Introduction

Application Considerations

Altivar 680 Low Harmonic Process Drives are designed for use in two operating modes that can optimize the drive nominal rating according to the system constraints:

Normal duty (ND): Dedicated mode for applications requiring a slight overload (up to 110%) with a motor power no higher than the drive nominal power
Heavy duty (HD): Dedicated mode for applications requiring a significant overload (up to 150%) with a motor power no higher than the drive nominal power derated by one rating.

Normal Duty (Left) and Heavy Duty (Right) Modes

About this Document

This instruction bulletin contains specifications, installation, operation, and maintenance information for the Altivar 680 (ATV680) Low Harmonic Process Drives. Since the process drive is engineered to order, your equipment may not have the same features, functions, or characteristics described in this document. For information specific to your process drive, consult the additional documentation shipped with it. The following document is also available from the Technical Library at www.se.com:

NHA60269, Drives Systems Installation and Maintenance

NHA60269 contains important information on installation, operation, service, and maintenance of this product. Read NHA60269, Drives Systems Installation and Maintenance before performing any work on or with this product.

To replace documents, download them from the Technical Library at www.se.com or contact your local Schneider Electric field office.

Terminology

The following terminology is used in this instruction bulletin:

Enclosed drive or process drive refers to the combination of the drive, enclosure, and the power and control circuits that constitute the Altivar 680 Low Harmonic Process Drives.
Bypass, or integral bypass starter, refers to the optional, integrated full-voltage combination starter in the process drive. When provided, the integral bypass starter may be used to start and run the motor in the unlikely event that the drive becomes inoperable.

Product Overview

The Altivar 680 Low Harmonic Drive System is a packaged, high-performance solution for low harmonic applications. This Active Front End (AFE) drive features a three-level input switching stage which reduces common mode voltage and improves performance and efficiency due to custom designed filtering and the three-level design. As such, it provides reduced motor bearing currents and improves the average motor lifespan.

The basic equipment contains active in-feed modules and filter components as well as inverter modules, semiconductor fuses, a main switch, a dv/dt filter from 300 hp (200 kW) for the protection of the motor, and spacious mains and bus bars for connection of power cables.

This new technology reaches a total distortion factor, THD(i), of around 2% and therefore fulfills the requirements according to IEEE 519 of THD(i) < 5% in the case of distorted mains voltage.

This robust, adjustable speed drive system is UL 508A Listed for all ratings, with selectable control and power configurations. It is available in Types 1 and 12, in the following ranges. See Dimensions for frame dimensions.

Frame 1a: 150–250 hp (110–160 kW) ND and 125–200 hp (90–130 kW) HD
Frame 2a: 300–500 hp (200–310 kW) ND and 250–400 hp (160–250 kW) HD
Frame 3a: 600–700 hp (400–500 kW) ND and 500–600 hp (310–400 kW) HD
Frame 4a: 900 hp (630 kW) ND and hp (500 kW) HD

Three-Level Approach

The three-level input switching stage shares many features with two-level active front ends, but with the addition of some important features. The third level is created by the connection of switches between the mains voltage and midpoint of the DC bus (see Three-Level Input Switching), allowing for a third level of switching:

0 V
One-half of the DC bus voltage and
Full DC bus voltage.

The result is better command and control of the currents flowing to and from the drive.

Three-Level Input Switching

Benefits

4 Q operation in modern three-level design
Total current distortion factor THD(i) ~2%
Compliant with IEEE 519 even in distorted networks
Extended motor life due to reduction of isolation stress on factor 2
Enhanced efficiency compared to the classic 2-level AFE design
Compact dimensions due to optimized filter components

Altivar 680 Low Harmonic Process Drive, 150–900 hp, available in Types 1 and 12

Standard Features

Process Drive without Bypass (150–900 hp ND and 125–700 hp HD)

The following are standard features for the process drive without bypass, when no options are ordered:

Robustness of high overload capacity, with overload capability of 10%
An Ethernet port maximizes services such as connection to the control room and full process transparency.
Circuit breaker disconnect
Four enclosure frame sizes
UL Listed per UL 508A
100,000 AIC short-circuit rating
Disconnect handle with lockout/tagout provisions
Door mounted keypad holder and display
One form C AFC Trip contact
One form C AFC Run Mode contact
Six programmable digital inputs
Standard 3% input impedance
Standard color RAL735
Controller programming
- Acceleration (ACC): 10 s
- Deceleration (DEC): 10 s
- Low speed (LSP): 3 Hz
White component mounting plate
Removable conduit entry plate on floor-mounted enclosures
Class 10 overload protection

Process Drive with Bypass (up to and including 250 hp)

The following are standard features for the process drive with bypass when no options are ordered:

Circuit breaker disconnect
UL Listed per UL 508A
100,000 AIC short-circuit rating
Disconnect handle with lockout/tagout provisions
Hand-Off-Auto (H-O-A) selector switch and manual speed potentiometer
AFC-Off-Bypass and Test-Normal selector switches
Door-mounted keypad display
One form C AFC Trip contact
One form C AFC Run Mode contact
One Form C contact for remote indication of Bypass operation
Manual trip condition reset in Off position of H-O-A selector switch
Interlock / Run Permissive wired to the user terminal block
Controller programming
- Acceleration (ACC): 10 s
- Deceleration (DEC): 10 s
- Low speed (LSP): 3 Hz
White component mounting plate
Removable conduit entry plate on floor-mounted enclosures
Class 20 overload protection
Overload Trip (yellow) and Bypass (yellow) pilot lights
Bypass and isolation contactors with mechanical and electrical interlocking
Bypass and isolation contactor sequencing provides true motor isolation
Remote bypass operation using Auto Start contacts

Installation and Maintenance Instructions

DANGER
hazard of electric shock, explosion, or arc flash Read and understand the instructions in bulletin NHA60269, Drives Systems Installation and Maintenance, before performing any procedures in this bulletin. Failure to follow these instructions will result in death or serious injury.

DANGER
hazard of electric shock, explosion, or arc flash Read and understand this manual before installing or operating the enclosed drive. Installation, adjustment, repair, and maintenance must be performed by qualified personnel. The user is responsible for compliance with national and local electrical codes with respect to grounding of all equipment. Many parts of this equipment, including the printed circuit boards, operate at the line voltage. DO NOT TOUCH. Use only electrically insulated tools. DO NOT touch unshielded components or terminal strip screw connections with voltage present. DO NOT short across terminals PA/+ and PC/- or across the DC bus capacitors. Before servicing the equipment: Disconnect the power, including the external control power that may be present. The circuit breaker or disconnecting switch does not always open all circuits. Lock the circuit breaker or disconnecting switch in the opened position. Place a “DO NOT TURN ON” label on the circuit breaker or disconnect switch of the enclosed drive. Wait 15 minutes to allow the DC bus capacitors to discharge. Then follow the “DC Bus Voltage Measurement Procedure” in bulletin NHA60269, Drives Systems Installation and Maintenance to verify that the DC voltage is less than 42 V. The enclosed drive LED is not an indicator of the absence of DC bus voltage. Install and close all covers before applying power or starting and stopping the equipment. Failure to follow these instructions will result in death or serious injury.

DANGER

hazard of electric shock, explosion, or arc flash

Read and understand this manual before installing or operating the enclosed drive. Installation, adjustment, repair, and maintenance must be performed by qualified personnel.
The user is responsible for compliance with national and local electrical codes with respect to grounding of all equipment.
Many parts of this equipment, including the printed circuit boards, operate at the line voltage. DO NOT TOUCH. Use only electrically insulated tools.
DO NOT touch unshielded components or terminal strip screw connections with voltage present.
DO NOT short across terminals PA/+ and PC/- or across the DC bus capacitors.
Before servicing the equipment:
Disconnect the power, including the external control power that may be present. The circuit breaker or disconnecting switch does not always open all circuits.
Lock the circuit breaker or disconnecting switch in the opened position.
Place a “DO NOT TURN ON” label on the circuit breaker or disconnect switch of the enclosed drive.
Wait 15 minutes to allow the DC bus capacitors to discharge. Then follow the “DC Bus Voltage Measurement Procedure” in bulletin NHA60269, Drives Systems Installation and Maintenance to verify that the DC voltage is less than 42 V. The enclosed drive LED is not an indicator of the absence of DC bus voltage.
Install and close all covers before applying power or starting and stopping the equipment.

Failure to follow these instructions will result in death or serious injury.

DANGER
Hazard of electric shock, explosion, or arc flash Do not install or operate any enclosed drive that appears damaged. If you find shipping damage, notify the carrier and your Schneider Electric sales representative. Failure to follow these instructions will result in death or serious injury.

CAUTION
RISK OF BURNS AND ROTATING FAN BLADES Make sure that the device is sufficiently cooled and that the permitted ambient conditions are maintained. Do not touch components inside the enclosure. Heat sinks, chokes, and transformers may remain hot after removing power. Before opening the enclosure, ensure that the fans are not running. After switching off the voltage supply, the device fans may continue running for some time. Failure to follow these instructions can result in injury or equipment damage.

CAUTION

RISK OF BURNS AND ROTATING FAN BLADES

Make sure that the device is sufficiently cooled and that the permitted ambient conditions are maintained.
Do not touch components inside the enclosure. Heat sinks, chokes, and transformers may remain hot after removing power.
Before opening the enclosure, ensure that the fans are not running. After switching off the voltage supply, the device fans may continue running for some time.

Failure to follow these instructions can result in injury or equipment damage.

Operation Instructions

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Before working on this equipment, turn off all power supplying it and perform the “DC Bus Voltage Measurement Procedure” in bulletin NHA60269, Drives Systems Installation and Maintenance. Failure to follow these instructions will result in death or serious injury.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH This equipment must be installed and serviced only by qualified personnel. Qualified personnel performing diagnostics or troubleshooting that requires electrical conductors to be energized must comply with: NFPA® 70E® – Standard for Electrical Safety Requirements for Employee Workplaces® CSA Z462 – Workplace Electrical Safety OSHA Standards – 29 CFR Part 1910 Subpart S Electrical NOM-029-STPS – Maintenance of Electrical Installations in the Workplace, Safety Conditions Other national and local electrical codes that may apply Failure to follow these instructions will result in death or serious injury.

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

This equipment must be installed and serviced only by qualified personnel.
Qualified personnel performing diagnostics or troubleshooting that requires electrical conductors to be energized must comply with:
NFPA® 70E® – Standard for Electrical Safety Requirements for Employee Workplaces®
CSA Z462 – Workplace Electrical Safety
OSHA Standards – 29 CFR Part 1910 Subpart S Electrical
NOM-029-STPS – Maintenance of Electrical Installations in the Workplace, Safety Conditions
Other national and local electrical codes that may apply

Failure to follow these instructions will result in death or serious injury.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Properly ground the enclosed drive before applying power. Close and secure the enclosure doors before applying power. • Certain adjustments and test procedures require that power be applied to this enclosed drive. Exercise extreme caution as hazardous voltages exist. The enclosure door must be closed and secured while turning on power or starting and stopping this enclosed drive. Always follow practices and procedures from NFPA® 70E® Standard for Electrical Safety in the Workplace®, CSA Z462, NOM-029-STPS – Maintenance of Electrical Installations in the Workplace, Safety Conditions, and other applicable regulations defining safe electrical work practices. Certain adjustments and test procedures require that power be applied to this enclosed drive. Exercise extreme caution as hazardous voltages exist. The enclosure door must be closed and secured while turning on power or starting and stopping this enclosed drive. Always follow practices and procedures from NFPA® 70E®, CSA Z462, NOM-029-STPS, and other applicable regulations defining safe electrical work practices. Failure to follow these instructions will result in death or serious injury.

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Properly ground the enclosed drive before applying power.
Close and secure the enclosure doors before applying power.
• Certain adjustments and test procedures require that power be applied to this enclosed drive. Exercise extreme caution as hazardous voltages exist. The enclosure door must be closed and secured while turning on power or starting and stopping this enclosed drive. Always follow practices and procedures from NFPA® 70E® Standard for Electrical Safety in the Workplace®, CSA Z462, NOM-029-STPS – Maintenance of Electrical Installations in the Workplace, Safety Conditions, and other applicable regulations defining safe electrical work practices.
Certain adjustments and test procedures require that power be applied to this enclosed drive. Exercise extreme caution as hazardous voltages exist. The enclosure door must be closed and secured while turning on power or starting and stopping this enclosed drive. Always follow practices and procedures from NFPA® 70E®, CSA Z462, NOM-029-STPS, and other applicable regulations defining safe electrical work practices.

Failure to follow these instructions will result in death or serious injury.

WARNING
LOSS OF CONTROL The designer of any control scheme must consider the potential failure modes of control paths and, for certain critical control functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are emergency stop and over travel stop. Separate or redundant control paths must be provided for critical control functions. System control paths may include communication links. Consideration must be given to the implications of anticipated transmission delays or failures of the link.* Each implementation of the ATV680 Process Drive must be individually and thoroughly tested for proper operation before being placed into service. Failure to follow these instructions can result in death, serious injury, or equipment damage.

WARNING

LOSS OF CONTROL

The designer of any control scheme must consider the potential failure modes of control paths and, for certain critical control functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are emergency stop and over travel stop.
Separate or redundant control paths must be provided for critical control functions.
System control paths may include communication links. Consideration must be given to the implications of anticipated transmission delays or failures of the link.*
Each implementation of the ATV680 Process Drive must be individually and thoroughly tested for proper operation before being placed into service.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

CAUTION
INCOMPATIBLE LINE VOLTAGE Before powering up and configuring the equipment, ensure that the line voltage is compatible with the supply voltage shown on the enclosed drive nameplate. The enclosed drive may be damaged if the line voltage is not compatible. Failure to follow these instructions can result in injury or equipment damage.

WARNING: This product can expose you to chemicals including lead and lead compounds, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.