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User Guide

Mentor MPHigh performance DC drive25A to 7400A, 480V to 690VTwo or four quadrant operation

Part Number: 0476-0000-05Issue: 5

www.controltechniques.com


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General InformationThe manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installationor adjustment of the optional operating parameters of the equipment or from mismatching the variable speed drive with themotor.

The contents of this guide are believed to be correct at the time of printing. In the interests of a commitment to a policy ofcontinuous development and improvement, the manufacturer reserves the right to change the specification of the productor its performance, or the contents of the guide, without notice.

All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical ormechanical including photocopying, recording or by an information storage or retrieval system, without permission in writing

from the publisher.Drive firmware versionThis product is supplied with the latest software versions. If this drive is to be connected to an existing system or machine,all drive software versions should be verified to confirm the same functionality as drives of the same model already present.This may also apply to drives returned from a Control Techniques Service Centre or Repair Centre. If there is any doubtplease contact the supplier of the product.

This drive contains two software versions which can be checked by looking at Pr 11.29 (di14/0.49 ) and Pr 11.34 . This takesthe form of xx.yy.zz where Pr 11.29 (di14/0.49 ) displays xx.yy and Pr 11.34 displays zz for the user software. Powersoftware is displayed at Pr 11.56 and takes the form of xx.yy. (e.g. for software version 01.06.00, Pr 11.29 (di14/0.49 ) =1.06 and Pr 11.34 displays 0 which is compatible with power software version 01.09, Pr 11.56 = 1.09).

Environmental statementControl Techniques is committed to minimising the environmental impacts of its manufacturing operations and of itsproducts throughout their life cycle. To this end, we operate an Environmental Management System (EMS) which iscertified to the International Standard ISO 14001. Further information on the EMS, our Environmental Policy and otherrelevant information is available on request, or can be found at www.greendrives.com.

The electronic variable-speed drives manufactured by Control Techniques have the potential to save energy and (throughincreased machine/process efficiency) reduce raw material consumption and scrap throughout their long working lifetime.In typical applications, these positive environmental effects far outweigh the negative impacts of product manufacture andend-of-life disposal.

Nevertheless, when the products eventually reach the end of their useful life, they must not be discarded but should insteadbe recycled by a specialist recycler of electronic equipment. Recyclers will find the products easy to dismantle into theirmajor component parts for efficient recycling. Many parts snap together and can be separated without the use of tools, while

other parts are secured with conventional fasteners. Virtually all parts of the product are suitable for recycling.Product packaging is of good quality and can be re-used. Large products are packed in wooden crates, while smallerproducts come in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, thesecontainers can be recycled. Polythene, used on the protective film and bags for wrapping product, can be recycled in thesame way. Control Techniques' packaging strategy prefers easily-recyclable materials of low environmental impact, andregular reviews identify opportunities for improvement. When preparing to recycle or dispose of any product or packaging,please observe local legislation and best practice.

REACH legislationEC Regulation 1907/2006 on the Registration, Evaluation, Authorisation and restriction of Chemicals (REACH) requires thesupplier of an article to inform the recipient if it contains more than a specified proportion of any substance which isconsidered by the European Chemicals Agency (ECHA) to be a Substance of Very High Concern (SVHC) and is thereforelisted by them as a candidate for compulsory authorisation.

For current information on how this requirement applies in relation to specific Control Techniques products, pleaseapproach your usual contact in the first instance. Control Techniques position statement can be viewed at:

http://www.controltechniques.com/REACH

Copyright October 2011 Control Techniques Ltd

Issue Number: 5

Firmware versions:

User: 01.06.00 onwards Power: 01.09.00 onwards


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Mentor MP User Guide 3Issue : 5 www.controltechniques.com

Contents

1 Safety Information .................................51.1 Warnings, Cautions and Notes .............................51.2 Electrical safety - general warning ........................51.3 System design and safety of personnel ................51.4 Environmental limits ..............................................51.5 Access ..................................................................5

1.6 Fire protection .......................................................51.7 Compliance with regulations .................................51.8 Motor .....................................................................51.9 Mechanical brake control ......................................51.10 Adjusting parameters ............................................51.11 Electrical installation .............................................5

2 Product information ..............................62.1 Current ratings ......................................................62.2 Model number .......................................................72.3 Compatible encoders ............................................82.4 Nameplate description ..........................................82.5 Drive features and options ....................................92.6 Items supplied with the drive ...............................12

3 Mechanical Installation .......................133.1 Safety ..................................................................133.2 Planning the installation ......................................133.3 Terminal cover removal ......................................143.4 Mounting method ................................................173.5 Installing and removing the terminal shrouds .....253.6 Enclosure ............................................................273.7 Heatsink fan operation ........................................283.8 IP rating (Ingress Protection) ..............................283.9 Electrical terminals ..............................................29

3.10 Routine maintenance ..........................................32

4 Electrical installation ..........................334.1 Electrical connections .........................................344.2 Ground connections ............................................364.3 AC supply requirements ......................................374.4 Line reactors .......................................................384.5 Control 24 Vdc supply .........................................384.6 Cable and fuse size ratings .................................394.7 External suppressor resistor ...............................474.8 Ground leakage ..................................................494.9 EMC (Electromagnetic compatibility) ..................494.10 Serial communications connections ....................514.11 Shield connections ..............................................524.12 Connecting the fan on size 2C and 2D drives .....524.13 Control connections ............................................534.14 General ...............................................................544.15 Connecting an encoder .......................................57

5 Getting started .....................................595.1 Understanding the display ..................................595.2 Keypad operation ................................................595.3 Menu 0 (sub block) .............................................615.4 Pre-defined sub blocks .......................................625.5 Menu 0 (linear) ....................................................63

5.6 Menu structure ....................................................635.7 Advanced menus ................................................645.8 Saving parameters ..............................................645.9 Restoring parameter defaults ..............................645.10 Differences between European and USA

defaults ...............................................................655.11 Displaying parameters with non-default values

only .....................................................................655.12 Displaying destination parameters only ..............655.13 Parameter access level and security ..................655.14 Serial communications ........................................66

6 Basic parameters ................................676.1 Full descriptions ..................................................68

7 Running the motor ..............................767.1 Quick start commissioning / start-up (from

European defaults) ..............................................777.2 Quick start commissioning / start-up

(from USA defaults) ............................................797.3 CTSoft software commissioning / start-up tool ....807.4 Setting up a feedback device ..............................81

8 Optimization .........................................828.1 Armature current .................................................82

8.2 Speed feedback ..................................................828.3 Field current ........................................................828.4 Current loop gains self-tuning .............................828.5 Speed loop gains tuning .....................................838.6 Current limit tapers ..............................................84

9 SMARTCARD operation ......................859.1 Introduction .........................................................859.2 Easy saving and reading .....................................859.3 Transferring data .................................................859.4 Data block header information ............................879.5 SMARTCARD parameters ..................................879.6 SMARTCARD trips .............................................88

10 Onboard PLC .......................................9010.1 Onboard PLC and SYPT Lite ..............................9010.2 Benefits ...............................................................9010.3 Limitations ...........................................................9010.4 Getting started ....................................................9110.5 Onboard PLC parameters ...................................9110.6 Onboard PLC trips ..............................................9210.7 Onboard PLC and the SMARTCARD .................92


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4 Mentor MP User Guidewww.controltechniques.com Issue: 5

11 Advanced parameters .........................9311.1 Menu 1: Speed reference ....................................9811.2 Menu 2: Ramps .................................................10211.3 Menu 3: Speed feedback and speed control .....10511.4 Menu 4: Torque and current control ..................10711.5 Menu 5: Motor and field control .........................11211.6 Menu 6: Sequencer and clock ...........................11711.7 Menu 7: Analog I/O ...........................................11911.8 Menu 8: Digital I/O ............................................121

11.9 Menu 9: Programmable logic, motorizedpot and binary sum ............................................12511.10 Menu 10: Status and trips .... .............................12811.11 Menu 11: General drive set-up ..........................12911.12 Menu 12: Threshold detectors, variable

selectors and brake control function .................13011.13 Menu 13: Position control ..................................13611.14 Menu 14: User PID controller ............................14011.15 Menus 15, 16 and 17: Solutions Module slots ..14311.16 Menu 18: Application menu 1 ............................14411.17 Menu 19: Application menu 2 ............................14411.18 Menu 20: Application menu 3 ............................14411.19 Menu 21: Second motor parameters .................14511.20 Menu 22: Additional Menu 0 set-up ..................14511.21 Menu 23: Header selections .............................145

12 Technical data ....................................14612.1 Drive technical data ...........................................14612.2 Cable and fuse size ratings ...............................15212.3 Optional external EMC filters ............................176

13 Diagnostics ........................................17713.1 Trip indications ..................................................17713.2 Trip categories ..................................................18413.3 Alarm indications ...............................................185

13.4 Status indications ..............................................18513.5 Displaying the trip history ..................................18513.6 Behavior of the drive when tripped ....................18513.7 Trip masking ......................................................185

14 UL information ...................................18614.1 Common UL Information ...................................18614.2 AC supply specification .....................................18614.3 Maximum ratings ...............................................18614.4 Parallel operation ..............................................18614.5 Safety label .......................................................18614.6 UL Listed accessories .......................................186


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Running themotor Optimization

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OnboardPLC

Advancedparameters

Technicaldata Diagnostics

ULinformation

Mentor MP User Guide 5Issue: 5 www.controltechniques.com

1 Safety Information1.1 Warnings, Cautions and Notes

A Note contains information which helps to ensure correct operation ofthe product.

1.2 Electrical safety - general warningThe voltages used in the drive can cause severe electrical shock and/orburns, and could be lethal. Extreme care is necessary at all times whenworking with or adjacent to the drive.

Specific warnings are given at the relevant places in this Guide.

1.3 System design and safety ofpersonnel

The drive is intended as a component for professional incorporation intocomplete equipment or system. If installed incorrectly, the drive maypresent a safety hazard.The drive uses high voltages and currents, carries a high level of storedelectrical energy, and is used to control equipment which can causeinjury.System design, installation, commissioning / start-up and maintenancemust be carried out by personnel who have the necessary training andexperience. They must read this safety information and this guidecarefully.

The STOP and START controls or electrical inputs of the drive mustnot be relied upon to ensure safety of personnel. They do notisolate dangerous voltages from the output of the drive or f rom anyexternal option unit. The supply must be disconnected by anapproved electrical isolation device before gaining access to theelectrical connections.The drive is not intended to be used for safety-related functions.Careful consideration must be given to the function of the drive whichmight result in a hazard, either through its intended behaviour or throughincorrect operation due to a fault. In any application where a malfunctionof the drive or its control system could lead to or allow damage, loss orinjury, a risk analysis must be carried out, and where necessary, furthermeasures taken to reduce the risk - for example, an over-speedprotection device in case of failure of the speed control, or a fail-safemechanical brake in case of loss of motor braking.

1.4 Environmental limitsInstructions within the supplied data and information within this UserGuide regarding transport, storage, installation and the use of the drivemust be complied with, including the specified environmental limits.Drives must not be subjected to excessive physical force.

1.5 Access Access must be restricted to authorized personnel only. Safetyregulations which apply at the place of use must be complied with.

1.6 Fire protectionThe drive enclosure is not classified as a fire enclosure. A separate fireenclosure must be provided. For further information, refer to section3.2.5 Electromagnetic compatibility on page 13 .

1.7 Compliance with regulationsThe installer is responsible for complying with all relevant regulations,such as national wiring regulations, accident prevention regulations andelectromagnetic compatibility (EMC) regulations. Particular attention

must be given to the cross-sectional areas of conductors, the selectionof fuses and other protection, and protective ground (earth) connections.This User Guide contains instructions for achieving compliance withspecific EMC standards.Within the European Union, all machinery in which this product is usedmust comply with the following directives:

2006/42/EC: Safety of machinery2004/108/EC: Electromagnetic compatibility

1.8 Motor Ensure the motor is installed in accordance with the manufacturer'srecommendations. Ensure the motor shaft is not exposed.Low speeds may cause the motor to overheat because the cooling fanbecomes less effective. The motor should be installed with a protectionthermistor. If necessary, an electric forced ventilation fan should beused.The values of the motor parameters set in the drive affect the protectionof the motor. The default values in the drive should not be relied upon.It is essential that the correct value is entered into Pr 5.07 (SE07, 0.28 ),Motor rated current. This affects the thermal protection of the motor.

1.9 Mechanical brake controlThe brake control functions are provided to allow well co-ordinatedoperation of an external brake with the drive. While both hardware andsoftware are designed to high standards of quality and robustness, theyare not intended for use as safety functions, i.e. where a fault or failurewould result in a risk of injury. In any application where the incorrectoperation of the brake release mechanism could result in injury,

independent protection devices of proven integrity must also beincorporated.

1.10 Adjusting parametersSome parameters have a profound effect on the operation of the drive.They must not be altered without careful consideration of the impact onthe controlled system. Measures must be taken to prevent unwantedchanges due to error or tampering.

1.11 Electrical installation1.11.1 Electric shock riskThe voltages present in the following locations can cause severe electricshock and may be lethal: AC supply cables and connections

Output cables and connections Many internal parts of the drive, and external option unitsUnless otherwise indicated, control terminals are single insulated andmust not be touched.

1.11.2 Stored chargeThe drive contains capacitors that remain charged to a potentially lethalvoltage after the AC supply has been disconnected. If the drive has beenenergized, the AC supply must be isolated at least ten minutes beforework may continue.

A Warning contains information which is essential foravoiding a safety hazard.

A Caution contains information which is necessary foravoiding a risk of damage to the product or other equipment.

WARNING

CAUTION

NOTE


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2 Product informationTable 2-1 Model to frame size cross reference

2.1 Current ratingsThe power ratings for the 480 V, 575 V and 690 V configurations areshown in Table 2-2 , Table 2-3 and Table 2-4 .

The continuous current ratings given are for a maximum ambienttemperature of 40 C (104 F) and an altitude of 1000 m. For operationat higher temperatures and altitudes de-rating is required.

For further information see Chapter 12 Technical data on page 146 .

Table 2-2 480 V current ratings


* For this rating at 575 V, 150 % overload time is 20 s at 40 C and 30s at35 C.


* For this rating at 690 V, 150 % overload time is 20 s at 40 C and 30 s

at 35 C.Maximum continuous input current

The values of maximum continuous input current are given to aid theselection of cables and fuses. These values are stated for worst-casecondition.

For current ratings above 1850 A then parallel connection of the drives isrequired. However, this function is not implemented on firmwareversions V01.05.02 and earlier.

Model

Frame480 VEN/IECcULus

575 VEN/IEC

cULus to 600 V

690 VEN/IEC

MP25A4(R) MP25A5(R)

1AMP45A4(R) MP45A5(R)MP75A4(R) MP75A5(R)

MP105A4(R) MP105A5(R)1BMP155A4(R) MP155A5(R)

MP210A4(R) MP210A5(R)MP350A4(R) MP350A5(R) MP350A6(R)

2AMP420A4(R)

MP470A5(R) MP470A6(R)MP550A4(R)MP700A4(R) MP700A5(R) MP700A6(R)

2BMP825A4(R) MP825A5(R) MP825A6(R)MP900A4(R)MP1200A4 MP1200A5 MP1200A6

2CMP1850A4 MP1850A5 MP1850A6MP1200A4R MP1200A5R MP1200A6R

2DMP1850A4R MP1850A5R MP1850A6R

Model

AC inputcurrent

DC output currentTypical motor

power

Continuous Continuous150 %

overload@ 400Vdc

@ 500Vdc

A A A kW hp

MP25A4(R) 22 25 37.5 9 15

MP45A4(R) 40 45 67.5 15 27

MP75A4(R) 67 75 112.5 27 45

MP105A4(R) 94 105 157.5 37.5 60

MP155A4(R) 139 155 232.5 56 90

MP210A4(R) 188 210 315 75 125

MP350A4(R) 295 350 525 125 200

MP420A4(R) 350 420 630 150 250MP550A4(R) 450 550 825 200 300

MP700A4(R) 585 700 1050 250 400

MP825A4(R) 665 825 1237.5 300 500

MP900A4(R) 725 900 1350 340 550

MP1200A4(R) 1050 1200 1800 450 750

MP1850A4(R) 1570 1850 2775 700 1150

Model

AC inputcurrent

DC output current Typical motorpower

(With Vdc =630 V)Continuous Continuous

150 %overload

A A A kW hp

MP25A5(R) 22 25 37.5 14 18

MP45A5(R) 40 45 67.5 25 33

MP75A5(R) 67 75 112.5 42 56

MP105A5(R) 94 105 157.5 58 78

MP155A5(R) 139 155 232.5 88 115

MP210A5(R) 188 210 315 120 160

MP350A5(R) 295 350 525 195 260

MP470A5(R) 395 470* 705 265 355

MP700A5(R) 585 700 1050 395 530

MP825A5(R) 665 825* 1237.5 465 620

MP1200A5(R) 1050 1200 1800 680 910

MP1850A5(R) 1570 1850 2775 1045 1400

Model

AC inputcurrent

DC output Current Typical motorpower (WithVdc = 760 V)Continuous Continuous

150 %Overload

A A A kW hp

MP350A6(R) 295 350 525 240 320

MP470A6(R) 395 470* 705 320 425

MP700A6(R) 585 700 1050 480 640

MP825A6(R) 665 825* 1237.5 650 850

MP1200A6(R) 1050 1200 1800 850 1150

MP1850A6(R) 1570 1850 2775 1300 1750

NOTE


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2.1.1 Typical short-term overload limitsThe maximum percentage overload limit changes depending on the selected motor.

Variations in motor rated current will result in changes in the maximum possible overload as detailed in the Mentor MP Advanced User Guide .

Figure 2-1 can be used to determine the maximum overload duration available for overloads between 100 % and 150 %. For example the maximumoverload available for a period of 60 seconds is 124 %.

Figure 2-1 Maximum overload duration available

Overload of 150 % for 30 s is available up to a maximum of 10 repetitions per hour.

2.2 Model number The way in which the model numbers for the Mentor MP range are formed is described in Figure 2-2 .

Figure 2-2 Model number

100

105

110

115

120

125

130

135

140

145

150

155

160

0 1 0

2 0

3 0

4 0

5 0

6 0

7 0

8 0

9 0

1 0 0

1 1 0

1 2 0

1 3 0

1 4 0

1 5 0

1 6 0

1 7 0

1 8 0

2 0 0

overload duration (seconds)

overload (%)

NOTE

Mentor product lineMP :

Continuous armature current rating (A)

Voltage rating4 = 480 V 24 V to 480 V -20 % +10 %5 = 575 V 500 V to 575 V -10 % +10 %6 = 690 V 500 V to 690 V -10 % +10 %

Mentor Platform

MP 2 0 01 4 R

RBlank

- 4 quadrant operation- 2 quadrant operation

A


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2.3 Compatible encodersTable 2-5 Encoders compatible with Mentor MP

2.4 Nameplate descriptionFigure 2-3 Typical drive rating label

2.4.1 Output currentThe continuous output current ratings given on the rating label are for maximum 40 C (104 F) and 1000 m altitude. Derating is required for higherambient temperatures >40 C (104 F) and higher altitude. For derating information, refer to section 12.1.12 Altitude on page 151 .

2.4.2 Input currentThe input current is affected by the supply voltage, frequency and load inductance. The input current given on the rating label is the typical inputcurrent.

Encoder typePr 3.38

(Fb07, 0.77)setting

Quadrature incremental encoders with or withoutmarker pulse

Ab (0)

Frequency and direction incremental encoders withor without marker pulse

Fd (1)

Forward / reverse incremental encoders with orwithout marker pulse

Fr (2)

Model

Auxiliary input voltage/frequency/current

Field outputvoltage current

Line input voltage/frequency/current

Armature output voltage/current/overload

Rating

Customer anddate code

Approvals

Serial number IP Rating

Key to approvals

UL approval Worldwide

CE approval Europe

C Tick approval Australia

RoHS compliant Europe

R


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2.5 Drive features and optionsFigure 2-4 Drive features and options on size 1

Figure 2-5 Drive features and options for size 2

* A SMARTCARD is provided as standard. For further information, refer to Chapter 9 SMARTCARD operation on page 85 .

SM-Keypad /MP-Keypad

Automa tion FieldbusFeedback

SMARTCARD*

Keypadconnection

Slot 1

Slot 2

Slot 3

Solutions Modules

Serial port connector

Control terminals

FXMP25 connection

Auxilia ry connectionsand field

Field fuses

DCterminals

AC terminals

CT Comms cable

Identificationmarker rail

Machinefeedbackterminals

FXMP25

M

STOREDCHARGE10min

Mode /Reset

FXMP25 Field regulator

P a r a m

e t e r - P r 0 . 3 0

r E A d +

A u t o +

P r o g

+

b o o t +

Automation FieldbusFeedback

SMARTCARD*

SM-Keypad /MP-Keypad

Keypad connection

Slot 1

Slot 2

Slot 3

Solutions Modules

Serial port connector

Control terminals

FXMP25 connection

Auxiliary connectionsand field

Field fuses

AC termina ls

CT Comms cable

Identificationmarker rail


DCterminals

Paralleling port

FXMP25

M

STORED CHARGE10 min

Mode /Reset

Internalfans

FXMP25 Field regulator

P a r a m e t e r

- P r 0 . 3 0

r E A d +

A u t o

+

P r o g +

b o o t +


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2.5.1 Options available for Mentor MP All Solutions Modules are color-coded in order to make identification easy. The following table shows the color-code key and gives further details ontheir function.

Table 2-6 Solutions Module identification

Type Solutions Module Color Name Further Details

Feedback

Light GreenSM-UniversalEncoder Plus

Universal Feedback interfaceFeedback interface for the following devices:

Brown SM-Encoder Plus

Incremental encoder interfaceFeedback interface for incremental encoders withoutcommutation signals.No simulated encoder outputs available

Dark BrownSM-Encoder OutputPlus

Incremental encoder interfaceFeedback interface for incremental encoders withoutcommutation signals.Simulated encoder output for quadrature, frequency anddirection signals

N/A15-way D-typeconverter

Drive encoder input converter Provides screw terminal interface for encoder wiring and spadeterminal for shield

N/ASingle endedencoder interface(15 V or 24 V)

Single ended encoder interfaceProvides an interface for single ended ABZ encoder signals,such as those from hall effect sensors. 15 V and 24 V versionsare available.

Automation (I/O

Expansion)

Yellow SM-I/O Plus

Extended I/O interfaceIncreases the I/O capability by adding the following to theexisting I/O in the drive:

Yellow SM-I/O 32

Extended I/O interfaceIncrease the I/O capability by adding the following to theexisting I/O in the drive: High speed digital I/O x 32 +24 V output

Dark Yellow SM-I/O Lite

Additional I/O1 x Analog input ( 10 V bi-polar or current modes)1 x Analog output (0 to 10 V or current modes)3 x Digital input and 1 x Relay

Dark Red SM-I/O Timer Additional I/O with real time clock

As per SM-I/O Lite but with the addition of a Real Time Clockfor scheduling drive running

Turquoise SM-I/O PELV

Isolated I/O to NAMUR NE37 specificationsFor chemical industry applications1 x Analog input (current modes)2 x Analog outputs (current modes)4 x Digital input / outputs, 1 x Digital input, 2 x Relay outputs

Olive SM-I/O 120VAdditional I/O conforming to IEC 61131-2 120 Vac6 digital inputs and 2 relay outputs rated for 120 Vac operation

Cobalt BlueSM-I/O 24VProtected

Additional I/O with overvoltage protection up to 48 V2 x Analog outputs (current modes)4 x Digital input / outputs, 3 x Digital inputs, 2 x Relay outputs

Inputs Outputs Incremental encoders Quadrature

SinCos encoders Frequency and direction SSI encoders SSI simulated outputs EnDat encoders

Digital inputs x 3 Analog output (voltage) x 1 Digital I/O x 3 Relay x 2 Analog inputs (voltage) x 2


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Table 2-7 Keypad identification

Table 2-8 Serial comms lead

Table 2-9 External field control

Automation(Applications)

Moss GreenSM-ApplicationsPlus

Applications Processor (with CTNet)

2nd processor for running pre-defined and /or customer createdapplication software with CTNet support. Enhancedperformance over SM-Applications

WhiteSM-Applications LiteV2

Applications Processor

2nd processor for running pre-defined and /or customer createdapplication software. Enhanced performance over SM-

Applications Lite

Golden brown SM-Register Applications Processor 2nd processor for running position capture functionality withCTNet support.

Fieldbus

PurpleSM-PROFIBUS DP-V1

Profibus optionPROFIBUS DP adapter for communications with the drive

Medium Grey SM-DeviceNetDeviceNet optionDevicenet adapter for communications with the drive

Dark Grey SM-INTERBUSInterbus optionInterbus adapter for communications with the drive

Light Grey SM-CANopenCANopen optionCANopen adapter for communications with the drive

Beige SM-Ethernet

Ethernet option10 base-T / 100 base-T; Supports web pages, SMTP mail andmultiple protocols: DHCP IP addressing; Standard RJ45connection

Brown Red SM-EtherCATEtherCAT optionEtherCAT adapter for communications with the drive

Table 2-6 Solutions Module identification

Type Solutions Module Color Name Further Details

Keypad Name Further Details

SM-KeypadLED keypad optionKeypad with a LED display

MP-KeypadLCD keypad optionKeypad with an alpha-numeric LCD display with Help function

Serial comms lead Name Further Details

CT Comms cableCT EIA (RS) -232 (4500-0087)CT USB (4500-0096)

External field controller Name Further Details

FXMP25For external control of field windings up to 25 A, with field reversal capability. For furtherinformation, please see the FXMP25 User Guide .

FXMP25

M

STORED CHARGE10 min

Mode /Reset


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2.6 Items supplied with the driveThe drive is supplied with a printed manual, a SMARTCARD, a safety information booklet, an accessory kit box including the items shown in Table 2-10 , and a CD ROM containing all related product documentation and software tools.

Table 2-10 Parts supplied with the drive

Description Size 1 Size 2A / 2B Size 2C / 2D

Control connectors

Tacho connector

Relay connectors

UL warning label

UL warning label forheatsink temperature

Grounding bracket

Terminal cover grommets

Terminal shrouds

Terminal shroud basecovers

M4 Screws

Mounting feet bracket

CAUTIONRisk of Electric Shock

Power down unit 10minutesbefore removing cover


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3 Mechanical Installation3.1 Safety

3.2 Planning the installationThe following considerations must be made when planning theinstallation:

3.2.1 Access Access must be restricted to personnel only. Safety regulations whichapply at the place of use must be complied with.

3.2.2 Environmental protectionThe drive must be protected from:

moisture, including dripping water or spraying water andcondensation. An anti-condensation heater may be required, whichmust be switched off when the drive is running

contamination with electrically conductive material contamination with any form of dust which may restrict the fan, or

impair airflow over various components temperature beyond the specified operating and storage ranges corrosive gasses

3.2.3 CoolingThe heat produced by the drive must be removed without its specifiedoperating temperature being exceeded. Note that a sealed enclosuregives much reduced cooling compared with a ventilated one, and mayneed to be larger and/or use internal air circulating fans.

For further information, refer to section 3.6.2 Enclosure sizing onpage 27 .

3.2.4 Electrical safetyThe installation must be safe under normal and fault conditions.Electrical installation instructions are given in Chapter 4 Electricalinstallation on page 33 .

3.2.5 Electromagnetic compatibilityIf it is necessary to meet strict emission limits, or if it is known thatelectromagnetically sensitive equipment is located nearby, then fullprecautions must be observed. The use of an external EMC filter may berequired at the drive inputs, which must be located very close to thedrives.

Space must be made available for the filters and allowance made forcarefully segregated wiring. Both levels of precautions are covered inTable 12-44 Immunity compliance on page 175 .

3.2.6 Hazardous areasThe drive must not be located in a classified hazardous area unless it isinstalled in an approved enclosure and the installation is certified.

3.2.7 Fire protectionThe drive enclosure is not classified as a fire enclosure. A separate fireenclosure must be provided.

For installation in the USA, a NEMA 12 enclosure is suitable.

For installation outside the USA, the following (based on IEC 62109-1,standard for PV inverters) is recommended.

Enclosure can be metal and/or polymeric, polymer must meetrequirements which can be summarized for larger enclosures as usingmaterials meeting at least UL 94 class 5VB at the point of minimumthickness.

Air filter assemblies to be at least class V-2.

The location and size of the bottom shall cover the area shown in Figure3-1 overleaf.

Follow the instructions

The mechanical and electrical installation instructions mustbe adhered to. Any questions or doubt should be referred tothe supplier of the equipment. It is the responsibility of theowner or user to ensure that the installation of the drive andany external option unit, and the way in which they are

operated and maintained, comply with the requirements ofthe Health and Safety at Work Act in the United Kingdom orapplicable legislation and regulations and codes of practicein the country in which the equipment is used.

Competence of the installer

The drive must be installed by professional assemblers whoare familiar with the requirements for safety and EMC. Theassembler is responsible for ensuring that the end product orsystem complies with all the relevant laws in the countrywhere it is to be used.

If the drive has been used at high load levels for a period oftime, the heatsink can reach temperatures in excess of70 C (158 F). Human contact with the heatsink should beprevented.

Enclosure

The drive is intended to be mounted in an enclosure whichprevents access except by trained and authorizedpersonnel, and which prevents the ingress of contamination.It is designed for use in an environment classified aspollution degree 2 in accordance with IEC 60664-1. Thismeans that only dry, non-conducting contamination isacceptable.

The drive enclosure is not classified as a fire enclosure. Aseparate fire enclosure must be provided. For furtherinformation, refer to section 3.2.5 Electromagnetic

compatibility on page 13 .

Many of the drives in this product range weigh in excess of15 kg (33 lb). Use appropriate safeguards when lifting thesemodels.See section 3.4 Mounting method on page 17 .

IP ratingIt is the installers responsibility to ensure that any enclosurewhich allows access to drives from model sizes 2A to 2Dwhile the product is energized, provides protection againstcontact and ingress to the requirements of IP20. Refer tosection 12-8 IP rating on page 151 .

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING


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Any part of the side which is within the area traced out by the 5 angle isalso considered to be part of the bottom of the fire enclosure.

Figure 3-1 Fire enclosure bottom layout

The bottom, including the part of the side considered to be part of thebottom, must be designed to prevent escape of burning material - eitherby having no openings or by having a baffle construction.

This means that openings for cables etc. must be sealed with materialsmeeting the 5VB requirement, or else have a baffle above. See Figure 3-2 for acceptable baffle construction. This does not apply for mounting inan enclosed electrical operating area (restricted access) with concretefloor.

Figure 3-2 Fire enclosure baffle construction

3.3 Terminal cover removal

3.3.1 Removing the terminal coversThe drive is installed with one control terminal cover.

Figure 3-3 Removing the control terminal cover (size 1 shown)

To remove the terminal cover, undo the screw and slide the terminal cover downwards.

When replacing the terminal covers the screw should be tightened with a maximum torque of 1 N m (0.7 Ib ft).

Drive

5o

5o

Isolation deviceThe AC supply must be disconnected from the drive using anapproved isolation device before any cover is removed fromthe drive or before any servicing work is performed.

Stored chargeThe drive contains capacitors that remain charged to apotentially lethal voltage after the AC supply has beendisconnected. If the drive has been energized, the AC

supply must be isolated at least ten minutes before workmay continue.

N o t l e s st h a n 2 X B a f f l e p l a t e s ( m a y b e

a b o v e o r b e l o w b o t t o mo f e n c lo s u r e )

X

B o t t o m o f f i r ee n c lo s u r e

Not lessthan 2times X Baffle plates (may be above or

below bottom of enclosure)

Bottom of fire enclosure

X

WARNING

WARNING

Pozi Pz2


15/194

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3.3.2 Removing the finger-guard and break-outsFigure 3-4 Removing the finger-guard break-outs

Place finger-guard on a flat solid surface and hit relevant break-outs withhammer as shown (1). Continue until all required break-outs are removed(2). Remove any flash / sharp edges once the break-outs are removed.

3.3.3 Installation and removal of a Solutions Module

Figure 3-5 Installation and removal of the Solutions Module

1. To install the Solutions Module, press down in the direction shownabove until it clicks into place.

2. To remove the Solutions Module, press inwards at the points shown(A) and pull in the direction shown (B).

3. The drive has the facility for all three Solutions Module slots to beused at the same time, as illustrated.

It is recommended that the Solutions Module slots are used in thefollowing order: slot 3, slot 2 and slot 1.

1 2

All sizes

Please power down the drive before removing / installing theSolutions Module. Failure to do so may cause damage toproduct

CAUTION

A

B

Solutions Modulein slot 1



A

NOTE


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Figure 3-6 Removal and installation of a keypad

To fit, align the MP-Keypad and press gently in the direction shown untilit clicks into position (A).

To remove, while pressing the tabs inwards (B), gently lift the MP-Keypad in the direction indicated (C).

The keypad can be installed / removed while the drive is powered up and

running a motor, providing that the drive is not operating in keypadmode.

Be aware of possible live terminals when installing thekeypad.

WARNING

B

B

C

A

NOTE


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3.4 Mounting methodThe Mentor MP can only be surface mounted.

Figure 3-7 Overall size 1A dimensions

1. The two outer holes must be used for mounting the Mentor MP.

With the SMARTCARD installed to the drive, the depth measurementincreases by 7.6 mm (0.30 in).

Fans are only installed to the MP75A4(R) and MP75A5(R).

If the drive has been used at high load levels for a period oftime, the heatsink can reach temperatures in excess of 70 C(158 F). Human contact with the heatsink should beprevented.

Many of the drives in this product range weigh in excess of 15kg (33lb). Use appropriate safeguards when lifting thesemodels.

WARNING

WARNING

293mm (11.54in)

250mm (9.84in)

444mm(17.48in)

222mm(8.74in)

95mm(3.74in)

222mm (8.74in) 170mm (6.69in)

6.5mm (0.26in)

250mm (9.84in)

40mm(1.58in)

22mm(0.87in)

380mm(14.96in)

4 holes tosuit M6

1

1

1

1

MA1

MA2

NOTE

NOTE


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Figure 3-8 Overall size 1B dimensions

1. The two outer holes must be used for mounting the Mentor MP.

With the SMARTCARD installed to the drive, the depth measurement increases by 7.6 mm (0.30 in).

293mm (11.54in)

250mm (9.84in)

444mm(17.48in)

251mm(9.88in)

124mm(4.88in)

170mm (6.69in)

6.5mm (0.26in)

250mm (9.84in)

40mm(1.58in)

22mm(0.87in)

380mm(14.96in)

4 holes tosuit M6

1

1

1

1

1

MA1

MA2

NOTE


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Figure 3-9 Installing the mounting feet bracket on size 1 drives

Figure 3-10 Overall size 2A / 2B dimensions with terminal shrouds attached


1

1

2

MA1

MA2

453mm (17.84in)

495mm (19.49in)

640mm(25.20in)

85mm(3.35in)

301mm (11.85in)

472mm (18.58)

68mm(2.68in)

126mm(4.96in)

11.5mm (0.45in)

495mm (19.49in)

80mm(3.15in)

80mm(3.15in)

65mm(2.56in)

8 holes to

suit M8

302mm(11.89in)

93mm(3.66in)

NOTE

The bottom mounting bracket (1) should be installed to the back platefirst with the screws fully tightened.

The drive should then be lowered onto the bracket and slotted in.

The top mounting bracket (2) should then be slotted into the driveand the top holes marked for mounting (380 mm [14.96 in] from thecentre of the holes on the bottom mounting bracket).

Once the holes have been drilled, fix the top mounting bracketaccordingly and tighten the screws.

It is not necessary to tighten the bottom mounting brackets with thedrive in place. The brackets are designed to clamp the drive heatsinkagainst the back plate.


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Figure 3-11 Overall size 2A dimensions without terminal shrouds attached

Figure 3-12 Overall size 2B dimensions without terminal shrouds attached


495mm (19.49in)453mm (17.84in)

149mm (5.87in) 140mm (5.51in) 140mm (5.51in) 66mm (2.60in)

30mm(1.18in)

30mm(1.18in)

30mm(1.18in) 15mm

(0.59in)

11mm(0.43in)

25mm(0.98in)

25mm(0.98in)

77mm(3.03in)

90mm(3.54in)

5mm(0.20in) 126mm(4.96in)

5mm(0.20in)

141mm (5.55in)

472mm (18.58 in)

68mm(2.68in)

126mm(4.96in)

11.5mm (0.45in)

495mm (19.49in)

80mm(3.15in)

80mm(3.15in)

65mm(2.56in)

8 holes tosuit M8

302mm(11.89in)

495mm (19.49in)453mm (17.84in)

149mm (5.87in) 140mm (5.51in) 140mm (5.51in) 66mm (2.60in)

30mm(1.18in)

30mm(1.18in)

30mm(1.18in)

53mm

(2.09in)

38mm

(1.50in)

77mm(3.03in)

90mm(3.54in)

40mm(1.58in)

40mm(1.58in)

302mm(11.89in)

8mm(0.32in)

126mm (4.96in)

141mm (5.55in)8mm

(0.32in)

472mm (18.58)

68mm(2.68in)

126mm(4.96in)

11.5mm (0.45in)

495mm (19.49in)

80mm(3.15in)

80mm(3.15in)

65mm(2.56in)

8 holes tosuit M8

NOTE


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Figure 3-13 Size 2C front view and mounting dimensions

6mm (0.24in)

1 7 5 m m

( 6

. 9 i n )

5mm(0.2in)

1 7 5 m m

( 6

. 9 i n )

405mm (15.94)

2 4 8 m m

( 9

. 7 6 i n )

2 0 2 m m

( 7

. 9 5 i n )

3 2 1 m m

( 1 2

. 6 4 i n )

6 0 5 m m

( 2 3

. 8 2 i n )

1 2 4 m m

( 4 . 8

9 i n )

1 7 5 m m

( 6

. 9 i n )

555mm (21.85in)

452mm (17.8in)

2 0 2 m m

( 7 . 9 5 i n )

390mm (15.35in)

25mm(0.98in)

25mm(0.98in)

110.8(4.36in)

25mm(0.98in)

115.8(4.56in)

25mm(0.98in)

27mm(1.06in)30mm

(1.18in)

25mm(0.98in)

26mm(1.02in)


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Figure 3-14 Size 2C back-plate and mounting detail

1. M10 eye-bolts can be inserted in the location shown for lifting the drive. These are not supplied with the drive.

With the SMARTCARD installed in the drive, the depth measurement increases by 7.6 mm (0.30 in).

394mm (15.51in)

6 0 5 m m

( 2 3

. 8 2 i n )

5 3 m m

( 2 . 0

9 i n )

2 8 8 m m

( 1 1

. 3 4 i n )

450mm (17.72in)

1 0 5 0 m m

( 4 1

. 3 4 i n )

306mm (12.05in)

611mm (24.05in)

35mm(1.38in)

38mm(1.5in)

59mm(2.32in)

270mm(10.63in)

4 holesto suit M10

260mm(10.24in)

180mm (7.09in) 180mm (7.09in)

90mm(3.54in)

90mm(3.54in)

68.5mm(2.70in)

50mm(1.97in)

190mm(7.48in)

240mm(9.45in)

333mm (13.11in)

83.5(3.29in)

210mm(8.27in)

Rear

Front8 holes 7mm

1

9mm(0.35in)

NOTE

NOTE


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Figure 3-15 Size 2D front view and mounting dimensions

1 2 4 m m

( 4 . 8

8 i n )

6mm(0.24in)

1 0 6 5 m m

( 4 1

. 9 3 i n )

3 5 6 m m

( 1 4

. 0 2 i n )

2 4 8 m m

( 9

. 7 6 i n )

405mm (15.94in)

3 2 1 m m

( 1 2

. 6 4 i n )

3 3 0 m m

( 1 3

. 0 i n )

555mm (21.85in)

3 3 0 m m

( 1 3

. 0 i n )

3 3 0 m m

( 1 3

. 0 i n )

452mm (17.8in)

2 0 2 m m

( 7

. 9 5 i n )

390mm (15.35in)

25mm(0.98in)

25mm(0.98in)

25mm(0.98in)

25mm(0.98in)

25mm(0.98in)

190mm(7.48in)

186mm(7.32in)

4mm(0.16in)

26mm(1.02in)

27mm(1.06in)

30mm(1.18in)


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Figure 3-16 Size 2D back-plate and mounting detail

1. M10 eye-bolts can be inserted in the location shown for lifting the drive. These are not supplied with the drive.


53mm(2.09in)

1 0 6 5 m m

( 4 1

. 9 3 i n )

2 8 8 m m

( 1 1

. 3 4 i n )

450mm (17.72in)

394mm (15.51in)

1 5 1 0 m m

( 5 9

. 4 5 i n )

611mm (24.06in)

306mm (12.05in)

4 holesto suit M10

35mm(1.38in)

260mm(10.24in)

180mm (7.09in) 180mm (7.09in)

90mm(3.54in)

90mm(3.54in)

68.5mm(2.70in)

50mm(1.97in)

190mm(7.48in)

240mm(9.45in)

333mm (13.11in)

8 holes 7mm

83.5mm(3.29in)

210mm(8.27in)

1

38mm(1.5in)

9mm(0.35in)

NOTE

NOTE


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Figure 3-17 Mounting methods of size 2C / 2D air duct The Mentor MP size 2C and 2D air duct can be turned 180 to suit thecustomers infrastructure.

There is no seal provided with this product for sealing off the gap aroundthe air duct when mounted.

3.5 Installing and removing the terminal shroudsFigure 3-18 Installing the terminal shrouds on size 1 drives

1. Thread the AC supply and DC output connectors through the grommets provided and connect them to the drive.2. Place the terminal shroud over the top of the connectors and click into place (3).

NOTE

1

2

3


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Figure 3-19 Removing the terminal shrouds on size 1 drives

1. Insert the screwdriver as shown.2. Lever in the direction shown to unclip the terminal shroud and remove.

Figure 3-20 Installing the terminal shrouds on size 2 drives

1. Assemble the cable to the busbar.2. Place the terminal shroud base cover underneath the cable in the orientation shown.3. Place the terminal shroud over the cable in the orientation shown, slide the terminal shroud on to the base cover in the direction shown until it

clicks in to place.4. For all power connections slide in the terminal shroud sub-assembly in the direction as shown.5. Insert the 2 x M4 x 16 screws using a pozi drive screwdriver.

To remove the terminal shrouds, please reverse the process above.

1 2

L1 L2 L3

A1 A2

1 2 3

NOTE


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3.6 Enclosure3.6.1 Enclosure layoutPlease observe the clearances in the diagram below taking into account any appropriate notes for other devices / auxiliary equipment when planningthe installation.Figure 3-21 Enclosure layout

3.6.2 Enclosure sizingRefer to Table 12-4 in section 12.1.4 Power dissipation on page 150 fordrive losses.

Add the dissipation figures for each drive that is to be installed in theenclosure.

Add the power dissipation figures for each EMC filter that is to beinstalled in the enclosure.

Calculate the total heat dissipation (in Watts) of any other equipment tobe installed in the enclosure.

Add the figures of all of the above to get a total heat dissipation figure (inWatts) for the equipment in the enclosure.

Calculating the size of a sealed enclosureThe enclosure transfers internally generated heat into the surroundingair by natural convection. The larger the surface area of the enclosurewalls, the better is the dissipation capability. Only the surfaces of theenclosure that are not in contact with a wall or floor can dissipate heat.

Calculate the minimum required unobstructed surface area A e for theenclosure from:

Where:

Ae Unobstructed surface area in m2 (1 m 2 = 10.9 ft 2)

Text Maximum expected temperature inoC outside the

enclosure

Tint Maximum permissible temperature inoC inside the

enclosure

P Power in Watts dissipated by all heat sources in the

enclosure

k Heat transmission coefficient of the enclosure material

in W/m 2/ oC

ExampleTo calculate the size of an enclosure for the following:

Two MP25A4 models operating under full load conditions Maximum ambient temperature inside the enclosure: 40 C Maximum ambient temperature outside the enclosure: 30 C

Dissipation of each drive: 125 W

Dissipation from other heat generating equipment in the enclosure. 22 W(max).

Total dissipation: (2 x 125) + 22 = 272 W.

Enclosure

AC supply contactor,line chokes and fuses

Externalcontroller

Ensure minimum clearancesare maintained for the drive.Forced or convection air-flowmust not be restricted by anyobject or cabling

Auxillarysupply

Signal cablesPlan for all signal cablesto be routed at least300mm (12in) from thedrive and any power cable

Armatureconnectioncable

Fieldconnection cable

100 mm(4in)

100 mm(4in)

A

A

MA1

MA2

NoteFor EMC compliance:1) Power cabling must be at least 100mm (4in) from the drive in all directions2) Ensure direct metal contact at drive and filter mounting points (any paint must be removed)

100mm for Size 1 drives

200mm for Size 2A/2B drives

A

NoteFor Size 2C/2D drivesleave a clearance of 100mmaround the drive.

AeP

k T in t Tex t ( )----------------------------------------=


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The enclosure is to be made from painted 2 mm (0.079 in) sheet steel

having a heat transmission coefficient of 5.5 W/m 2/oC. Only the top,front, and two sides of the enclosure are free to dissipate heat.

The value of 5.5 W/m 2/ C can generally be used with a sheet steelenclosure (exact values can be obtained by the supplier of the material).If in any doubt, allow for a greater margin in the temperature rise.

Figure 3-22 Enclosure having front, sides and top panels free todissipate heat

Insert the following values:Tint 40 C

Text 30 Ck 5.5P 272 W

The minimum required heat conducting area is then:

= 4.945 m 2 (53.90 ft 2) (1 m 2 = 10.9 ft 2)

Estimate two of the enclosure dimensions - the height (H) and depth ( D),for instance. Calculate the width (W) from:

Inserting H = 2m and D = 0.6m, obtain the minimum width:

=0.979 m (38.5 in)

If the enclosure is too large for the space available, it can be madesmaller only by attending to one or all of the following:

Reducing the ambient temperature outside the enclosure, and/orapplying forced-air cooling to the outside of the enclosure

Reducing the number of drives in the enclosure Removing other heat-generating equipment

Calculating the air-flow in a ventilated enclosureThe dimensions of the enclosure are required only for accommodatingthe equipment. The equipment is cooled by the forced air flow.

Calculate the minimum required volume of ventilating air from:

Where:

V Air-flow in m 3 per hour (1 m 3/hr = 0.59 ft 3/min)Text Maximum expected temperature in C outside the

enclosureTint Maximum permissible temperature in C inside the

enclosureP Power in Watts dissipated by all heat sources in the

enclosure

k Ratio of

Where:P 0 is the air pressure at sea levelP I is the air pressure at the installation

Typically use a factor of 1.2 to 1.3, to allow also for pressure-drops indirty air-filters.

Example

To calculate the size of an enclosure for the following:

Three MP45A4 models operating under full load conditions Maximum ambient temperature inside the enclosure: 40 C

Maximum ambient temperature outside the enclosure: 30 CDissipation of each drive: 168W

Dissipation from other heat generating equipment. 45 W

Total dissipation: (3 x 168) + 45 = 549 W

Insert the following values:Tint 40 CText 30 Ck 1.3P 549 W

Then:

= 214.1 m 3 /hr (126.3 ft 3 /min) (1 m 3/ hr = 0.59 ft 3/min)

3.7 Heatsink fan operationMentor MP drives rated 75 A to 900 A are ventilated by internallysupplied fans.

Ensure the minimum clearances around the drive are maintained toallow the air to flow freely. The air flow figures are listed below:

Size 1A - 0.5 cubic metres per minute.

Size 1B - 2.8 cubic metres per minute.

Size 2A - 7.8 cubic metres per minute.

Size 2B - 7.8 cubic metres per minute.

Mentor MP drives rated 1200 A and above are ventilated by externallysupplied fans. Please refer to section 4.12 Connecting the fan on size2C and 2D drives on page 52 for more information.The air flow figures are listed below:

Size 2C - 22 cubic metres per minute.

Size 2D - 22 cubic metres per minute.

The drive controls the fan operation based on the temperature of theheatsink and the drives thermal model system.

3.8 IP rating (Ingress Protection)

An explanation of IP rating is provided in section 12.1.13 IP rating onpage 151 .

W

H

D

Ae272W

5.5 40 30 ( )-------------------------------- -=

WAe 2H D

H D+------------------------- -=

W4.945 2 2 0.6( )

2 0.6+-----------------------------------------------------=

V 3k PT in t Tex t ---------------------------=

P oP l-------

IP rating

It is the installers responsibility to ensure that any enclosurewhich allows access to drives from frame sizes 2A to 2Dwhile the product is energized, provides protection against

contact and ingress to the requirements of IP20.

V 3 1.3 54940 30

----------------------------------=

WARNING


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3.9 Electrical terminals3.9.1 Location of the power and ground terminalsFigure 3-23 Location of the power and ground terminals on size 1 drives

M8 nut / 13 mm AF

AC input

M8 nut13mm AF

DC output

T25 Torx

Groundconnections

Tachoconnections

3.5 mm

Relayconnections

3.5mm5mm Auxiliary

connections

Control andencoder

connections2.5 mm

5mm


MA1 MA2


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Figure 3-24 Location of the power and ground terminals on size 2A and 2B drives

5mm


Tachoconnections

5mm Auxiliary

connections

Control andencoder

connections2.5 mm

Relayconnections

3.5mm

3.5 mm

T25 Torx

Groundconnections

M12 nut 19mm AF

DC output

Size 2A:

Size 2B:

M10 nut 17mm AF

AC input

M12 nut 19mm AF

Size 2A:

Size 2B:

M10 nut 17mm AF


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Figure 3-25 Location of the power and ground terminals on size 2C and 2D drives

3.9.2 Terminal sizes and torque settings

3.9.3 Torque settingsTable 3-1 Drive control, status relay and encoder terminal data

Table 3-2 Drive auxiliary and machine armature terminal data

Table 3-3 Drive power stage terminals on size 1 drives

Table 3-4 Drive power stage terminals on size 2 drives

Control andencoder

connections

2.5mm

S i z e2

C / 2 D:

M1 2 n

u t 1 9 mm A F

5mm


5mm Auxiliary

connectionsRelay

connections

3.5mm

T25 Torx

Groundconnections

Tachoconnections

3.5mm

S i z e2

C / 2 D:

M1 2 n

u t 1

9 mm A F

A CI n

p u t

D C O u t p u t

To avoid a fire hazard and maintain validity of the UL listing,adhere to the specified tightening torques for the power andground terminals. Refer to the following tables.

Model Connection type Torque setting

All Plug-in terminal block 0.5 N m (4.5 lb in)


All Terminal block 0.5 N m (4.5 lb in)

WARNING


All M8 stud 10 N m (89.0 lb in)


Size 2A M10 stud 15 N m (133.0 lb in)Size 2B

M12 stud 30 N m (266.0 Ib in)Size 2CSize 2D


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3.10 Routine maintenanceThe drive should be installed in a cool, clean, well ventilated location. Contact of moisture and dust with the drive should be prevented.

Regular checks of the following should be carried out to ensure drive / installation reliability are maximized:

Environment

Ambient temperature Ensure the enclosure temperature remains at or below maximum specified

DustEnsure the drive remains dust free check that the heatsink and drive fan are not gathering dust.The lifetime of the fan is reduced in dusty environments.

Moisture Ensure the drive enclosure shows no signs of condensation

Enclosure

Enclosure door filters Ensure filters are not blocked and that air is free to flow

Electrical

Screw connections Ensure all screw terminals remain tight

Crimp terminalsEnsure all crimp terminals remains tight check for any discoloration which could indicateoverheating

Cables Check all cables for signs of damage


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4 Electrical installationMany cable management features have been incorporated into theproduct and accessories, this chapter shows how to optimize them. Keyfeatures include:

EMC compliance Product rating, fusing and cabling information External suppressor resistor details (selection / ratings)

Electric shock riskThe voltages present in the following locations can causesevere electric shock and may be lethal:

AC supply cables and connections DC cables, and connections Many internal parts of the drive, and external option unitsUnless otherwise indicated, control terminals are singleinsulated and must not be touched.

Isolation deviceThe AC supply must be disconnected from the drive usingan approved isolation device before any cover is removedfrom the drive or before any servicing work is performed.

STOP functionThe STOP function does not remove dangerous voltagesfrom the drive, the motor or any external option units.

Drives are suitable for use on supplies of installationcategory III and lower, according to IEC 60664-1. Thismeans they may be connected permanently to the supply atits origin in a building, but for outdoor installation additionalover-voltage suppression (transient voltage surgesuppression) must be provided to reduce category IV tocategory III.

Permanent magnet motors

Permanent magnet motors generate electrical power if theyare rotated, even when the supply to the drive isdisconnected. If that happens then the drive will becomeenergized through its motor terminals.If the motor load is capable of rotating the motor when thesupply is disconnected, then the motor must be isolated fromthe drive before gaining access to any live parts.

WARNING

WARNING

WARNING

WARNING

WARNING


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4.1 Electrical connectionsRefer to Figure 4-1 and Figure 4-2 to understand the function of the different power connectionsFigure 4-1 Power connections for 480 V drive

1. End user must provide 230 / 115 Vac supply for the internal fans on frame sizes C and D, see section 4.12 on page 52 .* For fuse ratings refer to section 4.6 Cable and fuse size ratings on page 39 .

**For further information on EMC filters, see section 4.9.3 EMC filter information on page 50 .

* * *

a n AC Supply

Semiconductor fuses

L1 L2 L3

L1 L2 L3

Isolator

E1 E3 L12 L11 F+ F-

Linereactor

61 62 63RLY2

A1

A2

DC fusefor 4Q only

Fieldon / off

21 22 23 24 25 26 27 28 29 30 31

24V Driveenable

Linecontactor

Input power terminals

Armatureterminals

Auxiliary connections

Control connections

Motor

Fan supply (where applicable)

Linecontactorcoil

250Vacmaximum

10A

10A* * *

Branchfuses

Branchfuses

**Optional EMC field filter

**Optional EMCarmature filter

MA1

MA2

1

A1

A2 A1

A2

2 QuadrantDrives 4 QuadrantDrives


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Figure 4-2 Power connections for 575 V / 600 V / 690 V drives

1. End user must provide 230 / 115 Vac supply for the internal fans on frame sizes C and D, see section 4.12 on page 52 .* For fuse ratings refer to section 4.6 Cable and fuse size ratings on page 39 .

** The transformer must have zero phase delay.

* * *

Main AC Supply

Semiconductor fuses

L1 L2 L3

L1 L2 L3

Isolator

E1 E3 L12 L11 F+ F-

Linereactor

61 62 63RLY2

A1

A2

DC fusefor 4Q only

Fieldon / off

21 22 23 24 25 26 27 28 29 30 31

24V Driveenable

Linecontactor

Input power terminals

Armatureterminals

Auxiliary connections

Control connections

Motor

Fan supply (where applicable)

Linecontactorcoil

250Vacmaximum

* * *

575 / 690Vac

480Vacmaximum

10A 10A

**

Branchfuses

Branchfuses

MA1

MA2

1

A1

A2 A1

A2

2 QuadrantDrives

4 QuadrantDrives


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4.2 Ground connectionsThe drive must be connected to the system ground of the AC supply.The ground wiring must conform to local regulations and codes ofpractice.

Figure 4-3 Location of ground connection on size 1 drives

Figure 4-4 Location of ground connections on size 2A / 2B drives

Figure 4-5 Location of ground connections on size 2C / 2D drives

Electrochemical corrosion of grounding terminalsEnsure that grounding terminals are protected againstcorrosion i.e. as could be caused by condensation.

Ground loop impedance

The ground loop impedance must conform to therequirements of local safety regulations.The drive must be grounded by a connection capable ofcarrying the prospective fault current until the protectivedevice (fuse, etc,) disconnects the AC supply.The ground connections must be inspected and tested atappropriate intervals.

WARNING

WARNING

Groundconnection

MA1

MA2

Groundconnections

Ground connection


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4.3 AC supply requirementsThe standard drive is rated for a nominal supply voltage up to 480 V rms.

An optional rating of 575 V rms is available for size 1 drives.

An optional rating of 575 V rms and 690 V rms is available for size 2drives.

4.3.1 Supply typesDrives rated for supply voltages of up to 575 V (rated up to 210 A) and600 V (350 A and above), are suitable for use with any supply type i.e.TN-S, TN-C-S, TT, IT with grounding at any potential i.e neutral, centreor corner (Grounded delta).

Grounded delta supplies >575 V are not permitted for drives rated up toand including 210 A. Grounded delta supplies >600 V are not permittedfor drives rated 350 A and above.

4.3.2 Supply fault currentThe maximum fault current level of the supply to all circuits is 100 kAsubject to the capability of the semiconductor fuse fitted.

4.3.3 MOV ground disconnectThe facility for disconnecting the jumper (link) between varistors andground is provided for special circumstances, where a sustained highvoltage may be present between lines and ground, for example during ahigh potential test or in certain situations with IT supplies and multiplegenerators. If the jumper (link) is disconnected then the immunity of thedrive to high voltage impulses is reduced. It is then only suitable for usewith supplies having overvoltage category II, i.e. not for connection atthe origin of the low voltage supply within a building.

Figure 4-6 Removing the MOV ground connection on size 1 drives

The method for disconnecting the MOV ground connection on size 1drives is shown below:

1. Remove the M4 x 16 screw using T20 Torx driver.2. Remove the M4 x 12 screw using T20 Torx driver.

3. Remove the plate.4. Re-fit the M4 x 12 screw using T20 Torx driver and tighten to a

torque of 0.6 N m (0.44 Ib ft).5. Fit a M4 x 16 nylon screw (not supplied) and tighten to a torque of

0.25 N m (0.18 Ib ft).

Figure 4-7 Removing the MOV ground connection on size 2A / 2Bdrives

The method for disconnecting the MOV ground connection on size 2A /2B drives is shown below:

1. Remove the M4 x 30 screw using T20 Torx driver .If re-installing the M4 x 30 screw using T20 Torx driver, the screw mustbe tightened to a torque of 2.5 N m (1.84 Ib ft).

Figure 4-8 Removing the MOV ground connection on size 2C / 2Ddrives

The method for disconnecting the MOV ground connection on size 2C /2D drives is shown in Figure 4-8 above:

1. Remove the M4 x 30 screw using T20 Torx driver .If re-fitting the M4 x 30 screw using T20 Torx driver, the screw must betightened to a torque of 2.5 N m (1.84 Ib ft).

Grounded delta supplies exceeding 575 V are not permittedfor drives up to and including 210 A. Grounded deltasupplies exceeding 600 V are not permitted for drives rated

350 A and above.

The M4 x 16 screw (1) should not be re-used if the plate (3)is not re-installed. Instead a nylon screw should be used.

WARNING

1

2

34

5

WARNING

1


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4.3.4 Main AC supply (L1, L2, L3)Table 4-1 Three phase AC supply

4.4 Line reactorsThe Mentor MP, in common with all naturally commutated thyristordrives, causes voltage notches at the input supply terminals. In order toavoid disturbance to other equipment using the same supply, theaddition of external line inductance is strongly recommended in order torestrict the depth of the notches imposed on the shared supply. This isgenerally not necessary where a dedicated transformer is used to supplythe drive.

The following recommendations for added line inductance, have beencalculated based on the power drive systems standard: EN 61800-3:2004 Adjustable speed electrical power drive systems Part 3: EMCrequirements and specific test methods.

The current ratings specified in Table 4-2 are for typical motor currents

where the motor current ripple is no more than 50 % of drive rating.Table 4-2 Minimum required line inductance for a typical

application (50 % ripple content)

1. The above assumes the supply has 1.5 % impedance.2. Assumes a minimum supply rating of 5 kA and a maximum rating of

60 kA.

4.4.1 Auxiliary AC supply and connectionsTable 4-3 Terminal functions

Table 4-4 Line to line supply

Each drive has an onboard field controller with the following current

ratings.Table 4-5 Field controller current ratings

4.4.2 Supply requirementsMaximum supply in-balance: 2 % negative phase sequence (equivalentto 3 % voltage in-balance between phases)

Frequency range: 45 to 65 Hz (maximum rate of frequency change is7 Hz/s).

4.5 Control 24 Vdc supplyThe 24 Vdc input has three main functions.

It can be used to supplement the drive's own internal 24 V whenmultiple SM-Universal Encoder Plus, SM-Encoder Output Plus, SM-I/O Plus, or SM-I/O 32 modules are being used and the currentdrawn by these modules is greater than the drive can supply. (If toomuch current is drawn from the drive, the drive will initiate a 'PS.24V' trip).

SpecificationProduct voltage variant

480 V 575 V 690 V

Maximum nominal supply 480 V 575 V 690 VTolerance +10 %Minimum nominal supply 24 V 500 VTolerance -20 % -10 %

Driverated

current

System voltage Typicalcurrentrating

Maximumcurrentrating400 V 480 V 575 V 690 V

A H H H H A A25 220 260 320 21 2245 220 260 320 38 4075 220 260 320 63 67

105 220 260 320 88 94155 160 190 230 130 139210 120 140 170 176 188350 71 85 110 120 293 295420 59 71 351 350470 80 91 393 395550 45 54 460 450700 36 43 53 61 586 585825 45 52 690 665900 28 33 753 725

1200 21 25 31 36 1004 10501850 18 23 29 32 1570 1655

NOTE

NOTE

Terminals Function

E1, E3 Supply for control electronics and field controller.

L11, L12Field on / off. When L11 and L12 are open the supply isdisconnected to the field regulator so there will be no fieldcurrent.

F+, F- Field supply to the motor.

MA1, MA2

These terminals are used to provide feedback from themotor armature terminals. This is required when the userhas a contactor in the main DC armature connection.When the contactor is opened the drive will still bereceiving armature feedback. This allows the fieldregulator to function correctly when the contactor is open.

Specification Value

Maximum nominal supply 480 VTolerance +10 %Minimum nominal supply 208 VTolerance -10 %

Model

Maximumauxiliary

supply inputcurrent

A

Maximumcontinuousfield current

ratingA

MP25A4(R) MP25A5(R)

13 8

MP45A4(R) MP45A5(R)

MP75A4(R) MP75A5(R)

MP105A4(R) MP105A5(R)

MP155A4(R) MP155A5(R)

MP210A4(R) MP210A5(R)

MP350A4(R) MP350A5(R) MP350A6(R)

23 20

MP420A4(R)

MP470A5(R) MP470A6(R)

MP550A4(R)

MP700A4(R) MP700A5(R) MP700A6(R)

MP825A4(R) MP825A5(R) MP825A6(R)

MP900A4(R)

MP1200A4 MP1200A5 MP1200A6

MP1850A4 MP1850A5 MP1850A6

M

mentor_mp_ug_iss_5

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