BONFIGLIOLI Active Manuel utilisateur

AND UTOMATION OLUTIONSAS

IPNDUSTRY ROCESS

ACTIVE and

ACTIVE Cube

Installation manual - Cold Plate

Frequency inverter 230 V / 400 V

11/06 1

General points on the documentation

This documentation is valid for the frequency inverter series ACT and ACU in "Cold

Plate" variant (type designation ACT xxx-xxx C, ACU xxx-xxx C).

The "Cold Plate" variant differs from the frequency inverter series ACT and ACU de-

scribed in the instructions only as regards the design of the heat sink. The installation

instructions complement the documentation by the information relatin

to the varian

details. For all other instructions and information, in particular the safety instructions,

refer to the instructions included in the scope of supply.

The documentation and additional information can be requested via your local repre-

sentation of the company BONFIGLIOLI.

The following pictograms and si

nal words are used for the purposes of the present

documentation:

Danger

Danger refers to an immediate threat. Non-compliance with the precaution described

may result in death, serious injury or material damage.

Warning

Warning refers to a possible threat. Non-compliance with the warnin

may result in

death, serious injury or material damage.

Caution

Caution refers to an indirect threat. Non-compliance may result in personal or material

damage.

Attention

Attention refers to a possible operational behavior or an undesired condition that can

occur in accordance with the reference text.

Note

Note and the related text provide useful information which supplements the corre-

sponding part of the documentation.

Warning:

he specifications and instructions contained in the documentation mus

be complied with strictly during installation and commissioning. Only quali-

fied staff who has read the documentation and, in particular, the safety

instructions carefully is allowed to carry out installation or commissionin

work or to operate the frequency inverters. The term „Qualified Staff“

refers to anybody who is familiar with the installation, assembly, commis-

sioning and operation of the frequency inverter and has the proper qualifi-

cation for the job.

2 11/06

TABLE OF CONTENTS

1Scope of Supply for Devices in "Cold Plate" Variant...................................................... 3

1.1 ACT/ACU 201 (up to 3.0 kW) and ACT/ACU 401 (up to 4.0 kW)............................. 3

1.2 ACT/ACU 201 (4.0 to 9.2 kW) and ACT/ACU 401 (5.5 to 15.0 kW) ........................ 4

1.3 ACT/ACU 401 (18.5 to 30.0 kW).............................................................................. 5

2Technical data................................................................................................................ 6

2.1 ACT/ACU 201 (0.55 to 3.0 kW, 230 V) .................................................................... 6

2.2 ACT/ACU 201 (4.0 to 9.2 kW, 230 V)....................................................................... 6

2.3 ACT/ACU 401 (0.55 to 4.0 kW, 400 V) .................................................................... 7

2.4 ACT/ACU 401 (5.5 to 15.0 kW, 400 V) .................................................................... 7

2.5 ACT/ACU 401 (18.5 to 30.0 kW, 400 V) .................................................................. 7

3Range of application ...................................................................................................... 8

4Thermal properties of the heat sink............................................................................... 9

4.1 Thermal resistance .................................................................................................. 9

4.1.1 ACT/ACU 201 (0.55 to 3.0 kW, 230 V).....................................................................10

4.1.2 ACT/ACU 201 (4.0 to 9.2 kW, 230 V).......................................................................10

4.1.3 ACT/ACU 401 (0.55 to 4.0 kW, 400 V).....................................................................11

4.1.4 ACT/ACU 401 (5.5 to 15.0 kW, 400 V).....................................................................11

4.1.5 ACT/ACU 401 (18.5 to 30.0 kW, 400 V)...................................................................12

4.2 Fan and liquid cooling............................................................................................ 13

5Application notes ......................................................................................................... 14

6Mechanical installation ................................................................................................ 15

6.1 ACT/ACU 201 (up to 3.0 kW) and ACT/ACU 401 (up to 4.0 KW) .......................... 15

6.2 ACT/ACU 201 (4.0 to 9.2 kW) and ACT/ACU 401 (5.5 to 15.0 kW) ...................... 16

6.3 ACT/ACU 401 (18.5 to 30.0 kW)............................................................................ 17

6.4 Installation ............................................................................................................ 18

7Temperature Monitoring.............................................................................................. 18

11/06 3

1Scope of Supply for Devices in "Cold Plate" Variant

he scope of supply of the "Cold Plate" variant differs from the scope defined in the

operatin

instructions as re

ards the heat sink desi

n and the standard fixtures which

are not required in this variant.

1.1 ACT/ACU 201 (up to 3.0 kW) and ACT/ACU 401 (up to

4.0 kW)

Scope of Supply

Scope of supply

Frequency inverter

Terminal bar X1 (Phoenix ZEC 1,5/ST7,5)

Plug-in terminals for mains connection and DC networking

Terminal bar X10 (Phoenix ZEC 1,5/3ST5,0)

Plug-in terminals for relay output

Instructions and installation instructions for the device in "Cold Plate" variant,

CD ROM with manuals

Terminal bar X2 (Phoenix ZEC 1,5/ST7,5)

Plug-in terminal for braking resistor and motor connection

Control terminals X210A / X210B (Wieland DST85/RM3,5)

Plug-in terminal for connection of control signals

Note: Immediately check the

oods received for quality, quantity and type.

Obvious defects such as exterior dama

e of the packin

and/or the uni

must be notified to the sender within seven days for insurance reasons.

4 11/06

1.2 ACT/ACU 201 (4.0 to 9.2 kW) and ACT/ACU 401 (5.5 to

15.0 kW)

Scope of Supply

Scope of supply

Frequency inverter

Terminal bar X10 (Phoenix ZEC 1,5/3ST5,0)

Plug-in terminals for relay output

Instructions and installation instructions for the device in "Cold Plate" variant,

CD ROM with manuals

Control terminal X210A / X210B (Wieland DST85/RM3,5)

Plug-in terminal for connection of control signals

Note: Immediately check the

oods received for quality, quantity and type.

Obvious defects such as exterior dama

e of the packin

and/or the uni

must be notified to the sender within seven days for insurance reasons.

11/06 5

1.3 ACT/ACU 401 (18.5 to 30.0 kW)

Scope of Supply

Scope of supply

Frequency inverter

Terminal bar X10 (Phoenix ZEC 1,5/3ST5,0)

Plug-in terminals for relay output

Instructions and installation instructions for the device in "Cold Plate" variant,

CD ROM with manuals

Control terminal X210A / X210B (Wieland DST85/RM3,5)

Plug-in terminal for connection of control signals

Note: Immediately check the goods received for quality, quantity and type.

Obvious defects such as exterior dama

e of the packin

and/or the uni

must be notified to the sender within seven days for insurance reasons.

6 11/06

2Technical data

The following tables contain the technical data of the frequency inverter series ACT and

ACU in the "Cold Plate" variant. The recommended motor shaft output applies to the

corresponding nominal voltage of the frequency inverter according to the instructions a

a switchin

frequency of 2 kHz. The wei

hts and dimensions differ from the data listed

in the instructions. The dimensions are valid for the frequency inverter without plug-in

terminals and with cold plate in the "Cold Plate" device variant. For the other technical

data refer to the enclosed instructions.

2.1 ACT/ACU 201 (0.55 to 3.0 kW, 230 V)

Type designation

ACT/ACU 201 -05 -07 -09 -11 -13 -15

Motor-side output

Recommended

motor shaft output P kW 0.55 0.75 1.1 1.5 2.2 3.0

Mechanical

Dimensions

HxWxD mm 190x82x140 250x85x140

Weight (approx.) m kg 1.2 1.6

Type of protection - - IP20 (EN60529)

Installation position - - vertical

Environmental conditions

Energy dissipation

(at 2 kHz switching

frequency) P W 43 53 73 84 115 170

Coolant temperature Tn °C 0 ... 40 (3K3 DIN IEC 721-3-3)

2.2 ACT/ACU 201 (4.0 to 9.2 kW, 230 V)

Type designation

ACT/ACU 201 -18 -19 -21 -22

Motor-side output

Recommended

motor shaft output P kW 4.0 5.5 7.5 9.2

Mechanical

Dimensions

HxWxD mm 250x125x144 250x150x144

Weight (approx.) m kg 2.2 3.1

Type of protection - - IP20 (EN60529)

Installation position - - vertical

Environmental conditions

Energy dissipation

(at 2 kHz switching

frequency) P W 200 225 310 420

Coolant temperature Tn °C 0 ... 40 (3K3 DIN IEC 721-3-3)

11/06 7

2.3 ACT/ACU 401 (0.55 to 4.0 kW, 400 V)

Type designation

ACT/ACU 401 -05 -07 -09 -11 -12 -13 -15 -18

Motor-side output

Recommended

motor shaft output P kW 0.55 0.75 1.1 1.5 1.85 2.2 3.0 4.0

Mechanical

Dimensions

HxWxD mm 190x82x140 250x85x140

Weight (approx.) m kg 1.2 1.6

Type of protection - - IP20 (EN60529)

Installation position - - vertical

Environmental conditions

Energy dissipation

(at 2 kHz switching

frequency) P W 40 46 58 68 68 87 115 130

Coolant temperature Tn °C 0 ... 40 (3K3 DIN IEC 721-3-3)

2.4 ACT/ACU 401 (5.5 to 15.0 kW, 400 V)

Type designation

ACT/ACU 401 -19 -21 -22 -23 -25

Motor-side output

Recommended

motor shaft output P kW 5.5 7.5 9.2 11.0 15.0

Mechanical

Dimensions

HxWxD mm 250x125x144 250x150x144

Weight (approx.) m kg 2.2 3.1

Type of protection - - IP20 (EN60529)

Installation position - - vertical

Environmental conditions

Energy dissipation

(at 2 kHz switching

frequency) P W 145 200 225 240 310

Coolant temperature Tn °C 0 ... 40 (3K3 DIN IEC 721-3-3)

2.5 ACT/ACU 401 (18.5 to 30.0 kW, 400 V)

Type designation

ACT/ACU 401 -27 -29 -31

Motor-side output

Recommended

motor shaft output P kW 18.5 22.0 30.0

Mechanical

Dimensions

HxWxD mm 250x225x171

Weight (approx.) m kg 8.0

Type of protection - - IP20 (EN60529)

Installation position - - vertical

Environmental conditions

Energy dissipation

(at 2 kHz switching

frequency) P W 420 470 750

Coolant temperature Tn °C 0 ... 40 (3K3 DIN IEC 721-3-3)

8 11/06

3Range of application

Warning: Durin

operation, the heat sink can reach a temperature of up to 75 °C.

Do not touch the heat sink during operation.

he heat sink may be hot even some time after the frequency inverter was

switched off.

The “Cold Plate” variant enables installation of the frequency inverter on suitable sur-

faces which have sufficient thermal conductivity to dissipate the heat developin

durin

the operation of the frequency inverter.

This enables the use of the frequency inverter in the following applications:

-Installation in a housing, where a high type of protection is required but the vol-

ume of the housing limits thermal compensation.

-Use in highly polluted cooling air affecting the function and service life of the fan.

-Use of several frequency inverters in limited space conditions, e.

. installation o

frequency inverters on a liquid-cooled plate (sum cooler).

-Direct assembly on (or in) a machine case, with parts of the machine constructions

taking over the cooling function.

Note: Frequency inverters with a continuous output >15 kW require an im-

provement of the efficiency of the heat sink by means of suitable fans,

liquid cooling or other measures improving the cooling capacity of the hea

sink.

11/06 9

4Thermal properties of the heat sink

The heat in the frequency inverter due to the energy dissipation of the electronic com-

ponents (rectifier and IGBT) must be dissipated to a heat sink via the cold plate of the

frequency inverter.

The capacity to dissipate this heat mainly depends on the size of the heat sink surface,

the ambient temperature and the heat transmission resistance. An increase of the heat

transmission rate can only be realized to a certain extent by increasin

the surface o

the heat sink. An additional increase of the heat dissipation by increasin

the heat sin

is not possible.

he frequency inverter should be mounted with the cold plate on a heat sink with the

lowest thermal resistance possible.

4.1 Thermal resistance

The thermal resistance Rth is calculated from the difference between the maximum

heat sink temperature and the ambient temperature, referred to the ener

y dissipation

of the frequency inverter. The ambient temperature to be considered refers to the

immediate environment of the frequency inverter.

umaxk

th PTT

R−

Max. permissible heat sink temperature of the frequency inverter Tkmax = 75 °C

Ambient temperature of the cold plate of the frequency inverter TU= 35 °C

Difference between the maximum heat sink temperature and the

ambient temperature (Tk max -TU) ΔT = 40 K

Energy to be dissipated by the heat sink

Pv= depends on

type

Note: During installation, the following items must be considered in order to mini-

mize the thermal resistance:

-The installation surface must at least be as large as the cold plate sur-

face.

-The contact surface must be plane and have a good thermal conductiv-

ity.

he thermal limits of the frequency inverter and the cold plate must be

considered when determining the dimensions.

For the max. permissible thermal resistance Rth and the device-specific energy dissipa-

tion Pv, refer to the following table. The thermal resistance Rth is given in the unit Kel-

vin per Watt (K/W). Additionally, the thermal radiation of the frequency inverter is

indicated.

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