HVX9000 AF Drives User Manual August 2006 Supersedes April 2005 TD04008003E For more information visit: www.EatonElectrical.com HVX9000 AF Drives User Manual August 2006 Important Notice – Please Read The product discussed in this literature is subject to terms and conditions outlined in Eaton Electrical Inc. selling policies. The sole source governing the rights and remedies of any purchaser of this equipment is the relevant Eaton Electrical Inc. selling policy. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton Electrical Inc. 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: Cutler-Hammer® HVX9000 Drives TD04008003E For more information visit: www.EatonElectrical.com i HVX9000 AF Drives User Manual August 2006 ii For more information visit: www.EatonElectrical.com TD04008003E HVX9000 AF Drives User Manual August 2006 Table of Contents LIST OF FIGURES — FOR LISTING BY TOPIC SEE APPENDIX D . . . . . . . . . . . . . . . . . . . . iv LIST OF TABLES — FOR LISTING BY TOPIC SEE APPENDIX D . . . . . . . . . . . . . . . . . . . . . vii SAFETY Definitions and Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Hazardous High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Warnings, Cautions and Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x CHAPTER 1 — OVERVIEW How to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Catalog Numbering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 CHAPTER 2 — MOUNTING Space Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Environmental Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Standard Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 CHAPTER 3 — POWER WIRING Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 UL Compatible Cable Selection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Standard Wiring Diagrams and Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Power and Motor Wiring Terminal Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Checking the Cable and Motor Insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 CHAPTER 4 — CONTROL WIRING General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Control Wiring Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 CHAPTER 5 — INTELLIPASS BYPASS OPTION Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Catalog Number Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 IntelliPass Control Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 CHAPTER 6 — MENU INFORMATION Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Start-Up Wizard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Menu Navigation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 CHAPTER 7 — START-UP Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 CHA PTER 8 — APPLICATION INFORMATION Parameter Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 APPENDIX A — TECHNICAL DATA Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Power Loss and Switching Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 EMC Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20 Warranty and Liability Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21 APPENDIX B — PARAMETER TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 APPENDIX C — FAULT AND WARNING CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 APPENDIX D — FIGURES AND TABLES BY TOPICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 TD04008003E For more information visit: www.EatonElectrical.com iii HVX9000 AF Drives User Manual August 2006 List of Figures — For Listing by Topic see Appendix D Figure 2-1: Mounting Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Figure 3-1: Input Power and Motor Cable Stripping and Wire Lengths . . . . . . . . . . . . . . . 3-4 Figure 3-2: Wiring Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Figure 3-3: Ground Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Figure 3-4: Cable Protection Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Figure 3-5: Principle Wiring Diagram of HVX Power Unit, FR4, FR5 and FR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Figure 3-6: Principle Wiring Diagram of HVX Power Unit, FR6, FR7 and FR8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Figure 3-7: Principle Wiring Diagram of HVX Power Unit, FR9 and FR10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Figure 3-8: FR4 Power and Motor Wiring Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Figure 3-9: FR5 Power and Motor Wiring Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Figure 3-10: FR6 Power and Motor Wiring Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Figure 3-11: FR7 Power and Motor Wiring Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Figure 3-12: FR8 Power and Motor Wiring Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Figure 3-13: FR9 Power and Motor Wiring Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Figure 4-1: Option Board Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Figure 4-2: Option Board A9 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Figure 4-3: Option Board A9 Jumper Location and Settings (Slot A) . . . . . . . . . . . . . . . . . 4-5 Figure 4-4: Option Board A2 Wiring Diagram (Slot B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Figure 4-5: Option Board A2 Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Figure 4-6: Positive/Negative Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Figure 5-1: HVX IntelliPass/IntelliDisconnect Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Figure 5-2: HVX Series Enclosed Drive Dimensions — Box A . . . . . . . . . . . . . . . . . . . . . . . 5-3 Figure 5-3: HVX Series Enclosed Drive Dimensions — Box B . . . . . . . . . . . . . . . . . . . . . . . 5-4 Figure 5-4: HVX Series Enclosed Drive Dimensions — Box C . . . . . . . . . . . . . . . . . . . . . . . 5-5 Figure 5-5: HVX Series Enclosed Drive Dimensions — Box A . . . . . . . . . . . . . . . . . . . . . . . 5-6 Figure 5-6: HVX Series Enclosed Drive Dimensions — Box B . . . . . . . . . . . . . . . . . . . . . . . 5-7 Figure 5-7: HVX Series Enclosed Drive Dimensions — Box C . . . . . . . . . . . . . . . . . . . . . . . 5-8 Figure 5-8: Identification of TYPE 3R Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Figure 5-9: Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Figure 5-10: Schematic for Static Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Figure 5-11: Identification of TYPE 1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Figure 5-12: IntelliPass Power and Motor Terminal Wiring Example . . . . . . . . . . . . . . . . . 5-21 Figure 5-13: IntelliPass Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Figure 5-14: Option Board B5 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Figure 5-15: Option Board B5 Terminal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Figure 6-1: Keypad and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Figure 6-2: Operate Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Figure 6-3: Enable Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Figure 6-4: Main Menu Navigation — 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Figure 6-5: Main Menu Navigation — 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Figure 6-6: Parameter Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Figure 6-7: Keypad Control Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Figure 6-8: System Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Figure 6-9: Expander Board Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Figure 6-10: Digital Inputs DIN1, DIN2, DIN3 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Figure 6-11: Digital Inputs DIN4, DIN5, DIN6 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Figure 6-12: Digital Outputs DO1, RO1, RO2 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 iv For more information visit: www.EatonElectrical.com TD04008003E HVX9000 AF Drives User Manual August 2006 List of Figures — For Listing by Topic see Appendix D, continued Figure 6-13: Active Fault Display Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Figure 6-14: Sample Fault History Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Figure 6-15: Operate Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Figure 8-1: DC Braking Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Figure 8-2: AI1 Signal Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Figure 8-3: AI2 Signal Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Figure 8-4: Control Place B with and without Reference Scaling . . . . . . . . . . . . . . . . . . . . 8-12 Figure 8-5: Analog Output Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Figure 8-6: Analog Output Inversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Figure 8-7: Analog Output Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Figure 8-8: Output Frequency Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 Figure 8-9: External Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25 Figure 8-10: Acceleration/Deceleration Curve (S-Shaped) . . . . . . . . . . . . . . . . . . . . . . . . . 8-29 Figure 8-11: DC Braking Time When Stop Mode = Coasting . . . . . . . . . . . . . . . . . . . . . . . . 8-31 Figure 8-12: DC Braking Time When Stop Mode = Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32 Figure 8-13: DC Braking Time at Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32 Figure 8-14: Skip Frequency Area Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34 Figure 8-15: Ramp Speed Scaling Between Skip Frequencies . . . . . . . . . . . . . . . . . . . . . . 8-34 Figure 8-16: Linear and Squared Change of Motor Voltage . . . . . . . . . . . . . . . . . . . . . . . . 8-36 Figure 8-17: Programmable V/f Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37 Figure 8-18: Motor Cooling Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41 Figure 8-19: Motor Temperature Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42 Figure 8-20: Stall Characteristics Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43 Figure 8-21: Minimum Load Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44 Figure 8-22: Underload Time Counter Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45 Figure 8-23: Example of Automatic Restart with Two Restarts . . . . . . . . . . . . . . . . . . . . . . 8-46 Figure 8-24: Frequency Reference Logic of the Fire Mode PID Application When Running in Fire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49 Figure 8-25: Examples of Actual Value Signal Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52 Figure 8-26: PID Controller D-Time, Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54 Figure 8-27: PID Controller D-Time, Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55 Figure 8-28: PID Controller D-Time, Example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55 Figure 8-29: Frequency Converter Sleep Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57 Figure 8-30: PID Output + Motor Potentiometer Reference . . . . . . . . . . . . . . . . . . . . . . . . . 8-58 Figure A-1: Power Loss as Function of Switching Frequency: 1 – 3 hp 230V, 1-1/2 – 7-1/2 hp 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Figure A-2: Power Loss as Function of Switching Frequency: 5 – 10 hp 230V, 10 – 20 hp 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Figure A-3: Power Loss as Function of Switching Frequency: 15 – 20 hp 230V, 25 – 40 hp 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Figure A-4: Power Loss as Function of Switching Frequency: 50 – 75 hp 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Figure A-5: Power Loss as Function of Switching Frequency: 100 – 150 hp 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Figure A-6: Power Loss as Function of Switching Frequency: 200 – 250 hp 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Figure A-7: NEMA Type 1 and NEMA Type 12 HVX9000 Drive Dimensions, FR4, FR5 and FR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 Figure A-8: HVX9000 Dimensions, NEMA Type 1 and NEMA Type 12 with Flange Kit, FR4, FR5 and FR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 TD04008003E For more information visit: www.EatonElectrical.com v HVX9000 AF Drives User Manual August 2006 List of Figures — For Listing by Topic see Appendix D, continued Figure A-9: HVX9000 Dimensions, NEMA Type 1 and NEMA Type 12, FR7 . . . . . . . . . . . . A-10 Figure A-10: HVX9000 Dimensions, NEMA Type 1 and NEMA Type 12, FR8 . . . . . . . . . . . A-11 Figure A-11: HVX9000 Dimensions, NEMA Type 1 and NEMA Type 12, with Flange Kit, FR7 and FR8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12 Figure A-12: HVX9000 Dimensions, NEMA Type 1 and NEMA Type 12, FR9 . . . . . . . . . . . A-13 Figure A-13: HVX9000 Dimensions, NEMA Type 1 and NEMA Type 12 FR9 . . . . . . . . . . . A-14 Figure A-14: HVX9000 Dimensions, NEMA Type 1 and NEMA Type 12 FR9 with Flange Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15 Figure A-15: HVX9000 Dimensions, NEMA Type 1 and NEMA Type 12 FR10 Freestanding Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16 Figure A-16: HVX9000 Dimensions, FR10 Open Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17 Figure A-17: HVX9000 Dimensions, NEMA Type 1 FR11 Freestanding Drive . . . . . . . . . . A-18 Figure A-18: HVX9000 Dimensions, FR11 Open Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19 vi For more information visit: www.EatonElectrical.com TD04008003E HVX9000 AF Drives User Manual August 2006 List of Tables — For Listing by Topic see Appendix D Table 1-1: HVX9000 Drive Catalog Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Table 2-1: Space Requirements for Mounting an HVX9000 Drive . . . . . . . . . . . . . . . . . . . 2-1 Table 2-2: Cooling Airflow Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Table 3-1: Cable Spacings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Table 3-2: Cable and Fuse Sizes — 208 – 240V Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Table 3-3: Cable and Fuse Sizes — 380 – 500V Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Table 3-4: Cable and Fuse Sizes — 575 – 690V Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Table 3-5: Maximum Symmetrical Supply Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Table 3-6: Power Connection Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Table 3-7: Power and Motor Cable Stripping Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Table 4-1: Tightening Torques of Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Table 4-2: Control Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Table 4-3: Option Board A9 Terminal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Table 4-4: Option Board A2 Terminal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Table 5-1: HVX IntelliPass Drive Catalog Numbering System . . . . . . . . . . . . . . . . . . . . . . 5-1 Table 5-2: NEMA TYPE 1 IntelliPass/IntelliDisconnect Drive Dimensions . . . . . . . . . . . . . 5-2 Table 5-3: HVX Series TYPE 12 Enclosed IntelliPass/IntelliDisconnect Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Table 5-4: HVX Series TYPE 12 Enclosed IntelliPass/IntelliDisconnect Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Table 5-5: HVX Series TYPE 12 Enclosed IntelliPass/IntelliDisconnect Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Table 5-6: HVX Series TYPE 3R Enclosed IntelliPass/IntelliDisconnect Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Table 5-7: HVX Series TYPE 3R Enclosed IntelliPass/IntelliDisconnect Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Table 5-8: HVX Series TYPE 3R Enclosed IntelliPass/IntelliDisconnect Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Table 5-9: Bypass Power Wiring Instructions — TYPE 3R and 12 . . . . . . . . . . . . . . . . . . . . 5-10 Table 5-10: Static Checks of Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Table 5-11: Static Checks of Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Table 5-12: Static Checks of DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Table 5-13: Bypass Power Wiring Instructions — TYPE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Table 5-14: Option Board B5 Terminal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Table 6-1: LCD Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Table 6-2: LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Table 6-3: Navigation Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Table 6-4: Operate Menu Items — IntelliPass Application Example . . . . . . . . . . . . . . . . . . 6-5 Table 6-5: Total Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Table 6-6: Trip Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Table 6-7: Software Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Table 6-8: Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Table 6-9: Hardware Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Table 6-10: Slot A Expander Board Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Table 6-11: Monitoring Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Table 6-12: Fault Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Table 6-13: Fault Time Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Table 6-14: Operate Menu Items — IntelliPass Application Example . . . . . . . . . . . . . . . . . 6-25 Table 8-1: Scaling Factor for the Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Table 8-2: DO1 Function Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 TD04008003E For more information visit: www.EatonElectrical.com vii HVX9000 AF Drives User Manual August 2006 List of Tables — For Listing by Topic see Appendix D, continued Table 8-3: RO1 Function Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Table 8-4: RO2 Function Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Table 8-5: RO3 Content Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Table 8-6: Scaling Factor for the Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 Table 8-7: Scaling Factor for the Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28 Table 8-8: Binary Inputs for Seven Preset Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59 Table 8-9: Fieldbus Output Selection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62 Table A-1: HVX9000 Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Table A-2: 230V I Output Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 L Table A-3: 480V I Output Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 L Table A-4: 575V I Output Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 L Table A-5: HVX9000 Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 Table A-6: Dimensions for HVX9000, FR4, FR5 and FR6 with Flange Kit . . . . . . . . . . . . . . A-9 Table A-7: Dimensions for the Flange Opening, FR4 to FR6 . . . . . . . . . . . . . . . . . . . . . . . . A-9 Table A-8: HVX9000 Drive Dimensions, FR7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10 Table A-9: HVX9000 Drive Dimensions, FR8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11 Table A-10: Dimensions for HVX9000, FR7 and FR8 with Flange Kit . . . . . . . . . . . . . . . . . A-12 Table A-11: Dimensions for the Flange Opening, FR7/FR8 . . . . . . . . . . . . . . . . . . . . . . . . . A-12 Table A-12: HVX9000 Drive Dimensions, FR9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13 Table A-13: Dimensions for HVX9000, FR9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14 Table A-14: Dimensions for HVX9000, FR9 with Flange Kit . . . . . . . . . . . . . . . . . . . . . . . . . A-15 Table A-15: Dimensions for HVX9000, FR10 Freestanding Drive . . . . . . . . . . . . . . . . . . . . A-16 Table A-16: Dimensions for HVX9000, FR10 Open Chassis . . . . . . . . . . . . . . . . . . . . . . . . . A-17 Table A-17: Dimensions for HVX9000, NEMA Type 1 FR11 Freestanding Drive . . . . . . . . A-18 Table A-18: Dimensions for HVX9000, FR11 Open Chassis . . . . . . . . . . . . . . . . . . . . . . . . . A-19 Table B-1: Parameter Group G1.1: Basic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Table B-2: Parameter Group G1.2: Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Table B-3: Parameter Group G1.3: Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 Table B-4: Parameter Group G1.4: Drive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8 Table B-5: Parameter Group G1.5: Skip Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9 Table B-6: Parameter Group G1.6: Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9 Table B-7: Parameter Group G1.7: Protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10 Table B-8: Parameter Group G1.8: Auto-Restart Parameters . . . . . . . . . . . . . . . . . . . . . . . B-11 Table B-9: Parameter Group G1.9: Fire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12 Table B-10: Parameter Group G1.10: IntelliPass Parameters . . . . . . . . . . . . . . . . . . . . . . . B-12 Table B-11: Parameter Group G1.11: PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13 Table B-12: Parameter Group G1.12: Preset Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14 Table B-13: Parameter Group G1.13: Communication Bus . . . . . . . . . . . . . . . . . . . . . . . . . B-15 Table B-14: Monitoring Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-16 Table C-1: Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 viii For more information visit: www.EatonElectrical.com TD04008003E