Bermar BRC10 User manual

User Guide
Inverter BRC10
Variable Speed A.C. drive for induction
motors
Part Number: 0478-0725-05
Issue: 05

Compliance Information
Manufacturer's EU Authorized Representative: BER-MAR SRL, Via C. Bassi, 28/A, 40015 S.Vincenzo di Galliera, Bologna, Italy. Tel +39 051
812120, [email protected]
Original instructions
With reference to the UK Supply of Machinery (Safety) Regulations 2008 and the EU Machinery Directive 2006/42/EC, the English version of this
Manual constitutes the original instructions. Manuals published in other languages are translations of the original instructions and the English language
version of this Manual prevails over any other language version in the event of inconsistency.
Warranty and liability
The contents of this Manual are presented for information purposes only, and while every effort has been made to ensure their accuracy, they are not
to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All
sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs, specifications
or performance of our products at any time without notice. For full details of the warranty terms applicable to the product, contact the supplier of the
product.
In no event and under no circumstances shall we be liable for damages and failures due to misuse, abuse, improper installation, or abnormal conditions
of temperature, dust, or corrosion, or failures due to operation outside the published ratings for the product, nor shall we be liable for consequential
and incidental damages of any kind.
Environmental management
We operate an Environmental Management System which complies with the requirements of ISO 14001:2015.
Restriction and control of hazardous substances
The products covered by this Manual comply with the following legislation and regulations on the restriction and control of hazardous substances:
UK Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012
UK REACH etc. (Amendment etc.) (EU Exit) Regulations 2020, European Union REACH Regulation EC 1907/2006
EU restriction of the Use of certain Hazardous Substances in Electrical and Electronic Equipment (RoHS) - Directive 2011/65/EU
EC Regulation 1907/2006 on the Registration, Evaluation, authorisation, and restriction of Chemicals (REACH)
Chinese Administrative Measures for Restriction of Hazardous Substances in Electrical and Electronic Products 2016/07/01
U.S. Environmental Protection Agency ("EPA") regulations under the Toxic Substances Control Act ("TSCA")
MEPC 68/21 / Add.1, Annex 17, Resolution MEPC.269(68) 2015 Guidelines for the development of the inventory of hazardous materials
The products covered by this Manual do not contain asbestos.
Conflict minerals
With reference to the Conflict Minerals (Compliance) (Northern Ireland) (EU Exit) Regulations 2020, the U.S. Dodd-Frank Wall Street Reform and
Consumer Protection Act and Regulation (EU) 2017/821 of the European Parliament and of the European Council:
We have implemented due diligence measures for responsible sourcing, we conduct conflict minerals surveys of relevant suppliers, we continually
review due diligence information received from suppliers against company expectations and our review process includes corrective action
management. We are not required to file an annual conflict minerals disclosure.
Disposal and recycling (WEEE)
Copyright and trade marks
No part of this Manual may be reproduced or transmitted in any form or by any means including by photocopying, recording or by an information storage
or retrieval system, without our permission in writing.
The products covered by this Manual fall within the scope of the UK Waste Electrical and Electronic Equipment Regulations 2013, EU
Directive 2012/19/EU amended by EU Directive 2018/849 (EU) on Waste Electrical and Electronic Equipment (WEEE).
When electronic products reach the end of their useful life, they must not be disposed of along with domestic waste but should be
recycled by a specialist recycler of electronic equipment. Our products are designed to be easily dismantled into their major component
parts for efficient recycling. Most materials used in our products are suitable for recycling.
Our product packaging is of good quality and can be re-used. Smaller products are packaged in strong cardboard cartons which have a
high recycled fibre content. Cartons can be re-used and recycled. Polythene, used in protective film and bags for the ground screws, can
be recycled. When preparing to recycle or dispose of any product or packaging, please observe local legislation and best practice.

Inverter BRC10 User Guide 3
Contents
1 Safety information .................................4
1.1 Important safety information .................................4
1.2 Responsibility ........................................................4
1.3 Compliance with regulations .................................4
1.4 Electrical hazards ..................................................4
1.5 Mechanical hazards ..............................................4
1.6 Motor .....................................................................4
1.7 Adjusting parameters ............................................5
1.8 Electromagnetic compatibility (EMC) ....................5
1.9 Grounding .............................................................5
1.10 Fuses and circuit breakers ....................................5
1.11 RCD ......................................................................5
1.12 Safety of the control circuits ..................................5
1.13 Terminal connections and torque settings 5
1.14 Environmental limits ..............................................5
1.15 Enclosure ..............................................................5
1.16 Hazardous environments ......................................5
1.17 Access to equipment .............................................5
1.18 Routine maintenance ............................................5
1.19 Repairs ..................................................................5
1.20 Hazardous materials .............................................5
2 Product information ..............................6
2.1 Introduction ...........................................................6
2.2 Model number .......................................................6
2.3 Rating information .................................................7
2.4 Date code format ..................................................7
2.5 Drive ratings ..........................................................8
2.6 Motor sizing ...........................................................8
2.7 Drive features ........................................................9
3 Mechanical installation .......................10
3.1 Planning the installation ......................................10
3.2 Drive dimensions and mounting ..........................11
3.3 Enclosure dimensions .........................................13
3.4 Drive fan operation ..............................................15
3.5 Routine maintenance ..........................................15
4 Electrical installation ..........................16
4.1 Power connections ..............................................16
4.2 Terminal torque settings .....................................18
4.3 Cable selection ...................................................18
4.4 Fuse and MCB selection .....................................20
4.5 Supply requirements ...........................................21
4.6 Ground leakage ..................................................24
4.7 Electromagnetic compatibility (EMC) ..................25
4.8 Control connections ............................................30
4.9 Communication connections ...............................33
5 Getting started .....................................35
5.1 Understanding the display ..................................35
5.2 Using the keypad ................................................36
5.3 Understanding the menu structure ......................38
5.4 Saving parameters ..............................................38
5.5 Restoring parameter defaults ..............................38
5.6 Drive security ......................................................38
6 Running the motor ..............................39
6.1 Basic setup .........................................................39
6.2 Controlling the motor speed ................................40
6.3 Running, stopping and controlling motor direction ..
45
6.4 Connecting motor thermistors .............................49
7 Drive parameters .................................50
7.1 Menu 0 - FastStart ..............................................50
7.2 Single line parameter descriptions ......................51
7.3 Parameter descriptions .......................................56
8 Communications .................................94
8.1 MODBUS RTU specification ...............................94
8.2 Controlling the motor with MODBUS ...................99
9 Diagnostics ........................................101
9.1 Alarms ...............................................................101
9.2 Errors ................................................................102
10 Technical data ...................................106
10.1 Drive derating ....................................................106
10.2 Power dissipation ..............................................108
10.3 Drive storage .....................................................108
10.4 Emission compliance ........................................109
10.5 Maximum cable lengths ....................................110
10.6 Starts per hour ..................................................110
10.7 Start-up time .....................................................110
10.8 Maximum output frequency ...............................110
10.9 Accuracy and resolution ....................................110
10.10 Acoustic noise ...................................................111
10.11 Corrosive gasses ..............................................111
10.12 IP rating .............................................................111
10.13 Vibration ...........................................................112
11 UL Listing Information ......................113
11.1 UL file reference ................................................113
11.2 Environment ......................................................113
11.3 Mounting ...........................................................113
11.4 Terminal torque .................................................113
11.5 Wiring ................................................................113
11.6 Ground connections ..........................................113
11.7 Over voltage category .......................................113
11.8 Branch circuit protection ...................................113
11.9 Solid state short circuit protection .....................113
11.10 Short circuit current rating (SCCR) ...................113
11.11 Motor overload protection .................................113

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4Inverter BRC10 User Guide
1 Safety information
1.1 Important safety information
Specific warnings are given at the relevant places in this User Guide as
follows:
A Note contains information which helps to ensure correct operation of
the product.
1.1.1 Hazards
This User Guide applies to the Inverter BRC10 which are Basic Drive
Modules (BDM) and auxiliary equipment. All safety information within
this guide must be observed. In all applications the hazards associated
with powerful electrical drive is present.
1.2 Responsibility
It is the responsibility of the installer to ensure the safety of the complete
Power Drive System (PDS), so as to avoid the risk of injury in normal
operation, in the event of a fault and of reasonably foreseeable misuse.
The manufacturer of the BDM drive accepts no liability for any
consequences resulting from inappropriate, negligent, or incorrect
system design and installation or as a result of drive failure.
Drives are intended as components for professional incorporation into
complete systems. The drive uses high voltages and currents, has a
high level of stored electrical energy, and is used to control equipment
which can cause injury and generate excessive acoustic noise. If
installed incorrectly the drive may present a safety hazard.
System design, installation, commissioning, start-up and maintenance
must be carried out by personnel with the necessary training and
competence who must read all of the safety information and instructions
in this User Guide.
1.3 Compliance with regulations
The installer is responsible of ensuring that the PDS complies with all
applicable laws, regulations, and codes in the country where it is to be
used, including but not limited to the following:
UK Electrical Equipment (Safety) Regulations 2016
EU Low Voltage Directive 2014/35
UK Electromagnetic Compatibility Regulations 2016
EU Electromagnetic Compatibility Directive 2014/30/EU
UK Supply of Machinery (Safety) Regulations 2008
EU Machinery Directive 2006/42/EC
USA National Electric Code (NEC)
Canadian Electrical Code.
Particular attention must be given to the cross-sectional areas of
conductors, the selection of fuses or other protection, and protective
ground (earth) connections. This guide contains instructions for
achieving compliance with specific EMC standards.
1.4 Electrical hazards
The voltages used in the drive can cause severe electrical shock and/or
burns and could be lethal. Care is necessary when working with or
adjacent to the drive. Hazardous voltage may be present in any of the
following locations:
• A.C. supply cables and connections
• Motor cables and connections
• Relay cable and connections
• Many internal parts of the drive.
No commands remove dangerous voltages from the drive or motor. E.g.
stop, rdy or inh.
1.4.1 Mechanical to electrical energy
Unsafe voltages can be present on the drive even with the A.C. supply
disconnected if the motor shaft is mechanically driven by another source
of power.
1.4.2 Stored electrical charge
1.4.3 Products connected by plug and socket
If a plug and socket are used to connect the PDS / BDM to the supply,
the plug should conform to IEC60309.
A hazard may exist where the drive is incorporated into a product which
is connected to the supply by a plug and socket. When unplugged, the
pins of the plug may be connected to the drive supply, which is
separated from the charge stored in the capacitor only by semiconductor
devices. A means must be provided for automatically isolating the plug
from the drive - e.g. a contactor, or the use of shrouded pins.
It is recommended to remove the EMC filter disconnect screw and fit a
type B RCD fitted on the drive side of the plug.
1.5 Mechanical hazards
In any application where a malfunction of the drive or its control system
could lead to or allow damage, loss, or injury, a risk analysis must be
carried out, and where necessary, further measures taken to reduce the
risk. For example, an over-speed protection device in case of failure of
the speed control, or a fail-safe mechanical brake in case of loss of
motor braking. None of the drive functions should be used to ensure
safety of personnel.
1.6 Motor
The safety of the motor under variable speed conditions must be
ensured. To avoid the risk of physical injury, do not exceed the maximum
specified speed of the motor.
Low speeds may cause the motor to overheat because the cooling fan
becomes less effective, causing a fire hazard. The motor should be
installed with a protection thermistor. If necessary, an electric forced vent
fan should be used.
The values of the motor parameters set in the drive affect the protection
of the motor. The default values in the drive must not be relied upon. It
is essential that the correct value is entered in the Motor Rated Current
parameter from the motor nameplate.
The drive has electronic motor overload protection and typical overloads
are 150 % for 60 s (from cold) or 150 % for 8 s (from hot). The protection
includes speed sensitivity and thermal memory retention through power
cycle and disable. See Thermal Protection Action (P3.21) for details.
This type of warning contains information which is essential
for avoiding an electric shock.
This type of warning contains information which is essential
for avoiding a safety hazard.
A Caution contains information which is necessary for
avoiding a risk of damage to the product or other equipment.
WARNING
WARNING
CAUTION
NOTE
Risk of Electric Shock.
The drive contains capacitors that remain charged to a
potentially lethal voltage after the A.C. supply has been
disconnected. If the drive has been energized, the A.C.
supply must be isolated for at least 5 minutes before work
may continue. In the event of a failure the stored charge could
remain longer.
WARNING

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1.7 Adjusting parameters
Some parameters have a profound effect on the operation of the drive
e.g. enable auto restart. They must not be altered without careful
consideration of the impact on the controlled system and should be
conducted by qualified personnel. Measures must be taken to prevent
unwanted changes due to error or tampering e.g. set Security PIN
(P4.02) or use a locked enclosure.
1.8 Electromagnetic compatibility (EMC)
Installation instructions for a range of EMC environments are provided in
this User Guide. If the installation is poorly designed or other equipment
does not comply with suitable standards for EMC, the product might
cause or suffer from disturbance due to electromagnetic interaction with
other equipment. It is the responsibility of the installer to ensure that the
equipment or system into which the product is incorporated complies
with the relevant EMC legislation in the place of use.
1.9 Grounding
The drive must be grounded by a conductor(s) sufficient to carry the
prospective fault current in the event of a fault and in a zone of
equipotential bonding. The ground loop impedance must conform to the
requirements of local safety regulations.
If the EMC filter disconnect screw is fitted (as delivered)
The protective earth shall be two conductors of the same cross-sectional
area and material as the supply phases or the minimum size of the
protective earthing conductor to comply with the local safety regulations
for high protective earthing conductor current equipment.
Each protective earth conductor including the protective earth conductor
to the motor must use a separate means of connection. Four tapped
holes are provided (2 x M3 and 2 x M4). If the cable management
bracket is used, then any additional protective earth conductors can be
connected to the cable management bracket.
If aluminium cables are used, then the copper cross-sectional areas
should be increased by 60 %.
If the EMC filter disconnect screw is removed
If the protective earth conductor is part of the supply cable, the cross
section of the protective earth must have minimum area equivalent to
the supply phases. If individual cores are used the protective earth
should have a minimum cross section area of 2.5 mm² (if copper) with
strain relief or 4 mm² (if copper) without strain relief or have a minimum
area equivalent to the supply phase conductors whichever is the
greatest.
1.10 Fuses and circuit breakers
The A.C. supply to the drive must be installed with suitable protection
against overload to provide branch circuit protection in accordance with
local safety regulations, e.g. the National Electrical Code (NEC), the
Canadian Electrical Code. Failure to observe this requirement will cause
a risk of fire.
The integral solid-state short circuit protection of the drive does not
provide branch circuit protection. Branch circuit protection must be
provided in accordance with the National Electrical Code and any
additional local codes.
Opening or failure of the branch circuit protective device may be an
indication that a fault has occurred and to reduce the risk of fire or
electric shock, the equipment and the branch circuit protective device
should be examined and tested and replaced if damaged.
1.11 RCD
1.12 Safety of the control circuits
The drive is protective class I where user protection from electric shock
is achieved through a combination of insulation and a protective ground.
The control terminals and 485 Communications port are isolated from
the power circuits in the drive by double/reinforced insulation which
meets the requirements for PELV. The installer must ensure that the
external circuits do not compromise this insulation barrier. If the control
circuits are to be connected to circuits classified as Safety Extra Low
Voltage (SELV) - for example, to a personal computer - an additional
basic barrier must be included in order to maintain the SELV
classification.
1.13 Terminal connections and torque
settings
Loose power connections are a fire risk. Always ensure that terminals
are tightened to the specified torques. Refer to the tables in section 4
Electrical installation.
1.14 Environmental limits
Instructions in this guide regarding transport, storage, installation and
use of the equipment must be complied with, including the specified
environmental limits. This includes temperature, humidity,
contamination, shock and vibration. Drives must not be subjected to
excessive physical force.
1.15 Enclosure
The Basic Drive Module (BDM) must be mounted in an enclosure which
prevents access except by trained and authorized personnel. The BDM
is not a fire enclosure. The BDM is designed for use in an environment
classified as pollution degree 2 by IEC 60664-1. This means that the
environment within the enclosure must be dry, non-conducting
contamination only. Any contamination must not obstruct air flow
1.16 Hazardous environments
The equipment must not be installed in a hazardous environment (e.g. a
potentially explosive environment) unless it is installed in an approved
enclosure and the installation is certified.
1.17 Access to equipment
Access must be restricted to authorized personnel only owing to the risk
of electric shock and the risk of unintended changes to the system
behaviour.
1.18 Routine maintenance
Regular inspections and maintenance should be carried out to ensure
the reliability if the drive is maximized. See detailed information in
section 3.5 Routine maintenance.
1.19 Repairs
Users must not attempt to repair a drive if it has failed, nor carry out fault
diagnosis other than through the use of the diagnostic features
described in this User Guide. It must be returned to an authorized
distributor. Users must not make any attempt at removing drive plastics
to inspect the internal parts of the drive.
1.20 Hazardous materials
RoHS, REACH WEEE etc. details are available at www.drive-setup.com/
environment
Touch current in the protective earthing conductor exceeds
3.5 mA.
CAUTION
This product can cause a D.C. current in the protective
earthing conductor. Where a residual current-operated
protective (RCD) or monitoring (RCM) device is used for
protection in case of direct or indirect contact, only an RCD or
RCM of Type B is allowed on the supply side of this product.
CAUTION

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2 Product information
2.1 Introduction
Inverter BRC10 is a general-purpose drive that delivers maximum machine performance of induction motors for a range of applications. The voltage
and power rating of the drive should be chosen to suit the mains supply and the induction motor to be controlled.
The default setting of drive parameters have been selected for the majority of use cases but can be adjusted to optimize the drive for a specific
application.
2.2 Model number
The way in which the model numbers for the Inverter BRC10 are formed is illustrated below:
Figure 2-1 Model number
Other Variants
Identification Label
Derivative Electrical Specifications
I.BRC10 001 D00110
Product Line
I.BRC10
Frame Size:
Voltage Rating:
Power rating
- 0 10
Reserved:
1 - 100 V (100 - 120 ± 10%)
2 - 200 V (200 - 240 ± 10%) 3 ph
4 - 400 V (380 - 480 ± 10%)
S 1 ph- 200 V (200 - 240 ± 10%)
D 1 / 3 ph- 200 V (200 - 240 ± 10%)

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2.3 Rating information
Figure 2-2 Drive rating information
2.4 Date code format
The date code is provided in a four digit format. The first two digits indicate the year and the remaining two digits indicate the week number (within the
year).
Example:
A date code of 2110 would correspond to week 10 of year 2021.
Inverter BRC10
Made in UK
1.1 1.kW 5 hp
Ber-Mar
I.BRC1002400110-001
Voltage (V) Supply
240
Motor
0-240
13
f (Hz) 50/60 0-300
I (A) 15.3 6
Φ
Refer to user guide
Made in the UK
Nidec Industrial Automation Italy SpA,
Via Mario Idiomi 3/6 - 20057 Assago (MI)
E 171230
www.bermar.it
IP20 Pollution Degree 2
OVC III IE2-VSD
MAXIMUM SURROUNDING AIR
TEMPERATURE 60°C (WITH DERATE)
WARNING
RISK OF ELECTRIC SHOCK
DANGEROUS VOLTAGE MAYEXIST FOR
5 MINUTES AFTE REMOVING POWER
SUITABLE FOR USE ON A CIRCUIT CAPABLE
OF DELIVERING NOT MORE THAN 5K RMS
SYMMETRICALAMPERES, 240V MAXIMUM
AVERTISSEMENT
RISQUE DE CHOC ÉLECTRIQUE.UNE TENSION
DANGEREUSE PEUT ÉTRE PRÉSENTÉE JUSTQU-A
5 MINUTES APRÉA AVOIS COUPÉ L-ALIMENTATION
CONVIENTAUX CIRCUITS MON SUSCEPTIBLES
DE DÉLIVRER PLUS DE 5K AMPÉRES
SYMÉTRIQUES EFF, MAXIMUM 240V
Current rang
Frequency
No. of phases
Voltage
Power range
Model Number
Approvals
Side etched label
1001D00110
2144
8900000001
Date code
Serial number
Front etched label
Key to approvals
UKCA Great Britain
CE approval Europe
C Tick approval Australia
UL / cUL approval USA & Canada
RoHS compliant China
KC Certification Korea

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2.5 Drive ratings
Thecontinuouscurrentratings given beloware for a maximum ambient temperature of40 °C (104 °F),1000 m altitudeand 4 kHz switching
frequency. Derating may be required for higher switching frequencies, at an ambient
temperature > 40 °C (104 °F) and at higher altitude. For further
information, refer to section 10 Technical data
.
Table 2-1 200 V Drive ratings (200 to 240 V ±10 %)
Table 2-2 400 V Drive ratings (380 to 480 V ±10 %)
2.5.1 Drive overload limits
Typical short-term overload limits
The drive is rated to supply 150 % output current as an overload, such as when the motor is accelerating. During overload conditions, the internal
drive components get hot which limits the potential time the overload can be sustained.
Typical values are shown in the table below:
2.6 Motor sizing
The motor rated current generally should not exceed the maximum continuous output current of the drive as listed in Table 2-1 to Table 2-2.
The maximum output voltage of the drive is not able to exceed the input voltage. The rated voltage of the motor should be similar to the output voltage
of the drive. Motors can often be configured for different voltage ranges e.g. (star wye) or delta configuration of the windings. Ensure the configuration
matches the drive and supply voltages.
The drive will initiate an error if the drive output current exceeds the over-current threshold, which could occur in the event of a short circuit of the
motor output cables. The over-current threshold is the maximum current the drive can measure.
Model Supply
P
hases
Maximum Continuous
Output Current Peak Current Nominal Power at 230 V Motor power at 230 V
AA kW hp
1001S00025 1 1.6 2.4 0.25 0.33
1001S00037 1 2.4 3.6 0.37 0.5
1001S00075 1 4.6 6.9 0.75 1
1001D00110 1 / 3 6.6 9.9 1.1 1.5
1001D00150 1 / 3 7.5 11.25 1.5 2
1001D00220 1 / 3 10.6 15.9 2.2 3
Model Supply
P
hases
Maximum Continuous
Output Current Peak Current Nominal Power at 400 V Motor power at 460 V
AA kW hp
1002400037 3 1.2 1.8 0.37 0.5
1002400055 3 1.7 2.55 0.55 0.75
1002400075 3 2.2 3.3 0.75 1
1002400110 3 3.2 4.8 1.1 1.5
1002400150 3 3.7 5.55 1.5 2
1002400220 3 5.3 7.95 2.2 3
1003400300 3 7.2 10.8 3 3
1003400400 3 8.8 13.2 4 5
Starting Condition From Cold
(No previous output current)
From Hot
(Operating at 100 % output current)
Drive Output Current 150 % for 60 s 150 % for 8 s
The thermal protection may, in some cases, allow the drive to exceed these ratings. It is not recommended to run beyond the rating of the
drives as that will reduce the lifetime of the product and potentially void the warranty.
CAUTION

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2.7 Drive features
Figure 2-3 Features of the drive
2.7.1 Items supplied with the drive
Table 2-3 Items supplied with the drive
Key
1. DIN Rail Release
2. NFC Reader Location
3. Keypad
4. Display
5. Rating information (side of drive)*
6. Model number
7. Relay connections
8. Digital IO Connections
9. 485 communication Port
10. Analog I/O connections
11. EMC filter disconnect Screw **
12. A.C. supply and motor connections
13. Cable management bracket attachment points / alternative ground
connections (2 x size M3 screws not provided)
14. Ground (protective earth) connections (2 x M4 screws provided)
15. EMC backplate screw
*Always check the drive voltage rating is suitable for the installation
**Read information in section 4 Electrical installation before removal.
1
3
7
8
10
12
13
6
9
11
5
4
2
13
14 14
15
Description Further Details
2 x 8 mm M4 (Phillips/Slotted) These screws should be used to attach the ground cable as covered in section 4.1.3 Ground connections.

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3 Mechanical installation
This chapter describes how the drive is intended to be installed in an enclosure. Key features of this chapter include:
• Planning the installation
• Enclosure sizing and layout
• Drive dimensions
• Routine maintenance
During installation it is recommended that the vents on the drive are covered to prevent debris (e.g. wire off-cuts) from entering the drive.
3.1 Planning the installation
The following considerations outlined in this section must be made when planning the installation.
3.1.1 Access
Access must be restricted to authorized personnel only. Safety regulations which apply at the place of use must be complied with.
3.1.2 Environmental protection
The drive must be protected from:
• Moisture, including dripping water, spraying water and condensation. An anti-condensation heater may be required, which must 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 internal components
• Temperature beyond the specified operating and storage ranges
• Corrosive gasses
• Excessive vibration
3.1.3 Hazardous areas
The drive must not be located in a classified hazardous area unless it is installed in an approved enclosure and the installation is certified.
3.1.4 Cooling
The heat produced by the drive must be removed without its specified operating temperature being exceeded. Note that a sealed enclosure gives
substantially reduced cooling compared with a ventilated one, and may need to be larger and/or use internal air circulating fans.
For further information, refer to section 3.3.1 Enclosure sizing.
3.1.5 Fire protection
The drive enclosure is not classified as a fire enclosure. A separate fire enclosure 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 enclosures must meet at least UL 94 class 5VB at the point of minimum thickness.
Air filter assemblies to be at least class V-2.
Unless mounting in an enclosed electrical operating area (restricted access) with concrete floor, the area outlined in Figure 3-1 (the bottom and sides
of the enclosure within 5° marked ) must be designed to prevent escape of burning material - either by having no openings or by having a baffle
construction.
Figure 3-1 Fire enclosure bottom layout
Openings for cables etc. must be sealed with materials meeting the 5VB requirement, or else have a baffle above. See Figure 3-2 for acceptable
baffle construction. The distance below the drive where this applies to the enclosure wall = Distance from the cabinet wall to the drive ÷0.0875.
NOTE
1

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Figure 3-2 Fire enclosure baffle construction
3.2 Drive dimensions and mounting
Figure 3-3 below shows the overall dimensions of the drive. The mounting location marked is only found on BRC1003 drive.
Figure 3-3 Overall dimensions
Table 3-1 Overall dimensions
Not less
th a n 2 X B a ffle p la te s (m ay b e
a b o ve o r b e low b o tto m
of enclosure)
X
Bottom of fire
enclosure
Not less
than 2
times ‘X’ Baffle plates (may be above or
below bottom of enclosure)
Bottom of fire enclosure
X
1
Model Number HWDWeight
mm in mm in mm in kg lb
BRC1001 156 6.14 68 2.70 130 5.12 0.7 1.54
BRC1002 192 7.56 68 2.70 132 5.20 0.8 1.76
BRC1003 192 7.56 90 3.54 132 5.20 1 2.2

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3.2.1 DIN rail mounting
The DIN rail mounting mechanism has been designed so no tools are required to install and remove the drive from a DIN rail. To install the drive on
the DIN rail:
1. Press the DIN rail release
2. Position the top mounting lugs correctly on the DIN rail
3. Ensure drive is secure before releasing the DIN rail clip
4. Install DIN rail end stops either side of the drive to prevent lateral movement
The DIN rail (TS35) used should be 7.5 mm (0.3 in) to conform to ISO/EN 60715. Dimensions from the top of the drive to the DIN rail center can be
found in Table 3-2.
No additional screws are required to support the drive when it is installed on a DIN rail. However, if the drive is to be installed on a residential supply
or near sensitive equipment it may be required that the EMC backplate screw (bottom-central) be installed to ensure direct-metal contact between the
drive and cabinet. See section section 4.7 Electromagnetic compatibility (EMC).
Figure 3-4 DIN rail release location
Figure 3-5 DIN rail dimensions
Table 3-2 DIN rail dimensions
The EMC backplate screw is located slightly off centre on the frame size 3 drive (BRC1003).
Model Number DIN E1 W E2 E3 Mounting Hole
Diameter
mm in mm in mm in mm in mm in mm in
BRC1001 46 1.81 152 5.99 68 2.70 34 1.34 34 1.34 4.8 0.19
BRC1002 46 1.81 187 7.36 68 2.70 34 1.34 34 1.34 4.8 0.19
BRC1003 46 1.81 187 7.36 90 3.54 50 2.17 40 1.77 4.8 0.19
NOTE

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3.2.2 Mounting on a backplate
The following drawings show the dimensions of the drive and mounting holes to allow a backplate to be prepared. A drill template for wall mounting is
included on the drive packaging for quick installation.
Figure 3-6 Mounting dimensions
Fourth mounting hole in the bottom left corner is only found on BRC1003 drive.
Table 3-3 Mounting dimensions and torque settings
3.3 Enclosure dimensions
Please observe the clearances in Figure 3-7 taking into account any appropriate notes for other devices / auxiliary equipment when planning the
installation.
Cables should be routed carefully to ensure that the airflow in and out of the product is not impeded.
Figure 3-7 Enclosure layout
Table 3-4 Drive clearances
NOTE
Model Number M1 M2 M3 M4 ∅Torque setting
mm in mm in mm in mm in mm in Nm lb in
BRC1001 145 5.71 45 1.77 22 0.89 22 0.89 4.8 0.19 1.5 13.28
BRC1002 180 7.11 45 1.77 22 0.89 22 0.89 4.8 0.19 1.5 13.28
BRC1003 180 7.11 65 2.56 37 1.48 27 1.06 4.8 0.19 1.5 13.28
Drive Clearances BRC1001S00025 All other drives
A 100 mm (3.94 in) 45 mm (1.77 in)
B 0 mm (0 in)
NOTE
Enclosure
A C supply..
contactor and
fuses or MCB
Locate as
required
External
controller
B
B B
A
A
The external EMC filter can be bookcase
mounted (next to the drive) or footprint mounted
(with the drive mounted onto the filter). The filter
must make good direct electrical contact with the
metal backplate. Any paint or other non-
conducting coating must be removed.
The output connections of the filter should
be placed as close as possible to the drive
supply terminals to ensure the wires
between the filter and drive input asare
short as possible.
Ensure minimum clearances are
maintained for the drive and
external EMC filter. Forced or
convection air-flow must not be
restricted by any object or cabling.

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3.3.1 Enclosure sizing
Correctly sizing an enclosure for the drive is an important aspect of the installation process and if over-looked can cause the enclosure temperature to
rise excessively making the drive less efficient. The calculations for sizing an enclosure are based on the total heat dissipation of the equipment inside
the enclosure which can be calculated as follows:
1. Add the dissipation figures from section 10.2 Power dissipation for each drive that is to be installed in the enclosure.
2. Calculate the total heat dissipation (in Watts) of any other equipment (such as EMC filters) to be installed in the enclosure.
3. Add the heat dissipation figures obtained above. This gives a figure in Watts for the total heat that will be dissipated inside the enclosure.
Follow the equations below to calculate the minimum required unobstructed surface area and the minimum air-flow required. Select the enclosure
(cabinet) and enclosure fan based on the values produced.
3.3.1.1 Calculating the size of a sealed enclosure
The enclosure transfers internally generated heat into the surrounding air by natural convection (or external forced air flow); the greater the surface
area of the enclosure walls, the better is the dissipation capability. Only the surfaces of the enclosure that are unobstructed (not in contact with a wall
or floor) can dissipate heat.
Calculate the minimum required unobstructed surface area Aefor the enclosure from:
Where:
Ae= Unobstructed surface area in m2 (1 m2= 10.9 ft2)
P = Power in Watts dissipated by all heat sources in the enclosure
k= Heat transmission coefficient of the enclosure material in W/m2/°C
Typical values of heat transmission:
• Polypropylene PP: 0.1 - 0.22
• Stainless steel: 16 - 24
• Aluminium: 205 - 250
Tint = Maximum permissible temperature in °C inside the enclosure
Text = Maximum expected temperature in °C outside the enclosure
3.3.1.2 Calculating the air-flow in a ventilated enclosure
The dimensions of the enclosure are required only for accommodating the equipment. The equipment is cooled by the forced air flow.
Calculate the minimum required volume of ventilating air from:
Where:
V= Air-flow in m3 per hour (1 m3/hr = 0.59 ft3/min)
P = Power in Watts dissipated by all heat sources in the enclosure
Tint = Maximum permissible temperature in °C inside the enclosure
Text = Maximum expected temperature in °C outside the enclosure
k= Ratio of
Where:
•P0 is the air pressure at sea level
•PI is the air pressure at the installation
Typically, a factor of 1.2 to 1.3 can be used. This will allow for any pressure drops in dirty air-filters.
Ae= P
k(Tint - Text)
V = 3kP
Tint - Text
P0
PI

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3.3.1.3 Enclosure design and drive ambient temperature
Drive derating is required for operation in high ambient temperatures.
Totally enclosing the drive in either a sealed cabinet (no airflow) or in a well-ventilated cabinet makes a significant difference on drive cooling.
The chosen method affects the ambient temperature value (Trate) which should be used for any necessary derating to ensure sufficient cooling for the
whole of the drive.
The ambient temperature for the four different combinations is defined below:
1. Totally enclosed with no air flow (<2 m/s) over the drive Trate = Tint + 5 °C
2. Totally enclosed with air flow (>2 m/s) over the drive Trate = Tint
Where:
Tint = Temperature inside the cabinet
Trate = Temperature used to select current rating from tables in section 10 Technical data.
3.4 Drive fan operation
I.BRC1001S00025 drive is cooled by natural convection. All other drives are ventilated by an internally controlled fan that will turn on when required
to keep the drive cool.
Ensure the minimum clearances around the drive are maintained to allow air to flow freely.
3.5 Routine maintenance
Regular checks of the following should be carried out to ensure the drive reliability is maximized:
Table 3-5 Routine maintenance
Environment
Ambient temperature Ensure the enclosure temperature remains at or below maximum specified.
Dust Ensure the drive remains dust free. The lifetime of the fan is reduced in dusty environments. If the fibre filter accessory is
used, ensure it remains clear and free of dust.
Moisture Ensure the drive enclosure shows no signs of condensation. If moisture is discovered, an anti-condensation heater may
be required which must be switched off when the drive is running to prevent excess heating.
Enclosure
Enclosure particle filters Ensure filters are not blocked and that air is free to flow in and out of the enclosure.
Electrical
Screw connections Ensure all screw terminals remain tight
Crimp terminals Ensure all crimp terminals remain tight – check for any discoloration which could indicate overheating
Cables Check all cables for signs of damage
Ground connections Must be inspected and tested at appropriate intervals

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4 Electrical installation
This chapter covers information relevant to the electrical installation of the product. This includes but is not limited to:
• Supply, motor and ground connections
• Torque settings
• Cable sizes
• Fuse & MCB selection
• Supply requirements and optional line reactor selection
• Ground leakage, touch currents and RCDs
• Electromagnetic compatibility (EMC)
• Control connections
4.1 Power connections
4.1.1 Single phase supply connections
Figure 4-1 Single phase power connections
For dual-rated drives, single phase connections should be made to L1 and L2.
Before proceeding ensure all of the warnings in section 1 Safety information. have been read and are understood.
WARNING
Power Terminals (I.BRC10034XXXXX): 5 mm (3/16 in) flat-blade screwdriver.
Power Terminals (all other models): 3 mm (1/8 in) flat-blade screwdriver.
Control Terminals (all models) : 3 mm (1/8 in) flat-blade screwdriver.
L1 L2 U V W
Op onal EMC Filterti
Op onal Line Reactorti
Live Neutral
Ground
Fuses /
MCB
Supply

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4.1.2 Three phase supply connections
Figure 4-2 Three phase power connections
For dual-rated drives (BRC1001D), single phase connections should be made to L1 and L2.
4.1.3 Ground connections
The supply and motor ground connections are made using the ground busbar located at the bottom of the drive as shown in Figure 4-3. The drive
must be connected to the system ground of the A.C. supply. The ground wiring must conform to local regulations and codes of practice.
Figure 4-3 Ground connections (Size 1 shown)
4.1.4 Protective ground cable ratings
Minimum ground conductor size
Two copper conductors of the same cross-sectional area as the input phase conductor.
If the drive is connected via a plug/socket conforming to IEC60309 then a single protective earthing conductor of at least 2.5 mm2as part of a multi-
conductor cable with adequate strain relief is permitted.
L1 L2
Op onal EMC Filterti
Op onal Line Reactorti
L1 L2
Ground
Fuses /
MCB
Supply
L3
L3
U V W
The ground loop impedance must conform to the requirements of local safety regulations. The drive must be grounded by a connection
capable of carrying the prospective fault current until the protective device (fuse, MCB) disconnects the A.C. supply. The ground
connections must be inspected and tested at appropriate intervals.
WARNING

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4.2 Terminal torque settings
To avoid a fire hazard and maintain validity of the UL listing, adhere to the specified tightening torques for all terminals.
Table 4-1 Drive power terminal torque settings
4.3 Cable selection
IEC cable sizes assume copper conductor, PVC insulation, installation method B2 and ambient temperature of 40 °C (104 °F). For UL, cables must
be rated for 60 °C (140 °F) operation and copper only. Cables must be provided with mechanical protection against damage and be rated for a
voltage in excess of the maximum supply voltage.
Table 4-2 Cable ratings (200 V Drive)
Cables marked † need to be rated for 90 °C and 1.5 mm2in order to terminate with a ferrule.
Table 4-3 Cable ratings (400 V Drive)
The nominal motor cable sizes assume that the motor maximum current matches that of the drive. Where a motor of reduced rating is used the cable
rating may be chosen to match that of the motor. To ensure that the motor and cable are protected against overload, the drive must be programmed
with the correct motor rated current. A fuse or other protection must be included in all live connections to the A.C. supply.
Drive Voltage Rating 100 V 200 V 400 V
Recommended
Torque Setting
Power Connections 0.5 Nm (4.4 lb in) 0.6 Nm (5.3 lb in)
Ground Connections 1.5 Nm (13.3 lb in)
Control Connections (Including Relay) 0.4 Nm (3.5 lb in)
The nominal cable sizes below are for guidance only. The mounting and grouping of cables will affect their current-carrying capacity, in
some cases smaller cables may be acceptable but in other cases a larger cable is required to avoid excessive temperature or voltage drop.
Refer to local wiring regulations for the correct size of cables.
CAUTION
Model Number Supply Phases
Cables IEC60364-5-52
mm²
UL61800-5-1
AWG
Supply Motor
Supply Motor
Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum
1001S00025 1 1.5 2.5 1.5 2.5 24 12 24 12
1001S00037 1 1.5 2.5 1.5 2.5 22 12 22 12
1001S00075 1 1.5 2.5 1.5 2.5 18 12 18 12
1001D00110 12.5†2.5 1.5 2.5 16 12 16 12
3 1.5 2.5 1.5 2.5 16 12 16 12
1001D00150 12.5†2.5 1.5 2.5 16 12 14 12
32.5†2.5 1.5 2.5 16 12 14 12
1001D00220 1 4 6 1.5 2.5 14 8 14 12
3 4 6 1.5 2.5 14 8 14 12
NOTE
Model Number Supply
phases
Cables IEC60364-5-52
mm²
UL61800-5-1
AWG
Supply Motor
Supply Motor
Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum
1002400037 3 1.5 4 1.5 4 24 10 24 10
1002400055 3 1.5 4 1.5 4 22 10 22 10
1002400075 3 1.5 4 1.5 4 22 10 22 10
1002400110 3 1.5 4 1.5 4 20 10 20 10
1002400150 3 1.5 4 1.5 4 20 10 20 10
1002400220 3 1.5 4 1.5 4 18 10 18 10
1003400300 3 2.5 4 1.5 4 16 10 16 10
1003400400 3 2.5 4 1.5 4 14 10 14 10
NOTE

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Table 4-4 Terminal maximum cable size
*This is per connection, so with two ground connections the maximum total cable size is 12 mm2.
4.3.1 Cable lengths
Since capacitance in the motor cable causes loading on the output of the drive, ensure the cable length does not exceed 50 m. For motor lengths to
comply to a particular EMC level, such as C1, refer to the cable lengths given in section 10.4 Emission compliance.
4.3.2 High capacitance / reduced diameter motor cables
The maximum cable length of 50 m must be reduced to 25 m if high capacitance or reduced diameter motor cables are used. Most cables have an
insulating jacket between the cores and the armor or shield; these cables have a low capacitance and are recommended. (Figure 4-4 shows how to
identify the two types).
Figure 4-4 Cable construction influencing the capacitance
The maximum motor cable lengths specified in section 4.3.1 Cable lengths. are for cables that are shielded and contain four cores. Typical
capacitance for this type of cable is 130 pF/m (i.e. from one core to all others and the shield connected together).
Drive Voltage Rating 200 V 400 V
Drive Frame Size BRC1002, BRC1003 BRC1004 All Frame Sizes
Maximum Cable
Size
Supply Terminals
2.5 mm2 (12 AWG)
6 mm2(8 AWG)
4 mm2 (10 AWG)
Motor Output Terminals 2.5 mm2 (12 AWG)
Ground Connections* 6 mm2 (8 AWG)
Control Terminals
(Including Relay) 1.5 mm2 (16 AWG)
Normal capacitance
Shield or armor
separated from the cores
High capacitance
Shield or armor close
to the cores

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4.4 Fuse and MCB selection
The fuses and MCBs recommended below are maximum values to protect the recommended cables and prevent noise errors during normal
operation. If smaller cables are used, smaller protection devices may be required.
The voltage rating of fuses and MCBs must be greater than or equal to the highest supply voltage of the system.
Table 4-5 Fuse and MCB selection
* For UL installations, the circuit breaker must be listed under category control number DIVQ / DIVQ7, rated 600 Vac with a short circuit rating > 5 kA.
In other installations, circuit breakers compliant with EN IEC 60947-2 are recommended, with > 5 kA short circuit breaking capacity.
When protected by fuses or circuit breakers with maximum ratings as specified in Table 4-5, this product is suitable for use on a circuit capable of
delivering not more than 5,000 RMS symmetrical amperes, 480 V maximum (up to the rated voltage of the drive module).
Model Number Rated Current Rated Power Supply
Phases
Max supply
Current
IEC* UL*
Fuses
Class gG
MCB
Type C
Fuses
Class CC, J or T
MCB
Type C
AkWhp A A A
200 V Drive (200 to 240 V ±10 %)
1001S00025 1.6 0.25 0.33 1 3.8 6 6 6 15
1001S00037 2.4 0.37 0.5 1 4.7 6 6 6 15
1001S00075 4.6 0.75 1 1 9.5 12 12 15 15
1001D00110 6.6 1.1 1.5 1 15.3 16 20 20 20
3 12.2 16 16 15 15
1001D00150 7.5 1.5 2 1 18.4 20 25 25 20
3 14.3 16 16 20 20
1001D00220 10.6 2.2 3 1 26.1 32 32 35 30
3 19.7 25 25 25 25
400 V Drive (380 to 480 V ±10 %)
1002400037 1.2 0.37 0.5 3 1.9 4 6 6 15
1002400055 1.7 0.55 0.75 3 2.5 4 6 6 15
1002400075 2.2 0.75 1 3 3.0 4 6 6 15
1002400110 3.2 1.1 1.5 3 4.5 6 6 6 15
1002400150 3.7 1.5 2 3 5.6 8 8 10 15
1002400220 5.3 2.2 3 3 8.2 10 16 15 15
1003400300 7.2 3 3 3 13.2 16 16 20 15
1003400400 8.8 4 5 3 16.0 20 20 25 20