Parker AC20 Series Assembly instructions

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DOC-0017-04-EN-A
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AC20 Series
Variable Speed Drive
Hardware Installation Manual

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1 Safety Requirements
IMPORTANT: Please read this information BEFORE installing the equipment.
The contents of this manual have been verified against the associated hardware and software. Although
every effort has been taken to ensure the accuracy of this document, it may be necessary without notice, to
make amendments or correct omissions.
Parker Hannifin Manufacturing cannot accept responsibility for damage, injury, or expenses resulting there
from.
1.1 Intended Users
This manual is to be made available to all persons who are required to install, configure or service
equipment described herein, or any other associated operation.
The information given is intended to highlight safety issues, and to enable the user to obtain maximum
benefit from the equipment.
1.2 Application Area
The equipment described is intended for industrial motor speed control utilising AC induction motors or PMAC
motors.
1.3 Personnel
Installation, operation and maintenance of the equipment should be carried out by competent personnel. A
competent person is someone who is technically qualified and familiar with all safety information and
established safety practices; with the installation process, operation and maintenance of this equipment;
and with all the hazards involved.
1.4 Product Warnings, Cautions and Information notices
Special attention must be paid to the information presented in warning, caution and information notices when
they appear in this manual. Definitions of caution, warning and information notices are shown below:
DANGER
Risk of electric shock
WARNING
Hot surfaces
WARNING
Warns of danger to personnel. Refer to documentation.
CAUTION
Warns of danger to equipment. Refer to documentation.
EARTH / GROUND
Protective Earth Conductor Terminal
INFORMATION
Read further information before proceeding.

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1.5 Hazards
Electric Shocks
DANGER!
Ignoring the following may result in injury:
•This equipment can endanger life by exposure to rotating machinery
and high voltages.
•The equipment must be permanently earthed due to the high earth
leakage current, and the inverter motor must be connected to an
appropriate safety earth.
•Ensure all incoming supplies are isolated before working on the
equipment. Be aware that there may be more than one supply
connection to the inverter.
•There may still be dangerous voltages present at power terminals
(motor output, supply input phases, DC bus and the brake, where
fitted) when the motor is at standstill or is stopped.
•For measurements use only a meter to IEC 61010 (CAT III or higher).
Always begin using the highest range.
CAT I and CAT II meters must not be used on this product.
•Allow at least 10 minutes for the inverter's capacitors to discharge to
safe voltage levels (<50V). Use the specified meter capable of
measuring up to 1000V dc & ac rms to confirm that less than 50V is
present between all power terminals and between power terminals and
earth.
•Unless otherwise stated, this product must NOT be dismantled. In the
event of a fault the inverter must be returned. Refer to "Routine
Maintenance and Repair".

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Safety & EMC Requirements
Where there is a conflict between safety and EMC requirements, personnel safety shall always take
precedence.
Safety
WARNING!
Ignoring the following may result in injury or
damage to equipment:
•
Never perform high voltage resistance checks on the wiring without
first disconnecting the inverter from the circuit being tested.
•Whilst ensuring ventilation is sufficient, provide guarding and /or
additional safety systems to prevent injury or damage to equipment.
•When replacing an inverter in an application and before returning to
use, it is essential that all user defined parameters for the product’s
operation are correctly installed.
•When replacing an inverter in an application and before returning to
use, it is essential that all user defined parameters for the product’s
operation are correctly installed.
•All control and signal terminals are SELV, i.e. protected by double
insulation. Ensure all external wiring is rated for the highest system
voltage.
•Thermal sensors contained within the motor must have at least basic
insulation.
•All exposed metalwork in the Inverter is protected by basic insulation
and bonded to a safety earth.
•RCDs are not recommended for use with this product but, where their
use is mandatory, only Type B RCDs should be used.
EMC
WARNING!
Ignoring the following may result in injury or
damage to equipment:
•In a domestic environment this product may cause radio interference in
which case supplementary mitigation measures may be required.
•This equipment contains electrostatic discharge (ESD) sensitive parts.
Observe static control precautions when handling, installing and
servicing this product.
•This is a product of the restricted sales distribution class according to
IEC 61800-3. It is designated as “professional equipment” as defined in
EN61000-3-2 for AC20: Frame sizes 2 (excluding 1ø 2.2kW), & 3
(400V products only). Permission of the supply authority shall be
obtained before connection to the public low voltage supply.
For all other Frame sizes not specified above, connection to the public
LV supply must be agreed case by case between manufacturer,
installer or user and distribution network operator.

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Application Risk & Risk Assessment
Application Risk
CAUTION!
•The specifications, processes and circuitry described herein are for
guidance only and may need to be adapted to the user’s specific
application.
•Parker cannot guarantee the suitability of the equipment described in
this Manual for individual applications.
Risk Assessment
CAUTION!
•Under fault conditions, power loss or unintended operating conditions,
the inverter may not operate as intended. In particular:
oStored energy might not discharge to safe levels as quickly as
suggested and can still be present even though the inverter
appears to be switched off.
oThe motor's direction of rotation might not be controlled.
oThe motor speed might not be controlled.
oThe motor might be energized.
•An inverter is a component within an inverter system that may
influence its operation or effects under a fault condition. Consideration
must be given to:
oStored energy
oSupply disconnects
oSequencing logic
o
Unintended operation

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2 Manufacturing Location
Germany
Parker Hannifin Manufacturing Germany GmbH & Co. KG
Electromechanical & Pneumatic Division [EMPD]
Robert-Bosch-Strasse 22
77656 Offenburg (Germany)
Tel.: + 49 (0781) 509-0
Fax: + 49 (0781) 509-98176
Internet: www.parker.com/eme
E-mail: EM-[email protected]
Certified according to ISO 9001:2015
Parker Hannifin Manufacturing Germany GmbH & Co KG - Sitz: Bielefeld - Amtsgericht: Bielefeld HRA 15699
Partner liable to unlimited extent: Parker Hannifin GmbH, Sitz Bielefeld, Amtsgericht Bielefeld HRB 35489
Geschäftsführung der PARKER Hannifin GmbH: Dr.-Ing. Hans-Jürgen Haas, Kees Veraart, Chairman of the board: Dr.-Ing. Gerd Scheffel

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3 Table of Contents
1Safety Requirements........................................................................................................................... 2
1.1 Intended Users............................................................................................................................ 2
1.2 Application Area .......................................................................................................................... 2
1.3 Personnel .................................................................................................................................... 2
1.4 Product Warnings, Cautions and Information notices................................................................. 2
1.5 Hazards ....................................................................................................................................... 3
Electric Shocks ............................................................................................................................................. 3
Safety & EMC Requirements ........................................................................................................................ 4
Application Risk & Risk Assessment............................................................................................................. 5
2Manufacturing Location...................................................................................................................... 6
3Table of Contents ................................................................................................................................ 7
4Introduction........................................................................................................................................ 10
4.1 About this Hardware Installation Manual .................................................................................. 10
Users.......................................................................................................................................................... 10
Manual Organisation................................................................................................................................... 10
Manual Revision ......................................................................................................................................... 10
4.2 Before You Start… .................................................................................................................... 10
Equipment Inspection ................................................................................................................................. 10
Equipment Storage ..................................................................................................................................... 10
Initial Steps................................................................................................................................................. 11
Unpacking the Product ............................................................................................................................... 11
5Product Overview .............................................................................................................................. 12
6Installation.......................................................................................................................................... 15
6.1 Mechanical ................................................................................................................................ 15
Product Dimensions & Weights................................................................................................................... 15
Product Fixing Dimensions ......................................................................................................................... 17
Lifting the Inverter ....................................................................................................................................... 18
Mounting the Inverter.................................................................................................................................. 19
Ventilation Clearance Requirements........................................................................................................... 20
Wiring Bracket (Frames 2 – 5) .................................................................................................................... 22
6.2 Electrical.................................................................................................................................... 23
Power Stack Wiring .................................................................................................................................... 23
Control Board Wiring .................................................................................................................................. 38
Control Board Communications Wiring ....................................................................................................... 43
6.3 Option Cards ............................................................................................................................. 45
Order Codes............................................................................................................................................... 45
Installation .................................................................................................................................................. 45
Wiring ......................................................................................................................................................... 47
6.4 Communication Interface Option Cards.................................................................................... 50
Order Codes............................................................................................................................................... 50
Installation .................................................................................................................................................. 50
6.5 µSD Memory Card .................................................................................................................... 54
Installation .................................................................................................................................................. 54
6.6 Remote Mounted 6901 MMI...................................................................................................... 56
Order Codes............................................................................................................................................... 56
Installation .................................................................................................................................................. 56
Cable Connection ....................................................................................................................................... 57
7Associated Equipment...................................................................................................................... 59
7.1 AC Line Fuses........................................................................................................................... 60
1ø, 230V Products ...................................................................................................................................... 60
3ø, 230V Products ...................................................................................................................................... 60
3ø, 400V Products ...................................................................................................................................... 60
7.2 External EMC Filter ................................................................................................................... 61
7.3 AC Line Choke .......................................................................................................................... 61
1ø, 230V Products ...................................................................................................................................... 61
3ø, 230V Products ...................................................................................................................................... 61
3ø, 400V Products ...................................................................................................................................... 62
Calculation.................................................................................................................................................. 62

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7.4 Dynamic Braking Resistor......................................................................................................... 63
Resistor Power Requirement Calculation.................................................................................................... 63
Resistor Selection....................................................................................................................................... 63
Resistor Protection Devices........................................................................................................................ 64
7.5 AC Motor Choke........................................................................................................................ 65
1ø, 230V Products ...................................................................................................................................... 65
3ø, 230V Products ...................................................................................................................................... 66
3ø, 400V Products ...................................................................................................................................... 66
Calculation.................................................................................................................................................. 67
8Safe Torque Off (STO): SIL2, PLd.................................................................................................... 68
8.1 Overview ................................................................................................................................... 68
Introduction................................................................................................................................................. 68
STO Functional Description ........................................................................................................................ 69
8.2 Alignment to European Standards ............................................................................................ 69
EN ISO13849-1:2015 (Safety of machinery – Safety-related parts of control systems) ............................... 69
EN61800-5-2:2017 (Adjustable speed electrical power drive systems) & EN61508:2010 (Functional safety of
electrical/electronic/programmable electronic safety-related systems) ........................................................................ 70
8.3 Specification .............................................................................................................................. 70
Safety ......................................................................................................................................................... 70
EMC ........................................................................................................................................................... 71
8.4 STO Operation .......................................................................................................................... 71
Terminal Identifications ............................................................................................................................... 71
Input State Truth Table ............................................................................................................................... 72
Example Applications ................................................................................................................................. 72
Technical Specification ............................................................................................................................... 77
8.5 STO Safety Warnings & Limitations.......................................................................................... 77
8.6 STO Functional Checks ............................................................................................................ 79
Comprehensive Checks.............................................................................................................................. 80
Test Protocol Specimen.............................................................................................................................. 82
Regular Checks .......................................................................................................................................... 82
8.7 STO Troubleshooting ................................................................................................................ 83
9Basic Drive Operation....................................................................................................................... 84
9.1 ‘Local’ Operation ....................................................................................................................... 84
Minimum Connections ................................................................................................................................ 84
Onboard Drive Keypad & Display Overview................................................................................................ 85
6901 Remote Keypad & Display Overview.................................................................................................. 87
Keypad Menu Navigation Examples ........................................................................................................... 89
Basic Drive Setup ....................................................................................................................................... 90
9.2 ‘Remote’ Operation (Using Pre-Defined Macro’s)..................................................................... 98
Enable ‘Remote’ Control Mode ................................................................................................................... 98
Selecting & Loading A Macro...................................................................................................................... 98
Running The Drive...................................................................................................................................... 99
Application ‘1’: Standard (Basic Speed Control)........................................................................................ 100
Application ‘2’: Auto / Manual.................................................................................................................... 101
Application ‘3’: Presets.............................................................................................................................. 102
Application ‘4’: Raise / Lower .................................................................................................................... 103
Application ‘5’: PID.................................................................................................................................... 104
Application ‘6’: Aux Comms ...................................................................................................................... 105
9.3 External +24V Power-Up Mode .............................................................................................. 106
24V Active Functionality............................................................................................................................ 106
10 Routine Maintenance & Repair ...................................................................................................... 107
10.1 Routine Maintenance .............................................................................................................. 107
10.2 Preventative Maintenance....................................................................................................... 107
Main Duct Cooling Fans............................................................................................................................ 107
DC Link Capacitors................................................................................................................................... 107
10.3 Repair...................................................................................................................................... 107
11 Compliance ...................................................................................................................................... 108
11.1 Applicable Standards .............................................................................................................. 108
11.2 European Compliance............................................................................................................. 108
CE Marking............................................................................................................................................... 108
EMC Compliance...................................................................................................................................... 110
EMC Standards ........................................................................................................................................ 110
EMC Installation Guidance ....................................................................................................................... 117
Harmonic Information ............................................................................................................................... 123

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11.3 North American & Canadian Compliance ............................................................................... 133
North American Compliance ..................................................................................................................... 133
Canadian Compliance .............................................................................................................................. 133
North American & Canadian Compliance Information ............................................................................... 133
11.4 Environmental Compliance ..................................................................................................... 135
REACH (Restriction, Evaluation, Authorisation & Restriction of Chemicals).............................................. 135
RoHS (Restriction of Hazardous Substances)........................................................................................... 135
WEEE (Waste Electrical & Electronic Equipment)..................................................................................... 135
12 AC20 Series Product Codes........................................................................................................... 136
13 Technical Information ..................................................................................................................... 137
13.1 General Product Ratings......................................................................................................... 137
Environment ............................................................................................................................................. 137
Safety ....................................................................................................................................................... 137
Earthing .................................................................................................................................................... 137
Mains Supply ............................................................................................................................................ 137
13.2 AC Line Fed Power Stack Ratings.......................................................................................... 138
1ø, 230V Products .................................................................................................................................... 138
3ø, 230V Products .................................................................................................................................... 138
3ø, 400V Products.................................................................................................................................... 138
13.3 Internal Brake Switch Ratings ................................................................................................. 139
1ø, 230V Products .................................................................................................................................... 139
3ø, 230V Products .................................................................................................................................... 139
3ø, 400V Products .................................................................................................................................... 140
13.4 Control Board Ratings............................................................................................................. 140
Analogue Inputs........................................................................................................................................ 140
Analogue Outputs ..................................................................................................................................... 141
Digital Inputs............................................................................................................................................. 141
Digital Outputs .......................................................................................................................................... 142
Relay Outputs........................................................................................................................................... 142
Motor Thermistor Input.............................................................................................................................. 142
User +24V Output..................................................................................................................................... 142
External +24V Auxiliary Input.................................................................................................................... 143
STO Inputs ............................................................................................................................................... 143
13.5 Encoder Feedback Option Card Ratings ................................................................................ 144
Encoder Inputs ......................................................................................................................................... 144
Power Supply Output................................................................................................................................ 144
13.6 GPIO Option Card Ratings...................................................................................................... 145
Analogue Inputs........................................................................................................................................ 145
Analogue Outputs ..................................................................................................................................... 145
Digital Input .............................................................................................................................................. 145
Digital Output............................................................................................................................................ 146
+10V Reference Voltage Output ............................................................................................................... 146
-10V Reference Voltage Output ................................................................................................................ 146
Appendix A: Power Stack Circuit Overview ........................................................................................... 147
1ø, 230V Products.................................................................................................................................................... 147
3ø, 230V Products.................................................................................................................................................... 147
3ø, 400V Products.................................................................................................................................................... 149

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4 Introduction
4.1 About this Hardware Installation Manual
Users
This Manual is intended for use by the installer of the AC20 series Inverters. It assumes a reasonable level
of understanding in this discipline.
There is a separate Software Reference Manual – DOC-0017-13 “AC20 Series – Software Reference
Manual”, that is intended for use by the user and programmer of the AC20 series Inverters.
Manual Organisation
This Hardware Installation Manual is organised into chapters, indicated by the numbering on the edge of
each page.
If the manual is to be printed, it is designed so that it should be printed double-sided using the long-edge for
binding.
The Manual is ordered in a sequence that takes the user through the product installation process, resulting
in the basic operation of the drive.
Information for the full AC20 product is referred to as “the Inverter” or “drive” throughout the manual.
Product coding: Any “x” within a product code indicates there are variants. See ‘Chapter 12: AC20 Series
Product Codes’ section for more information.
Manual Revision
This revision replaces all previous revisions of this document. Parker has made every effort to ensure that
this document is complete and accurate at the time of printing. In accordance with our policy of continuous
product improvement, all data in this document is subject to change or correction without prior notice.
4.2 Before You Start…
Equipment Inspection
At the point of receipt of your product, check:
- For signs of transit damage.
- That the product code on the box label matches your order.
Equipment Storage
If the product is not being installed immediately, store the unit:
- In a well-ventilated place.
- Away from high temperatures and humidity,
- Away from dust or metal particles.
Storage Temperature:
-25°C to 55°C
Shipping Temperature:
-25°C to 70°C