefore be carried out in accordance with the Deposit of Poisonous Waste Act 1972 and the Control of Pollution Act 1974, or with the latest legislation. Some devices within this equipment may contain beryllium oxide as an isolating barrier. Such devices must be disposed of as harmful waste. 3. FIRE

The products when used within the specified limits do not present a fire hazard. Electronic devices within this equipment may contain arsenic, beryllium, lead, mercury, selenium, tellurium or similar hazardous materials or compounds, which, if exposed to high temperature may emit toxic or noxious fumes. Most device encapsulation materials are flammable and care should be taken in the disposal of the equipment, and, in the event of a fire, the handling of damaged equipment. Toxic fumes may be emitted if the devices are burned. 4. HANDLING

Normal handling of the equipment is safe. However, care must be exercised with those devices incorporating glass or plastic. If these devices are broken or damaged, precautions must be taken against the hazards that may arise. For broken glass or ceramic protective clothing such as gloves must be worn. For toxic materials, vapour, skin contact and inhalation must be avoided.

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5. SUBSTANCES

Substances that may be included in this equipment are:Arsenic Beryllium oxide Boric acid Ethylene Glycol Phosphoric acid Phthalic acid Tributylamine Triethylamine Silver Cadmium Certain substances such as those containing arsenic, beryllium, indium, lead, lithium, selenium, tantalum, etc. may be toxic by ingestion or inhalation. Beryllium oxide dust is toxic if inhaled or if particles enter the skin through a cut or abrasion. Electrolytic capacitors contain a non-carcinogenic electrolyte, which has a low acute toxicity, which may cause slight irritation to the skin if contact is prolonged. 6. HAZARDOUS COMPONENTS

Components that may include hazardous substances are:Batteries Optical Devices Thyristors Electrolytic capacitors All encapsulated Devices Contactors 7. PRECAUTIONS Lithium Arsenic Beryllium Oxide Electrolyte. Plastic (generates an inhalation risk in a fire). Silver Cadmium

Precautions to be followed in the event of damage to the equipment except where special precautions to be followed are listed above, include:After skin contact wash thoroughly with soap and water. If contact is where the skin is broken, medical advice should be sought. wash immediately with copious amounts of water and seek medical advice. seek medical advice.

After eye contact After inhalation

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Packaged Products SCOPE

This publication should be read in conjunction with the appropriate Standard Product and/or ALSPA MV DELTA Technical Manuals. This publication should be regarded as part of the Packaged Product, it should be retained for the life of the product and passed on to any subsequent owner or user. This document provides additional information on installation, commissioning, and operation of a Packaged Product.

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Packaged Products Contents

Section ACKNOWLEDGEMENTS ........................................................ SAFETY INSTRUCTIONS ........................................................ CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH ............ SCOPE OF THIS MANUAL ..................................................... CONTENTS ......................................................................... Page ii iii vi viii ix

INTRODUCTION

1-1

2 2.1 2.2

SPECIFICATION Standard specification Customised general specification

2-1

3 3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.4 3.5 3.5.1 3.5.2 3.5.3

INSTALLATION Introduction Mechanical installation Receipt of equipment Preparation of installation area Installation of equipment Installation of cooling system Electrical installation Incoming and outgoing connection Earth connections External services Replacement of shrouds and covers Additional requirements for electromagnetic compatibility Torque settings Busbar copperwork torque settings Nut and bolt torque settings Terminal torque settings

3-1

4 4.1

OPERATING INFORMATION Introduction

4-1

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5 5.1 COMMISSIONING Introduction 5-1

6 6.1 6.2 6.3 6.4

DRAWINGS Introduction Outline and foundation plan General arrangement Circuit diagrams

6-1

7 7.1 7.2 7.2.1 7.3 7.3.1 7.4 7.4.1 7.5

MAINTENANCE Introduction Air filters Replacement air filters Cubicle fans Replacement cubicle fans Fuses Replacement of fuses Cooling system

7-1

8 8.1 8.2 8.3

CERTIFICATION Introduction Test instructions Release note

8-1

9 9.1 9.2

COMPONENT LIST Introduction Component list

9-1

10 A A1 A2 A3 A4

APPENDICES SHROUDING STATEMENT Regulations Statement Component shrouding categories Comments on shrouding categories A-1

B B1

ADDITIONAL INSTALLATION INSTRUCTIONS Introduction

B-1

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B2 Procedure

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Packaged Products Introduction

Introduction

This manual describes the Packaged Products Drive and is a supplement to the standard product technical manual of the drive product housed in the Packaged Cubicle. The Package is a cubicle or suite of cubicles which contain a variable speed drive module or DC dive module with additional components required to meet the needs of the particular application chosen either from Converteam's standard options list or customised. IT IS MOST IMPORTANT that users of this equipment read the standard product technical manuals, which this supplement accompanies, and in particular take note of the safety warning notices that they contain. The Standard Product Technical Manuals with which this supplement should be read are: T1676ENG - ALSPA MV3000 Getting Started Manual for AC-fed Drives MicroCubicle Style Products Only. T2002ENG - ALSPA MV3000 Getting Started Manual for Active Energy Management Drives MicroCubicle Style Products Only. T1679ENG - ALSPA MV3000C Software Technical Manual for AC-Fed models MV3058A4A1 to MV3242A6A1 and for DC-fed models MV3059B400 to MV3482B600. T1684 T1686 T1694 T2013EN T2017EN T2034EN T1968 T1689 T1693EN ALSPA MV3000 Dynamic Braking Units MV3DB Series. ALSPA MV3000C Direct FIP manual. ALSPA MVS3007-4002 Profibus Field Bus Coupler. ALSPA MV3000 CANopen Fieldbus Facility Technical Manual. ALSPA MV3000 DeviceNet Technical Manual. ALSPA MV3000 Ethernet Interface Technical Manual. ALSPA MV3000 CAN Port 2 Fieldbus. ALSPA MV3000C Delta Technical Manual. ALSPA MV DELTA Liquid Cooled Drive System Technical Manual for MVRL2100-4601 & MVDL643-4701 690V ac rated products Contains : T1622 T1647 T1654 T1641 T1681 78263 T1621 ALSPA GD LOM Technical Manual. ALSPA GD4000 Application Guide. Manual for GDF 3kHz Ripple Filter.

ALSPA GD DELTA Technical Manual and Assembly Instructions. ALSPA LCD Delta Technical Manual. ALSPA Micro 2 Technical Manual. ALSPA Micro 3 Technical Manual.

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Introduction

T1625 T1662 T1622 T1623 T1687 T1655 T1803 -

ALSPA DC Drives Frame Size 4 Supplement to Technical Manuals for ALSPA Micro 2 & 3. ALSPA DC3000 Technical Manual. ALSPA GD LOM Technical Manual. ALSPA 400 Amp Dynamic Braking Unit Technical Manual. ALSPA GDB400HV 400Amp 690V Dynamic Braking Unit Technical Manual. ALSPA 100 Amp Dynamic Braking Unit Technical Manual. ALSPA 20 Amp Dynamic Braking Unit Technical Manual.

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Packaged Products Specification

2.1 STANDARD SPECIFICATION

Specification

Refer to the Standard Product Technical Manuals for the standard product specifications. The standards listed below apply to the cubicle and to the components used inside the cubicle where applicable, unless otherwise stated. Protection : : : : To IEC 529, BS EN 60529.1992. IP21 "Protection against ingress of solid objects greater than 12.0mm and vertically dripping water". IP54 "Dust protected and protection against splashing water". Refer to the Customer Specification (Section 2.2) for the protection category of the equipment. To IEC 947-3, BS EN 60947-3. Utilisation category AC-21A. To IEC 947-3, BS EN 60947-3. Utilisation category AC-21A. To IEC 947-4, IEC 158-1, BS 5424. Utilisation category AC-1. To IEC 158-1. To IEC 947-2, BS 4752. To IEC 947-5-1. To IEC 947-5-1. To IEC 947-5-1. To BS 4794 Part 2, IEC 337-2. To BS 89 Part 1. To IEC 269, BS 88. Hellerman to IEC 684, BS 3858 type 3. To IEC 947-7-1, BS EN 60947-7-1 1991. To IEC 947-7-1, BS EN 60947-7-1 1991. To IEC 947-1. To EN 60335-1.

Isolators 3-pole

Isolators 6-pole

AC Contactors

DC Contactors Moulded Case Circuit Breakers Pushbuttons Key Switches Selector Switches Transformer Lamps Indicating instruments Fuses Cable Ferrules Control Terminals Power terminals Control Relays Cubicle cooling fans

: : : : : : : : : : : : :

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Packaged Products Installation Instructions

WARNING: FOR AC DRIVES ONLY

Installation Instructions

THIS EQUIPMENT HAS A WEIGHT IN EXCESS OF 20Kg. IT SHOULD BE MOVED WITH LIFTING APPARATUS.

HIGH VOLTAGES AND HIGH STORED ENERGY LEVELS ALL ELECTRICAL SUPPLIES MUST BE ISOLATED AND ALL MOTORS CONNECTED TO THE EQUIPMENT MUST BE AT A STANDSTILL FOR A PERIOD OF 5 MINUTES BEFORE ACCESS TO THE EQUIPMENT IS ALLOWED.

ALL EQUIPMENT PROVIDED MUST BE CONNECTED TO EARTH (GROUND) FROM THE EARTH TERMINAL PROVIDED. THE MINIMUM SIZE OF PROTECTIVE CONDUCTOR MUST BE IN ACCORDANCE WITH LOCAL SAFETY REGULATIONS.

HIGH LEAKAGE CURRENT EARTH (GROUND) CONNECTIONS TO THIS EQUIPMENT AND THE MOTOR(S) DRIVEN BY THE EQUIPMENT MUST BE CONNECTED AT ALL TIMES. HIGH VOLTAGES ALL DOORS MUST BE CLOSED AND ALL SHROUDS AND COVERS IN PLACE BEFORE THE EQUIPMENT IS ENERGISED.

WARNING: FOR DC DRIVES THIS EQUIPMENT HAS A WEIGHT IN EXCESS OF 20Kg. IT SHOULD BE MOVED WITH LIFTING APPARATUS. ALL EQUIPMENT PROVIDED MUST BE CONNECTED TO EARTH (GROUND) FROM THE EARTH TERMINAL PROVIDED. THE MINIMUM SIZE OF PROTECTIVE CONDUCTOR MUST BE IN ACCORDANCE WITH LOCAL SAFETY REGULATIONS. HIGH VOLTAGES ALL DOORS MUST BE CLOSED AND ALL SHROUDS AND COVERS IN PLACE BEFORE THE EQUIPMENT IS ENERGISED.

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Packaged Products
CAUTION 3.1

Installation Instructions

This product must not be used as a single item safety system. The product may be used as a component in a voting safety system. All conductors connected to this product must be restrained INTRODUCTION

This instruction gives a general guide for the safe installation of the equipment. Further details are also given in the Standard Product Technical Manuals. For Delta based equipment refer also to the appropriate DELTA Technical Manual and Assembly Instructions. 3.2 3.2.1 1. MECHANICAL INSTALLATION RECEIPT OF EQUIPMENT Lifting of the equipment must be carried out by a competent person using lifting equipment and moving methods approved for the weight of the cubicle The equipment should be lifted via the eyebolts or holes (lifting angles) provided. Unpack or uncrate as appropriate and inspect the equipment. Ensure all loose packing material is carefully removed from the equipment. Check against delivery note.

2. 3.

4. 5.

Report any damage or shortages to the company within 3 days of receipt of equipment. The following details should be quoted. List of damaged or missing items with names and part numbers. Description of damage. Delivery/Advice note numbers and dates and order and item number. 6. 7. Before lifting equipment ensure all doors, loose items, etc. are secure. Care should be taken to avoid damage to any front mounted components and/or rear ducting. Equipment must be kept vertical at all times. If equipment has to be stored - Re-pack in its original packaging material. Ensure the equipment is stored in a clean dry atmosphere, preferably at room temperature. Do not exceed storage temperature limits given in the Standard Product Technical Manual or the ALSPA MV DELTA Technical Manual and Assembly Instructions. Note also that the storage temperature limits for products containing batteries are different to the values given for products without batteries. Extended storage If equipment is stored for a period of more than 3 months, cubicle cooling fans and delta cooling fans MUST BE rotated manually. This must be repeated at 3 monthly intervals.

8. 9.

10.

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3.2.2 1. PREPARATION OF INSTALLATION AREA

Installation Instructions

Prepare the foundation according to foundation plan. Refer to the Outline and Foundation Plan for details. Prepare cable ducts and trenches as required. Prepare ventilation ducts if required. Ensure standing surface is level to facilitate alignment. Allow sufficient room for doors to be fully opened. Refer to the Outline and Foundation Plan for details of the clearances required. Allow sufficient room for access to cubicle with doors fully opened. Equipment must be sited so that the ventilation openings are never obstructed. The minimum clearance is 150mm unless otherwise stated on the Outline and Foundation Plan. Secure equipment to foundation using size M12 bolts, unless otherwise stated on the Outline and Foundation Plan. INSTALLATION OF EQUIPMENT Lifting of the equipment must be carried out by a competent person using lifting equipment and moving methods approved for the weight of the cubicle. Lifting of the equipment must be via holes (lifting angles) or eyebolts provided. As an alternative the cubicle may be moved using rollers, a minimum of four per cubicle using appropriate methods. If the equipment requires levering into position then follow the instructions given in Appendix B of this manual. Before lifting the equipment ensure all doors, loose items, etc. are secure. Care should be taken to avoid damage to any front mounted components and/or rear ducting. The equipment must be kept vertical at all times. Consult the Outline and Foundation Plan for the position of the equipment on the foundation and details of the fixings required. Having established the level required, shims should be used under the base frames to square up alignment and the base then fixed to the floor via the fixing holes and bolts. Check that damage has not been done to any of the cubicle seals during lifting. Mount equipment supplied loose, e.g. large transformers, roof mounted resistor boxes etc. Refer to the Outline and Foundation Plan, and also the General Arrangement Drawing. INSTALLATION OF COOLING SYSTEM

2. 3. 4. 5.

6. 7.

8.

3.2.3 1.

2.

3. 4.

5. 6.

7.

8. 9.

3.2.4

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Packaged Products

Installation Instructions

Prior to the coolant being loaded into the cooling system the following checks must be carried out. 1. Check the tightness of the internal cooling fluid pipe joints and connections. Also check internal cooling fluid pipes has not been damaged during transit. Check all flexible cooling fluid pipes are securely fastened within the enclosure. Check all connections to cooling fluid pipes are made correctly. Check external connections to cooling system for integrity.

2. 3. 4.

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3.3 1. ELECTRICAL INSTALLATION

Installation Instructions

If not previously done, install the equipment according to the instructions detailed in Section 3.2. Ensure power terminals are tightened to the correct torque loading, as detailed in Section 3.5. When long boards are shipped in sections connect intersection wiring, if applicable to appropriate terminals. Refer to circuit diagram and / or, wiring diagram. Connect busbars if applicable using the joining plates, nuts, bolts and washers provided ensuring correct torque tightening, as detailed in Section 3.5. Remove any packaging material from inside the equipment and dispose of in accordance with the relevant legislation. INCOMING AND OUTGOING CONNECTIONS

2.

3.

4.

3.3.1 CAUTION

This equipment contains solid state devices, which may be affected by electrostatic discharge. Static handling precautions in accordance with Protection of Electrostatic Devices, Part 1, General Requirements, EN 1000015Pt.1 (1990) must be observed.

High voltage insulation tests can damage this equipment. Cables/external components to be insulation tested must be disconnected from this equipment. 1. Ensure all power terminals are tightened to the correct torque loading. Refer to Section 3.5. Ensure that the remote ends of all incoming connections are disconnected or isolated before making them off. Remove and prepare the gland plate and base sealing slits if fitted to accommodate incoming and outgoing cables. Remove terminal shrouds and cut to fit where appropriate. Connect the supply cable to the appropriate terminals ensuring correct phase rotation. See cable schedule and / or wiring diagram taking note of any EMC requirements. Connect main and control cables to appropriate terminals. See cable schedule if supplied and / or wiring diagram. Connect auxiliary supply cables to the appropriate terminals. e.g. cubicle lighting and / or heater supply. See cable schedule and / or wiring diagram.

2.

3.

4. 5.

6.

7.

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Packaged Products
3.3.2 1. 2. EARTH CONNECTION

Installation Instructions

Ensure all earth terminals are tightened to the correct torque loading. See section 3.5. When long boards are shipped in sections connect the earth bar using the joining plates, nuts, bolts and washers provided. Check the earth continuity of the installed boards to the supply earth. Connect incoming earth connection to the earth bar. See cable schedule for size of earth connection. If cable schedules are not supplied by the company then earthing is to be carried out as laid down in the appropriate statutory regulation. EXTERNAL SERVICES Install and connect ventilation ducts and fans, water-cooling equipment, compressed air supplies etc. if relevant. REPLACEMENT OF SHROUDS AND COVERS Ensure all terminal shrouds, component shrouds, covers and gland plates that may have been removed during installation of the equipment are replaced. Ensure that where terminal shrouds have been cut to fit, the shrouds do not touch any cabling . All metal covers and gland plates that may have been removed during installation of the equipment must be replaced using their original fixings in order to not compromise the earth bonding of the equipment. ADDITIONAL REQUIREMENTS FOR ELECTROMAGNETIC COMPATIBILITY

3.

3.3.3 1.

3.3.4 1.

2.

3.

3.4

For cubicles fitted with an EMC filter Refer to Standard Product Technical Manual EMC Appendix or more information and additional safety requirements for products fitted with filters. For Delta based equipment refer also to the ALSPA DELTA Technical Manual and Assembly Instructions section. Note in particular the following requirements concerning Packaged Products cubicles. 1. The enclosure doors must be closed. 2. The fixing of the gland plate to the enclosure walls or metal framework to which the outer walls are electrically bonded. The following amendments to the EMC Appendix of the ALSPA GD2000E Technical Manual, the EMC Appendix of the ALSPA GD3000 Technical Manual, the EMC Appendix of the ALSPA GD3000E Technical Manual and the Harmonic and EMC Recommendations section of the ALSPA MV3000C Getting Started Manual are applicable to Packaged Products cubicles. 3.4 Contactor suppression All coils fitted inside the cubicle have suppression components fitted as standard. No extra suppression is required. 3.6 Control Connections

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Packaged Products

Installation Instructions

Control connections required by the user may be connected to a user termination block fitted inside the cubicle. Refer to circuit diagram for more information on termination details. 3.5 3.5.1 TORQUE SETTINGS BUSBAR COPPERWORK TORQUE SETTINGS

All busbar joints on copperwork are to be tightened using torque spanners/wrenches adjusted to the setting shown in Error! Reference source not found..

Table 1
TORQUE SETTING TERMINAL SIZE lbs. ft M8 M10 M12 3.5.2 NUT AND BOLT TORQUE SETTINGS 15 30 45 Nm 20 40 64

The recommended tightening torques for electrical and mechanical bolted connections which use Zinc plated and passivated nuts and bolts are given in Error! Reference source not found.. The torque settings given in Error! Reference source not found. apply to: 1) 2) Grade 8.8 steel screws and bolts Grade 8 steel nuts

fitted with a single turn spring washer under the nut and the threads being zinc plated, passivated and fitted dry with one thread length protruding.

Table 2
8.8 bolt size ELECTRICAL CONNECTIONS lbs. ft M5 M6 M8 M10 M12 M16 NOTES 2.5 to 4 5 to 7.4 8 to 12 20 to 30 30 to 48 65 to 100 Nm 3.5 to 5.5 7 to 10 10.5 to 16 27 to 40 40 to 65 90 to 135 MECHANICAL CONNECTIONS lbs. ft 3 to 4.5 5 to 7.5 12 to 18 25 to 35 40 to 60 100 to 150 Nm 4 to 6 7 to 10 16 to 25 34 to 47 54 to 82 135 to 200

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Installation Instructions

Electrical connections are for connection of copper conduction crimps to device terminals and all copperwork except busbars. For busbars see section 3.5.1.

3.5.3 3.5.3.1

TERMINAL TORQUE SETTINGS CONTROL TERMINALS

Table 3
TERMINAL TYPE TORQUE SETTING lbs. ft Nm SOLID CONDUCTOR SIZE (mm2) STRANDED INSULATION STRIPPING LENGTH 10mm 12mm

SAK 2.5 SAK 4 IMPORTANT

0.3 to 0.5 0.4 to 0.7

0.4 to 0.7 0.5 to 1

0.5 to 6 0.5 to 6

1.5 to 4 1.5 to 6

The stripping length stated in Table 3 must be observed so that creepage and clearance paths are not reduced by improper connection. 3.5.3.2 POWER TERMINALS

Table 4
TERMINAL TYPE SAKG 28 II SAKG 32 II SAKG 40 II SAKG 46 II SAKG 54 II STUD SIZE M6 M8 M10 M12 M16 TORQUE SETTING lbs. ft 2.2 to 4.4 4.4 to 8.8 7.4 to 15 10 to 22.9 18 to 44 Nm 3 to 6 6 to 12 10 to 20 14 to 31 25 to 60 CONDUCTOR SIZE mm2 35 70 95 150 240

FITTING INSTRUCTIONS FOR SAKG TERMINALS When tightening the clamping screw, it is recommended that the conductor be held against the tightening direction in order to avoid any deformation of the mounting rail and to keep the terminal foot free of torsional forces. IMPORTANT To ensure terminals are shrouded after conductors have been connected replace covers provided with terminals. NOTE

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Packaged Products

Installation Instructions

The rated conductor size of the terminal block is the connectable conductor size specified by the manufacturer on which specific thermal, mechanical and electrical requirements are based.

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Packaged Products Operating Information

Operating Information

WARNING THE COMBINED AUDIO NOISE EMITTED BY FANS IN AN INSTALLATION MAY BE GREATER THAN 70db(A) DEPENDENT ON THE AIRFLOW PATH. THE AUDIO NOISE LEVEL IN AN INSTALLATION SHOULD BE MEASURED. EAR DEFENDERS SHOULD BE USED WHEN THE AUDIBLE NOISE LEVEL EXCEEDS 70db(A). IN THE EVENT OF FIRE TOXIC OR NOXIOUS FUMES CAN BE EMITTED

CAUTION Air used to cool this product is unfiltered. Air ejected from the product may contain particles of dirt. Air outlets should deflect the air away from the eyes. 4.1 INTRODUCTION

Refer to the Standard Product Technical Manual for product operating information.

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Packaged Products Commissioning

Commissioning

WARNING: FOR AC DRIVES ONLY HIGH VOLTAGES AND HIGH STORED ENERGY LEVELS ALL ELECTRICAL SUPPLIES MUST BE ISOLATED AND ALL MOTORS CONNECTED TO THE EQUIPMENT MUST BE AT A STANDSTILL FOR A PERIOD OF 5 MINUTES BEFORE ACCESS TO THE EQUIPMENT IS ALLOWED. HIGH VOLTAGES ALL DOORS MUST BE CLOSED AND ALL SHROUDS AND COVERS IN PLACE BEFORE THE EQUIPMENT IS ENERGISED.

WARNING: FOR DC DRIVES ONLY HIGH VOLTAGES ALL DOORS MUST BE CLOSED AND ALL SHROUDS AND COVERS IN PLACE BEFORE THE EQUIPMENT IS ENERGISED.

CAUTION When the product is reset to factory default, all customised parameter settings will be lost. A note of customised parameter settings should be made before the drive is reset. They can be re-entered as required. 5.1 INTRODUCTION Refer to the Standard Product Technical Manual for product commissioning information. For liquid cooled systems refer to the commissioning section of the Standard Product Manual for liquid cooled equipment. Reference should also be made to the Test Instructions, Section 8.2 of this manual, for a list of the customised parameters applicable to the drive fitted in the cubicle. The Test Instructions also give details of component settings such as timers, relay timers and earth fault relays which may be included in the cubicle design.

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Packaged Products Drawings

6.1 INTRODUCTION

Drawings

The drawings enclosed with this manual relate only to the packaged product supplied with this manual. For more details of the ALSPA MV3000 User Termination Panel control connections refer to the Standard Product Technical Manual. The following drawings are included as standard in this section.

6.2

OUTLINE AND FOUNDATION PLAN

The Outline and Foundation Plan provides details of the foundations and fixing holes required to secure the cubicle.

6.3

GENERAL ARRANGEMENT

The General Arrangement Drawing is included for assistance in finding the location of the components listed in Section 9.2 of this manual.

6.4

CIRCUIT DIAGRAMS

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Maintenance

WARNING: FOR AC DRIVES ONLY HIGH VOLTAGES AND HIGH STORED ENERGY LEVELS ALL ELECTRICAL SUPPLIES MUST BE ISOLATED AND ALL MOTORS CONNECTED TO THE EQUIPMENT MUST BE AT A STANDSTILL FOR A PERIOD OF 5 MINUTES BEFORE ACCESS TO THE EQUIPMENT IS ALLOWED. HIGH VOLTAGES ALL DOORS MUST BE CLOSED AND ALL SHROUDS AND COVERS IN PLACE BEFORE THE EQUIPMENT IS ENERGISED.

WARNING: FOR DC DRIVES ONLY HIGH VOLTAGES ALL DOORS MUST BE CLOSED AND ALL SHROUDS AND COVERS IN PLACE BEFORE THE EQUIPMENT IS ENERGISED.

7.1

INTRODUCTION

Details of maintenance schedules for standard drives products are given in the appropriate Standard Product Technical Manuals. The following additional information is applicable to the Packaged Products cubicles.

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7.2 AIR FILTERS

Maintenance

Filter Mats where fitted should be cleaned or replaced periodically depending on the air conditions. To replace the filter mats remove the filter grill. 7.2.1 7.2.1.1 REPLACEMENT AIR FILTERS STANDARD FILTER MATS

For filtering of all types of dust from a particle size of greater than 10m. FILTER MAT ORDER NUMBER SK3172.100 SK3173.100 7.2.1.2 FINE FILTER MATS FAN AND FILTER UNIT SK3325.115 SK3326.115 OUTLET FILTER SK3325.200 SK3326.200

For filtering with extremely fine dust with particle sizes of less than 10m. FILTER MAT ORDER NUMBER SK3182.100 SK3183.100 FAN AND FILTER UNIT SK3325.115 SK3326.115 OUTLET FILTER SK3325.200 SK3326.200

Replacement filter mats are available directly from the following manufacturer. MANUFACTURER ADDRESS RITTAL LIMITED

Braithwell Way Hellaby Ind. Est. Hellaby, Rotherham S66 8QY

TELEPHONE

01709 704000

Refer to Section 9.2, the component list, of this manual, for the filter type fitted.

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7.3 FANS

Maintenance

All fans including Cubicle cooling fans, Delta cooling fans and BDM cooling fans should be checked. The fans should be checked and cleaned every 6 months regardless of air conditions. 7.3.1 REPLACEMENT CUBICLE FANS

Refer to Section 9.2, the component list, of this manual, for the fan type fitted in the cubicle. 7.3.1.1 FAN FILTER UNITS

Fan filter units SK3325.115 and SK3326.115 are available directly from Rittal Limited at the address given below. MANUFACTURER ADDRESS RITTAL LIMITED

Braithwell Way Hellaby Ind. Est. Hellaby, Rotherham S66 8QY

TELEPHONE 7.3.1.2

01709 704000

FAN ASSEMBLY

Fan Assembly 41Y5500/10 contains four fans of type 4500N. The fans are available directly from PAPST Motors Limited at the address given below. MANUFACTURER ADDRESS PAPST MOTORS LIMITED

East Portway Andover Hants SP10 3RT

TELEPHONE

01264 333388

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7.4 FUSES

Maintenance

Refer to the component list, Section 9.2 of this manual, for a list of the fuses fitted in the cubicle. Note that the standard product contains no user serviceable parts. 7.4.1 REPLACEMENT OF FUSES

Ensure all shrouds and covers that may have been removed during the replacement of any fuses are replaced. Fuses fitted inside the cubicle are available from the following manufacturers. MANUFACTURER ADDRESS GE POWER CONTROLS LTD

East Lancashire Road Liverpool L10 5HB

TELEPHONE

0151 524 1122 BUSSMANN DIVISION

MANUFACTURER ADDRESS

Copper (UK) Limited Burton-on-the-Wolds Leicestershire LE12 5TH TELEPHONE 01509 880737 BELLING LEE

MANUFACTURER ADDRESS

Exning Road Newmarket Suffolk CB8 0AX

MANUFACTURER ADDRESS

GOULD INC.

374 Merrimac Street Newburyport MA 01950 USA

7.5

COOLING SYSTEM

The cooling system must be checked periodically. For further details of the checks to be carried out refer to maintenance section of the Standard Product Manual for liquid cooled equipment.

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8.1 INTRODUCTION

Certification

This section includes the following information and certification. 8.2 TEST INSTRUCTIONS

A copy of the test instructions is included in this section. The instructions include a list of all nondefault parameters that have been changed from their default settings. The following information is relevant to the testing of Packaged Products Cubicles. EMC filters, door mounted fans and Delta cooling fans are NOT flash tested on the advice of the relevant manufacturers.

8.3

RELEASE NOTE

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9.1 INTRODUCTION

Component list

The standard products contain no user serviceable parts. There are no parts contained within the cubicle that require returning to Converteam Ltd for disposal. For more information on disposing of component contained within this equipment refer to the information contained in the Control of Substances Hazardous to Health Section of this manual and also of the Standard Product Technical Manual. 9.2 COMPONENT LIST

A list of the standard product and electro-mechanical components contained within the cubicle is included in this section. The component manufacturers names and order codes are also included for spares ordering and/or component re-ordering. Refer also to the Circuit Diagram and the General Arrangement for component functions and locations within the cubicle.

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Appendix A: Shrouding Statement

Shrouding Statement
A1 REGULATIONS

The Low Voltage Directive [73/23/EEC; The Low Voltage Electrical Equipment (safety) Regulations 1994] states the following: The regulations apply to any electrical equipment (including any electrical apparatus or device) designed or adapted for use with voltages (in the case of Alternating Current) of not less than 50 volts nor more than 1,000 volts or (in the case of Direct Current) of not less than 75 volts nor more than 1,500 volts. The principal elements of the safety objectives for electrical equipment designed for use within these voltage limits is : A1.1 General conditions a) The essential characteristics, the recognition and observance of which will ensure that electrical equipment will be used safely and in applications for which it was made, shall be MARKED on the equipment, or, if this is not possible, on an accompanying notice. b) The MANUFACTURER'S or BRAND NAME or TRADEMARK should be clearly printed in the electrical equipment or, where that is not possible, on the packaging. c) The electrical equipment, together with its component parts should be made in such away as to ensure that it can be SAFELY and PROPERLY ASSEMBLED and CONNECTED. d) The electrical equipment should be so designed and manufactured as to ensure that PROTECTION AGAINST THE HAZARDS set out in points 2 and 3 of this schedule is providing that the equipment is used in applications for which it was made and is adequately maintained. A1.2 Protection against hazards arising from the electrical equipment a) That persons and domestic animals are adequately protected against danger of physical injury or other harm that might be caused by ELECTRICAL CONTACT DIRECT or INDIRECT. b) That TEMPERATURES, ARCS or RADIATION, which could cause danger, are not produced. c) That persons, domestic animals and property are adequately protected against NONELECTRICAL DANGERS CAUSED BY THE ELECTRICAL EQUIPMENT which are revealed by experience. d) That INSULATION must be suitable for foreseeable conditions. A1.3 Protection against hazards which may be caused by external influences on the electrical equipment a) That the electrical equipment meets the expected MECHANICAL REQUIREMENTS in such a way that persons, domestic animals and property are not endangered. b) That the electrical equipment shall be RESISTANT TO NON-MECHANICAL INFLUENCES in expected environmental conditions, in such a way that persons, domestic animals and property are not endangered. c) That in foreseeable conditions of OVERLOADS the electrical equipment shall not endanger persons, domestic animals and property.

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A2 STATEMENT

Appendix A: Shrouding Statement

Any item or component with voltages greater than those specified in the Low Voltage Directive (50 volts AC; 75 volts DC) must be positioned, insulated or shrouded to prevent accidents.

Such items or components may be: Positioned where they cannot be accidentally touched. Insulated safely such that live parts cannot be accidentally touched. Shrouded such that live parts cannot be accidentally touched.

NOTE: It may be necessary to shroud components to IP2X, dependant upon contract requirements. Note on implications Items and components may be fully insulated, insulated except for certain areas such as terminals, or uninsulated. They may or may not have integral or self-shrouding for uninsulated areas incorporated into their design or may have separate shrouding specially designed to fit available from the manufacturer. Therefore, in order to decide whether and where independent shrouding has to be fitted, it is necessary to examine not only each item or component on its own merits, but also how they fit together and are interconnected with each other and external items or sources of supply. Also sufficient information is not always available at the time of the initial review. Therefore, inspection in test followed by corrective action as found necessary is an important part of the shrouding procedure. Note on what this document does not cover Accidents which might follow the deliberate evasion of safety measures provided (e.g. the deliberate dismantling and / or removal of shrouds or covers, non-replacement of shrouds or covers after removal, the deliberate climbing up equipment, the deliberate reaching round shrouding, the deliberate insertion of material especially if uninsulated, the deliberate use of screwdrivers with uninsulated blades on terminals that could not otherwise be touched, unauthorised access and "meddling" inside cubicle, etc..) is not the subject of this document. It is the responsibility of the user to ensure persons using / maintaining / etc. the subject drive package are adequately trained and know what they can do and must not do. Clearly, this also is not the subject of this document.

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A3 COMPONENT SHROUDING CATEGORIES

Appendix A: Shrouding Statement

Components can be classified into the following categories. CATEGORY 1 Those components, which are inherently safe, as they do not have voltages in excess of 50VAC or 75VDC, connected to their terminals and do not therefore need shrouding.

CATEGORY 2A Those components which are inherently protected by virtue of their design, so that parts carrying dangerous voltages are protected against accidental contact and additional shrouding is not required.

CATEGORY 2B Those components, which are inherently protected by virtue of their design, so that parts carrying dangerous voltages are protected against, contact to IP2X and additional shrouding is not required.

CATEGORY 3A Those components which carry dangerous voltages and which are not inherently safe but which have a manufacturers shroud which, when fitted correctly, will prevent accidental contact with live parts.

CATEGORY 3B Those components which carry dangerous voltages and which are not inherently safe but which have a manufacturers shroud which, when fitted correctly, will prevent contact with live parts to IP2X.

CATEGORY 4 Those components, which carry dangerous voltages and which, are not inherently safe and do not have a manufacturers shroud. For these items a specially designed shroud is required.

CATEGORY 5 Those components, not identifiable by a Device Reference, which carry dangerous voltages, which require special shrouds. These would include, for example, high and low power terminals and power distribution busbars.

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A4 COMMENTS ON SHROUDING CATEGORIES

Appendix A: Shrouding Statement

1. A 48VDC-coil relay with shrouded terminals may, at first sight, seem to be category 1 but if any of its contacts are wired as 'voltage free' contacts to cubicle terminals, then they could later be energised with a dangerous voltage. The correct classification would be category 2A or 2B depending on the relay. 2. Newer components will tend to be category 2A or 2B because of better mouldings, giving better protection. Beware older components and those, which are higher current rated; the connection stalks may be too large and cable lugs can extend beyond the 'safe' part of the connection. In such cases there may be a suitable manufacturer's shroud giving category 3A or 3B or a special shroud may be needed to give category 4. For example, the large Telemecanique AC contactors (LC1-F780) and some large Holec isolators need special shrouds. 3. Where contactors have surge suppression fitted then the suppressor(s) may need to be shrouded. For example SP15 and SP21 components used for DC contactor suppression should be covered by the contactor shroud. 4. Control terminals will generally be category 2B, large clamp terminals may be category 2A but stud type terminals may be category 3A, 3B or 4. Front doors can be opened at any time, even if the door interlock has to be defeated to do so. This is normal during site commissioning and for routine checking and any power terminals or copperwork should be shrouded against accidental contact. If rear doors are fitted, it is probable that there are also components fitted at the rear and the doors are not interlocked. They can be considered to be available for opening at any time and any components, which are fitted at the rear, should be reviewed. If rear covers are fitted, requiring the use of a tool to remove them, then it is probable that there are no components fitted at the rear which require frequent access and therefore shrouding may not be needed. All this assumes that a main power isolator (and possibly an auxiliary isolator) have been included in Converteam supply so that the person requiring access has the means to remove the power before gaining access. Caution is still required if 'voltage free' contacts or other supplies have been introduced by others. 5. Incoming supplies to any isolators could still be live when the isolator is switched off. These terminals should therefore be suitably shrouded and labelled. 6. Copper busbars require consideration. 7. When designing shrouds attention must be given to the normal activities of fault finding and commissioning. Shrouds should not normally be designed to cover two or more unrelated components such as fuses and contactors. Covering of associated components such as terminals is reasonable but must be thought about e.g. grouping of different voltages. Care should also be taken to ensure that any shrouds will not damage cable insulation (by cutting, chaffing etc.). 8. Shroud design must not prevent adequate cooling airflow. They must not be a heat trap and must not prevent adequate escape of heat from heat producing items.

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Appendix B: Additional Installation Instructions

Additional Installation Instructions

B1 INTRODUCTION

Wherever possible, cubicles should be moved using approved moving methods. When it is absolutely necessary to use crowbars or levers, do NOT use them directly on the lower flange of the cabinet plinths. Use instead the levering accessory provided. B2 PROCEDURE

Using the accessory, utilising several at once to either provide the necessary leverage point as shown in Figure 2 or as a fulcrum as shown in Figure 3. Care should be taken to avoid damage to the paint or steelwork. Blocks KC3/50Y2096/01 and Retainers KC3/50Y3408/01 are available from Converteam Ltd.

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Appendix B: Additional Installation Instructions

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