h-max-installation-manual-mn04008005e.pdf

H-Max™ Series Variable Frequency Drive

Installation Manual Effective May 2017 Supersedes September 2011

H-Max Series Variable Frequency Drive

H-Max Series Variable Frequency Drive MN04008005E—May 2017 www.eaton.com i

Disclaimer of Warranties and Limitation of Liability

The information, recommendations, descriptions, and safety notations in this document are based on Eaton Corporation’s (“Eaton”) experience and judgment, and may not cover all contingencies. If further information is required, an Eaton sales office should be consulted.

Sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser.

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR

IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR

MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING

CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE

OBLIGATION OF EATON. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME

PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations, and descriptions contained herein.

The information contained in this manual is subject to change without notice.

Cover Photo: H-Max Series Drives ii H-Max Series Variable Frequency Drive MN04008005E—May 2017 www.eaton.com

Support Services

The goal of Eaton is to ensure your greatest possible satisfaction with the operation of our products. We are dedicated to providing fast, friendly, and accurate assistance. That is why we offer you so many ways to get the support you need. Whether it’s by phone, fax, or e-mail, you can access Eaton’s support information 24 hours a day, seven days a week.

Our wide range of services is listed below.

You should contact your local distributor for product pricing, availability, ordering, expediting, and repairs.

Web Site Use the Eaton Web site to find product information. You can also find information on local distributors or Eaton’s sales offices.

Web Site Address www.eaton.com/drives

EatonCare Customer Support Center Call the EatonCare Support Center if you need assistance with placing an order, stock availability or proof of shipment, expediting an existing order, emergency shipments, product price information, returns other than warranty returns, and information on local distributors or sales offices.

Voice: 877-ETN-CARE (877-386-2273) (8:00 a.m.–6:00 p.m. Eastern Time U.S. [UTC –5])

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If you are in the U.S. or Canada, and have OI or PLC questions, you can take advantage of our toll-free line for technical assistance with hardware and software product selection, system design and installation, and system debugging and diagnostics. Technical support engineers are available for calls during regular business hours.

Drives Technical Resource Center Voice: 800-322-4986 or +1 828-651-0984 (8:00 a.m.–5:00 p.m. Central Time U.S. [UTC –6]) Fax: +1 920-262-6070 e-mail: TRCDrives@Eaton.com

For Customers in Europe, Contact:

Eaton Industries GmbH Electrical Sector After Sales Service Hein-Moeller-Str. 7-11 D-53115 Bonn

Phone: +49 (0) 228 6 02-3640 Fax: +49 (0) 228 6 02-61400 Hotline: +49 (0) 180 5 223822 e-mail: AfterSalesEGBonn@Eaton.com www.moeller.net/aftersales

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Table of Contents

SAFETY

Definitions and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Hazardous High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

ENGINEERING

Introduction Electrical Power Network Safety and Switching EMC Measures Motor and Application

SYSTEM OVERVIEW

Component Identification Selection Criteria Proper Use Maintenance and Inspection Storage Service and Warranty

H-MAX SERIES OVERVIEW

How to Use this Manual Receiving and Inspection Catalog Number Selection Power Ratings and Product Selection Electrical Installation

INSTALLATION REQUIREMENTS

Standard Mounting Instructions NEMA Type 1/12 Open Drives (1–250 hp) Power Wiring Selection Cable Routing Control Board EMC Installation Checking the Cable and Motor Insulation

APPENDIX A

Technical Data

APPENDIX B

Cable Power and Motor Wiring Guidelines

APPENDIX C

Dimension Drawings iv H-Max Series Variable Frequency Drive MN04008005E—May 2017 www.eaton.com

List of Figures

Figure 1. Drive System (PDS) Figure 2. AC Power Networks with Grounded Center Point (TN-/TT Networks) Figure 3. EMC Environment and Category Figure 4. Parallel Connection of Several Motors to One Frequency Inverter Figure 5. Example of a Motor Ratings Plate Figure 6. Star and Delta Circuit Types Figure 7. V/Hz-Characteristic Curve Figure 8. Bypass Motor Control (Example) Figure 9. H-Max Series Figure 10. Description of the H-Max Figure 11. Block Diagram, Elements of H-Max Frequency Inverters Figure 12. Selection Criteria Figure 13. Rating Plate Figure 14. Approval Sticker Figure 15. Carton Labels (U.S.)

Figure 16. H-Max Series Drives Figure 17. Mounting Space Figure 18. Mounting Drive Dimensions—FS4–FS7 Figure 19. Mounting Drive Dimensions—FS8 and FS9 Figure 20. Input Power and Motor Cable Stripping Lengths Figure 21. Wiring the VFD Figure 22. H-Max Series Variable Frequency Drive Figure 23. DIP Switch Functionality Figure 24. Digital Input Ground Isolation Figure 25. EMC-Compliant Setup (Example: H-Max) Figure 26. Cable Description Figure 27. Locations of the EMC-Jumpers in Frames FS4 to FS6 Figure 28. Three-Phase Input Connection Figure 29. Connection to Power Section Figure 30. Ground Connection Figure 31. Removing the Jumper, FS5 as Example Figure 32. Grounding Bar Location, FS8 Figure 33. Removing the EMC Jumper, FS7 and FS8 Figure 34. Detaching the DC Grounding Bus Bar from Frame, FS7 Figure 35. Molex Connector Placement, FS9 Figure 36. Removing the EMC Jumper, FS9 Figure 37. Product Modified Sticker Figure 38. FS4 Dimension Drawing Figure 39. FS4 Dimension Drawing Flange Mount Figure 40. FS5 Dimension Drawing Figure 41. FS5 Dimension Drawing Flange Mount Figure 42. FS6 Dimension Drawing Figure 43. FS6 Dimension Drawing Flange Mount Figure 44. FS7 Dimension Drawing Figure 45. FS7 Dimension Drawing Flange Mount Figure 46. FS8 Dimension Drawing IP00 Figure 47. FS8 Dimension Drawing IP2154 Flange Mount Figure 48. FS8 Dimension Drawing Flange Mount Figure 49. FS9 Dimension Drawing Figure 50. FS9 Dimension Drawing IP2154 Figure 51. FS9 Dimension Drawing Flange Mount

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List of Tables

Table 1. Identification on the Residual-Current Circuit-Breakers Table 2. Assignment of Frequency Inverters to Example Motor Circuit Table 3. Maintenance Measures and Intervals Table 4. NEMA Type 1/IP21 or NEMA Type 12/IP54 Table 5. NEMA Type 1/IP21 or NEMA Type 12/IP54 Table 6. NEMA Type 1/IP21 or NEMA Type 12/IP54 Table 7. H-Max Series Variable Frequency Drive Option Boards Table 8. Space Requirements for Mounting the H-Max Series VFD and Airflow Table 9. Mounting Drive Dimensions—FS4–FS7 Table 10. Mounting Drive Dimensions—FS8 and FS9 Table 11. Power Connection Tightening Torque Table 12. Spacing Between Parallel Motor Cables Table 13. Maximum Cable Length by Frame Size without DV/DT

Protected C2 Ratings Table 14. Input Power and Motor Cable Stripping and Wire Lengths Table 15. LED Status Table 16. DIP Switch Table 17. International EMC Protection Cable Requirements Table 18. H-Max Technical Data Table 19. Standard I/O Board Table 20. Relay Board 1 Table 21. Relay Board 2 Table 22. North America Cable and Fuse Sizes—208–240 Vac Ratings Table 23. North America Cable and Fuse Sizes—380–480 Vac Ratings Table 24. North America Cable and Fuse Sizes—525–600 Vac Ratings Table 25. International Cable and Fuse Sizes 380–480 Vac Ratings vi H-Max Series Variable Frequency Drive MN04008005E—May 2017 www.eaton.com

Safety

Warning!

Dangerous Electrical Voltage!

Before Commencing the Installation

● Disconnect the power supply of the device

● Ensure that devices cannot be accidentally restarted

● Verify isolation from the supply

● Earth and short circuit the device

● Cover or enclose any adjacent live components

● Follow the engineering instructions (IL04020001E) for the device concerned

● Only suitably qualified personnel in accordance with EN 50110-1/-2 (VDE 0105 Part 100) may work on this device/system

● Before installation and before touching the device ensure that you are free of electrostatic charge

● The functional earth (FE, PES) must be connected to the protective earth (PE) or the potential equalization. The system installer is responsible for implementing this connection

● Connecting cables and signal lines should be installed so that inductive or capacitive interference does not impair the automation functions

● Install automation devices and related operating elements in such a way that they are well protected against unintentional operation

● Suitable safety hardware and software measures should be implemented for the I/O interface so that an open circuit on the signal side does not result in undefined states in the automation devices

● Ensure a reliable electrical isolation of the extra-low voltage of the 24V supply. Only use power supply units complying with IEC 60364-4-41 (VDE 0100 Part 410) or

HD384.4.41 S2

● Deviations of the input voltage from the rated value must not exceed the tolerance limits given in the specifications, otherwise this may cause malfunction and dangerous operation

● Emergency stop devices complying with IEC/EN 60204-1 must be effective in all operating modes of the automation devices. Unlatching the emergency-stop devices must not cause a restart

● Devices that are designed for mounting in housings or control cabinets must only be operated and controlled after they have been installed and with the housing closed.

Desktop or portable units must only be operated and controlled in enclosed housings

● Measures should be taken to ensure the proper restart of programs interrupted after a voltage dip or failure. This should not cause dangerous operating states even for a short time. If necessary, emergency-stop devices should be implemented

● Wherever faults in the automation system may cause injury or material damage, external measures must be implemented to ensure a safe operating state in the event of a fault or malfunction (for example, by means of separate limit switches, mechanical interlocks, and so on)

● Depending on their degree of protection, variable frequency drives may contain live bright metal parts, moving or rotating components, or hot surfaces during and immediately after operation

● Removal of the required covers, improper installation, or incorrect operation of motor or variable frequency drive may cause the failure of the device and may lead to serious injury or damage

● The applicable national accident prevention and safety regulations apply to all work carried out on live variable frequency drives

● The electrical installation must be carried out in accordance with the relevant regulations (for example, with regard to cable cross sections, fuses, PE)

● Transport, installation, commissioning, and maintenance work must be carried out only by qualified personnel (IEC 60364, HD 384 and national occupational safety regulations)

● Installations containing variable frequency drives must be provided with additional monitoring and protective devices in accordance with the applicable safety regulations.

Modifications to the variable frequency drives using the operating software are permitted

● All covers and doors must be kept closed during operation

● To reduce hazards for people or equipment, the user must include in the machine design measures that restrict the consequences of a malfunction or failure of the drive (increased motor speed or sudden standstill of motor).

These measures include:

● Other independent devices for monitoring safety-related variables (speed, travel, end positions, and so on)

● Electrical or non-electrical system-wide measures (electrical or mechanical interlocks)

● Never touch live parts or cable connections of the variable frequency drive after it has been disconnected from the power supply. Due to the charge in the capacitors, these parts may still be live after disconnection. Fit appropriate warning signs

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Safety

Definitions and Symbols

WARNING

This symbol indicates high voltage. It calls your attention to items or operations that could be dangerous to you and other persons operating this equipment. Read the message and follow the instructions carefully.

This symbol is the “Safety Alert Symbol.” It occurs with either of two signal words: CAUTION or WARNING, as described below.

WARNING

Indicates a potentially hazardous situation which, if not avoided, can result in serious injury or death.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, can result in minor to moderate injury, or serious damage to the product. The situation described in the CAUTION may, if not avoided, lead to serious results.

Important safety measures are described in CAUTION (as well as WARNING).

Hazardous High Voltage

WARNING

Motor control equipment and electronic controllers are connected to hazardous line voltages. When servicing drives and electronic controllers, there may be exposed components with housings or protrusions at or above line potential. Extreme care should be taken to protect against shock.

Stand on an insulating pad and make it a habit to use only one hand when checking components. Always work with another person in case an emergency occurs. Disconnect power before checking controllers or performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electronic controllers or rotating machinery.

Warnings and Cautions

CAUTION

When selecting the cable cross-section, take the voltage drop under load conditions into account.

The consideration of other standards (for example, VDE 0113 or VDE 0289) is the responsibility of the user.

CAUTION

The specified minimum PE conductor cross-sections (EN 50178, VDE 0160) must be maintained.

WARNING

With frequency inverters, only AC/DC sensitive residual current circuit breakers (RCD type B) are to be used

(EN 50178, IEC 755).

CAUTION

Debounced inputs may not be used in the safety circuit diagram.

Residual current circuit breakers (RCD) are only to be installed between the AC power supply network and the frequency inverter.

CAUTION

Debounced inputs may not be used in the safety circuit diagram.

If you are connecting multiple motors on one frequency inverter, you must design the contactors for the individual motors according to utilization category AC-3.

Selecting the motor contactor is done according to the rated operational current of the motor to be connected.

CAUTION

Debounced inputs may not be used in the safety circuit diagram.

A changeover between the frequency inverter and the input supply must take place in a voltage-free state.

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WARNING

The frequency inverter outputs (U, V, W) must not be connected to the input voltage (destruction of the device, risk of fire).

CAUTION

Debounced inputs may not be used in the safety circuit diagram.

Switch S1 must switch only when frequency inverter T1 is at zero current.

WARNING

Carry out wiring work only after the frequency inverter has been correctly mounted and secured.

WARNING

Electric shock hazard—risk of injuries!

Carry out wiring work only if the unit is de-energized.

CAUTION

Debounced inputs may not be used in the safety circuit diagram.

Fire hazard!

Only use cables, protective switches, and contactors that feature the indicated permissible nominal current value.

CAUTION

Debounced inputs may not be used in the safety circuit diagram.

Ground contact currents in frequency inverters are greater than 3.5 mA (AC). According to product standard IEC/EN 61800-5-1, an additional equipment grounding conductor must be connected, or the cross-section of the equipment grounding conductor must be at least 0.39 in2 (10 mm2).

WARNING

The components in the frequency inverter’s power section remain energized up to five (5) minutes after the supply voltage has been switched off (intermediate circuit capacitor discharging time).

Pay attention to hazard warnings!

WARNING

Do not perform any modifications on the AC drive when it is connected to mains.

CAUTION

Before connecting the AC drive to mains make sure that the EMC protection class settings of the drive are appropriately made.

DANGER

5 MIN

Engineering

H-Max Series Variable Frequency Drive MN04008005E—May 2017 www.eaton.com 1

Engineering

Introduction This chapter describes the most important features in the energy circuit of a drive system (PDS = Power Drive System) that you should take into consideration in your project planning.

Figure 1. Drive System (PDS) c b a

L1

L2

L3

PE

d f h g e

RCD

L1 L2

PE U V W

L3 PE

M

PES

PES

I > I > I > i

Item Number Description

1 Network configuration, input voltage, input frequency, interaction with p.f. correction systems

2 Breakers, fuses, and cable cross-sections

3 Protection of persons and domestic animals with residual-current protective devices

4 Input contactor

5 Frequency inverter: mounting, installation; power connection;

EMC measures; circuit examples

6 Motor reactor, dv/dt filter, sine-wave filter

7 Motor protection; thermistor

8 Cable lengths, motor cables, shielding (EMC)

9 Motor and application, parallel operation of multiple motors on a frequency inverter, bypass circuit; DC braking

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Electrical Power Network

Input Connection and Configuration The H-Max series frequency inverters can be connected and operated with all control-point grounded AC power networks (see IEC 60364 for more information).

Figure 2. AC Power Networks with Grounded Center Point (TN-/TT Networks)

While planning the project, consider a symmetrical distribution to the three external conductors, if multiple frequency inverters with single-phase supplies are to be connected. The total current of all single-phase consumers is not to cause an overload of the neutral conductor (N-conductor).

The connection and operation of frequency inverters to asymmetrically grounded TN networks (phase-grounded Delta network “Grounded Delta”, USA) or non-grounded or high-resistance grounded (over 30 ohms) IT networks is only conditionally permissible.

If the H-Max frequency inverters are connected to an asymmetrically grounded network or to an IT network (non-grounded, insulated), the internal interference suppression filter must be disconnected (unscrew the screw marked EMC, see “Installation in IT System” on Page 37).

The required filtering for electromagnetic compatibility (EMC) is then no longer present.

Measures for electromagnetic compatibility are mandatory in a drive system in order to meet the legal requirements for EMC and low voltage regulations.

Good grounding measures are a prerequisite for the effective insert of further measures such as shielding or filters.

Without respective grounding measures, further steps are superfluous.

Input Voltage and Frequency The standardized input voltages (IEC 60038, VDE017-1) for energy suppliers (EVU) guarantee the following conditions at the transition points:

● Deviation from the rated value of voltage: maximum ±10%

● Deviation in voltage phase balance: maximum ±3%

● Deviation from rated value of the frequency:

maximum ±4%

The broad tolerance band of the H-Max frequency inverter considers the rated value for European as (EU: ULN = 230V/400V, 50 Hz) and American as (USA: ULN = 240V/480V, 60 Hz) standard voltages:

● 230V, 50 Hz (EU) and 240V, 60 Hz (USA) at HMX32

● 400V, 50 Hz (EU) and 480V, 60 Hz (USA) at HMX34_

● 600V, 60 Hz at HMX35

For the bottom voltage value, the permitted voltage drop of 4% in the consumer circuits is also taken into account, therefore a total of ULN –14%.

● 200V device class (HMX32):

208V –10% to 240V +10% (188V –0% to 264V +0%)

● 400V device class (HMX34):

380V –10% to 480V +10% (342V –0% to 528V +0%)

● 600V device class (HMX35):

525V –10% to 600V +10%

The permitted frequency range is 50/60 Hz (48 Hz –0% –66 Hz +0%).

L2

N

L1

L3

PE

L2

PEN

L1

L3

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Voltage Balance Because of the uneven loading on the conductor, and with the direct connection of greater power ratings, deviations from the ideal voltage form and asymmetrical voltages can be caused in three-phase AC power networks. These asymmetric divergences in the input voltage can lead to different loading of the diodes in input rectifiers with three-phase supplied frequency inverters, and as a result, an advance failure of this diode.

In the project planning for the connection of three-phase supplied frequency inverters (HMX32, HMX34), consider only AC power networks that handle permitted asymmetric divergences in the input voltage +3%.

If this condition is not fulfilled, or symmetry at the connection location is not known, the use of an assigned main choke is recommended.

Total Harmonic Distortion (THD) The THD (Total Harmonic Distortion) is a measurement for the occurring harmonic distortion of the sinusoidal oscillation (input power side) input variables with the frequency inverter. It is given in percent of the total value.

U1 = fundamental component THD k = 0.1 K = 10% ~ –20 dB (THD suppression)

With H-Max series frequency inverters, the permitted value for the total harmonic distortion THD is >120%.

Idle Power Compensation Devices Compensation on the power supply side is not required for H-Max series frequency inverters. From the AC power supply network, they take on very little reactive power of the fundamental harmonics (cos ~ 0.98).

In the AC power networks with non-choked idle current compensation devices, current deviations can enable parallel resonance and undefinable circumstances.

In the project planning for the connection of frequency inverters to AC power networks with undefined circumstances, consider using main chokes.

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Safety and Switching

Fuses and Cable Cross-Sections The fuses and wire cross-sections allocated for power-side connections depend on the rated input current ILN of the frequency inverter (without input reactor).

CAUTION

When selecting the cable cross-section, take the voltage drop under load conditions into account.

The consideration of other standards (for example, VDE 0113 or VDE 0289) is the responsibility of the user.

The national and regional standards (for example VDE 0113, EN 60204) must be observed and the necessary approvals (for example UL) at the site of installation must be fulfilled.

When the device is operated in a UL-approved system, use only UL-approved breakers, fuses, fuse bases, and cables.

The leakage currents to ground (to EN 50178) are greater than 3.5 mA. The connection terminals marked PE and the housing must be connected with the ground circuit.

CAUTION

The specified minimum PE conductor cross-sections (EN 50178, VDE 0160) must be maintained.

Choose the cross-section of the PE conductor in the motor lines at least as large as the cross-section of the phase lines (U, V, W).

Cables and Fuses The cross-sections of the cables and line protection fuses used must correspond with local standards.

For an installation in accordance with UL guidelines, the fuses and copper cable that are UL-approved and have a heat-resistance of 167° to 194°F (75° to 90°C) are to be used.

Use power cables with insulation according to the specified input voltages for the permanent installation. A shielded cable is not required on the input side.

A completely (360°) shielded low impedance cable is required on the motor side. The length of the motor cable depends on the RFI class and must not exceed 500 ft (153m) without additional filtering.

Residual-Current Device (RCD) RCD (Residual Current Device): Residual current device, residual current circuit breaker (FI circuit breaker).

Residual current circuit breakers protect persons and animals from the existence (not the origination) of impermissibly high contact voltages. They prevent dangerous, and in some cases deadly injuries caused by electrical accidents, and also serve as fire prevention.

WARNING

With frequency inverters, only AC/DC sensitive residual current circuit breakers (RCD type B) are to be used

(EN 50178, IEC 755).

Table 1. Identification on the Residual-Current Circuit-Breakers

Frequency inverters work internally with rectified AC currents. If an error occurs, the DC currents can block a type A RCD circuit breaker from triggering and therefore disable the protective functionality.

CAUTION

Debounced inputs may not be used in the safety circuit diagram.

Residual current circuit breakers (RCD) are only to be installed between the AC power supply network and the frequency inverter.

Safety-relevant leakage currents can occur while handling and when operating the frequency inverter, if the frequency inverter is not grounded (because of a fault).

Leakage currents to ground are mainly caused by foreign capacities with frequency inverters; between the motor phases and the shielding of the motor cable and via the Y-capacitors of the noise filter. The size of the leakage current is mainly dependent upon the:

● length of the motor cable

● shielding of the motor cable

● height of the pulse frequency (switching frequency of the inverter)

● design of the noise filter

● grounding measures at the site of the motor

AC/DC sensitive (RCD, type B)

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The leakage current to ground is greater than 3.5 mA with a frequency inverter. Based on the requirements of EN 50178, an increased ground (PE) has to be connected. The cable cross-section must be at least 10 mm2 or consist of two separately connected ground cables.

Residual current circuit breakers must be suitable for:

● the protection of installations with DC current component in case of fault scenario (RCD type B)

● high leakage currents (300 mA)

● brief discharges of pulse current spikes

Input Contactor The input contactor enables an operational switching on and off of the supply voltage for the frequency inverter, and switching off in case of a fault.

The input contactor is designed based on the input current (ILN) of the frequency inverter and the utilization category AC-1 (IEC 60947). Input contactors and the assignment to H-Max frequency inverters are explained in the appendix.

While planning the project, make sure that inching operation is not done via the input contactor of the frequency inverter on frequency-controlled drives, but through a controller input of the frequency inverter.

The maximum permitted operating frequency of the input voltage with the H-Max frequency inverter is one time per minute (normal operation).

EMC Measures Electrical components in a system (machine) have a reciprocal effect on each other. Each device not only emits interference but is also affected by it. The interference can be produced by galvanic, capacitive, and/or inductive sources, or by electromagnetic radiation. In practice, the limit between line-conducted interference and emitted interference is around 30 MHz. Above 30 MHz, cables and conductors act like antennas that radiate electromagnetic waves.

Electromagnetic compatibility (EMC) for frequency controlled drives (variable speed drives) is implemented in accordance with product standard IEC/EN 61800-3. This includes the complete power drive system (PDS), from the input supply to the motor, including all components, as well as cables (see figure on Page 1). This type of drive system can consist of several individual drives.

The generic standards of the individual components in a PDS compliant with IEC/EN 61800-3 do not apply. These component manufacturers, however, must offer solutions that ensure standards-compliant use.

In Europe, maintaining the EMC guidelines is mandatory.

A declaration of conformity (CE) always refers to a “typical” power drive system (PDS). The responsibility to comply with the legally stipulated limit values and thus the provision of electromagnetic compatibility is ultimately the responsibility of the end user or system operator. This operator must also take measures to minimize or remove emission in the environment concerned (see figure below). He must also use means to increase the interference immunity of the devices of the system.

With their high interference immunity up to category C2, H-Max frequency inverters are ideal for use in commercial networks (1st environment).

Figure 3. EMC Environment and Category

Public Medium-Voltage Supply Grid

Public Low-Voltage Supply Grid

Industry Grid 1

Industry Grid 2

Measuring Point

Category C1

Category C1/C2 Category C3/C4 Category C3/C4

1st Enviroment 2nd Enviroment

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Motor and Application

Motor Selection General recommendations for motor selection:

● Use three-phase powered asynchronous motors with short-circuit rotors and surface cooling, also called asynchronous motors or standard motors for the frequency-controlled drive system (PDS). Other specifications such as external rotor motors, slip-ring motors, reluctance motors, synchronous or servo motors can also be run with a frequency inverter, but normally require additional planning and discussion with the motor manufacturer

● Use only motors with at least heat class F (311°F [155°C] maximum steady state temperature)

● Four-pole motors are preferred (synchronous speed:

1500 min–1 at 50 Hz or 1800 min–1 at 60 Hz)

● Take the operating conditions into account for S1 operation

(IEC 60034-1)

● When operating multiple motors in parallel on one frequency inverter, the motor output should not be more than three power classes apart

● Ensure that the motor is not overdimensioned. If a motor in speed control mode is underdimensioned, the motor rating must only be one rating level lower

Connecting Motors in Parallel The H-Max frequency inverters allow parallel operation of several motors using multi-pump application control mode:

● Multi-pump application: several motors with the same or different rated operational data. The sum of all motor currents must be less than the frequency inverter’s rated operational current

● Multi-pump application: parallel control of several motors.

The sum of the motor currents plus the motors’ inrush currents must be less than the frequency inverter’s rated operational current

Parallel operation at different motor speeds can be implemented only by changing the number of pole pairs and/ or changing the motor’s transmission ratio.

CAUTION

Debounced inputs may not be used in the safety circuit diagram.

If you are connecting multiple motors on one frequency inverter, you must design the contactors for the individual motors according to utilization category AC-3.

Selecting the motor contactor is done according to the rated operational current of the motor to be connected.

Figure 4. Parallel Connection of Several Motors to One Frequency Inverter

Connecting motors in parallel reduces the load resistance at the frequency inverter output. The total stator inductance is lower and the leakage capacity of the lines greater. As a result, the current distortion is greater than in a single-motor circuit. To reduce the current distortion, you should use motor reactors (see [1] in figure above) in the output of the frequency inverter.

The current consumption of all motors connected in parallel must not exceed the frequency inverter’s rated output current I2N.

Electronic motor protection cannot be used when operating the frequency inverter with several parallel connected motors. You must, however, protect each motor with thermistors and/or overload relays.

The use of a motor protective circuit breaker at the frequency inverter’s output can lead to nuisance tripping.

F1

M1

Q12Q11

F2

M2

Q13

F3

M3

U1 V1 W1 U1 V1 W1 U1 V1 W1

M

3 ˜

M

3 ˜

M

3 ˜

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Motor and Circuit Type The motor’s stator winding can be connected in a star or delta configuration, in accordance with the rated operational data on the nameplate.

Figure 5. Example of a Motor Ratings Plate

Figure 6. Star and Delta Circuit Types

The three-phase motor with the rating plate based on the figure shown above, can be run in a star or delta connection.

The operational characteristic curve is determined by the ratio of motor voltage and motor frequency, in this case.

87-Hz Characteristic Curve In the delta circuit with 400V and 87 Hz, the motor shown in the figure above was released with three times-fold output (~1.3 kW).

Because of the higher thermal loading, using only the next higher motor output according to the list (1.1 kW) is recommended. The motor (in this example) therefore still has 1.47-fold higher output compared with the listed output (0.75 kW).

With the 87-Hz characteristic curve, the motor also works in the range from 50 to 87 Hz with an unattenuated field. The pull-out torque remains at the same level as in input operation with 50 Hz.

The heat class of the motor must be at least F in 87-Hz operation.

Figure 7. V/Hz-Characteristic Curve

The following table shows the allocation of possible frequency inverters depending on the input voltage and the type of circuit.

Table 2. Assignment of Frequency Inverters to Example Motor Circuit (See Figure Above)

Notes 1 Star connection: 400V, 50 Hz.

2 Delta connection: 230V, 50 Hz.

3 Delta connection: 400V, 87 Hz.

4 Note the permitted limit values of the motor.

/400 V230 3.5/2

0.75S1 0.79coskW

RPM1430 50 Hz

A

U1 V1 W1

W2 U2 V2

U1 V1 W1

W2 U2 V2

U2 (V) f (Hz)fmax

Frequency Inverters HMX32AG3D7 HMX34AG3D4 HMX34AG4D8

Rated operational current 3.7A 3.4A 4.8A

Input voltage 3 AC 230V 3 AC 400V 3 AC 400V

Motor circuit Delta Star Delta

V/Hz-characteristic curve 2 1 3

Motor current 3.5A 2.0A 3.5A

Motor voltage (ratings plate) 230V 400V 230V

Motor speed 1430 min–1 1430 min–1 2474 min–1 4

Motor frequency 50 Hz 50 Hz 87 Hz 4

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Bypass Operation If you want to have the option of operating the motor with the frequency inverter or directly from the input supply, the input branches must be interlocked mechanically.

CAUTION

Debounced inputs may not be used in the safety circuit diagram.

A changeover between the frequency inverter and the input supply must take place in a voltage-free state.

WARNING

The frequency inverter outputs (U, V, W) must not be connected to the input voltage (destruction of the device, risk of fire).

Figure 8. Bypass Motor Control (Example)

CAUTION

Debounced inputs may not be used in the safety circuit diagram.

Switch S1 must switch only when frequency inverter T1 is at zero current.

Contactors and switches (S1) in the frequency inverter output and for the direct start must be designed based on utilization category AC-3 for the rated operational current of the motor.

Connecting EX Motors Note the following when connecting explosion-protected motors:

● The frequency inverter must be installed outside the EX area

● Note the branch- and country-specific standards for explosion-protected areas (ATEX 100a)

● Note the standards and information of the motor manufacturer regarding operation on frequency inverters— for example, if motor reactors (du/dt-limiting) or sinus filters are specified

● Temperature monitors in the motor windings (thermistor, thermo-Click) are not to be connected directly to frequency inverters but must be connected via an approved trigger apparatus for EX areas

Item Number Description

1 Input/bypass contactor

2 Output contactor

Q1

I> I>I>

Q11

S1

M1

T1

M

3~

L1 L2 L3

L1L2L3

U V W

System Overview

H-Max Series Variable Frequency Drive MN04008005E—May 2017 www.eaton.com 9

System Overview

Component Identification

Figure 9. H-Max Series Figure 10. Description of the H-Max

Features

The H-Max frequency inverter converts the voltage and frequency of an existing AC network into a DC voltage. This DC voltage is used to generate a three-phase AC voltage with variable frequency and assigned amplitude values for the variable speed control of three-phase asynchronous motors.

Item Number Description

1 Frequency inverter HMX-_

2 I/O option boards

3 Motor reactor DEX-LM3, sinusoidal filter SFB400

4 Keypad

OK

BYPASS

START

STOP

RESET

Back

2 sec.

HOA

Item Number Description

1 Mounting holes

2 Device fan

3 Front cover

4 Power terminals

5 Keypad with display

OK

HOA

BYPASS

START

STOP

RESET

Back

2 sec.

1 2

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Figure 11. Block Diagram, Elements of H-Max Frequency Inverters

Item Number Description

1 Supply L1, L2/N, L3, PE, input supply voltage ULN = Ue at 50/60 Hz:

HMX32: 200V class, three-phase input connection (3 AC 230V/240V) HMX34: 400V class, three-phase input connection (3 AC 400V/480V) HMX35: 575V class, three-phase input connection (3 AC 575V/600V)

2 Internal interference suppression filter, category C2 to IEC/EN 61800-3 EMC-connection of internal interference suppression filter to PE

3 Rectifier bridge, converts the AC voltage of the electrical network into DC voltage

4 DC link with charging resistor, capacitor and switching mode power supply unit (SMPS = Switching Mode Power Supply):

DC link voltage UDC with three-phase input connection (3 AC): UDC = 1.41 x ULN

5 Inverter. The IGBT based inverter converts the DC voltage of the DC link (UDC) into a three-phase AC voltage (U2) with variable amplitude and frequency (f2). Sinusoidal pulse width modulation (PWM) with V/f control can be switched to speed control with slip compensation

6 Motor connection U/T1, V/T2, W/T3 with output voltage U2 (0–100% Ue) and output frequency f2 (0–320 Hz) output current (I2):

HMX32: 3.7–310A

HMX34: 3.4–310A

HMX35: 3.9–208A

100% at an ambient temperature of 104°F (40°C) with an overload capacity of 110% for 60s every 600s and a starting current of 200% for 2s every 20s

7 Keypad with control buttons, graphic display, control voltage, control signal terminals, microswitches, and interface for the PC interface module (option)

8 Three-phase asynchronous motor, variable speed control of three-phase asynchronous motor for assigned motor shaft power values (P2):

HMX32: 0.55–90 kW (230V, 50 Hz) or 0.75–125 hp (230V, 60 Hz) HMX34: 1.1–160 kW (400V, 50 Hz) or 1.5–250 hp (460V, 60 Hz) HMX35: 3–200 hp (600V, 60 Hz)

9 DC link—chokes, to minimize current harmonics

R+

EMC

L1

L2

L3

PE

R–

M 3 ~

U/T1

V/T2

W/T3

PE

H-Max Series Variable Frequency Drive MN04008005E—May 2017 www.eaton.com 11

Selection Criteria

The frequency inverter [3] is selected according to the supply voltage ULN of the input supply [1] and the rated current of the assigned motor [2]. The circuit type ( / ) of the motor must be selected according to the supply voltage [1]. The rated output current Ie of the frequency inverter must be greater than/equal to the rated motor current.

Figure 12. Selection Criteria

When selecting the drive, the following criteria must be known:

● Type of motor (three-phase asynchronous motor)

● Input voltage = rated operating voltage of the motor (for example, 3 AC~400V)

● Rated motor current (guide value, dependent on the circuit type and the supply voltage)

● Load torque (quadratic, constant)

● Starting torque

● Ambient temperature (rated value 122°F [50°C])

When connecting multiple motors in parallel to the output of a frequency inverter, the motor currents are added geometrically—separated by effective and idle current components. When you select a frequency inverter, make sure that it can supply the total resulting current. If necessary, for dampening and compensating the deviating current values, motor reactors or sinusoidal filters must be connected between the frequency inverter and the motor.

The parallel connection of multiple motors in the output of the frequency inverter is only permitted with V/Hz-characteristic curve control.

If you connect a motor to an operational frequency inverter, the motor draws a multiple of its rated operational current.

When you select a frequency inverter, make sure that the starting current plus the sum of the currents of the running motors will not exceed the rated output current of the frequency inverter.

Switching in the output of the frequency inverter is only permitted with V/Hz-characteristic curve control.

U, I, f

400/690V / 15.2/8.8A

7.5 0.82coskW min–11410 50 Hz

I

OK

BACK

RESET LOC

REM

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Proper Use The H-Max frequency inverters are not domestic appliances.

They are designed only for use as HVAC or pumping system components.

The H-Max frequency inverters are electrical apparatus for controlling variable speed drives with three-phase motors.

They are designed for installation in machines or for use in combination with other components within a machine or system.

After installation in a machine, the frequency inverters must not be taken into operation until the associated machine has been confirmed to comply with the safety requirements of Machinery Safety Directive (MSD) 89/392/EEC (meets the requirements of EN 60204). The user of the equipment is responsible for ensuring that the machine use complies with the relevant EU Directives.

The CE markings on the H-Max frequency inverter confirm that, when used in a typical drive configuration, the apparatus complies with the European Low Voltage Directive (LVD) and the EMC Directives (Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/336/EEC, as amended by

93/68/EEC).

In the described system configurations, H-Max frequency inverters are suitable for use in public and non-public networks.

A connection to IT networks (networks without reference to earth potential) is permissible only to a limited extent, because the device’s built-in filter capacitors connect the network with the earth potential (enclosure). On earth free networks, this can lead to dangerous situations or damage to the device (isolation monitoring required).

To the output of the frequency inverter (terminals U, V, W) you must not:

● connect a voltage or capacitive loads (for example, phase compensation capacitors)

● connect multiple frequency inverters in parallel

● make a direct connection to the input (bypass)

Observe the technical data and connection requirements. For additional information, refer to the equipment nameplate or label at the frequency inverter, and the documentation.

Any other usage constitutes improper use.

Maintenance and Inspection H-Max frequency inverters are maintenance free. However, external influences may affect the function and the lifespan of the H-Max frequency inverter. We therefore recommend that the devices are checked regularly and the following maintenance measures are carried out at the specified intervals.

There are no plans for replacing or repairing individual components of H-Max frequency inverters.

If the H-Max frequency inverter is damaged by external influences, repair is not possible. Dispose of the device in accordance with the respectively applicable environmental laws and provisions for the disposal of electrical or electronic devices.

Table 3. Maintenance Measures and Intervals

Maintenance Measure Maintenance Interval

Clean cooling vents (cooling slits) If required

Check the fan function 6–24 months (depending on the environment)

Filter in the switching cabinet doors (see manufacturer specifications)

6–24 months (depending on the environment)

Check the tightening torques of the terminals (control signal terminals, power terminals)

Regularly

Check connection terminals and all metallic surfaces for corrosion

6–24 months (depending on the environment)

H-Max Series Variable Frequency Drive MN04008005E—May 2017 www.eaton.com 13

Storage If the frequency inverter is stored before use, suitable ambient conditions must be ensured at the site of storage:

● Storage temperature: –40° to 158°F (–40° to 70°C)

● Relative average air humidity: <95%, noncondensing

(EN 50178)

● Thin film capacitors are used to allow up to five years non-powered shelf life

Service and Warranty In the unlikely event that you have a problem with your H-Max frequency inverter, please contact your local sales office.

When you call, have the following information ready:

● the exact frequency inverter part no. (see nameplate)

● the date of purchase

● a detailed description of the problem that has occurred with the frequency inverter

If some of the information printed on the nameplate is not legible, please state only the information that is clearly legible. This information can also be found on the cover of the control terminals.

Information concerning the guarantee can be found in the Eaton General Terms and Conditions of Sale.

H-Max Series Overview

14 H-Max Series Variable Frequency Drive MN04008005E—May 2017 www.eaton.com

H-Max Series Overview

This chapter describes the purpose and contents of this manual, the receiving inspection recommendations and the H-Max Series Open Drive catalog numbering system.

How to Use this Manual

The purpose of this manual is to provide you with information necessary to install, set and customize parameters, start up, troubleshoot and maintain the Eaton H-Max Series variable frequency drives (VFD). To provide for safe installation and operation of the equipment, read the safety guidelines at the beginning of this manual and follow the procedures outlined in the following chapters before connecting power to the H-Max Series VFD. Keep this operating manual handy and distribute to all users, technicians and maintenance personnel for reference.

Receiving and Inspection

The H-Max Series VFD has met a stringent series of factory quality requirements before shipment. It is possible that packaging or equipment damage may have occurred during shipment. After receiving your H-Max Series VFD, please check for the following:

Check to make sure that the package includes the Installation Manual (MN04008005E), Quick Start Guide (MN04008004E) and accessory packet. The accessory packet includes:

● Rubber grommets

● EMC grounding clamps for power cables

● Control cable grounding clamps

● EMC jumper locking clips

● M4 screw for EMC level change (FS7 only)

● Additional grounding screw

● Real time clock battery

● UL conduit plate

Inspect the unit to ensure it was not damaged during shipment.

Make sure that the part number indicated on the nameplate corresponds with the catalog number on your order.

If shipping damage has occurred, please contact and file a claim with the carrier involved immediately.

If the delivery does not correspond to your order, please contact your Eaton Electrical representative.

Note: Do not destroy the packing. The template printed on the protective cardboard can be used for marking the mounting points of the H-Max VFD on the wall or in a cabinet.

H-Max Series Variable Frequency Drive MN04008005E—May 2017 www.eaton.com 15

Figure 13. Rating Plate

Figure 14. Approval Sticker

Figure 15. Carton Labels (U.S.)

Type:

Input:

Output:

Power (IL):

Chassis:

HMX34AG3D421-B

Vin/Uin 3~AC, 380-480, 50/60 Hz, 3.4 A Vout/Uout 3~AC, 0- Vin/Uin, 0-320 Hz, 3.4 A @ 40°C, 2.7A @ 50°C 1.5HP: 480V / 1.1kW: 400V NEMA Type 1/IP21

M ad e in Fin lan d

S/N:123456789012

VAC LISTED

9D42

Code:12345678901234567890123456789012345

B.ID: 09391

S/N:123456789012

AC DRIVE 0020510471

Type: HMX34AG01221-B

S/N: V12345678901

Code:

07W09

Style: H34AG01221EB

Frequency inverter Frequenzumrichter Convertiesseur des fréquences

EATON CORPORATION

1 234567 890128

Powering Business Worldwide

Marks:

INPUT: Uin 3~ AC,380-480V, 50/60 Hz,12A OUTPUT: 3~ AC, 0 -Uin, 0-320 Hz, 12A Power (IL): 5.5kW: 400V/7.5HP: 480V

Firmware:

Application: ®

Made in Finland

LISTED

9D42

POWER CONVERSION EQUIPMENT

U.S. Carton Label

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Catalog Number Selection

Figure 16. H-Max Series Drives

Notes All boards are varnished (conformed coated). Corrosion resistant.

Battery included in all drives for real-time clock.

Keypad kit includes HOA bypass.

Keypad kit includes HOA, back reset for Europe application.

EMI/RFI filters included.

DC link choke included.

Notes All boards are varnished (conformed coated). Corrosion resistant.

Battery included in all drives for real-time clock. Three year lifetime.

Keypad kit includes HOA bypass.

Keypad kit includes HOA, back reset for Europe application.

EMI/RFI filters included.

DC link choke included.

HMX 3 4 A G 3D4 2 1 - N

Software Series

A–Z

Keypad

G = Graphical panel

Voltage

2 = 200–240 V 4 = 380–480 V 5 = 525–600 V

Phase

3 = Three-phase

Product

HMX = HVAC drive

Enclosure

1 = Open NEMA Type 1 IP21 2 = Open NEMA Type 12 IP54

Input Options Frame and Voltage Specific

2 = EMC C2

Braking/Application

N = No brake chopper (low overload)

Amperes

200–240 Volts 380–480 Volts 525–600 Volts

3D7 = 3.7 A–0.75 hp, 0.55 kW 4D8 = 4.8 A–1 hp, 0.75 kW 6D6 = 6.6 A–1.5 hp, 1.1 kW 8D0 = 8 A–2 hp, 1.5 kW 011 = 11 A–3 hp, 2.2 kW 012 = 12 A–4 hp, 3 kW 018 = 18 A–5 hp, 4 kW 024 = 24 A–7.5 hp, 5.5 kW 031 = 31 A–10 hp, 7.5 kW 048 = 48 A–15 hp, 11 kW 062 = 62 A–20 hp, 15 kW 075 = 75 A–25 hp, 18.5 kW 088 = 88 A–30 hp, 22 kW 105 = 105 A–40 hp, 30 kW 140 = 140 A–50 hp, 37 kW 170 = 170 A–60 hp, 45 kW 205 = 205 A–75 hp, 55 kW 261 = 261 A–100 hp, 75 kW 310 = 310 A–125 hp, 90 kW

3D4 = 3.4 A–1.5 hp, 1.1 kW 4D8 = 4.8–2 hp, 1.5 kW 5D6 = 5.6 A–3 hp, 2.2 kW 8D0 = 8 A–4 hp, 3 kW 9D6 = 9.6 A–5 hp, 4 kW 012 = 12 A–7.5 hp, 5.5 kW 016 = 16 A–10 hp, 7.5 kW 023 = 23 A–15 hp, 11 kW 031 = 31 A–20 hp, 15 kW…