Unico 11100 Guide

11100 / 1105 / 1110 / 1120 / 1130 / 1200 / 1230
Variable-Frequency AC Drives
Guide to Installation,
Troubleshooting,
and Maintenance
11/2 to 1,000 hp
(1.1 to 750 kW)
For revisions ECL 10 and above

Notices
Copyright © 2000-2013 by Unico, Incorporated.
All rights reserved. No part of this publication may be copied, reproduced, or reduced to
any electronic media or machine-readable format without the prior written permission of
Unico, Inc.
The information contained in this manual is considered accurate to the best knowledge of
the supplier at the time of publication. The manufacturer, however, assumes no liability for
errors that may exist. The supplier reserves the right to change data and specifications
without notice.
All trade designations are provided without reference to the rights of their respective
owners.
Printed in the United States of America.
110941 ECL 007
1000.40–07 6/13

Table of Contents
Table of Contents
Table of Contents .............................................................................................1-1!
Safety Information ................................................................................................i!
Overview.............................................................................................................................. i!
Conventions Used ................................................................................................................ i!
General Precautions ............................................................................................................ ii!
Installation Precautions...................................................................................................... iii!
Application Precautions..................................................................................................... iii!
Service Precautions............................................................................................................ iv!
1!About the Manual .......................................................................................1-1!
1.1!Overview................................................................................................................ 1-1!
1.2!Contents ................................................................................................................. 1-1!
1.2.1!Intended Audience............................................................................................. 1-2!
2!Product Overview.......................................................................................2-1!
2.1!Overview................................................................................................................ 2-1!
2.2!Unpacking .............................................................................................................. 2-1!
2.2.1!Lifting Instructions ............................................................................................ 2-1!
2.2.2!Verify delivery................................................................................................... 2-2!
2.2.3!Inspect for damage ............................................................................................ 2-2!
2.2.4!Storage/Transportation ...................................................................................... 2-2!
2.2.5!Nameplate Identification ................................................................................... 2-2!
2.3!Family Overview.................................................................................................... 2-3!
2.3.1!Features.............................................................................................................. 2-3!
2.3.2!Drive Architecture ............................................................................................. 2-6!
2.4!Specifications ......................................................................................................... 2-9!
3!Mechanical Installation ..............................................................................3-1!
3.1!Overview................................................................................................................ 3-1!
3.2!Forms ..................................................................................................................... 3-1!
3.3!Installation Site Considerations ............................................................................. 3-1!
3.3.1!Enclosure ........................................................................................................... 3-1!
3.3.2!Operating Environment ..................................................................................... 3-2!
3.3.3!Cooling .............................................................................................................. 3-2!
3.4!Layout Considerations ........................................................................................... 3-3!
3.4.1!Dimensions and Weights................................................................................... 3-3!
3.4.2!Space Requirements .......................................................................................... 3-3!
3.4.3!Orientation......................................................................................................... 3-3!
3.4.4!Cable Routing.................................................................................................... 3-3!
3.5!Installation Procedure ............................................................................................ 3-4!
3.5.1!Foot Mounting ................................................................................................... 3-4!
3.5.2!Flush Mounting (Form 22X) ............................................................................. 3-5!
3.5.3!Flange Mounting ............................................................................................... 3-5!
3.6!Mounting the I/O Fanning Strip............................................................................. 3-5!

1000 Series / Guide to Installation, Troubleshooting, and Maintenance
4!Electrical Installation .................................................................................4-1!
4.1!Overview................................................................................................................ 4-1!
4.2!Wiring Requirements ............................................................................................. 4-1!
4.2.1!Standards and Codes.......................................................................................... 4-1!
4.2.2!Conductors......................................................................................................... 4-1!
4.2.3!Tightening Torque ............................................................................................. 4-1!
4.3!Insulation Tests ...................................................................................................... 4-2!
4.4!Ground Connections .............................................................................................. 4-2!
4.4.1!Ground the drive................................................................................................ 4-3!
4.4.2!Ground the Power Supply ................................................................................. 4-3!
4.4.3!Ground the Motor and Transducer .................................................................... 4-3!
4.4.4!Connect the Control Grounds............................................................................ 4-3!
4.5!Input Power Supply................................................................................................ 4-3!
4.5.1!Power Source Conditioning............................................................................... 4-4!
4.5.2!Connect the Power Supply .............................................................................. 4-18!
4.5.3!Input Protection ............................................................................................... 4-18!
4.6!Connect the Motor ............................................................................................... 4-18!
4.7!Connect the Dynamic Braking Resistor............................................................... 4-19!
4.8!Bus Connections .................................................................................................. 4-20!
4.8.1!Common-Bus Operation.................................................................................. 4-20!
4.9!Control Signal Connections ................................................................................. 4-47!
4.9.1!Wiring Precautions .......................................................................................... 4-47!
4.9.2!Digital I/O Connections (TB1)........................................................................ 4-51!
4.9.3!Analog I/O Connections (TB2, CON2)........................................................... 4-52!
4.9.4!Serial Connections (TB1, J1, J2, J3, J4, J6, J11, J12) ..................................... 4-52!
4.9.5!Feedback Interface Connections...................................................................... 4-53!
5!Troubleshooting/Maintenance ..................................................................5-1!
5.1!Overview................................................................................................................ 5-1!
5.2!Troubleshooting ..................................................................................................... 5-1!
5.2.1!Theory of Operation .......................................................................................... 5-1!
5.2.2!Rectifier Checking Procedure.......................................................................... 5-17!
5.2.3!Transistor Checking Procedure ....................................................................... 5-18!
5.3!Maintenance ......................................................................................................... 5-20!
5.3.1!Working Life ................................................................................................... 5-20!
5.3.2!Battery Life...................................................................................................... 5-20!
5.3.3!Disposal ........................................................................................................... 5-20!
5.4!Parts and Repairs.................................................................................................. 5-20!
5.4.1!Parts ................................................................................................................. 5-20!
5.4.2!Repairs............................................................................................................. 5-21!

Safety Information i
Safety Information
Overview
This section states important safety information that must be followed when installing,
operating, and servicing the drive. Study this information carefully before working on or
with the unit. Failure to follow these instructions may lead to personal injury or death or
to damage to the drive, motor, or driven equipment.
Additional safety instructions specific to the application software can be found in the
application documentation. Please study and follow those instructions as well.
Conventions Used
The following notation conventions are used throughout this manual to indicate
information important to personal safety or machine hazards.
!
Attention
Identifies information about practices or circumstances that can lead to
personal injury or death, property damage, or economic loss.

ii 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
General Precautions
!
Attention
Only qualified personnel with the proper skills, instruction, and familiarity
with the drive and its applications should install, start up, operate,
troubleshoot, and maintain the drive. You must be familiar with the
electrical and mechanical components of the system to perform the
procedures outlined in this manual. Failure to comply may result in personal
injury, death, and/or equipment damage.
!
Attention
Failure to take proper precautions for electrical hazard could cause injury or
death.
!
Attention
Failure to follow industry safety standards and instructions in this manual
could damage the drive and void the manufacturer’s warranty.
!
Attention
The drive may be sensitive to electrostatic discharge. Static precautions are
required when servicing or repairing the unit.
!
Attention
If an aluminum electrolytic capacitor in the drive fails from a build-up of
internal pressure, a safety vent will operate, spraying electrolyte vapor from
the capacitor. If a capacitor vents, avoid contact with the liquid, avoid
inhaling the vapors, and ventilate the area. If your skin comes in contact
with the electrolyte, flush it immediately with cold water. If electrolyte gets
in your eyes, immediately remove any contact lenses and flush the open
eyes with plenty of clean water. If electrolyte is ingested, dilute it by
drinking warm water and seek immediate medical attention.
!
Attention
Drives are intended for fixed, permanent connection to earthed three-phase
supply mains. Use of EMC filters along with the equipment will increase
leakage current in the protective conductor and may affect compatibility
with residual-current-operated protective devices.
!
Attention
The drive provides solid-state motor overload protection. The level of
protection is dependent upon the rating of the unit (given in Table 2-2) as
well as the software overload specified by the user. Please refer to the
application documentation for instructions on adjusting the overload.

Safety Information iii
Installation Precautions
!
Attention
An incorrectly installed or operated drive can result in damage to the
equipment it controls. Make certain installation and operating specifications
are followed.
!
Attention
To provide protection against electrical shock, drives must be mounted in
an enclosure meeting at least the requirements of Protective Type IP20 (or
NEMA equivalent) according to EN60529 and with top surfaces meeting at
least the requirements of IP40 (or NEMA equivalent). It is recommended
that a key or tool be required to open the enclosure and that enclosure doors
be interlocked with the electrical supply disconnect.
!
Attention
The drive and associated equipment must be properly earth grounded.
!
Attention
Any site insulation tests must be performed before making electrical
connections to the drive.
!
Attention
The drive is not equipped with a supply-disconnecting device. An external
supply-disconnecting device must be provided to isolate incoming electrical
supplies during installation and maintenance work. This device should
comply with the requirements of EN 60204-1 as well as all applicable
national and local regulations.
Application Precautions
!
Attention
Emergency stop devices shall be located at each operator control station and
at other operating stations where emergency stop may be required. Control
inputs and keypad motor-control functions do not generate an emergency
stop of the motor and do not remove power that can cause hazardous
conditions. Regardless of the operating state, the drive’s motor output
terminals may be at dangerous voltage levels whenever input power is
applied and the bus is charged.

iv 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
!
Attention
Drive functionality depends upon the application software installed. Some
application software offers automatic restart functions that allow the unit to
reset and resume operation after a fault. These functions must not be
enabled when hazardous conditions might arise from such action. Certain
features may present additional hazardous situations. Refer to the associated
application documentation for further safety information.
Service Precautions
!
Attention
Always disconnect and lock out all electrical supplies before working on the
drive or associated equipment. Do this before touching any electrical or
mechanical components associated with the drive application.
!
Attention
High voltage may be present even when all electrical power supplies are
disconnected. After switching off electrical power, wait at least 15 minutes
for bus circuit capacitors to discharge before working on the drive or
associated equipment. Use an appropriate voltmeter to further verify that
capacitors are discharged before beginning work. Do not rely exclusively on
the bus voltage indicator. Dangerous voltage levels may remain even when
the indicator is off.
!
Attention
High voltage may be present at the motor output terminals (U, V, W)
whenever input power is applied, regardless of whether the motor is
moving or not.
!
Attention
Before energizing the motor, verify that there are no loose components
associated with the drive train and that motor motion will not result in
injury or damage to the equipment.
Safe Service Practices
Follow industry-recognized safety procedures:
•Use only one hand to hold test equipment probes
•Wear approved eye protection
•Stand on insulated material
•Use an isolated oscilloscope
•Keep unnecessary personnel out of the work area
•Never leave a drive cabinet open or unattended

About the Manual 1-1
1About the Manual
1.1 Overview
This chapter describes the contents and intended audience of this document.
1.2 Contents
The manual provides the instructions and technical information necessary to install and
maintain the hardware of Unico’s 1000 family of AC drives. Specifically, the manual
pertains to units listed in Table 1-1. The 1140 Variable-Voltage AC Drive is covered
separately in publication 1140.40 (111-564).
Table 1-1—1000 Family
Drive
Description
1100
Variable-Frequency AC Drive
1105
Variable-Frequency AC Drive
1110
Phase-Converting AC Drive
1120
Modular AC Drive
1130
Line-Regenerative AC Drive
1200
Variable-Frequency AC Drive
1230
Line-Regenerative AC Drive
What’s covered
•Safety Instructions, discusses safety hazards and procedures important to anyone
working with the drive
•Chapter 2, Product Overview, tells how to receive the drive and provides an
overview of its architecture, features, and specifications
•Chapter 3, Mechanical Installation, provides instructions on physical installation
Chapter 4, Electrical Installation, explains the routine electrical connections
•Chapter 5, Troubleshooting/Maintenance, discusses troubleshooting and
maintenance of the drive hardware
What’s not covered
This manual does not address aspects of the drive that depend upon the application
software. Please refer to the application documentation for the following:
•Application-specific control signal wiring and definitions
•Operator interface instructions
•Start-up procedure
•Detailed description of drive features and modes of operation
•Parameter descriptions
•Fault identification and troubleshooting

1-2 1000 Series / Guide to Installation, Troubleshooting, and Maintenance
This manual is not intended to provide in-depth service instructions. For service beyond
that described in this manual, please contact Unico or your representative.
1.2.1 Intended Audience
The manual is intended for anyone who will be installing and servicing the drive.
Installation should be performed by qualified electrical personnel to ensure that correct
electrical practices and applicable electrical codes are applied.
The audience is expected to have a basic knowledge of physical and electrical
fundamentals, electrical wiring practices and components, and electrical schematics. No
prior experience with the drive is presumed or required.
Follow instructions
You can prevent injury and damage to the drive or equipment by carefully following the
procedures outlined in this manual.
Follow regulations
All electrical work should conform to the National Electrical Code as well as all state and
local government regulations. Please familiarize yourself with these regulations.
Read both manuals first
Read this manual and the application manual entirely before installing the drive.