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Altivar 78

Installation Manual Variable Speed Drive

APRIL 05

ATV78 variable speed drives


ip00 module installation

ATV780C20Y~ATV780C71Y
2•

INDEX

1. GENERAL 3
2. REQUIREMENTS 4
2.1 Environmental requirements 4
2.2 Cabinet 4
2.3 Accessories 5
3. PRODUCT HANDLING 6
3.1 Product type designation codes 6
3.2 Receipt of delivery 6
3.3 Receiving, unpacking and storing the product 6
3.4 Lifting the power module 7
3.5 Lifting AC chokes 7
4. INSTALLING AC CHOKEs 8
5. INSTALLING THE POWER MODULE 9
5.1 Preparing the enclosure 9
5.2 Mounting the power module 10
5.3 Grounding the power module 11
6. CONNECTING THE INTERNAL POWER CABLES 12
7. INSTALLING THE CONTROL UNIT 15
7.1 Connecting power supply and internal control cables 15
7.1.1 ATV 780C56Y to ATV780C71Y 15
8. PREPARING FOR EXTERNAL POWER CONNECTIONS 16
8.1 Installing mounting plate and input terminals 16
8.2 Installing fuses 17
8.3 Installing EMC grounding 17
8.4 Understanding the power unit topology 18
8.5 Connecting input and output power 18
8.5.1 Mains and motor cables 18
9. Control of main air flow 20
9.1 Arranging ventilation of the enclosure 20
9.2 Steering the internal air flow 21
9.3 Heat dissipation 22
9.4 Temperatures measured during test run 22
10. APPENDICES 23
10.1 Dimensional drawings, Power modules 23
10.2 Dimensional drawings, AC chokes 25
10.3 Optic fibre cables, signal lists and connections 27
10.3.1 ATV780C56Y to ATV780C71Y 27
GENERAL •3

1. GENERAL
This manual provides instructions for the installation of ATV780C20Y …. C71Y (frames FR10 to FR12)
variable speed drives in a cabinet, switchgear, or any other enclosure.
ATV780C20Y …. C71Y of frames FR10 to FR12 have 1 (FR10 and FR11) or 2 (FR12) power modules.
Therefore for frame FR12, you will need twice the number of drive accessories (such as cables,
terminals, chokes etc.) unless otherwise stated. Also note that ATV780C50Y requires two chokes
mounted in parallel. See Figure 14
The ATV78 C20 …. C71Y product series comprise the following variable speed drives:

Type code Frame size Nominal current Choke type


(partial)
Voltage range 525–690V
ATV780C20Y FR10 261A CHK 261
ATV780C25Y FR10 325A CHK 400
ATV780C31Y FR10 385A CHK 400
ATV780C35Y FR11 460A CHK 520
ATV780C45Y FR11 502A CHK 520
ATV780C50Y FR11 590A 2*CHK 400
ATV780C56Y FR12 650A 2*CHK 400
ATV780C63Y FR12 750A 2*CHK 400
ATV780C71Y FR12 820A 2*CHK 400
Table 1. ATV78 C20 …. C71Y variable speed drives, frames FR10…FR12

The variable speed drives can be installed in any enclosure that fulfils the requirements specified in
chapter 2. In the illustrations in this manual, Rittal TS8 is used as an example enclosure.
Installing ATV780C20Y …. C71Y variable speed drives in an enclosure involves the following steps:

• Installing the AC choke(s) (chapter 4)


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

General instructions for product handling are given in chapter 3. Dimensional drawings are found in
chapter 10.
NOTE: The installation of the variable speed drives must be done by certified electricians.
Safety regulations for electrical work must be followed during the installation work.

NOTE: Safe operation and full service lifetime of the product can be guaranteed only if the
installation instructions in this manual are followed.

NOTE: The product warranty is not valid if the product is handled in a way that does not comply
with the instructions in this manual and the User's Manual.

1
4• REQUIREMENTS

2. REQUIREMENTS
2.1 Environmental requirements
Refer to ATV78 User's Manual for information on required operating temperature, humidity, etc.
Leave sufficient free space around the enclosure so the air flow is not obstructed. Air is generally
sucked in from the front and exhausted upwards – leave at least 500 mm free space in front of the
enclosure and 200 mm above the enclosure – also see section 9.3.

NOTE! EN60439-1 specifies the ambient temperature for enclosed products at 35°C (24h
average)/40°C (maximum). The ventilation and cooling of the installation room must be
sufficient to keep the temperature below this level.

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

2.2 Cabinet
Width: Min. 600 mm
Depth: Min. 600 mm
Height: Min. 1800 mm if the AC choke is installed beneath the power
module, otherwise min. 1500 mm
Mechanical requirements: The cabinet must be able to support a total equipment weight
of 275 kg (if the power module and the AC choke are installed
in the same cabinet).
Protection class: This manual applies to IP21.
Construction: According to EN60439-1
Ventilation openings: Refer to section 9.1.
Table 2. Cabinet data for FR10

Width: Min. 800 mm


Depth: See Table 2.
Height: See Table 2.
Mechanical requirements: The cabinet must be able to support a total equipment weight
of 350 kg (if the power module and the AC choke are installed
in the same cabinet).
Protection class: This manual applies to IP21.
Construction: According to EN60439-1
Ventilation openings: Refer to section 9.1.
Table 3. Cabinet data for FR11

Width: Min. 1200 mm


Depth: See Table 2.
Height: See Table 2.
Mechanical requirements: See Table 2.
Protection class: This manual applies to IP21.
Construction: According to EN60439-1
Ventilation openings: Refer to section 9.1.
Table 4. Cabinet data for FR12
REQUIREMENTS •5

2.3 Accessories
Accessory Specification
Input terminals (optional) See Table 10.
Input power cables See User’s manual.
Internal power cables See Table 8
Output power cables See User’s manual.
Grounding cable Cu grounding cable, min. 35mm2/power
module. The cable must fulfill the local
regulations.
Mounting plates
Module mounting rails Must be able to carry a weight of the
power module (see Figure 2).
Fuse switch (optional) See Table 11.
EMC grounding Clamp size according to the output cable
diameter, see section 8.3.
PE rail See section 5.3
Table 5. Accessories data for FR10

2
6• PRODUCT HANDLING

3. PRODUCT HANDLING
3.1 Product type designation codes
Product type designation codes are found on the power module and the control unit. For an
explanation of the type designation codes, refer to the User's Manual.

3.2 Receipt of delivery


The standard delivery includes:
• Power module(s) with fixing frame(s) and with one integrated control unit
• AC choke(s)
• ATV780C56Y to ATV780C71Y units only: optical cable set for internal control connections
between power modules
• IP00 Module Installation manual
• User's manual.

The following optional equipment is delivered on request:


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

AC choke
Fibr
24V
for A
ATV

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

3.3 Receiving, unpacking and storing the product


The product is delivered packed in a plywood case, which can be recycled or destroyed by burning.
Instructions for receiving, handling and storing the product, as well as the general warranty terms
can be found in the User’s manual.
PRODUCT HANDLING •7

3.4 Lifting the power module


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

FR10: 123 kg
FR11: 210 kg
FR12: 2*123 kg

Figure 2. Lifting the power module

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

3.5 Lifting AC chokes


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

Choke Weight
CHK0261 53 kg
CHK0400 84 kg
CHK0520 115 kg

Figure 3. Lifting the AC choke

3
8• INSTALLING AC CHOKEs

4. INSTALLING AC CHOKES

Type code Frame size Choke type


(partial)
Voltage range 525–690V
ATV780C20Y FR10 CHK 261
ATV780C25Y FR10 CHK 400
ATV780C31Y FR10 CHK 400
ATV780C35Y FR11 CHK 520
ATV780C45Y FR11 CHK 520
ATV780C50Y FR11 2*CHK 400
ATV780C56Y FR12 2*CHK 400
ATV780C63Y FR12 2*CHK 400
ATV780C71Y FR12 2*CHK 400
Table 6. Choke types

The recommended location for the AC choke is the bottom part of the enclosure, where it should be
installed close to the rear wall. For a possible later installation of a fuse switch, it may be practical
to install the AC choke somewhat to the left.
Fasten the choke on an assembly plate or using mounting rails.

Figure 4. Installing the AC choke

NOTE! An upper support plate must be installed above the choke if the cabinet is transported in
a horizontal position. A possible fixed support plate must be equipped with air circulation
holes. See Figure 17 on page 21.
INSTALLING THE POWER MODULE •9

5. INSTALLING THE POWER MODULE


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

A A E

F
C

G
D

Figure 5. Preparing the enclosure for the power module

The power module should be fastened to the rear side of the enclosure as shown in Figure 6. For
this purpose, install two fixing bars on the rear wall of the cabinet at appropriate levels.
Note the following dimensions that are essential for placing the power module. All dimensions in
mm:
A B C D E F G
50* 100 1120 550 (290) 116 918 850 (590)
Table 7.

A = Minimum distance to the side walls or adjacent components.


* = Note that the two cabinets, in which the modules of ATV780C56Y to ATV 780C71Y are
installed, require no clearance between them.
B = Minimum distance from the top of the cabinet; This space is needed for the power cables (see
Figure 9).
C = Module height

5
10 • INSTALLING THE POWER MODULE

D = Minimum distance from the bottom of the enclosure if the AC choke is installed at the bottom
of the enclosure. If the choke is installed in another location, the distance must not, however,
be smaller than what is given in parentheses
E = Minimum distance from the cabinet door.
F = Minimum distance from the mounting rails to top of the cabinet.
G = Minimum distance from the mounting rails to the bottom of the cabinet. If the choke is
installed in another location, the distance must not, however, be smaller than what is given in
parentheses

See also the dimensional drawings in chapter 10.

5.2 Mounting the power module


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

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

NOTE! If the power module is installed before the AC choke, the centre of gravity is very high at
this stage. Make certain that the enclosure does not fall over during the assembly.
INSTALLING THE POWER MODULE • 11

5.3 Grounding the power module


Install a PE rail, for instance at the bottom front of the enclosure.

Connect a grounding cable from the grounding connector at the lower right hand side of the power
module frame to the PE rail of the enclosure. Use a copper grounding cable with a cross-sectional
area of at least 35 mm2 per power module, which obeys the local regulations for grounding cables.
See Figure 7 on page 11.

NOTE! The PE rail must be connected to external ground at the installation site according to
local regulations.

Grounding
cable

PE rail

Figure 7. Grounding the power module

5
12 • CONNECTING THE INTERNAL POWER CABLES

6. CONNECTING THE INTERNAL POWER CABLES

Power board

L1 L2 L3 B- B+/R+ R- U V W

BR
(option)

L1* L2* L3
M
3~

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

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

NOTE! The choke has two sets of output terminals designed for different voltages/frequencies.
Use the upper set for 500V/50Hz, 525V/50Hz, 600V/60Hz, and 690V/50Hz
NOTE! The connections for the external brake resistor are located at the top of the unit, beside
the L1-L3 power input terminals
CONNECTING THE INTERNAL POWER CABLES • 13

L3
L2
L1

L1 L2 L3

L1 L2 L3

Voltage / Frequency
500V/50Hz
525V/50Hz
575V/60Hz
690V/50Hz
L1 L2 L3

L1 L2 L3

L1 L2 L3

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

Product Temp. Cu cables


rating Cable size, Specification
mm2 per phase
ATV780C20Y
90°C 2*70 GENELEC HD 21.7 H07V2-K
ATV780C25Y
ATV780C31Y 70°C 2*95 Standard
ATV780C35Y 90°C 2*95 GENELEC HD 21.7 H07V2-K
ATV780C45Y
70°C 2*120 Standard
ATV780C50Y
ATV780C56Y 90°C 2*2*70 GENELEC HD 21.7 H07V2-K
ATV780C63Y
ATV780C71Y 70°C 2*2*95 Standard

Table 8. Required cable sizes for the internal power cables (90oC rating recommended)
14 • CONNECTING THE INTERNAL POWER CABLES

L3 L3
L2 L2
L1 L1

DC- DC+ R- L1 L2 L3 DC- DC+ R- L1 L2 L3

L1 L2 L3 L1 L2 L3

Fuses

L1 L2 L3 L1 L2 L3

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

Product Fuse ratings Recomm. fuse types


Current [A] Voltage (or equivalent)
ATV780C56Y 500 690V Bussmann 170M6202 (2 pcs)
ATV780C63Y 500 690V Bussmann 170M6202 (2 pcs)
ATV780C71Y 500 690V Bussmann 170M6202 (2 pcs)

Table 9. Fuse recommendations

The cable used to connect the DC bus must be at least 90 mm2.


INSTALLING THE CONTROL UNIT • 15

7. INSTALLING THE CONTROL UNIT


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

7.1 Connecting power supply and internal control cables


NOTE! Only ATV780C56Y to ATV780C71Y require connecting of cables by the customer.

7.1.1 ATV 780C56Y to ATV780C71Y


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

Min bending radius 50 mm

Power module 1
ASIC board

X10

FB board

X2

Power module 2
ASIC board

Star coupler board

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

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

7
16 • PREPARING FOR EXTERNAL POWER CONNECTIONS

8. PREPARING FOR EXTERNAL POWER CONNECTIONS


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

Voltage range 525–690V


Product Cu busbar, size
ATV780C20Y.... ATV780C31Y 30*6 mm
ATV780C35Y....ATV780C50Y 40*6 mm
ATV780C56Y....ATV780C71Y 2 pcs 30*6 mm
Table 10. Copper busbars

L1 L2 L3

Figure 12. Power input terminals

7
PREPARING FOR EXTERNAL POWER CONNECTIONS 17

8.2 Installing fuses


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

Product Fuse ratings Recomm. fuse types


Current [A] Voltage I2t at Un Size (or equivalent)
ATV780C20Y 700 690V 425000 2 Bussmann 170M5813 (3 pcs)
ATV780C25Y 700 690V 425000 2 Bussmann 170M5813 (3 pcs)
ATV780C31Y 700 690V 425000 2 Bussmann 170M5813 (3 pcs)
ATV780C35Y 1250 690V 1350000 3 Bussmann 170M8547 (3 pcs)
ATV780C45Y 1250 690V 1950000 3 Bussmann 170M8547 (3 pcs)
ATV780C50Y 700 690V 425000 2 Bussmann 170M5813 (6 pcs)
ATV780C56Y 700 690V 425000 2 Bussmann 170M5813 (6 pcs)
ATV780C63Y 700 690V 425000 2 Bussmann 170M5813 (6 pcs)
ATV780C71Y 700 690V 425000 2 Bussmann 170M5813 (6 pcs)
Table 11. Fuse recommendations

8.3 Installing EMC grounding


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

EMC grounding

PE rail Cable fixing clamps

Figure 13. Installing EMC grounding

7
18 • PREPARING FOR EXTERNAL POWER CONNECTIONS

8.4 Understanding the power unit topology


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

Note!
Min cable
length 5m

M M M

ATV780C20Y to ATV780C50Y ATV780C56Y to


ATV780C45Y Double input* ATV780C71Y
Single input Single output Double input
Single output Double output

Figure 14. Topology of mechanical sizes FR10 – FR12

8.5 Connecting input and output power


8.5.1 Mains and motor cables
The mains cables are connected to terminals L1, L2 and L3 and the motor cables to terminals
marked with U, V and W, see Figure 8.
In ATV780C50Y to ATV780C71Y an even number of input cables is required. In converters consisting
of double power modules (FR12) an even number of input cables and an even number of motor
cables is needed.

In types with double inputs (ATV780C50Y to ATV780C71Y) or outputs (ATV780C56Y to


ATV780C71Y) is it very important that the same cable dimensions, type and routing is used
for all cables. In case the cabling between the converter modules is not symmetrical,
WARNING unequal load inside converter might reduce loadability or even damage the converter.

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

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

7
PREPARING FOR EXTERNAL POWER CONNECTIONS 19

As a rule of thumb, cables and the fuses can be dimensioned according to the frequency converter
nominal OUTPUT current which you can find on the rating plate. Dimensioning according to the
output current is recommended because the frequency converter input current never significantly
exceeds the output current.
Table 12 shows the minimum dimensions of Cu- and Al-cables and the recommended aR fuse sizes.
If the motor temperature protection of the drive (see the Programming Manual, on the CD) is used
as an overload protection, the cable should be chosen accordingly. If three or more cables are used
in parallel (per block) in bigger units each cable requires a separate overload protection.

No of No of
IL Fuse In Mains and motor cable1)
Frame Type Bussmann fuse type supply motor
[A] [A] [mm2]
cables cables
Cu: 1*(3*185+95) Even/Odd Even/Odd
ATV780C20Y 261 170M5813 (3 pcs) 700
Al: 2*(3*120Al+41 Cu)
Cu: 1*(3*240+120) Even/Odd Even/Odd
FR10 ATV780C25Y 325 170M5813 (3 pcs) 700
Al: 2*(3*150Al+41Cu)
Cu: 2*(3*120+70) Even/Odd Even/Odd
ATV780C31Y 385 170M5813 (3 pcs) 700
Al: 2*(3*185Al+57Cu)
Cu: 2*(3*150+70) Even/Odd Even/Odd
ATV780C35Y 460 170M8547 (3 pcs) 1250
Al: 2*(3*240Al+72Cu)
Cu: 2*(3*185+95) Even/Odd Even/Odd
FR11
ATV780C45Y 502 170M8547 (3 pcs) 1250
Al: 2*(3*300Al+88 Cu)
Cu: 2*(3*240+120) Even Even/Odd
ATV780C50Y 590 170M5813 (6 pcs) 700
Al: 4*(3*120Al+41Cu)
Cu: 4*(3*95+50) Even Even
ATV780C56Y 650 170M5813 (6 pcs) 700
Al: 4*(3*150Al+41Cu)
Cu: 4*(3*120+70) Even Even
FR12
ATV780C63Y 750 170M5813 (6 pcs) 700
Al: 4*(3*150Al+41Cu)
Cu: 4*(3*150+70) Even Even
ATV780C71Y 820 170M5813 (6 pcs) 700
Al: 4*(3*185Al+57Cu)
Table 12. Cable recommendations

7
20 • Control of main air flow

9. CONTROL OF MAIN AIR FLOW

CAUTION! It is of utmost importance for the operation and lifetime of the frequency converter
that the enclosure is well ventilated to keep the temperature below the maximum
operating temperature. Repeated overheating will shorten the lifetime of the
converter.

9.1 Arranging ventilation of the enclosure


The enclosure door must be provided with air gaps for air
intake. To achieve sufficient cooling inside the cabinet, the
dimensions for the total area of free openings for
incoming air given in Table 9 must be followed. For
instance, there could be two screened gaps as presented in
Figure 0 (Manufacturer’s recommendation). This layout
2
ensures a sufficient air flow to the module fans as well as
cooling of the additional components.

Air outlet gaps must be situated on top of the cabinet. The


minimum effective air outlet area per converter frame is
given in Table 9.The cooling arrangements inside the cabinet
must be such that they prevent hot output air from mixing
with the incoming fresh air (see page 21 below). The
ventilation gaps must fulfil the requirements set by the
selected IP class. The examples in this manual apply to
protection class IP21.

During operation, air is sucked in and circulated by a fan


blower at the bottom of the power unit. If the power unit is 1
placed in the upper part of the cabinet, the fan blower will be
in the mid of the cabinet, at the height of the upper
ventilation grid.

FR10 FR11 FR12


1 2x13 dm2 2x20 dm2 2x26 dm2
2 7 dm2 11 dm2 14 dm2
Table 13. Ventilation requirements

Figure 15 Ventilation
arrangements on the cabinet

7
Control of main air flow 21

9.2 Steering the internal air flow


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

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

B. Install shields in the gaps between the power unit and the cabinet walls (B in the
figure below). Place the shields above the air outlet gaps at the sides of the module.

In ATV780C56Y to ATV780C71Y, close the opposing gaps in the upper part of the
cabinets with a sheet metal plate to ensure proper cooling.

A B
Air duct
Sheet metal

Shields

Touch protection
cover

Choke
upper
support

Mesh type
touch protection

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

7
22 • Control of main air flow

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

NOTE! If a flat roof is used, mount a V-shaped air guide on the underside of the roof to direct the
air flow horizontally. See Figure 18.

Figure 18. Roof structure seen from the side

9.3 Heat dissipation


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

Ploss [kW ] = Pmot [kW ]* 0.025

The following table shows the heat dissipation from the AC choke.

Choke Heat dissipation


CHK 261 460 W
CHK 400 570 W
CHK 520 810 W
Table 9-14. Heat dissipation from the AC choke

9.4 Temperatures measured during test run


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

Measurement Temperature [°C] Note


Ambient air 30 Outside enclosure
Fan intake air 36
Module input terminal 59 L2-phase
Output terminal 65 V-phase
AC choke 92 L2 winding surface
Table 9-15. Temperatures measured during an accepted test run

7
10. APPENDICES
10.1 Dimensional drawings, Power
modules

Figure 19. Power module dimensions, ATV780C20Y to ATV780C31Y


24 • APPENDICES

Without terminal cover:


709
225 225 67

DC- DC+ R- 1L11L2 1L3 2L1 2L2 2L3

225 225 67

506

With integrated control unit

Figure 20. Power module dimensions, ATV780C35Y to ATV780C50Y

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

7
APPENDICES 25
10.2 Dimensional drawings, AC chokes

CHK 520

497 204
43

1 1 1

40
20
3 3 3

2 2 2
200 145
0
244

165 165

Figure 21. Dimensions of AC choke CHK 520

CHK 400

350
238 39

1 1 1

30
15
3 3 3

2 2 2

140
150
275 262

120 120

Figure 22. Dimensions of AC choke CHK 400

7
26 • APPENDICES
CHK 261

206
39
1 1 1

30
15
3 3 3

2 2 2

150 min. 19mm


275 108
230

120 120
354

Figure 23. Dimensions of AC choke CHK 261

7
APPENDICES 27
10.3 Optic fibre cables, signal lists and connections
In frame ATV780C56Y to ATV780C71Y, which consist of two power modules, you will have to connect
the fibre cables from the star coupler board to the other power module. See chapter 3.2. Connect
the cables according to the figures below.

10.3.1 ATV780C56Y to ATV780C71Y

Star coupler board on control unit Terminals on ASIC board of power module 1

H8 Trip signal from power module 1 H8 H1 Gate control enable


H7 VaconBus data from ASIC 1 to control board H2 Phase U control
H7 H1
H6 VaconBus data from control board to ASIC 1 H3 Phase V control
H6 H2
H5 ADC synchronization, power module 1 U
H4 Phase W control
H4 Phase W control, power module 1 H5 H3 H5 ADC synchronization
V
H3 Phase V control, power module 1 H4 H4 H6 VaconBus data from control board to ASIC
H2 Phase U control, power module 1 W H7 VaconBus data from ASIC to control board
H3 H5
H1 Gate control enable, power module 1 T U Feedback phase U
H2 H6 V Feedback phase V
H18 Trip signal from power module 2
H1 H7 W Feedback phase W
H17 VaconBus data from ASIC 2 to control board
T Trip signal
H16 VaconBus data from control board to ASIC 2
H 18
H15 ADC synchronization, power module 2 H1
H14 Phase W control, power module 2 H 17
H2 Terminals on ASIC board of power module 2
H13 Phase V control, power module 2 H 16
H12 Phase U control, power module 2 H3 H1 Gate control enable
H 15 H2 Phase U control
H11 Gate control enable, power module 2 H4
H 14 H3 Phase V control
H23 Feedback phase W H5 H4 Phase W control
H 13
H22 Feedback phase V H6 H5 ADC synchronization
H21 Feedback phase U H 12 H6 VaconBus data from control board to ASIC
H7
H 11 H7 VaconBus data from ASIC to control board
H8 T Trip signal
H 23

H 22

H 21

Figure 24. Internal fibre cable connections, ATV780C56Y to ATV780C71Y