motortronics CSD Series Installation and operating instructions

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 73 -
CSD Series
Variable Frequency
AC Drive
½ - 30 HP
OPERATION & SERVICE MANUAL
MOTORTRONICS
Solid State AC Motor Control
REV2
7080601MN

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 74 -

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 75 -
Chapter 1: Introduction ................................................................................................ 1
1.1 General
1.2 Receiving
1.3 Warning
1.4 Theory of Operation
Chapter 2: Installation/Specifications ......................................................................... 4
2.1 Location
2.2 Mounting Dimensions
2.3 Specifications
Chapter 3: Wiring ........................................................................................................ 8
3.1 Main Power Wiring
3.2 Grounding
3.3 Power Connection Diagram
3.4 Control Terminal Function
3.5 Brake Motor Magnetic Contactor
3.6 Special Warnings for Wiring - Initial Power Up
3.7 External Brake Resistor Ratings
3.8 Power Terminal Block (TM1) Description
Chapter 4: Remote Control Function ........................................................................ 16
4.1 Control Terminal Block (TM2) Function Description
4.2 Function Description of Jumper
Chapter 5: Digital Operator Control/Keypad Operation .......................................... 22
5.1 Introduction
5.2 Function Parameter Setting
5.4 Function Descriptions
5.4 Special Function Setting
Chapter 6: Start-Up ..................................................................................................... 50
6.1 Checks Before Power-up
6.2 Checking Motor Rotation
6.3 Keypad Operation
6.4 Programming Terminal Strip Operation
6.5 Remote Operation
6.6 Initial Programming
6.7 Jumper Selection For Analog Frequency Signal
Chapter 7: Failure Indications ................................................................................... 54
7.1 Failure which cannot be reset by manual operation
7.2 Special Condition Indication
7.3 Failure which can be auto reset or reset by manual operation
7.4 Failure which can be reset by manual operation, but cannot be auto reset
7.5 Operation Error Indications
7.6 One Final Fault Note
Chapter 8: Troubleshooting ....................................................................................... 57
8.1 General Troubleshooting
8.2 Power Section Troubleshooting
8.3 Maintenance
Chapter 9: Reference ................................................................................................. 61
9.1 Measurement of Voltage and Current
9.2 Electromagnetic Compatibility of Inverters
9.3 Inverter Model Number Definitions
9.4 Extension Keypad Remote Cable
9.5 Drive Settings
Table of Contents

CSD Series Variable Frequency AC Drive
MOTORTRONICS
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CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 1 -
Chapter 1 - Introduction ThismanualprovidesdetailedprogramminginformationfortheCSD
SeriesadjustablefrequencyACdrive.Forbasicstartupinstructions
see the “Quick Startup” Manual.
1.1 General
TheCSD Series is a compact AC drive featuring front panel keypad
and display, plus an easy to use keypad mounted potentiometer.
The CSD Series combines application flexibility with ease of
operation.Itisideallysuitedfor thevastnumberof applicationswhere
variablespeedoperationistherequirement,but without the need for
extensiveprogramming. Inadditiontothemany conventionalfeatures
availableontoday’sdrives, theCSDSeries is capableofoperatingvia
RS232or RS485 via optional cabling andsoftware.
1.2 Receiving
Uponreceiptof this product you should immediately do thefollowing:
•Inspect the box for possible shipping damage (if damaged, you
should notify the freight carrier and file a claim within 15 days of
receipt).
•Verifythemodelnumber ontheboxmatches yourpurchaseorder.
•Confirmtheratingsstickerontheunitmatchesyour motor’scurrent
and voltage rating.
1.3 WARNING!
Do not service equipment with voltage applied! Unit can be the
source of fatal electrical shocks! To avoid shock hazard,
disconnect main power before working on the drive. More than
one disconnect switch may be required to de-energize the
equipment. Verify that the DC bus is completely discharged
beforeservicing. Warninglabels (not supplied) must be attached
to terminals, enclosure and control panel; also, take a VDC
reading. This should read 0 VDC prior to working on the unit.
Note:Unit does not provideoverspeed protection or incorporate
current limiting control.
1.4 Theory of Operation
1.4.1 Variable Speed Control of AC Motors
Astandardthree-phasemotor is designed to operate at fixed voltage
and fixed speed (frequency). To operate variable speed, a variable
frequency waveform must be supplied to power the motor. Because
ofthespatialdistribution and interconnections of the motor’s internal
windings,the applicationof three-phasepower willproducearotating
magneticfieldarounditsperiphery. Asshown in Figure 1-1, this field
may rotate either clockwise or counterclockwise, depending upon
thephase sequenceofthe three-phasesource. Thespeed ofrotation
of this magnetic field is called “synchronous speed”.
Figure 1-1
Direction of Rotation
Magnetic
Field
CW
CCW
(End View of Motor)

CSD Series Variable Frequency AC Drive
MOTORTRONICS
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This speed is described by this simple formula:
Where:
• Synchronous speed is in RPMs (Revolutions Per Minute)
• Poles are the number of poles built into the motor.
• Frequencyistheappliedfrequencyof the power fed to the motor.
As you can see, synchronous speed is directly proportional to the
applied frequency. By increasing or decreasing this frequency, you
can increase or decrease the rotational speed of the magnetic field.
This is the underlying theory behind the operation of the adjustable
frequencydrives.
Changingthespeedisonlyhalf theproblem. The motorwasdesigned
torun atafixedoperation pointasshownin thenameplate(frequency
voltage). This point can be described by a “volts per hertz” (V/Hz)
ratio which relates to the strength of the magnetic field. To maintain
constant field strength and constant torque, we must maintain this
ratio.Since we vary thefrequencytochange the synchronous speed,
we must simultaneously change the applied voltage to maintain the
necessary V/Hz ratio. As an example: For a constant torque
application, if the frequency is cut in half, the voltage must also be
cut in half as shown in Figure 1 - 2.
The final concept to be introduced is known as motor “slip”. The
actualtorqueoutputbyaninductionmotorisproportionaltotheproduct
of the V/Hz ratio and the slip. Slip is simply defined as the difference
betweensynchronousspeedandthe actual motor shaft speed. With
constantV/Hz excitation, themotormustslip to produce moretorque.
Thegreaterthetorquerequirement,thegreateramountofmotorslip
and the slower the resultant shaft speed.
1.4.2 Drive Power Section
Refer to Figure 1 - 3. The input (converter) of the power section is a
three-phase,rectifier bridge used to convert theincomingACvoltage
into DC voltage. This DC voltage is then filtered by the DC bus
capacitors to produce a clean, ripple-free DC level. The converter
alsoincludesa current limiting, pre-charge circuit. This circuit is used
tocontrolthecurrentinrush while the capacitors are building up their
charge when power is first applied to the drive unit. Once they are
charged, this circuit serves no further useful purpose, so it is
bypassed. The output (inverter) section consists of six transistors
which are switched by the microprocessor to produce the variable
voltage, variable frequency output waveform necessary to control
theV/HZratioasdiscussedintheprevious section. The result of this
switching is a “chopped up square wave” voltage that produces a
nearly sinusoidal motor current waveform.
Note: The shape of the voltage waveform prohibits accurate
measurement with most types of voltmeters. The most accurate
measurement is obtained by using a “rectifier” type AC voltmeter. If
this type of meter is unavailable, use an analog meter and check to
insure the three-phase output voltage is balanced (this shows all
transistors are switching evenly, even if the actual voltage reading is
meaningless).
Figure 1 - 2
Volts per Hertz Ratio
Figure 1 - 3
Power Section Block Diagram
Synchronous Speed = 120xFrequency
# of Poles
Operating Point
Frequency
Voltage
460 V
230 V
30 Hz 60 Hz

CSD Series Variable Frequency AC Drive
MOTORTRONICS
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TheCSDSeries unitoffersanoptionalfunctioncalleddynamicbraking.
Dynamicbraking,inadjustablefrequencydrives,allowsthe motor to
produce100%braking torque for a 10% duty cycle forfour-quadrant
operation (like DC regenerative drives). With dynamic braking, the
regenerative energy from the motor is dissipated by switching the
dynamicbrakingtransistorto shunt the regenerative current from the
DC bus capacitors through the braking resistor (See Figure 1 - 3).
Thiscircuit is optionalintheCSD drive line,pleasecontactthe factory
ifyourapplicationrequiresdynamicbraking.
1.4.3 Logic Section
Theheartofthedrive’scontrolsectionistheCentralProcessingUnit
(CPU).Thiscomponenthandlesthe logic functions, including output
waveformgeneration, monitoringofcommands,and self-diagnostics.
TheCPUalso simplifies troubleshooting and setup by displayingand
storing very specific, alpha-numeric fault codes displayed on the
keypad.Forexample,youcan immediatelydetermine ifanovercurrent
(OC)trip occurred during start, acceleration,decelerationorconstant
speed operation by the unique fault code corresponding to each of
theseconditions.
Theoutputwaveformis “sine-coded,Pulse WidthModulation(PWM)”,
whichgained wideacceptancebecauseof itshighstartingtorque and
smoothlowspeed motor rotation capabilities. In addition, the motor’s
“torqueperamp” ratio is good, implying a veryefficientoutputcurrent
waveform.The drive can acceptcontrolcommands(runor frequency
referenceinputs)fromeither the terminal strip or the integral keypad.
Theterminalfrequency reference command can be either0-10VDC,
0-5 VDC or 4-20 mA. The drive’s actual output frequency can be
monitoreddirectly from thekeypador from aremotemeterconnected
tothedrive’s analog meter output (0-10VDC, current regulated).
1.4.4 Motor Rating for Variable Speed Application
Motortronicsrecommends, whenever possible,theuse of “driveduty”
motors to prevent premature motor failures that may occur in some
variablefrequencydriveapplications. “Driveduty”motorshaveincreased
insulation on the first few turns of the motor, preventing failures from
“punchthrough”oftheinsulationin400-600voltclass,lowhorsepower
motors. “Punchthrough” is causedbyaproportionally higher amount
ofthe dv/dt outputofthe drive beingdroppedacross the firstfewturns
ofthemotor.“Drive duty” motors also provide rated cooling during all
speed ratings. This feature prevents failure due to reduced cooling
capabilitieswhen a TEFC (totallyenclosedfancooled) motor is being
runatreducedspeedandinconstanttorqueapplications. Motortronics
recommendsthat the motor manufacturer be consultedinallvariable
frequency drive applications to ensure that the motor will be able to
performthe application requirements.

CSD Series Variable Frequency AC Drive
MOTORTRONICS
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Figure 2 - 1
Location and Positioning
Table 2 A - Drive Heat Loss
Chapter 2 - Installation
2.1 Location
Proper location of the CSD Series is necessary to achieve specified
performanceandnormallifetime operation. The CSD Series should
always be installed in an area where the following conditions exist:
•Ambientoperatingtemperature:
Enclosed unit: -10 to 40° C (14 to 104° F).
Chassis unit: -10 to 50° C (14 to 122° F).
•Protected from rain and moisture
•Shielded from direct sunshine
•Free from metallic particles and corrosive gas.
Makesure thereissufficient clearancearoundthe CSD Seriesunit for
cooling,wiringand maintenance purposes.To maximize theeffective
airflow(and cooling), the inverter should be installed withitsheatsink
ribsorientedvertically.Wealsorecommendyouremovethefrontcover
ifpossible when youmountthe inverter insidealargerenclosure. This
will further improve the air flow over the electronic components and
improve the unit’s reliability. (Fig. 2 - 1). Refer to the chart below for
modelheatdissipationrequirementswhen installing your unit.
Model
Number Drive (HP)
Drive
Efficiency
(
%
)
Rated
Current
(
Amps
)
Drive Loss
(W)
Min. Req.
Air Vol.
(
CFM
)
Min. Sfc. Area.
Steel Box
(
Sq. Ft
)
Min. Sfc. Area
Fiberglass Box
(
Sq. Ft
)
CSD-2P5 0.5 95.56 3.1 23.25 4.04 4.65 7.27
CSD-201 1 96.74 4.5 33.75 5.87 6.75 10.55
CSD-202 2 97.26 7.5 56.25 9.78 11.25 17.58
CSD-203 3 97.44 10.5 78.75 13.70 15.75 24.61
CSD-205 5 97.44 17.5 131.25 22.83 26.25 41.02
CSD-207 7.5 97.47 26 195.00 33.91 39.00 60.94
CSD-210 10 97.44 35 262.50 45.65 52.50 82.03
CSD-215 15 97.61 49 367.50 63.91 73.50 114.84
CSD-220 20 97.66 64 480.00 83.48 96.00 150.00
CSD-230 30 97.87 87 652.50 113.48 130.50 203.91
CSD-401 1 97.64 2.3 24.15 4.20 4.83 7.55
CSD-402 2 98.04 3.8 39.90 6.94 7.98 12.47
CSD-403 3 98.21 5.2 54.60 9.50 10.92 17.06
CSD-405 5 98.19 8.8 92.40 16.07 18.48 28.88
CSD-407 7.5 98.21 13 136.50 23.74 27.30 42.66
CSD-410 10 98.20 17.5 183.75 31.96 36.75 57.42
CSD-415 15 98.28 25 262.50 45.65 52.50 82.03
CSD-420 20 98.35 32 336.00 58.43 67.20 105.00
CSD-430 30 98.35 48 504.00 87.65 100.80 157.50

CSD Series Variable Frequency AC Drive
MOTORTRONICS
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2.2 Dimensions
.
*These models accept single phase input (200/230V) without derating.
Figure 2 - 2A
NEMA1Dimensions
Figure 2 - 2B
NEMA4/4x Dimensions
Table 2B - Dimensions
CSD-2P5* 0.5 3.1 0.4 1 6
CSD-201* 1 4.5 0.75 1 6
CSD-202* 27.51.52 8
CSD-203* 3 10.5 2.2 3 8
CSD-205 5 17.5 3.7 3 9
CSD-207 7.5 26 5.5 4 9
CSD-210 10 35 7.5 4 10
CSD-215 15/20 49/55 11 5 11
CSD-220 20/25 64/72 15 5 11
CSD-230 30/40 87/98 22 5 11
CSD-401 1 2.3 0.75 2 7
CSD-402 23.81.52 7
CSD-403 35.22.23 8
CSD-405 58.83.73 9
CSD-407 7.5 13 5.5 4 10
CSD-410 10 17.5 7.5 4 10
CSD-415 15/20 25/28 11 5 11
CSD-420 20/25 32/36 15 5 11
CSD-430 30/40 48/54 22 5 11
KW NEMA 1
Dim. Ref. # NEMA 4/4X Dim. Ref. #
400V Class
(380 - 460V)
Model
Number Max HP CT/VT Rated Amps CT/VT KW NEMA 1
Dim. Ref. # NEMA 4/4X Dim. Ref. #
200V Class
(200 - 230V)
Model
Number Max HP CT/VT Rated Amps CT/VT
DEFGH I
1 5.9 3.8 0.2 6.4 4.2 5.3
2 6.9 5.4 0.2 7.3 5.9 6
3 8.1 6.9 0.2 8.5 7.3 6.5
4 11.3 7.3 0.2 11.9 7.8 7.8
5 15.2 9.3 0.3 15.8 9.9 9.5
6 8.9 7.1 0.21 9.5 7.9 5.7
7 10.8 8.3 0.21 11.8 9.1 8.4
898.40.281299
9 12 11 0.28 15.7 12.2 10
10 16.3 10.2 0.21 16.9 12.3 10.6
11 22 22.3 0.28 24 24.3 12.3
NEMA 1
NEMA 4/4X
Enclosure Dim.
Ref. # Mounting Dim. Overall Dimensions

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 6 -
2.3 Specifications
Table 2 C - Specifications
* These models accept single phase input (200-230V) without derating.
Model HP Rated Motor
(KW)
Rated
Current
(A)
Rated
Output
(KVA)
Input
Voltage Output Voltage
CSD-2P5* 0.5 0.4 3.1 1.2
CSD-201* 1 0.75 4.5 1.7
CSD-202* 2 1.5 7.5 2.9
CSD-203* 3 2.2 10.5 4.0
CSD-205 5 3.7 17.5 6.7
CSD-207 7.5 5.5 26 9.9
CSD-210 10 7.5 35 13.3
CSD-215 15 11 49 18.7
CSD-220 20 15 64 24.4
CSD-230 30 22 87 33.2
CSD-401 1 .75 2.3 1.7
CSD-402 2 1.5 3.8 2.9
CSD-403 3 2.2 5.2 4.0
CSD-405 5 3.7 8.8 6.7
CSD-407 7.5 5.5 13 9.9
CSD-410 10 7.5 17.5 13.3
CSD-415 15 11 25 19.1
CSD-420 20 15 32 24.4
CSD-430 30 22 48 36.6
1 or 3
Phase
200-230V
+10%
50/60 Hz
+5%
3 Phase
380-460V
+10%
50/60 Hz
+5%
3 Phase
200-230V
3 Phase
380-460V

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 7 -
1 - 12 KHz
0.1 - 400 Hz
Digital: 0.01%
Analog: 0.4%
0.01 HZ with computer of PLC control, 0.1 Hz with keypad control with frequency
above 100 Hz
0 - 5, 0 - 10V, 4 - 20mA, 10K Potentiometer
Optional card: Bi-polar ± 5 or ±10 Vdc command available. (Specify bi-polar
command signal range)
Programmable between 30% - 200%
2 separate programmable ACCEL/DECEL times
0.1 - 3600 SEC with 2 S-curves
Programmable DECEL or free run to stop
150% for up to 1 minute
Braking Torque 200V & 400V
Class
Standard braking torque = 20%
100% braking torque available with addition of optional resistors (plus braking
transistors on units rated 15HP and above)
18 patterns, one curve programmable
IGBT transistors in a sine-coded PWM (Pulse Width Modulated) firing scheme
Approximately 200% of unit rated current
150% for 1 minute
Programmable electronic thermal overload relay
200V Class: DC bus exceeds 427V
400V Class: DC bus exceeds 854V
200V Class: DC bus voltage drop < 200V
400V Class: DC bus voltage drop < 400V
Programmable 0~2 seconds: unit can be restarted via speed search
Motor coast to stop at blown fuse
Protected by thermister/thermostat
Via charge LED
Start -up Standard on all units
Running Standard on all units
Operation Signal Forward/Reverse operation; individual command
Multifunction
Input Selection Standard: 3 dry contact inputs only Optional: 120 Vac interface card
Multifunction
Output 1 output 35Vdc, 50mA maximum
Fault Output 250 Vac 1A, 30 Vdc 1A maximum
Frequency reference bias/gain, upper lower limit, auto/manual torque boos, frequency
meter gain calibration, auto reset attempt, skip frequency, S-curve: ACCEL/DECEL,
current limit, carrier frequency adjust (1 - 12 KHz), communication link function,
energy saver, vibration control, 7 process timers
Frequency command, output frequency, output current, output voltage, P-N bus
voltage, rotation direction, engineering units
Analog output (0-10V), possible to select output frequency, setting frequency, output
voltage and P-N bus voltage
NEMA 1 (IP20) standard, NEMA 4 /4X also available (up to 10HP)
Indoor (protected from gas and dust) 3,300 feet (without derating). Use in an
enclosure with filtered forced ventilation, or if standalone, in a clean pollution-free
environment
Enclosed: -10º C to 40º C (14º F to 104º F)
Chassis: -10º C to 50º C (14º F to 122º F)
-10º C to 50º C (14º F to 122º F)
0 - 95% non-condensing
0.5G
EMC 89/336/EEC
Approvals
UL listed and Canadian UL (cUL) listed, CE Approved
EMC
Environmental
Conditions
Instantaneous Overcurrent
Overload Capacity of Drive
Output
Signal
Enclosure
Humidity
Digital Operator Monitor
Built-in Functions
DC Bus Protection
Power Charge Indication
Vibration
Output Power Circuit
V/f Pattern
Overvoltage
Storage Temperature
Input
Signal
Analog Output Monitor
Location and Altitude
Ambient Temperature
Momentary Power Loss
Operation Conditions
Frequency Control Range
Frequency Accuracy
Frequency Resolution
Motor Overload Protection
Frequency Setting Signal
ACCEL/DECEL Time
Undervoltage
Heat Sink Fin Overheat
Ground Fault
Protection
Control CharacteristicsProtection Functions
Carrier Frequency
Stall Prevention
Starting Torque

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 8 -
Thischapterdealswiththe recommended wiring practices for the CSD
Series adjustablefrequency drive. Please remember,youmustalways
conformtotheNationalElectricalCode(NEC)andanyapplicablelocal
codes.Always make sure the keypaddisplay is off,that the red Charge
LED (LED 101) on the PC board is off, and the DC bus is discharged
beforeadding or changinganywiring!
WARNING!
Thissection involves workingwith potentially lethalvoltage levels!
Caution must be used to prevent personal harm.
3.1 Main Power Wiring
Mainpower wiring precautions:
Remember, the following wiring guidelines are only suggestions. You
must always conform to the NEC and your locally accepted wiring
practices.
Table 3 A - Suggested Power Circuit Wiring and Components
Note 1: See NEC article 430 and NEC article 310 for sizing or branch circuit
conductors.
Note 2: See NEC article 430 part D for motor branch circuit, short circuit and ground
fault protection sizing.
Note 3: See NEC article 250 for sizing of ground conductors.
Chapter 3 - Wiring
Model Min. Power
Wire Size
Max. Non-
Delay Fuse
(2)
Max. Delay
Fuse (2)
Max. Delay
Circuit
Breaker (2)
Min.
Ground
Wire Size
CSD-2P5
CSD-201
CSD-202 15 A 15 A 15 A
CSD-203
CSD-205
CSD-207 10 AWG 30 A 30 A 30 A 10 AWG
CSD-210 8 AWG 80 A 50 A 70 A 8 AWG
CSD-215 6 AWG 125 A 70 A 100 A
CSD-220 4 AWG 150 A 80 A 125 A
CSD-230 2 AWG 225 A 125 A 200 A 4 AWG
CSD-401
CSD-402
CSD-403
CSD-405
CSD-407
CSD-410
CSD-415 10 AWG 30 A 30 A 30 A 10 AWG
CSD-420 8 AWG 80 A 50 A 70 A 8 AWG
CSD-430 6 AWG 125 A 70 A 100 A 6 AWG
12 AWG
14 AWG
12 AWG
6 AWG
14 AWG
20 A
10 A
20 A
10 A
15 A
20 A
10 A
20 A
10 A
20 A
10 A
15 A
20A12 AWG
10 A
15 A
14 AWG
12 AWG
14 AWG

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 9 -
•NEVERCONNECTTHEINPUT POWER WIRINGTODRIVEOUTPUT
TERMINALST1, T2, T3.IF YOUDO, THEUNIT WILL BEDAMAGED.
• DO NOT touch any circuit components while AC power is on or
immediately after the main AC power is disconnected from the
unit. You MUST wait for the LED on the control board to
extinguish.
• DO NOT make any interconnection to the circuit before unit is
disconnected from the AC power line and the power LED on the
unit is extinguished. Failure to adhere to this warning could
result in serious or lethal injury.
•This unit is only intended for use in pollution degree 2 macro-
environmentorequivalent.
• Never use a MEGGER to check the motor wires while the drive is
connected.The semiconductor outputmodulewillbe destroyed bythe
hightransient voltage.
• If the source feeding the drive is greater than 500 KVA you should
installathree-phase,ACinput line reactortopreventpossible damage
totheinputrectifier bridge (3% impedance, minimum).
• If the input voltage imbalance is greater than 2%, you should also
applyanAC input line reactor (3% impedance, minimum).
• If you are using a single-phase input supply, be sure to connect the
incomingpowertoterminalsL1 and L2 of the drive.
• Makesurethereare no power factor correction capacitors connected
directly to the input or on the output leads of the drive.
• To comply with NEC requirements for branch circuit protection you
may need an externally fused disconnect.
• Recommendedvaluesforinput wiring are also given inTable3A.For
230 V units be sure to use wire rated for 300 volts; for 460 V.
• Always use UL/CSA approved wire and listed field wiring lug kits or
listed ring terminals.
• Physically separate power and control wiring. If they must cross, do
so at 90 degree angles.
• NeverinstallStart/StopMagneticContactor(MC)betweendrive output
terminalsandmotor. Thetransientde-energizingsurgeof themagnetic
contactor will destroy the unit or cause the drive to trip.
• Neveruse a Start/Stop Magnetic Contactor(MC) on thelinesideof the
drivetoStart/Stopthedrive.
• Useshieldedcableforallcontrolwiringconnectionsto theTM2 terminal
block. Ground the shield at the other end of the cable (not to the
drive).
• Use copper conductors only, size field wiring based on 75° C wire
only.
• Follow the Table 3 B for suitable supply circuits on specific drives.
(Informationbasedon UL 508 table 47.2, February 23, 1993.)
Table 3 B - Suitable Supply Circuits
Model Max Voltage Max Supply Short Circuit Rating
(Symmetrical Amperes)
CSD-2P5 to CSD-201 230V 1000
CSD-202 to 230 230V 5000
CSD-401 460V 1000
CSD-402 to 430 460V 5000

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 10 -
3.2 Grounding
Always be sure to make a positive ground connection to the Earth
terminalofthedrive. Thisisnecessary forboth protectionofpersonnel
and for reliable, trouble free operation. Following are additional
guidelinesfor propergrounding:
• See Table 3Afor minimum ground wire size.
• Resistance to ground should be 100 ohms or less.
• Neverground the drive with welding or other high current machines.
• Whenseveralunitsareusedtogethertheyshould all be grounded to
acommon pole.Alternatively, connecting alloftheEarth (E)terminals
togetherand running a single wire to theground pole is acceptable.
Be sure you do not form a ground loop with the ground wires.
• Wire must be class 1 wire with a voltage rating minimum of 300V for
230 VAC systems and 600V for 460 VAC systems.
• Control wiring should not be run in the same conduit or raceway with
poweror motor wiring.
3.3 Power Connection Diagram
Figure 3 - 1
Power Wiring Diagram
Motor Overload Protection
Motorsshouldhave external thermal overload protection. Due to the
characteristicsofvariablefrequencydriveapplications,thebestthermal
protection for the motor is using a thermostat imbedded in the stator
of the motor and interlocking this contact in the drive’s control logic.
Optional braking module
(Units 15HP and above)
Optional Braking Resistor
(Units 10 HP & below)
Note: In single phase input
applications, connect the
AC power source to L1
and L2.
External DC Choke
(Optional on units 15-30HP
Standard on units above 30 HP)

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 11 -
Figure 3 - 2
Control Terminal Function
3.4 Control Terminal Function

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 12 -
3.5 Brake Motor Magnetic Contactor
TheCSD Series generatesavariable voltageoutput.Forthis reason,
whenusing abrakemotor withthedrive,the brakepowersupply must
be connected directly to theAC line power. DO NOT take the power
from the drive output. Asuitable surge absorber should be installed
across the brake coil to prevent transient surge when the coil is de-
energized. See wiring diagram (Fig. 3 - 3) for possible brake coil
connections. See section 3.5.1 for suggested values of snubber
components.
Figure 3 - 3
Brake Coil Connections
Brake
Coil
CoilscancauseEMI (Electromagneticinterference).TominimizeEMI,
Motortronics recommends that all coils be installed with surge
suppression components. For AC coil brakes, use an R-C snubber
type suppressor. For DC Coil Brakes use a diode type suppressor
(See Table 3 C and Figure 3 - 4 for details).
3.5.1 Coil Surge Suppression Wiring

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 13 -
DiodeRatings
AC Coils DC Coils
*
*Current>
Voltage > 2 X Coil
CoilVA
CoilVoltage
DCSnubber
Figure 3 - 4
TypicalComponents
ACSnubber Ratings
Table 3 C 3.6 Line Reactors
•Source KVAmust be limited to less than 500 KVAto protect against
prematurerectifier assembly failure. IfsourceKVAexceeds500 KVA,
installationofappropriatereactorisrequired.Ifmultipledrivesareused,
installationofindividualreactorsisnotrequired(onereactorcapable
ofcombinedamperage is acceptable).
Table 3 D - Suggested Line Reactor Values
Model Number Part Number Current (Amps) Inductance
(
mH
)
CSD-2P5, 201 10-RL-00402 4 6
CSD -202 10-RL-00802 8 3
CSD-203 10-RL-01202 12 2.5
CSD-205 10-RL-01802 18 1.5
CSD-207 10-RL-02502 25 1.2
CSD-210 10-RL-03502 35 0.8
CSD-215 10-RL-04502 45 0.7
CSD-220 10-RL-05502 55 0.5
CSD-230 10-RL-08002 80 0.4
CSD-401 10-RL-00202 2 20
CSD-402, 403 10-RL-00403 4 9
CSD-405 10-RL-00803 8 5
CSD-407 10-RL-01203 12 4.2
CSD-410 10-RL-01803 18 2.5
CSD-415 10-RL-02503 25 2.0
CSD-420 10-RL-03503 35 1.2
CSD-430 10-RL-04503 45 1.2

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 14 -
3.6.1 Initial Power Up
•For initial test run procedure, see Chapter 7.
•Forinitialstart-upprocedure,see Chapter 6.
3.7 External Brake Resistor Ratings
Standardbraking torque forallmodels is 20%. For 100% braking
torqueexternalbrakingtransistors, resistors and/or a braking
modulemayneedto be added. (See chart below)
Table 3 E - External Brake Resistor Ratings
Model
Number Resistor Part Number Resistance (ohms) Watts Brake
Transistor
module
CSD-2P5 BRSD-21 200 60
CSD-201 BRSD-21 200 60
CSD-202 BRSD-22 100 150
CSD-203 BRSD-23 70 200
CSD-205 BRSD-25 40 300
CSD-207 BRSD-27 25 500
CSD-210 BRSD-210 20 600
CSD-215 RK1 13.6 800
CSD-220 RK2 10 900
CSD-230 RK3 8 1200
CSD-401 BRSD-41 750 60
CSD-402 BRSD-42 400 150
CSD-403 BRSD-43 250 200
CSD-405 BRSD-44 150 300
CSD-407 BRSD-48 100 500
CSD-410 BRSD-410 80 600
CSD-415 RK4 75 800
CSD-420 RK5 50 1200
CSD-430 RK6 32 1600
External Brake Resistor Values
N/A
DBM-100-230
N/A
DBM-50-460

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 15 -
3.8 Power Terminal Block (TM1) Description
Thecontrol partoftheCSDSeries driveistheTM1or PowerTerminal
Block (the large terminal block on the bottom PC board). Listed in
Table 3 F are the function descriptions of TM1. The symbols in
parenthesesare the European equivalentcodes.
Table 3 F - TM1 Descriptions
Table 3 G - TM1 Layout
Figure 3 - 5
TM1TerminalBlock
See Table 3 G for the terminal block configuration in your unit.
1.
2.
3.
4.
Table 3 H - TM Torque Specs
Follow the above diagram when wiring your CSD Series drive. Also:
•Neverconnect theinputpower wiringtothe driveterminalsT1, T2,T3,
P, or R.The drive will fail.
•AlwaysuseUL/CSA approved wiring and lugs.
•Always make a positive ground termination to the Earth terminal of
thedrive.
•The P & R terminals are for resistor attachment only. If you connect
power to these points, the drive will fail.
Symbol Function Description
L1 (R)
L2 (S)
L3 (T)
N External braking unit terminals
P
R
T1 (U)
T2 (V)
T3 (W)
P1, P External DC reactor terminals
Input terminals of AC line power:
Single Phase: L1/L2 (L1/L3 for CSD-230)
Three Phase: L1/L2/L3
Output terminals
External braking resistor terminals
Model
Number TM1 Layout
CSD-2P5
CSD-201
CSD-202
CSD-203
CSD-205
CSD-207
CSD-210
CSD-215 2
CSD-220 3
CSD-230 4
CSD-401
CSD-402
CSD-403
CSD-405
CSD-407
CSD-410
CSD-415
CSD-420
CSD-430
1
1
3
Model # TM1 Torque
S
p
ecs
TM2
Torque
S
p
ecs
CSD-2P5
CSD-201
CSD-202
16 LB-IN
CSD-203
CSD-205
CSD-207
CSD-210
CSD-215
CSD-220
CSD-230
CSD-401
CSD-402
CSD-403
CSD-405
CSD-407
CSD-410
CSD-415
CSD-420
CSD-430
12 LB-IN
13.8 LB-IN
13.8 LB-IN
22.1 LB-IN
22.1 LB-IN
16 LB-IN
7 LB-IN

CSD Series Variable Frequency AC Drive
MOTORTRONICS
- 16 -
Thissectionreviewstheexternalcontrolsand thespeedpotentiometer
on the keypad. If you are using the keypad (without the speed
potentiometer)youdo not need to review this section.
4.1 Control Terminal Block (TM2) Function Description
The control terminal block (TM2) is the block on the top PC board.
The following diagram illustrates the physical representation of the
terminal block (TM2) and the available connections when you open
the cover of the CSD enclosure. Connections 3-9 are dry contacts
only. Dry contact control wire connections must be less than 10 feet
in length. Motortronics recommends using shielded cable or twisted
pairs. Note TM2 torque specs is 7IN-LB.
As you finish each connection, complete the accompanying
programming.Carefully review alldiagramsand programming details
so the connections are made correctly.
1 TRIP 2
RELAY 3
FWD 4 REV 5 COM 6 SP1 7 SP2 8 SP3 9 RESET 10 SYN- 11 SYN+ 12 13 14
FM- 15
FM+
+-
Control ConnectionsTerminal(TM2)
Figure 4 - 1
TM2TerminalBlock
Wiring of control circuits (TM2) and
powercircuits(TM1)mustcomplywith
theseparationofcircuitsrequirements
so that there is a physical spacing
betweenconductorsofdifferentcircuits.
Theclass 2circuitsand limited voltage/
current circuits of TM2 are to be
connected with wires suitable for
connectionto the class1circuitsor line
voltage terminals of TM1. Use the two
lowerholes intheend plateforwiring to
the class 1 circuits of TM1. Use a
separatehole intheend plateforwiring
to the class 2 circuit of TM2.
Table 4 A- Terminal TM2 Connection Descriptions
Chapter 4 - Remote Control