SIGMA TEK FDD User manual

Power Installation Guide
SIGMATEK FDD
Frame 7 to 9
Issue: 12

Original Instructions
For the purposes of compliance with the EU Machinery Directive 2006/42/EC, the English version of this manual is
the Original Instructions. Manuals in other languages are Translations of the Original Instructions.
Documentation
Manuals are available to download from the following locations: https://www.sigmatek-automation.com
The information contained in this manual is believed to be correct at the time of printing and does not form part of
any contract. The manufacturer reserves the right to change the specification of the product and its performance,
and the contents of the manual, without notice.
Warranty and Liability
In no event and under no circumstances shall the manufacturer 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. The manufacturer is not liable for consequential and incidental damages. Contact the
supplier of the drive for full details of the warranty terms.
Restriction of Hazardous Substances (RoHS)
The products covered by this manual comply with European and International regulations on the Restriction of
Hazardous Substances including EU directive 2011/65/EU and the Chinese Administrative Measures for Restriction
of Hazardous Substances in Electrical and Electronic Products.
Disposal and Recycling (WEEE)
REACH legislation
EC Regulation 1907/2006 on the Registration, Evaluation, Authorisation and restriction of Chemicals (REACH)
requires the supplier of an article to inform the recipient if it contains more than a specified proportion of any
substance which is considered by the European Chemicals Agency (ECHA) to be a Substance of Very High
Concern (SVHC) and is therefore listed by them as a candidate for compulsory authorisation.
Copyright
The contents of this publication are believed to be correct at the time of printing. In the interests of a commitment to
a policy of continuous development and improvement, the manufacturer reserves the right to change the
specification of the product or its performance, or the contents of the guide, without notice.
All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical
or mechanical including photocopying, recording or by an information storage or retrieval system, without
permission in writing from the publisher.
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.
Sigmatek products are designed to be easily dismantled into their major component parts for
efficient recycling. The majority of materials used in the product are suitable for recycling.
Product packaging is of good quality and can be re-used. Large products are packed in wooden
crates. 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 wrapping the product, can be recycled. When preparing to recycle or dispose of any product
or packaging, please observe local legislation and best practice.

Sigmatek FDD Sizes 7 to 9 Power Installation Guide
Contents
1 Safety information ....................................................................................................5
1.1 Warnings, Cautions and Notes ................................................................................................... 5
1.2 Important safety information. Hazards. Competence of designers and installers ...................... 5
1.3 Responsibility ............................................................................................................................. 5
1.4 Compliance with regulations ....................................................................................................... 5
1.5 Electrical hazards ....................................................................................................................... 6
1.6 Stored electrical charge .............................................................................................................. 6
1.7 Mechanical hazards .................................................................................................................... 6
1.8 Access to equipment .................................................................................................................. 6
1.9 Environmental limits ................................................................................................................... 6
1.10 Hazardous environments ............................................................................................................ 6
1.11 Motor .......................................................................................................................................... 7
1.12 Mechanical brake control ............................................................................................................ 7
1.13 Adjusting parameters .................................................................................................................. 7
1.14 Electromagnetic compatibility (EMC) .......................................................................................... 7
2 Product information .................................................................................................8
2.1 Introduction ................................................................................................................................. 8
2.2 Model number ............................................................................................................................. 8
2.3 Nameplate description ................................................................................................................ 9
2.4 Ratings ..................................................................................................................................... 10
2.5 Drive features ........................................................................................................................... 12
3 Mechanical installation ..........................................................................................14
3.1 Safety information ..................................................................................................................... 14
3.2 Planning the installation ............................................................................................................ 15
3.3 Terminal cover removal ............................................................................................................ 17
3.4 Dimensions and mounting methods ......................................................................................... 19
3.5 Enclosure for standard drives ................................................................................................... 24
3.6 Enclosure design and drive ambient temperature .................................................................... 30
3.7 Heatsink fan operation .............................................................................................................. 30
3.8 Enclosing standard drive for high environmental protection ..................................................... 31
3.9 External EMC filter .................................................................................................................... 35
3.10 Terminal size and torque settings ............................................................................................. 40
3.11 Routine maintenance ................................................................................................................ 41
4 Electrical installation .............................................................................................46
4.1 Power and ground connections ................................................................................................47
4.2 AC Supply requirements ........................................................................................................... 50
4.3 Supplying the size 7, 8 and 9A drives with DC / DC bus paralleling ........................................ 54
4.4 Heatsink fan supply .................................................................................................................. 54
4.5 Ratings ..................................................................................................................................... 54
4.6 Output circuit and motor protection .......................................................................................... 55
4.7 Braking ..................................................................................................................................... 58
4.8 Ground leakage ........................................................................................................................ 61
4.9 EMC (Electromagnetic compatibility) ........................................................................................ 62
5 Technical data ........................................................................................................79
5.1 Drive technical data .................................................................................................................. 79
5.2 Optional external EMC filters .................................................................................................... 93

Sigmatek FDD Sizes 7 to 9 Power Installation Guide
6 UL lnformation ........................................................................................................94
6.1 UL file reference ........................................................................................................................94
6.2 Option modules, kits and accessories .......................................................................................94
6.3 Enclosure ratings ......................................................................................................................94
6.4 Mounting ...................................................................................................................................94
6.5 Environment ..............................................................................................................................95
6.6 Electrical Installation .................................................................................................................95
6.7 Motor overload protection and thermal memory retention ........................................................96
6.8 External Class 2 supply .............................................................................................................96

Sigmatek FDD Sizes 7 to 9 Power Installation Guide 5
Safety information
Product information Mechanical installation Electrical installation Technical data UL listing information
1 Safety information
1.1 Warnings, Cautions and Notes
1.2 Important safety information. Hazards. Competence of
designers and installers
This guide applies to products which control electric motors either directly (drives) or indirectly
(controllers, option modules and other auxiliary equipment and accessories). In all cases the hazards
associated with powerful electrical drives are present, and all safety information relating to drives and
associated equipment must be observed.
Specific warnings are given at the relevant places in this guide.
Drives and controllers are intended as components for professional incorporation into complete
systems. If installed incorrectly they may present a safety hazard. The drive uses high voltages and
currents, carries a high level of stored electrical energy, and is used to control equipment which can
cause injury. Close attention is required to the electrical installation and the system design to avoid
hazards either in normal operation or in the event of equipment malfunction. System design,
installation, commissioning/start-up and maintenance must be carried out by personnel who have the
necessary training and competence. They must read this safety information and this guide carefully.
1.3 Responsibility
It is the responsibility of the installer to ensure that the equipment is installed correctly with regard to
all instructions given in this guide. They must give due consideration to the safety of the complete
system, so as to avoid the risk of injury both in normal operation and in the event of a fault or of
reasonably foreseeable misuse.
The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or
incorrect installation of the equipment.
1.4 Compliance with regulations
The installer is responsible for complying with all relevant regulations, such as national wiring
regulations, accident prevention regulations and electromagnetic compatibility (EMC) regulations.
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.
All machinery to be supplied within the European Union in which this product is used must comply
with the following directives:
2006/42/EC Safety of machinery.
2014/30/EU: Electromagnetic Compatibility.
A 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.
A Note contains information, which helps to ensure correct operation of the product.
WARNING
CAUT IO N
NOTE

6Sigmatek FDD Sizes 7 to 9 Power Installation Guide
1.5 Electrical hazards
The voltages used in the drive can cause severe electrical shock and/or burns, and could be lethal.
Extreme care is necessary at all times when working with or adjacent to the drive. Hazardous voltage
may be present in any of the following locations:
• AC and DC supply cables and connections
• Output cables and connections
• Many internal parts of the drive, and external option units
Unless otherwise indicated, control terminals are single insulated and must not be touched.
The supply must be disconnected by an approved electrical isolation device before gaining access to
the electrical connections.
The STOP and Safe Torque Off functions of the drive do not isolate dangerous voltages from the
output of the drive or from any external option unit.
The drive must be installed in accordance with the instructions given in this guide. Failure to observe
the instructions could result in a fire hazard.
1.6 Stored electrical charge
The drive contains capacitors that remain charged to a potentially lethal voltage after the AC supply
has been disconnected. If the drive has been energized, the AC supply must be isolated at least ten
minutes before work may continue.
1.7 Mechanical hazards
Careful consideration must be given to the functions of the drive or controller which might result in a
hazard, either through their intended behaviour or through incorrect operation due to a fault. 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.
With the sole exception of the Safe Torque Off function, none of the drive functions must be
used to ensure safety of personnel, i.e. they must not be used for safety-related functions.
The Safe Torque Off function may be used in a safety-related application. The system designer is
responsible for ensuring that the complete system is safe and designed correctly according to the
relevant safety standards.
The design of safety-related control systems must only be done by personnel with the required
training and experience. The Safe Torque Off function will only ensure the safety of a machine if it is
correctly incorporated into a complete safety system. The system must be subject to a risk
assessment to confirm that the residual risk of an unsafe event is at an acceptable level for the
application.
1.8 Access to equipment
Access must be restricted to authorized personnel only. Safety regulations which apply at the place
of use must be complied with.
1.9 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.
1.10 Hazardous environments
The equipment must not be installed in a hazardous environment (i.e. a potentially explosive
environment).

Sigmatek FDD Sizes 7 to 9 Power Installation Guide 7
Safety information
Product information Mechanical installation Electrical installation Technical data UL listing information
1.11 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.
1.12 Mechanical brake control
Any brake control functions are provided to allow well co-ordinated operation of an external brake
with the drive. While both hardware and software are designed to high standards of quality and
robustness, they are not intended for use as safety functions, i.e. where a fault or failure would result
in a risk of injury. In any application where the incorrect operation of the brake release mechanism
could result in injury, independent protection devices of proven integrity must also be incorporated.
1.13 Adjusting parameters
Some parameters have a profound effect on the operation of the drive. They must not be altered
without careful consideration of the impact on the controlled system. Measures must be taken to
prevent unwanted changes due to error or tampering.
1.14 Electromagnetic compatibility (EMC)
Installation instructions for a range of EMC environments are provided in the relevant Power
Installation 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.

8Sigmatek FDD Sizes 7 to 9 Power Installation Guide
2 Product information
2.1 Introduction
This guide provides the information necessary to install the following drive models:
FDD3 frame 7 to 9
This guide focuses on the drive power section, for example: electrical installation of the supply /
motor cables and mechanical installation of the drive.
For information about the drive control section, for example: parameter set up information, control
and encoder connections, please refer to the Control User Guide.
2.2 Model number
The model numbers for the FDD product range are formed as illustrated below:
Figure 2-1 Model number
* Only shown on frame 9E and 10 identification label
For simplicity a Frame 9 drive with no internal choke (i.e. Model 09x.xxxxxE) is referred to as a
Frame 9E and a Frame 9 drive with an internal choke (i.e. Model 09x.xxxxxA) is referred to as a
Frame 9A. Any reference to Frame 9 is applicable to both sizes 9E and 9A.
Identification Label
Electrical Specifications
Derivative
Frame Size:
Voltage Rating:
Current Rating:
Heavy Duty current rating x 10
Power Format:
Reserved
0
Optional Build
Customer Code
01 A B 1 00
Customer Code:
00 = 50 Hz
01 = 60 Hz
Reserved:
Conformal Coating:
0 = Standard
IP / NEMA Rating :
1 = IP20 / NEMA 1
Brake Transistor:
B
N = No
= Brake
Cooling:
A = Air
Documentation
1
2 - 200 V (200 - 240± 10 %)
4 10 %)- 400 V (380 - 480±
Power
Format
FDD- 03 4 00078 A
Configuration
1
A - AC in AC out (with internal choke)
D - DC in AC out (Inverter)
C - AC in DC out (Rectifier)
E - AC in AC out (without internal choke)
T - AC in AC out (12P rectifier plus inverter)
Configuration:
1 - Standard
U - No Control
M - Master
F - Follower
Documentation:
1 - English
FDD
Product Line:
NOTE

Sigmatek FDD Sizes 7 to 9 Power Installation Guide 9
Safety information
Product information
Mechanical installation Electrical installation Technical data UL listing information
2.3 Nameplate description
Figure 2-2 Typical drive rating labels
Refer to Figure 2-1 Model number on page 8 for further information relating to the labels.
Date code format
The date code is four numbers. The first two numbers indicate the year and the
remaining numbers indicate the week of the year in which the drive was built.
Example:
A date code of 1710 would correspond to week 10 of year 2017.
FDD3 -094 02240 E10
Model Frame
Voltage
Heavy Duty
current rating
Power
format
Control pod fitted
Fan power
supply fitted
Refer to
User Guide
Normal/Heavy
Duty power rating
Approvals
Input phases & input current
Output phases & Heavy
Duty/Normal Duty rating
Serial number
Input voltage
Output voltage
Date code
110/132kW 1710
Model
Approvals
Input phases & input current
Output phases & Heavy
Duty/Normal Duty rating
Serial number
Input voltage
Output voltage
Date code
FDD-094 02240 E10 110/132kW 1710
Input frequencyInput frequency
Key to approvals
CE approval Europe
RCM regulatory
compliance mark Australia
UL / cUL approval USA & Canada
RoHS compliant Europe
Functional safety USA & Canada
Eurasian conformity Eurasia
R
NOTE

10 Sigmatek FDD Sizes 7 to 9 Power Installation Guide
2.4 Ratings
Table 2-1 400 V drive ratings, cable sizes and fuse ratings
* These fuses are fast acting.
** These ratings are for 2 kHz switching frequency. For ratings at 3 kHz switching frequency refer to the Power and
current ratings in section 5.1.2 Power and current ratings (Derating for switching frequency and
temperature) on page 80.
Table 2-2 Protective ground cable ratings
Fuses
The AC supply to the drive must be installed with suitable protection against overload and
short-circuits. The following section shows recommended fuse ratings. Failure to observe
this requirement will cause risk of fire.
Nominal cables sizes below are based on the cable installation method B2 (ref: IEC60364-
5-52:2001) unless otherwise specified, and are provided as a guide only. Ensure cables
used suit local wiring regulations.
Model
Max.
cont.
input
current
Fuse Nominal cable size Normal Duty Heavy Duty
European USA
IEC UL
Input Output Input Output
Max.
cont.
output
current
Nom
power
@
400 V
Motor
power
@
460 V
Max.
cont.
output
current
Nom
power
@
400 V
Motor
power
@
460 V
3ph Nom
Class
Nom
Class
AA A mm2mm2
AWG
or
kcmil
AWG
or
kcmil
AkWhpAkWhp
074.00660 74 100
gG
80 CC,
J or
T*
35 35 1 1 79 37 60 66 30 50
074.00770 88 100 100 50 50 2 2 94 45 60 77 37 60
074.01000 105 125 125 70 70 1/0 1/0 112 55 75 100 45 75
084.01340 155 250 gR 225 HSJ 2 x 50 2 x 50 2 x 1 2 x 1 155 75 100 134 55 100
084.01570 177 250 225 2 x 70 2 x 70 2 x 1/0 2 x 1/0 184 90 150 157 75 125
094.02000 232
315 gR
300
HSJ
2 x 70
(B1)
2 x 95
(B2) 2 x 3/0 2 x 2/0 221 110 150 200** 90 150
094.02240 267 350 2 x 95
(B1)
2 x 120
(B2) 2 x 4/0 2 x 4/0 266** 132 200 224** 110 150
Refer to Chapter 5.1 Drive technical data on page 79 for maximum fuse rating, maximum
cable size and peak currents.
Input phase conductor size Minimum ground conductor size
≤10 mm2Either 10 mm2 or two conductors of the same cross-sectional area as the input
phase conductor
> 10 mm2and ≤16 mm2The same cross-sectional area as the input phase conductor
> 16 mm2and ≤35 mm216 mm2
> 35 mm2Half of the cross-sectional area of the input phase conductor
WARNING
NOTE
NOTE