CDA3000 Lust CDA Inverter Servo Drive Manual
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DE EN FR IT ES CDA3000 Operation Manual Inverter Drive System 750 W - 132 kW D Sizes (BG) BG1 0,75kW BG2 0,75...2,2kW BG3 3,0...4,0kW BG4 5,5...7,5kW BG5 11...15kW 1a H1 ANTRIEBSTEC H1 ANTRIEBSTEC D-35633 HNIK Lahnau D-35633 HNIK H2 Lahnau H3 Typ: Typ: X4 H1 ANTRIEBSTEC D-35633 H2 HNIK Lahnau H2 H3 Typ: X4 H3 X4 Netz: Netz: Netz: Ausg.: Ausg.: U H1 ANTRIEBSTEC D-35633 Ausg.: HNIK Lahnau SN.: SN.: SN.: X1 X1 000.0 U 00.00 000.0 000.0 H2 H3 X4 Netz: 0000 Ausg.: HNIK Lahnau SN.: W X2 X2 X2 Typ: 000.0 L2 L3 X3 SN.: 00 X2 U V V W X3 X3 L1 L2 L3 CDA32.006 CDA32.008 CDA34.003 CDA34.005 CDA34.006 ACHTUNG WARNING ATTENTION Kondensatorent- capacitor disscharge temps de decharge ladezeit >3 Min. time >3 minutes. du condensteur Betriebsanleitung Pay attention to the >3 min. observer le beachten! operation manual! mode dèmploi! ! L- CDA34.045 CDA34.060 CDA34.072 RB+ RB X3 L- L1 L2 L3 ! X3 ACHTU Konde NG ladezensator L1 L2 L3 Betrie it >3 ent- WARN beachbsanleMin. capac ING ten! itung time itor dissch Pay >3 minute arge ATTEN attenti operat s. temps TION ion on to manuathe du conde de decha l! >3 min. nsteur rge mode observ dèmpl er oi! le L- RB ! RB+ U CDA34.008 CDA34.010 CDA34.014 CDA34.017 BG7 45...55kW BG8 75...132kW CDA34.090 CDA34.110 CDA34.143 CDA34.170 CDA34.250 CDA3000 Operation Manual D 00.00 0000 U RB+ BG6 22...37kW 000.0 X2 X1 W RB CDA32.004 H3 X4 Ausg.: 00 X1 ACHTUNG WARNING ATTENTION Kondensatorent- capacitor disscharge temps de decharge ladezeit >3 Min. time >3 minutes. du condensteur Betriebsanleitung Pay attention to the >3 min. observer le beachten! operation manual! mode dèmploi! L3 L- L1 ! ACHTUNG WARNING ATTENTION Kondensatorent- capacitor disscharge temps de decharge ladezeit >3 Min. time >3 minutes. du condensteur Betriebsanleitung Pay attention to the >3 min. observer le beachten! operation manual! mode dèmploi! L2 ACHTUNG WARNING ATTENTION Kondensatorent- capacitor disscharge temps de decharge ladezeit >3 Min. time >3 minutes. du condensteur Betriebsanleitung Pay attention to the >3 min. observer le beachten! operation manual! mode dèmploi! L- L1 RB+ RB H2 Netz: 00.00 0000 RB ! H1 ANTRIEBSTEC D-35633 00 00 V 00 Typ: 00.00 00.00 0000 0000 V W RB+ ID no.: 0840.00 B.5-00 • 08/2005 Valid from software version V3.2 We reserve the right to make technical changes. V W CDA34.024 CDA34.032 Dear user, Step Action Comment 1 This Operation Manual will enable you to install and commission the Guide to quick-starting CDA3000 drive system very quickly and easily. 2 Simply follow the step-by-step tables in sections 2/3/4. And away you go! Experience “Plug 'n Play” with the CDA3000. Signposts Contents 1 Safety 1 2 Mechanical installation 2 3 Installation 3 4 Commissioning 4 5 Diagnose/Fault rectification 5 Appendix: Technical data, Ambient conditions, Project planning notes, UL approbation A DE EN FR IT CDA3000 Operation Manual Overview Documentation If you want more information on the drive solutions presented here and on the full scope of software features of the drive system, please refer to the CDA3000 Application Manual. You can order the following documents from us, or download them free of charge from our website at www.lust-antriebstechnik.de: CDA3000 Order Catalogue Application Manual CDA3000 F1 D to select and order components of drive system Adaptation of the drive system to the application CANLust Communication Module Manual CANopen Communication Module Manual PROFIBUS-DP Communication Module Manual G2 G3 Project planning, installation and commissioning of the CDA3000 on the field bus Project planning, installation and commissioning of the CDA3000 on the field bus G1 Project planning, installation and commissioning of the CDA3000 on the field bus Pictograms ➢ Attention! Misoperation may result in damage to the drive or malfunctions. ➢ Danger from electrical tension! Improper behaviour may endanger human life. ➢ Danger from rotating parts! The drive may start running automatically. ➢ Note: Useful information CDA3000 Operation Manual Table of contents 1 Safety 1.1 Measures for your safety ........................................1-1 1.2 Intended use ............................................................1-3 1.3 Responsibility ..........................................................1-3 2 Mechanical installation 2.1 Notes for operation .................................................2-1 2.2 Mounting variants ...................................................2-1 2.3 Wall mounting .........................................................2-2 2.4 Cold plate ................................................................2-4 2.5 Push-through heat sink (Dx.x) ...............................2-7 3 Installation 3.1 Overview ..................................................................3-2 3.2 compliant installation .............................................3-3 3.3 Grounding lead connection .....................................3-6 3.4 Motor connection ....................................................3-7 3.5 Mains connection ....................................................3-9 3.6 DC network ............................................................3-11 3.7 Braking resistor (RB) ............................................3-12 3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.8.5 3.8.6 Control connections ..............................................3-13 Choice of terminal assignment ...........................3-14 Specification of control terminals .......................3-15 Terminal assignment 1 ......................................3-16 Terminal assignment 2 ......................................3-17 Terminal assignment 3 ......................................3-18 Encoder .............................................................3-19 DE EN FR IT ES FR CDA3000 Operation Manual 4 Commissioning 4.1 Choice of commissioning ....................................... 4-1 4.2 Standard commissioning ....................................... 4-2 4.3 KEYPAD commissioning ........................................... 4-4 4.4 DRIVEMANAGER commissioning ................................ 4-6 4.5 Direction check .....................................................4-11 4.6 4.6.1 4.6.2 Serial commissioning ........................................... 4-12 Serial commissioning with KEYPAD ..................... 4-12 Serial commissioning with DRIVEMANAGER .......... 4-14 4.7 Operation with KEYPAD KP200 ............................... 4-15 4.8 Operation with DRIVEMANAGER ............................... 4-18 4.9 Parameter list (selection) ..................................... 4-19 5 Diagnosis/Fault rectification 5.1 LEDs ........................................................................ 5-1 5.2 Error messages .......................................................5-2 Helpline ................................................................................ 5-3 Service/support .................................................................... 5-3 CDA3000 Operation Manual 5.3 User errors in KEYPAD operation ............................. 5-4 5.4 User errors in SMARTCARD operation .......................5-4 5.5 Errors in power switching ...................................... 5-4 5.6 Reset ....................................................................... 5-5 A Appendix A.1 Current capacity of inverter moduls ...................... A-3 A.2 Technical data ........................................................ A-5 A.3 Ambient conditions ................................................ A-8 A.4 Project planning notes, Cold plate ........................ A-9 A.5 Project planning notes for multimotor operation A-10 A.6 through use of a line choke ................................. A-12 A.7 Line filter .............................................................. A-14 A.8 UL approbation ..................................................... A-16 A.9 Layouts of all sizes .............................................. A-17 DE EN FR IT ES FR CDA3000 Operation Manual CDA3000 Operation Manual 1 1 Safety 1.1 Measures for your safety In order to avoid physical injury and/or material damage the following information must be read before initial start-up. The safety regulations must be strictly observed at any time: 2 Read the Operation Manual first! • Follow the safety instructions! • Follow the operation manual! 3 Electric drives are dangerous: • Electrical voltages > 230 V/460 V: Dangerously high voltages may still be present 10 minutes after the power is cut. You should therefore always check that no power is being applied! • Rotating parts • Hot surfaces Protection against magnetic and/or electromagnetic fields during installation and operation. • For persons with pacemakers, metal containing implants and hearing aids etc. access to the following areas is prohibited: − − Danger: CDA3000 Operation Manual Areas in which drive systems are installed, repaired and operated. Areas in which motors are assembled, repaired and operated. Motors with permanent magnets are sources of special dangers. 4 5 A If there is a necessity to access such areas a decision from a physician is required. 1-1 DE EN FR IT ES FR 1 Safety Your qualification: • In order to prevent personal injury and damage to property, only personnel with electrical engineering qualifications may work on the device. • The qualified personnel must familiarize themselves with the Operation Manual (refer to IEC364, DIN VDE0100). • Knowledge of national accident prevention regulations (e.g. VBG 4 in Germany) During installation observe the following instructions: • Always comply with the connection conditions and technical specifications. • Comply with the standards for electrical installations, such as regarding wire cross-section, grounding lead and ground connections. • Do not touch electronic components and contacts (electrostatic discharge may destroy components). Pictograms used in this manual The notes on safety describe the following danger classes. The danger class describes the risk which may arise when not complying with the note on safety. Warning symbols General explanation Attention! Operating errors may cause damage to or malfunction of the drive. Danger class acc.to ANSI Z 535 This may result in physical injury or damage to material. Danger, high voltage! Improper Danger to life or severe physical injury. behaviour may cause fatal accident. Danger from rotating parts! The drive may automatically start. CDA3000 Operation Manual 1-2 Danger to life or severe physical injury.. 1 Safety 1.2 Intended use Inverter modules are components for installation into stationary electric systems or machines. When installed in machines the commissioning of the drive controller (i. e. start-up of intended operation) is prohibited, unless it has been ascertained that the machine fully complies with the regulations of the EC-directive 98/37/EC (Machine Directive); compliance with EN 60204 is mandatory. Commissioning (i. e. starting intended operation) is only permitted when strictly complying with EMC-directive (89/336/EEC). The CDA3000 conforms to the Low Voltage Directive 73/23/EEC. For the drive controller the harmonized standards of series EN 50178/ DIN VDE 0160 in connection with EN 60439-1/ VDE 0660 part 500 and EN 60146/ VDE 0558 are applied. If the drive controller is used in special applications, e. g. in areas subject to explosion hazards, the applicable regulations and standards (e. g. in Ex-environments EN 50014 “General provisions” and EN 50018 “Flameproof housing”) must be strictly observed. Repairs must only be carried out by authorized repair workshops. Unauthorised opening and incorrect intervention could lead to physical injury or material damage. The warranty granted by LUST will become void. Note: 1.3 Responsibility The use of drive controllers in mobile equipment is assumed an exceptional environmental condition and is only permitted after a special agreement. Electronic devices are fundamentally not fail-safe. The company setting up and/or operating the machine or plant is itself responsible for ensuring that the drive is rendered safe if the device fails. EN 60204-1/DIN VDE 0113 “Safety of machines”, in the section on “Electrical equipment of machines”, stipulates safety requirements for electrical controls. They are intended to protect personnel and machinery, and to maintain the function capability of the machine or plant concerned, and must be observed. The function of an emergency off system does not necessarily have to cut the power supply to the drive. To protect against danger, it may be more beneficial to maintain individual drives in operation or to initiate specific safety sequences. Execution of the emergency off measure is assessed by means of a risk analysis of the machine or plant, including the CDA3000 Operation Manual 1-3 1 2 3 4 5 A DE EN FR IT ES FR 1 Safety electrical equipment to DIN EN 1050, and is determined with selection of the circuit category in accordance with DIN EN 954-1 “Safety of machines - Safety-related parts of controls”. CDA3000 Operation Manual 1-4 1 2 Mechanical installation 2 2.1 Notes for operation 2.1 Notes for operation .................................................2-1 2.2 Mounting variants ...................................................2-1 2.3 Wall mounting .........................................................2-2 2.4 Cold plate ................................................................2-4 2.5 Push-through heat sink (Dx.x) ...............................2-7 3 Please ensure that ... • • • • no damp enters the device no aggressive or conductive substances are in the immediate vicinity no drill chippings, screws or foreign bodies drop into the device the vent openings are not covered over, • the drive controllers are not used in mobile equipment 4 The device may otherwise be damaged. 2.2 Mounting variants Step 1 Action Comment Refer to the name plate to find out the The mounting variants differ in mounting variant of your inverter module. their mode of cooling. Name plate CDA3...,Wx.x 5 Continued on Mounting and cooling variant A Wall mounting Page 2-2 CDA3...,Cx.x Cold plate Page 2-4 Wx.x Cx.x CDA3...,Dx.x Table 2.1 CDA3000 Operation Manual Push-through heat sink Page 2-7 Dx.x Mounting and cooling variants 2-1 DE EN FR IT ES FR 2 Mechanical installation 2.3 Wall mounting Step Action Comment 1 Mark out the position of the tapped holes on the backing plate. Cut a tap for each fixing screw in the backing plate. Dimensional drawings/hole spacing see Table 2.2. The tapping area will provide you with good, full-area contact. 2 Mount the inverter module vertically on the backing plate. Pay attention to the mounting clearances! The contact surface must be metallically bright. 3 Mount the other components, such as the Mains filter max. 20 cm below mains filter, line choke etc., on the the inverter module backing plate. 4 Continue with the electrical installation in section 3. yyy ;; y;y; y ; ; ;;; yyy ; y ; y yyy ;;; y; y ;;; yyy ; CM-xxxx E1 F G E F UM-xxxx Figure 2.1 Mounting clearances (see Table 2.2) BG6 Note the following points: • Air must be able to flow unhindered through the device. • For mounting in switch cabinets with convection (= heat loss is discharged to the outside via the cabinet walls) an internal air circulation fan must always be fitted. • The backing plate must be well grounded. • The best result for effective EMC installation is attained with a chromated or galvanized backing plate. If backing plates are varnished, the coating must be removed in the area of the contact surface! CDA3000 Operation Manual 2-2 2 Mechanical installation CDA3...,Wx.x Weight [kg] BG12) 2.4 W (width) BG22) BG3 3.5 4.4 6.5 7.2 20 31 60 70 120 170 250 300 412 375 600 510 70 H (height) 245 D (depth) 195 A 270 235 BG64) BG5 330 220 218 40 C BG4 40 260 80 130 BG7 BG8 325 305 380 215 265 340 555 320 360 D∅ ∅ 4.8 ∅ 4.8 ∅6 ∅9 Screws 4 x M4 4 x M4 4 x M5 4 x M8 3) 485 0 50 45 – 3) 100 1001) G3) > 300 > 400 E E1 (with module)3) F D 2 3 A D 1 A BG3 BG4 BG5 BG6 BG7 BG8 BG1 BG2 H H C ;;; yyy yyy ;;; 4 C B B 5 T T 1) Additionally allow enough space at the bottom for the bending radii of the connecting cables. 2) Corresponding to cold plate version with accessory heat sink HS3X.xxx 3) Mounting clearances see Figure 2.1. 4) It is important that the air can flow from top to bottom unhindered through the device (size 6 only), if necessary install air shields. Table 2.2 CDA3000 Operation Manual Dimensional drawings: Wall mounting (dimensions in mm) 2-3 A DE EN FR IT ES FR 2 Mechanical installation 2.4 Cold plate Step Action Comment 1 Mark out the positions of the tapped holes on the backing plate or the cooler. Cut a tap for each fixing screw in the backing plate. Dimensional drawings/hole spacing see Table 2.3. The tapping area will provide you with good, full-area contact. 2 Clean the contact surface and coat it thinly and evenly with heat transfer compound. The contact surface must be metallically bright. 3 Mount the inverter module vertically on the backing plate or cooler. Tighten all screws to the same tightness. Pay attention to the mounting clearances! Size of cooling surface see Table 2.4. 4 Mount the other components, such as the Mains filter max. 20 cm below mains filter, line choke etc., on the the inverter module backing plate. 5 Continue with the electrical installation in section 3. yyy ;; y;y; y ; ; ;;; yyy ;y y ; yyy ;;; y; y ;;; yyy ; CM-xxxx F G E1 E F UM-xxxx Figure 2.2 Mounting clearances (see Table 2.3) CDA3000 Operation Manual 2-4 2 Mechanical installation CDA3...,Cx.x BG1 BG2 Weight [kg] 1.6 2.3 3.2 5.2 6.4 W (width) 70 70 100 150 200 H (height) 215 240 300 D (depth) 120 145 150 A C BG3 50 205 BG4 85 135 230 1 185 200 C1 – 100 D∅ ∅ 4.8 ∅ 5.5 Screws 4 x M4 6 x M5 E 0 0 E1 (with module) 45 2 15 100 G > 300 D D A 3 1) F A BG1 BG2 C BG5 4 BG3 BG4 BG5 H H C ;;; yyy yyyy ;;;; B C1 5 B A T T 1) Additionally allow enough space at the bottom for the bending radii of the connecting cables. Table 2.3 CDA3000 Operation Manual Dimensional drawings: Cold plate (dimensions in mm) 2-5 DE EN FR IT ES FR 2 Mechanical installation Note the following points: • Cooling can be attained either by a sufficiently large backing plate (see Table 2.4) or by an additional cooler. The cooler must be mounted centrally behind the hottest area (1) of the device. (1) • The temperature on the rear panel of the inverter module must not exceed 85.0 °C. At a temperature > 85° C the device shuts down automatically. It can only be restarted when it has cooled. • Required evenness of contact surface = 0.05 mm, maximum roughness of contact surface = roughness factor 6.3 . Size Power Inverter module PV at 4 kHz PV at 8/16 kHz RthK 3) [K/W] Backing plate (unvarnished steel min. cooling surface Ambient temperature BG1 0.75 kW CDA32.004,Cx.x 48 W 55 W 0.05 650x100mm = 0.065m² 45°C1), 40°C2) 1.1 kW CDA32.006,Cx.x 75 W 82 W 0.05 650x460mm = 0.3m² 45°C1), 40°C2) 1.5 kW CDA32.008,Cx.x 95 W 105 W 0.05 650x460mm = 0.3m² 45°C1), 40°C2) 0.75 kW CDA34.003,Cx.x 55 W 70 W 0.05 None 45°C1), 40°C2) 1.5 kW CDA34.005,Cx.x 80 W 112 W 0.05 650x460mm = 0.3m² 45°C1), 40°C2) 2.2 kW CDA34.006,Cx.x 106 W 148 W 0.05 3.0 kW CDA34.008,Cx.x 135 W 162 W 0.03 4.0 kW CDA34.010,Cx.x 172 W 207 W 0.03 0.02 BG2 BG3 BG4 BG5 5.5 kW CDA34.014,Cx.x 210 W 268 W 7.5 kW CDA34.017,Cx.x 255 W 325 W 0.02 11 kW CDA34.024,Cx.x 315 W 400 W 0.015 15 kW CDA34.032,Cx.x 400 W 510 W 0.015 An additional cooler is required to supply adequate cooling. Project planning notessee appendix A.4 If you have any further questions please consult your project engineer. 1) At a power stage clock frequency of 4 kHz 2) At a power stage clock frequency of 8 kHz 3) Thermal resistance between active cooling surface and cooler Table 2.4 Required cooling with cold plate Note the following points: • The backing plate must be grounded over a large area. • For mounting in switch cabinets with convection (= heat loss is discharged to the outside via the cabinet walls) an internal air circulation fan must always be fitted. • The best result for effective EMC installation is attained with a chromated or galvanized backing plate. If backing plates are varnished, the coating must be removed in the area of the contact surface! CDA3000 Operation Manual 2-6 2 Mechanical installation 2.5 Push-through heat sink (Dx.x) Step Action Comment 1 Mark out the positions of the tapped holes and the breakthrough on the backing plate. Cut a tap for each fixing screw in the backing plate. Dimensional drawings/hole spacing see Table 2.6. The tapping area will provide you with good, full-area contact. 2 Mount the inverter module vertically on the backing plate. Tighten all screws to the same tightness. Pay attention to the mounting clearances! The mounting seal must contact flush on the surface. 3 Mount the other components, such as the Mains filter max. 20 cm below mains filter, line choke etc., on the the inverter module backing plate. 4 Continue with the electrical installation in section 3. 1 2 3 Note the following points: • Distribution of power loss: Power loss Protection BG3 BG4 BG5 Outside (3) 70% 75% 80% Inside (4) 30% 25% 20% Heat sink side (3) IP54 IP54 IP54 ;y Machine side (4) IP20 IP20 yy ;; ;; yy • IP20 The all-round mounting collar must be fitted with a seal. The seal must fit flush on the surface and must not be damaged: (3) (1) Seal (2) Tapped hole for EMCcompatible contact (3) Outside (4) Inside (2) (4) 4 5 A (1) CDA3000 Operation Manual • The backing plate must be well grounded. • The best result for effective EMC installation is attained with a chromated or galvanized backing plate. If backing plates are varnished, the coating must be removed in the area of the contact surface! 2-7 DE EN FR IT ES FR yy ;; ; y ; y ; y ;;; yyy ; y ; y ; y yyy ;;; ; y y ;;; yy ; y 2 Mechanical installation CM-xxxx F G E1 E F UM-xxxx Figure 2.3 Mounting clearances (see Table 2.6) Dimensions of breakthrough BG3 BG4 BG5 W (width) 75 125 175 H (height) 305 305 305 H H B B Table 2.5 CDA3000 Operation Manual Breakthrough for push-through heat sink (dimensions in mm) 2-8 2 Mechanical installation CDA3...,Dx.x BG3 BG4 BG5 Weight [kg] 4.6 6.7 7.4 W (width) 110 160 210 H (height) 1 340 D (depth) T1 138, T2 80 T1 138, T2 135 A 90 140 190 A1 – 80 100 C 320 C1 200 D∅ ∅ 4.8 ∅ 4.8 ∅ 4.8 Screws 8 x M4 10 x M4 10 x M4 E 10 E1 (with module) 20 F 1001) G > 300 3 4 A D∅ 2 BG3 BG4 BG5 For more information on the ambient conditions see appendix A.3. C1 H C 5 B A1 T2 A T1 1) Additionally allow enough space at the bottom for the bending radii of the connecting cables. Table 2.6 CDA3000 Operation Manual Dimensional drawings: push-through heat sink (dimensions in mm) 2-9 DE EN FR IT ES FR 2 Mechanical installation CDA3000 Operation Manual 2-10 1 3 Installation 2 3.1 Overview ..................................................................3-2 3.2 compliant installation .............................................3-3 3.3 Grounding lead connection .....................................3-6 3.4 Motor connection ....................................................3-7 3.5 Mains connection ....................................................3-9 3.6 DC network ............................................................3-11 3.7 Braking resistor (RB) ............................................3-12 3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.8.5 3.8.6 Control connections ..............................................3-13 Choice of terminal assignment ...........................3-14 Specification of control terminals .......................3-15 Terminal assignment 1 ......................................3-16 Terminal assignment 2 ......................................3-17 Terminal assignment 3 ......................................3-18 Encoder .............................................................3-19 Attention: Installation must only be carried out by qualified electricians who have undergone instruction in the necessary accident prevention measures. CDA3000 Operation Manual 3-1 3 4 5 A DE EN FR IT ES FR 3 Installation 3.1 Overview L1 L2 L3 L1 N H1 H2 H3 (7) L- The terminal layout for all sizes is presented in Appendix A.9. L+ K1 K1 (1) X4 (1) X1 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 X1 U U (8) V V W W (2) FN L+ L+ RB RB L- L- N L2 (4) X2 L3 X3 L1 L1 CDA32.xxx CDA34.xxx RB (3) PE M 3~ ϑ (5) Figure 3.1 Overview of connections Key (1) Line choke1) filter1) 2) Explanation Reduces the voltage distortions in the system Suppresses line-borne interference emission (2) Mains (3) Braking resistor1) Required for repeated braking (4) Control conn. X2 Connection see section 3.8 (5) Motor PTC connection X3 For thermal monitoring of the motor, see section 3.4 (6) RS232 connection X4 For operation with KEYPADsee section 4.7/ Operation with DRIVEMANAGERsee section 4.8 (7) Connection for DC network Permits power exchange between servocontrollers, see section 3.6 (8) Software name plate Indicates the shipped software status 1) For supplementary components see CDA3000 Order Catalogue. 2) In inverter modules up to 7.5 kW (BG1 to BG4) the mains filter is built-in. CDA3000 Operation Manual (6) 3-2 3 Installation 3.2 compliant installation Inverter moduls are components intended for installation into industrially and commercially used equipment and machines. Commissioning (i. e. starting inteded operation) is only permitted when strictly complying with EMC-directive (89/336/EEC). 1 The installer/operator of a machine and/or equipment must provide evidence of the compliance with the protection targets stipulated in the EMC-directive. Attention: Compliance with the required EMC-protection targets is normally achieved by observing the installation instructions in this manual and using the appropriate radio interference suppression filters. Assignment of drive controller with internal line filter 2 3 All inverter moduls CDA are fitted with a sheet steel housing with aluminium-zink surface to improve the interference immunity factor as specified in IEC61800-3, environment 1 and 2. inverter moduls 0.37 kW to 7.5 kW are equipped with integrated line filters. With the measuring methods specified in the standard these inverter moduls comply with the EMC product standard IEC61800-3 for "Environment 1" (living area) and "Environment 2" (industrial area). − Public low voltage network (environment 1) living area: up to 10 m motor cable length, for more details see section A.7. Attention: This is a restricted availability product in accordance with IEC 61800-3. This product may cause radio interference in domestic environments; in such cases the operator may need to take appropriate countermeasures. − 4 Industrial low voltage network (environment 2) industrial area: up to 25 m motor cable length, for more details see section A.7. 5 A Assignment of drive controller with external line filter An external radio interference suppression filter (EMCxxx) is available for all inverter moduls. With this line filter the inverter moduls comply with the EMC product standard IEC61800-3 for "Environment 1" (living area) and "Environment 2" (industrial area). − CDA3000 Operation Manual Public low voltage network (environment 1) living area: up to 100 m motor cable length. 3-3 DE EN FR IT ES FR 3 Installation Attention: This is a restricted availability product in accordance with IEC 61800-3. This product may cause radio interference in domestic environments; in such cases the operator may need to take appropriate countermeasures. − Note: CDA3000 Operation Manual Industrial low voltage network (environment 2) industrial area: up to 150 m motor cable length. When using external line filters the status "general availability" can be reached too with shorter motor cable length. If this is of importance to you, please do not hesitate to contact our sales engineers or your projecting engineer. 3-4 3 Installation Subject Projecting and installation regulations PE-terminal equipotential bonding Use a bright backing plate. Use cables and/or ground straps with cross sections as large as possible. Route the PE-terminal connection for the components in a star-shaped fashion and ensure large area contact of earthing (PE) and shielding connecting on the PE-bar of the backing plate to establish a low-resistance HFconnection. PE-mains connection in accordance with DIN VDE 0100 part 540 1 • Mains connection < 10 mm² Protective conductor cross-section min. 10 mm² or use 2 conductors with a cross-section of the mains supply lines. 2 • Mains connection > 10 mm²: Use a protective conductor cross-section in compliance with the cross-section of the mains supply lines. • Route the motor cable separated from signal and mains supply lines. The minimum distance between motor cable and signal line/mains line must be 20 cm, if necessary us separator. 3 • Always route the motor cable without interruptions and the shortest way out of the control cabinet. Routing of cables • When using a motor contactor or a reactance control/motor filter, this should be directly mounted to the drive controller. Do not bare the core ends of the motor cable too soon. 4 • Avoid unnecessary cable lengths. The drive controllers must always be wired with screened motor cables and signal lines. A cable type with double copper braiding with 60 -70% coverage must be used for all screened connections. Cable type • Contactors, relays, solenoid valves (switched inductivities) must be wired with fuses. The wiring must be directly connected to the respective coil. Further hints for the control cabinet design • The switched inductivities should be at least 20 cm away from the process sontrolled assemblies. • Place larger consumers near the supply. • If possible enter signal lines only from one side. • Lines of the same electric circuit must be twisted. Crosstalk is generally reduced by routing cables in close vicinity to earthed plates. Connect residual strands at both ends with the control cabinet ground (earth). Supplementary information Table 3.1 CDA3000 Operation Manual 5 A Supplementary information can be found in the corresponding connection description Projecting and installation regulations 3-5 DE EN FR IT ES FR 3 Installation 3.3 Grounding lead connection Step Note: PE mains connection to DIN VDE 0100 part 540 Action Ground every inverter module! 1 Mains connection < 10 mm²: Grounding lead cross-section min. 10 mm² or use 2 wires with crosssection of mains leads. Also connect the grounding lead connections of all other components, such as the line choke, filter, etc., in star configuration, to the PE rail (main ground) in the switch cabinet. Mains connection > 10 mm²: Use grounding lead (PE) cross section according to cross-section of mains leads. ;;; ; ; ;; ;;; ;;; ; ;;; 2 in star Connect terminal X1/ configuration to the PE rail (main ground) in the switch cabinet. U1 U2 V1 V2 W1 W2 U1 U2 V1 V2 W1 W2 U1 U2 V1 V2 W1 W2 PE Figure 3.2 Star configuration layout of the grounding lead Note the following points: • The grounding lead must be laid out in star configuration to conform to the EMC standards. • The backing plate must be well grounded. • The motor cable, mains lead and control cable must be laid separately from each other. • Avoid loops, and lay cable over short distances. • The operational leakage current is > 3.5 mA. CDA3000 Operation Manual 3-6 3 Installation 3.4 Motor connection Step Action Comment 1 Define the wire cross-section dependent on the maximum current and ambient temperature. Wire cross-section to VDE0100, part 523, see section 3.5 “Mains connection”. 2 Wire the motor phases U, V, W by way of a shielded cable and ground the motor to Mount shield at both ends to reduce interference emission. . X1/ 3 Wire the temperature sensor PTC (if fitted) with separately shielded wires. The CDA3000 inverter modules are protected against shorting and ground faults at the terminals when in operation. In the event of a short-circuit or ground fault in the motor cable, the power stage is disabled and an error message is delivered. Mount shield at both ends to reduce interference emission. 1 2 X3 U V 1 U V W W M 3~ ϑ 3 2 X1 4 Figure 3.3 Connection of motor Note the following points: • Always use shielded cables to connect the motor. • Shield contact on the inverter module: − − CDA3000 Operation Manual For inverter modules BG1 ... 5 (0.37 ... 15 kW) there is an accessory shield (ST02, ST04 or ST05) permitting simple clip mounting with all-round contact. For inverter modules BG6 ... 8 (22 ... 132 kW) we recommend using a cable clamp rail with shield connection directly on the cable gland in the switch cabinet. • The motor at the inverter output may be shut off by means of a contactor or motor circuit-breaker. The inverter module cannot be damaged in the process. Circuit reference for „motor contactor“ see appendix A.5.1. • Multi-motor operation is possible; for project planning notes see Appendix A.5. 3-7 5 A DE EN FR IT ES FR 3 Installation Attention: If the inverter is operated as a controller with encoder (FOR motor control method), motor phases U,V and W must never be reversed! If the motor phases are reversed the inverter has no control over the motor. The motor may buck or accelerate in an uncontrolled manner (“race”). For proper EMC installation the motor terminal box must be HF-tight (metal or metallized plastic). For cable introduction, packing glands with large-area shield contact should be used. Terminal box (1) (1) Thermistor (PTC) (2) 2 (2) Packing gland with shield contact (3) Motor phases (4) Grounding lead connection ;; 1 U V W U V W (3) (4) Figure 3.4 Motor terminal box Motor temperature monitoring For thermal monitoring of the motor coil, a thermistor (PTC) may be connected to terminals X3/ϑ- and ϑ+. The type used must be set during commissioning in parameter 330-MOPTC (factory default setting is “off”). Sensor No PTC used Standard PTC Linear voltage evaluation TSS, thermostatic circuit-breaker - PTC to DIN44082 KTY84-130, (tolerance band yellow) Klixon Parameter 330-MOPTC = OFF DIN KTY TSS Measurement voltage UMAX – 12 V – Measuring range – 100 Ω to 15 kΩ – Tech. data Usable type Table 3.1 Motor temperature monitoring specification Attention: Contrary to DIN VDE 0660-303 (short circuit dedection < 20 Ω) the CDA3000 will note a short circuit at < 5 Ω. CDA3000 Operation Manual 3-8 3 Installation 3.5 Mains connection Step Action Comment 1 Define the wire cross-section dependent on maximum current and ambient temperature. Wire cross-section to VDE0100, part 523 2 Wire the inverter module with the mains filter, distance between filter unit and inverter modul max. 0.3 m (with unshielded cable)! Step not applicable for BG1 to BG4; up to 7.5 kW the mains filter is built-in. 3 Wire the line choke see Appendix A.5 Reduces the voltage distortions (THD) in the system and extends the service life. 4 Install a circuit-breaker K1 (power switch, contactor, etc.). Do not connect the power! 5 Use the mains fuses (type gL) or miniature circuit-breakers (trip characteristic C) to cut the mains power to all poles of the inverter. To protect the line in accordance with VDE636, part 1 Connection of the inverter module via a line choke with a short circuit voltage of 4 % of the mains voltage (uk = 4 %) is obligatory: 1. Where the inverter modules are connected to systems of environment class 3 and above, see EN 61000-2-4 see appendix A.6 2. For all inverter modules with a recommended motor connected load (4-pole standard motor) of 30 kVA or above (CDA34.060 ... CDA34.250) 3. Where there is a requirement to comply with the limit values for variable-speed electric drives (see standard EN 61800-3/ IEC 1800-3) 1 2 3 4 5 4. Where there is a dc link between multiple inverter modules X1 N L1 N CDA32.xxx A 1 x 230 V L1 K1 X1 L3 L2 L3 FN L1 L1 K1 Figure 3.5 Mains connection CDA3000 Operation Manual L2 3-9 CDA34.xxx 3 x 400/460 V DE EN FR IT ES FR 3 Installation Attention: Danger to life! Never wire or disconnect electrical connections while they are live! Before working on the device disconnect the power. Wait until the DC-link voltage at terminals X1/ RB+ and L- has fallen to the safety-low voltage before working on the device (approx. 5 minutes). Note the following points: • Only all-current sensitive fault current breakers suitable for inverter operation may be used. • Switching the mains power: Cyclic power switching is permitted every 60 seconds; jog mode is not permitted. − − If switching is too frequent, the device protects itself by means of high-resistance isolation from the system. After a rest phase of a few minutes the device is ready to start once again. • TN network and TT network: Permitted without restriction. • IT network (insulated center point): Not permitted! • For details of measures to maintain UL approbation refer to Appendix A.8. Mains filter Size Power range Mains filter BG1 ... 4 0.75 ... 7.5 kW Internal BG5 ... 8 11 ... 132 kW External1) 1) For supplementary components see CDA3000 Order Catalogue. Note: Compliance with the limit curves (EN61800-3) to attenuate the lineborne interference voltage and the interference emitted from the inverter module depends on • use of a line choke (recommended), • the length of the motor cable and • the preset clock frequency (4, 8 or 16 kHz) of the inverter module power stage. For further information please consult your project engineer. CDA3000 Operation Manual 3-10 3 Installation Wire cross-section . Inverter module Device connected load [kVA] Max. possible wire cross-section of terminals [mm²] Recommended mains fusing (gL) [A] CDA32.004 1.7 2.5 1 x 10 CDA32.006 CDA32.008 CDA34.003 CDA34.005 2.3 3.0 1.6 3.0 2.5 1 x 16 1 x 16 3 x 10 3 x 10 CDA34.006 4.2 2.5 3 x 10 CDA34.008 CDA34.010 5.7 7.3 2.5 3 x 10 3 x 16 CDA34.014 CDA34.017 10.2 12.4 4.0 3 x 20 3 x 25 CDA34.024 CDA34.032 17.5 23.3 10 3 x 35 3 x 50 CDA34.045 CDA34.060 CDA34.072 32.8 43.8 52 25 3 x 50 3 x 63 3 x 80 CDA34.090 CDA34.110 65 80 50 3 x 100 3 x 125 CDA34.143 CDA34.170 104 124 Threaded bolt M8 3 x 160 3 x 200 CDA34.250 145 173 Threaded bolt M8 3 x 250 3 x 315 Table 3.2 3.6 DC network 1 2 3 4 Wire cross-sections and mains fuses (VDE0298 must be observed) The inverter modules run in regenerative operation (braking) in a DC network feed power into the DC network which is consumed by the motordriven inverter modules. 5 DC network operation of several inverter modules minimizes the power consumption from the mains and external braking resistors can be eliminated where appropriate. Note: CDA3000 Operation Manual It is essential that a DC network operation be checked at the project planning stage. Please consult your project engineer. 3-11 A DE EN FR IT ES FR 3 Installation 3.7 Braking resistor (RB) In regenerative operation, e.g. braking the drive, the motor feeds energy back into the inverter. This increases the voltage in the DC-link. If the voltage exceeds a threshold value, the internal braking transistor is activated and the regenerated power is converted into heat by way of a braking resistor. The switching transistor is installed as standard. The design of the external braking resistor depends on a number of drive factors: for example the load to be moved, the required dynamics of the drive or the braking and cycle duration. L+ RB RB X1 Figure 3.6 Braking resistor connection Note the following points: • The design of the braking resistor must be clarified at the project planning stage. • For details of the permissible minimum ohmic resistance of an externally installed braking resistor for the individual inverter modules refer to Appendix A.2. • Details of the peak braking power with an internal braking resistor (only with version CDA34 ...,Wx.x,BR) are also given in Appendix A.2. For further information please consult your project engineer. Attention: In device version CDA3X.xxx, Wx.x, BR the braking resistor is built-in. No additional braking resistor may be connected to terminals X1/L+ and RB; this would damage the inverter module. Attention: At warning message „excessive temperature at inverter heat sink“ the connected device must be separated from the mains, because an overvoltage of the mains leads to an overload of the braking resistor. Please integrate one of the digital outputs into your control concept, e.g. set OSDxx to WOTI (Warning heat sink temperature of device). CDA3000 Operation Manual 3-12 3 Installation 3.8 Control connections Step Action Comment Check whether your inverter module is Type: CDA32.004,C1.0 fitted Software: V 1xx.x CS: C1D1 a modified software package Data Set: (>V100.x) (standard software = Vx.xx-xx) SN.: 99120442 If this is the case, the control terminal assignment is different. Please Position of software name plate see contact your project engineer with regard to wiring and commissioning!! section 3.1 Page 3-2 1 ANTRIEBSTECHNIK D- 35633 Lahnau 1 2 Check whether you already have a SMARTCARD or a DRIVEMANAGER data set with a complete device setup. If this is the case, the control terminal assignment is different. Please contact your project engineer to obtain the terminal assignment! 2 Bulk customers For details of how to load the data set into the inverter module refer to section 4.6. 3 Choose a terminal assignment. see 3.8.1 “Choice of terminal assignment” 4 Wire the control terminals with shielded cables. The only essential signals are the ENPO signals and a start signal (STR or STL). Ground the cable shields over a wide area at both ends. Wire cross-section maximum 1.5 mm² or two cores per terminal each 0.5 mm² 5 Keep all contacts open (inputs inactive). 6 Check all connections again! Continue with commissioning in section 4. 3 4 5 Note the following points: CDA3000 Operation Manual • Always wire the control terminals with shielded cables. • Lay the control cables separately from the mains lead and motor cable. • The CDA3000 Application Manual presents more drive solutions. • For all shielded connections a cable type with double copper braiding with 60-70 % coverage must be used. 3-13 A DE EN FR IT ES FR 3 Installation 3.8.1 Choice of terminal assignment Selection Typical applications Control method • Project planning and commissioning are already complete. Serial commissioning Terminal assignment • Loading of an existing data set. • Pump, fan and extruder drivers and traction and lifting drives with low dynamics • Applications with dynamic load surges • Dynamic traction, lifting and rotational drives with speed control • With encoder feedback Obtain the terminal assignment from your project engineer. Page 4-12 Commissioning Assignment 1 Page 3-16 Assignment 2 Page 3-17 Assignment 1 Page 3-16 Assignment 2 Page 3-17 Assignment 3 Page 3-18 Voltage Frequency Control (VFC) • Multi-motor operation • Dynamic traction and rotational drives Continued on Sensorless Flux Control (SFC) - Only for asynchronous motor Field-Oriented Regulation (FOR) - Only for asynchronous motor Attention: With the SFC motor control mode (Sensorless Flux Control) no lifting drives and no applications with regenerative load torque1) can be operated at present. 1)All machinery counteracts the drive with a static torque. The static torque is generally termed load torque. If this load torque acts in the direction of movement, such as in lifting mechanisms, during lowering, then the term “regenerative load torque” is used. Note: CDA3000 Operation Manual During operation intensive load peaks or unintentional cancelling of the start effects in a loss of stator flow control of the SFC-control. So that a current overload shut-off or uncontrolled movements can occur. 3-14 3 Installation 3.8.2 Specification of control terminals Des. Specification Analog inputs ISA00 ISA01 • ISA00: UIN = +10 V DC, ±10 V DC, IIN = (0) 4-20 mA DC, switchable by software • ISA01: UIN = +10 V DC • Tolerance U: ± 1% v. M., I: ±1% of MV • 24 V digital input, PLC-compatible • Switching level Low/High: <4.8 V / >8 V DC • Resolution 10-bit • Rin=110kΩ • Floating against digital ground Analog output OSA00 • Tolerance U: ±2.5% of MV • Uout=+10 V DC, ROUT=100 Ω • Imax=5 mA, short-circuit-proof Digital inputs ISD00 ISD01 ISD02 ISD03 • • • • ENPO • Power stage enable = High level • Specification as ISDxx OSD00 • • • • • Short-circuit-proof PLC-compatible Imax = 50 mA Protection against inductive load High-side driver OSD01 • • • • • Short-circuit-proof with 24V supply from inverter module PLC-compatible Imax = 50mA No internal freewheeling diode; provide external protection High-side driver Relay output OSD02 • Relay 48 V / 1 A AC, changeover contact • Usage category AC1 • Operating delay approx. 10 ms Motor temperature PTC1/ 2 • max. 12 V DC, measuring range 100 Ω - 15 kΩ • Suitable for PTC to DIN 44082 or temperature sensor KTY84-130 (tolerance band yellow) or thermostatic circuit-breaker Voltage supply +10.5V • Reference voltage UR =10.5 V DC, short-circuit-proof • Imax = 5 mA +24V • Auxiliary voltage UV = 24 V DC, short-circuit-proof • Imax = 200 mA (overall, also includes driver currents for outputs OSD0x) The terminal scan cycle is 1 ms. Digital outputs PLC-compatible Switching level Low/High: <5 V / >18* V DC Imax at 24 V = 10 mA RIN = 3 kΩ 1 2 3 4 5 A *In the range >5 V / <18 V the response of the inputs is undefined. CDA3000 Operation Manual 3-15 DE EN FR IT ES FR 3 Installation 3.8.3 Terminal assignment 1 Terminal assignment in factory setting Preset solution “Clock drive, quick/slow jog”. Features Parameter • Quick jog/slow jog driving profile with two directions of rotation 152-ASTER = DRV_1 • Output for motor holding brake X2 Des. 20 OSD02 14 19 OSD02 11 18 OSD02 12 17 DGND Digital ground 16 OSD01 “Reference reached” message 15 OSD00 Output for motor holding brake 14 DGND Digital ground 13 UV 12 ISD03 Not assigned S1 11 ISD02 Selection of slow jog STL 10 ISD01 Start/Stop quick jog anti-clockwise STR 9 ISD00 Start/Stop quick jog clockwise ENPO 8 ENPO Power stage hardware enable 7 UV 6 UV + 5 OSA00 Actual frequency 0 ... FMAX 0 ... 10 V corresponds to - 4 AGND Analog ground 0 ... 10 V corresponds to 3 ISA01 Not assigned 2 ISA00 Not assigned 1 UR K0 +24V ~ H1 - K1 M 3~ 0 ... 10 V N1 Function Relay contact for “Ready” message Auxiliary voltage 24 V Auxiliary voltage 24 V Reference voltage 10.5 V, 5 mA Figure 3.7 Control terminals, traction drive without encoder evaluation CDA3000 Operation Manual 3-16 3 Installation 3.8.4 Terminal assignment 2 Preset solution “Analog reference and fixed frequency”. Features Parameter 1 • Analog speed input for two directions • Selection of fixed frequencies via binary coding of switches S1/S2 152-ASTER = ROT_6 • Functionally compatible with VF1000 K0 +24V Des. 20 OSD02 14 Function 19 OSD02 11 18 OSD02 12 Relay contact for “Ready” message 17 DGND Digital ground H2 16 OSD01 “Standstill” message H1 15 OSD00 “Reference reached” message 14 DGND Digital ground 13 UV S2 12 ISD03 S1 11 ISD02 Choice of fixed frequency (binary coded) * STL 10 ISD01 Start/Stop quick jog anti-clockwise STR 9 ISD00 Start/Stop quick jog clockwise ENPO 8 ENPO Power stage hardware enable 7 UV 6 UV + 5 OSA00 Actual frequency 0 ... FMAX - 4 AGND Analog ground 0 ... 10 V corresponds to 3 ISA01 Not assigned 2 ISA00 Reference 0 V ... + 10 V 1 UR 0 ... 10 V N1 R1 X2 ≥ 10 kΩ 2 3 Auxiliary voltage 24 V Auxiliary voltage 24 V Reference voltage 10.5 V, 5 mA 4 5 A *Function see section 4.3, Table 4.1 Figure 3.8 Terminal assignment, rotational drive without encoder evaluation Note: CDA3000 Operation Manual The terminal assignment applies to firmware V3.1 and higher 3-17 DE EN FR IT ES FR 3 Installation 3.8.5 Terminal assignment 3 Preset solution “Analog reference + correction, with rotary encoder”. Features Parameter • Analog speed input for two directions with speed correction 152-ASTER = ROT_2 • Encoder evaluation K0 +24V H2 H1 OSD02 14 Function 19 OSD02 11 18 OSD02 12 Relay contact for “Ready” message 17 DGND Digital ground 16 OSD01 “Reference reached” message 15 OSD00 “Standstill” message 14 DGND Digital ground + 13 UV B 12 ISD03 Encoder track B A 11 ISD02 Encoder track A STL 10 ISD01 Start/Stop anti-clockwise STR 9 ISD00 Start/Stop clockwise ENPO 8 ENPO Power stage hardware enable 7 UV 6 UV + 5 OSA00 Actual frequency 0 ... FMAX - 4 AGND Analog ground 3 ISA01 Correction reference* 0 V ... +10 V 2 ISA00 Reference 0 V ... + 10 V 1 UR M 3~ 0 ... 10 V N1 ≥ 10 kΩ R1 Des. 20 (1) N2 X2 Auxiliary voltage 24 V Auxiliary voltage 24 V R2 ≥ 10 kΩ (1) Reference voltage 10.5 V, 5 mA Only encoder type HTL (24V supply) usable. The encoder is evaluated only in control mode FOR. For notes on the rotary encoder see Figure 3.10. Figure 3.9 Control terminal assignment, rotational drive with encoder evaluation Correction reference*: For a description of the function refer to the CDA3000 Application Manual. CDA3000 Operation Manual 3-18 3 Installation 3.8.6 Encoder Specification of encoder connections: Des. Specification Digital inputs ISD02 ISD03 • flimit = 150 kHz • PLC-compatible (L = < 5 V, H = > 18 V) • Current consumption (encoder) max. 80 mA Connecting cable - • Screened twisted-pair cable with approx. 60 nF/km • Cable length max. 30 m A HTL encoder with 24 V supply can be connected to terminals X2/11 and 12. Permissible pulse counts are in the range from 32, 64, 128, 256, 512, 1 2 1024 ...to 16384 pulses per rev (2n where n = 5 to 14). + NPN 3 A PNP - Figure 3.10 Block diagram, HTL output circuit Maximum number of lines of encoder 6 9 ⋅ 10 LRmax = --------------n max LRmax = nmax = 4 Maximum number of lines of encoder in pulses per rev. Maximum speed of motor in rpm 5 Example of nmax = 6000 rpm: 6 Calculated: 9 ⋅ 10 LR max = --------------- = 1500 pulses per rev. 6000 Selected: An encoder with 1024 pulses per rev. Reasoning: 1500 pulses per rev. is not programmable - the nearest A possible value is 1024 pulses per rev. (binary 210) Minimum motor speed Formula for calculating the minimum motor speed depending on the encoder lines per revolution so that one pulse of the encoder can be evaluated each scan cycle of the inverter module. n min CDA3000 Operation Manual 3000 1 = ----------- ⋅ --------LR min LR = Number of lines of encoder in pulses per rev. nmin = Minimum speed of motor in rpm 3-19 DE EN FR IT ES FR 3 Installation CDA3000 Operation Manual 3-20 4 Commissioning 4 Commissioning 1 4.1 Choice of commissioning .......................................4-1 4.2 Standard commissioning ........................................4-2 4.3 KEYPAD commissioning ...........................................4-4 4.4 DRIVEMANAGER commissioning ................................4-6 4.5 Direction check .....................................................4-11 4.6 4.6.1 4.6.2 Serial commissioning ...........................................4-12 Serial commissioning with KEYPAD .....................4-12 Serial commissioning with DRIVEMANAGER ..........4-14 4.7 Operation with KEYPAD KP200 ...............................4-15 4.8 Operation with DRIVEMANAGER ...............................4-18 4.9 Parameter list (selection) .....................................4-19 Attention: Commissioning must only be carried out by qualified electricians who have undergone instruction in the necessary accident prevention measures. 4.1 Choice of commissioning 3 4 5 Standard commissioning CDA3000 Operation Manual 2 The device can be put into operation with its factory settings, without need of any other aids. KEYPAD commissioning The KEYPAD enables you to preset a number of basic parameters, such as rotating field limitation (FMAX), acceleration/deceleration ramps (ACCR/DECR) or fixed frequencies (FFIX) etc. DRIVEMANAGER commissioning The “DRIVEMANAGER 3.0” PC user interface enables you to customize your drive tasks in a user-friendly way. Serial commissioning To commission several identical drives, for example, you can transfer the data set of the first drive via KEYPAD with SMARTCARD or via DRIVEMANAGER to the following drives. 4-1 A DE EN FR IT ES FR 4 Commissioning 4.2 Standard commissioning This mode of commissioning is based on the factory setting. Precondition: • Inverter module is fully connected. • Recommended IEC standard motor (see section A.2) is connected. • Control terminals are wired as per terminal assignment 1, see page 3-16. Attention: Make sure that the rotating drive of your machine cannot cause any damage during commissioning (such as by overshooting a stop limit) and that there are no personnel inside the danger zone. . Step 1 2 Start drive 3 4 Action Note After power-on, inverter module Connect the mains power supply to performs a self-test (lasting approx. the inverter module. 1... 3 s). Quick jog = 50 Hz Check that your drive can be run at Slow jog = 20 Hz the factory set (FS) rotating field Acceleration ramp1) frequency and ramps. Deceleration and stop ramp1) Close ENPO contact. Enables power stage. Set drive to slow jog Close S1 = slow jog 5 Start drive by closing STL or STR contact. STL = start anti-clockwise STR = start clockwise 6 Check direction of rotation of motor shaft see section 4.5 “Direction check” 7 Brake drive by opening start contact. Drive brakes down to standstill. Open ENPO contact. Safely disables power stage. Commissioning is completed. Note: 1) Factory setting from BG1 to BG5 (15 kW) = 20 Hz/s, from BG6 (22 kW) to BG8 = 5 Hz/s CDA3000 Operation Manual If the connected IEC standard motor differs by more than two power classes from the rated power output of the inverter module, “DRIVEMANAGER commissioning” with automatic motor identification should be carried out, see section 4.4. The same applies to commissioning of special motors such as reluctance, synchronous or HF motors. Please consult your project engineer. 4-2 4 Commissioning Input signals of terminal assignment 1 (152-ASTER = DRV_1) 303-FMAX1 FMAX 590-ACCR1 f [Hz] 0 592-DECR1 270-FFIX1 594-STPR1 1 303-FMAX1 FMAX STR 1 0 STL 1 0 S1 1 0 2 t [s] Figure 4.1 Example of a quick/slow jog driving profile for two directions Output signals of terminal assignment 1 (152-ASTER = DRV_1) 3 FMAX f [Hz] 0 4 FMAX 1 H1 0 5 1 K1 0 t [s] Figure 4.2 Output signals dependent on driving profile H1 = Reference reached; K1 = Motor holding brake output signal CDA3000 Operation Manual 4-3 A DE EN FR IT ES FR 4 Commissioning 4.3 KEYPAD commissioning This mode of commissioning is performed with the KEYPAD control unit (accessory order designation: KP200). It enables a number of basic parameters to be adjusted directly. Precondition: • Inverter module is fully connected. • Recommended IEC standard motor (see section A.2) is connected. • Control terminals are wired as per terminal assignment 2, see page 3-17. • KP200 is plugged in. Attention: Make sure that the rotating drive of your machine cannot cause any damage during commissioning (such as by overshooting a stop limit) and that there are no personnel inside the danger zone. . Step 1 2 3 Action Note After power-on, inverter module Connect the mains power supply to performs a self-test (lasting approx. the inverter module. 1... 3 s). Rotating field frequency (FMAX) = 50Hz Check that your drive can be run at at reference value (R1) = 10 V the factory set (FS) rotating field Acceleration ramp1) frequency and ramps. Deceleration and stop ramp1) If this is not possible, change the parameters with the KEYPAD FMAX 303-FMAX1 Press the start/enter key once to Acceleration ramp 590-ACCR1 enter subject area _11UA and press Deceleration ramp 592-DECR1 the start/enter key again to select Stop ramp 594-STPR1 the parameter you want to change. Adapt parameter using cursor keys, confirm change with “start/enter” key. 4 5 Start drive 1 2 1) Factory setting from BG1 to BG5 (15 kW) = 20 Hz/s, from BG6 (22 kW) to BG8 = 5 Hz/s CDA3000 Operation Manual Select the preset solution Parameter 152-ASTER “Rotational drive 6” to “ROT_6” Press “stop/return” to return to “Menu”. Save setting by pressing both cursor keys simultaneously for 3 seconds. Close ENPO contact and set a low reference value with R1. Start drive by closing STL or STR contact. ENPO enables power stage. Motor accelerates to preset reference 3 Check direction of rotation of motor shaft see section 4.5 “Direction check” 4 5 Open start contact. Drive brakes down to standstill. Open ENPO contact. Safely disables power stage. Commissioning is completed. 4-4 4 Commissioning Note: If the connected IEC standard motor differs by more than two power classes from the rated power output of the inverter module, “DRIVEMANAGER commissioning” with automatic motor identification should be carried out, see section 4.4. The same applies to commissioning of special motors such as reluctance, synchronous or HF motors. Please consult your project engineer. 303-FMAX1 FMAX FFTB1 R1 2 FFTB3 FFTB2 R1 1 R1 R1 f [Hz] 0 FMAX 3 Input signals terminal assignment 2 (152-ASTER = ROT_6) R1 STR 1 0 STL 1 0 S1 1 0 S2 1 0 4 10 V 5V 0V Output signals terminal assignment 2 (152-ASTER = ROT_6) 5 H2 H1 t [s] H1 = Reference reached H2 = Standstill Figure 4.3 Signal characteristic dependent on driving profile (ASTER=ROT_6) Reference S2 (ISD03) S1(ISD02) ISA00 Analog reference at input ISA00 (R1) 0 0 active Table frequency 601-FFTB1 (FS = 10Hz) 0 1 inactive Table frequency 602-FFTB2 (FS = 15Hz) 1 0 inactive Table frequency 603-FFTB3 (FS = 20Hz) 1 1 inactive Table 4.1 CDA3000 Operation Manual A Scaling of binary coded inputs ISD02 (S1) and ISD03 (S2) 4-5 DE EN FR IT ES FR 4 Commissioning 4.4 DRIVEMANAGER commissioning The DRIVEMANAGER as from version 3.1 makes commissioning easier, especially the adaptation of your drive. It should be used specifically when commissioning with “SFC” or “FOR” mode. The following is an illustration of the commissioning procedure based on the example of the preset solution ROT_2. Precondition: • Inverter module is fully connected. • Control terminals are wired as per terminal assignment 3, see page 3-18. • The motor with encoder planned for the application is correctly connected. • All data of the motor (rating plate data) and the encoder are available. Attention: Make sure that the rotating drive of your machine cannot cause any damage during commissioning (such as by overshooting a stop limit) and that there are no personnel inside the danger zone. The main window contains the “Initial commissioning” button. Click on it to open up the Wizard, which will guide you in four steps through the commissioning process. CDA3000 Operation Manual 4-6 4 Commissioning 1. Preset solution... In this window you select the terminal assignment required for control of your application. 1 As a check, the terminal diagram and specimen applications are illustrated. 2 For our example please set ROT_2. 3 2. Control method... Different control methods have special advantages depending on the application. Three modes of control are available. For our example please set FOR(2). 4 5 Meaning VFC Application Voltage Frequency Control (factory setting) Sensorless Flux Control SFC • Only for asynchronous motors Field Oriented Regulation FOR • Encoder is necessary • Pump, fan and extruder applications • Traction and lifting drive with low dynamics • Multi-motor operation • Dynamic traction, lifting and rotational drives • Drives with dynamic load surges • Dynamic traction and rotational drives • Speed control with encoder feedback • only for asynchronous motors Table 4.2 CDA3000 Operation Manual A Choice of control method 4-7 DE EN FR IT ES FR 4 Commissioning 3. Motor data... By way of the automatic motor identification the characteristic data of IEC standard motors and ASM servomotors can be determined. The precondition for problem-free identification is that the rating plate data are present and correctly entered. Note: The data of the motor nominal point (max. rated power output of the motor) must always be entered. In 87 Hz applications (motor: 230 V, delta configuration) the converted 87 Hz data must be entered. For more information refer to the CDA3000 Application Manual. For our example this setting is required. Following identification of the motor, all control loops are automatically computed and the necessary parameter adjustments made. Precondition: • The motor is connected. • Hardware enabled ( = ENPO contact closed). 1 3 Step 1 2 3 4 2 Action Note Enter motor data see your motor type designation Click on “Start identification” button Takes approx. 3 min. Apply setting Values are transferred to device Re-open ENPO contact on device Power stage safely disabled Motor identification is complete CDA3000 Operation Manual 4-8 4 Commissioning Set lines per revolution of encoder used This setting is only required in “FOR” mode. 1 2 4. Change basic settings... In the last step you can adapt the basic setting of the preset solution to your application. The setting options vary according to the selected preset drive solution (here the example for ROT_2). 3 Test setting Attention: Make sure that the rotating drive of your machine cannot cause any damage during commissioning (such as by overshooting a stop limit) and that there are no personnel inside the danger zone. Step Action Note 1 Close ENPO contact. ENPO active enables power stage. 2 Set low reference with R1. see section “3.8.5 Terminal assignment 3” 3 Start drive by closing STL or STR contact. Motor accelerates to preset reference 4 If the motor runs uncontrolled and does Check phase position, motor and not accelerate up to the preset encoder connections, see section 4.5 reference, stop the drive (open STL or “Direction check” STR contact). 4 5 A Motor accelerates up to preset reference, commissioning can be continued. 5 CDA3000 Operation Manual Set correction reference with R2 4-9 Drive accelerates further by amount of correction reference. DE EN FR IT ES FR 4 Commissioning Step 6 7 Action Note Brake drive by opening start contact. Drive brakes down to standstill. Open ENPO contact. Safely disables power stage. Commissioning is completed. Input signals 303-FMAX1 FMAX 590-ACCR1 592-DECR1 594-STPR1 f [Hz] 0 FMAX R1 STR 1 0 STL 1 0 10 V 5V 0V R2 10 V 5V 0V t [ms] Figure 4.4 Example of a driving profile for two directions with correction reference (R2), 152-ASTER = ROT_2 FOR setting FOR is preset, and requires no further optimization for standard applications. Note: For more detailed information on optimizing • the speed control loop refer to the CDA3000 Application Manual. CDA3000 Operation Manual 4-10 4 Commissioning 4.5 Direction check Precondition: • Inverter module is fully connected. • The motor planned for the application is correctly connected. • Device set to VFC mode = Voltage Frequency Control (factory setting). • Enter a low reference value, e.g. slow jog. 1 1. Test phase position of motor connections. Step (1) (2) Action Note 1 Close ENPO contact. ENPO active enables power stage. 2 Start drive by closing STR contact. Motor accelerates to preset reference 3 Check direction of rotation of drive. 4 Brake drive by opening start contact. 5 Open ENPO contact. With STR active, motor rotates clockwise (2) (1) Direction of view. 3 Drive brakes down to standstill. ENPO inactive safely disables power stage. If direction is wrong, check phase Also check the control connections: position of motor connections. STR > term. X2/9 (ISD00) 6 2 4 If the direction matches the actuation, the test is completed. 2. Test encoder connection Precondition: • Inverter module is fully connected. • The motor with encoder planned for the application is correctly connected. • Device set to FOR mode = Field Oriented Regulation. Step 1 R 2 L 3 Action Note Open ENPO contact. Power stage safely disabled. Turn motor shaft clockwise by hand In status display: (1) Direction of view, (2) Clockwise. Right (clockwise) = no preceding sign Left A (anti-clockwise) = neg. preceding sign. If assignment is wrong, check wiring of encoder. If the direction matches the display, the test is completed. CDA3000 Operation Manual 5 4-11 DE EN FR IT ES FR 4 Commissioning 4.6 Serial commissioning Apply this mode of commissioning if you want to put several identical drives into operation (serial commissioning). The same inverter type and motor must be set for each drive in an identical application. If you already have a complete data set, skip the subsection headed “Save data set to SMARTCARD” (with KEYPAD) or “Save data set from device to file” (with DRIVEMANAGER). Note: 4.6.1 Serial commissioning with KEYPAD Do not load the firmware V180.x (for inverter modules in execution HF) in the standard inverter modul . By loading the firmware the error message E-COPU39 will be signalised one-time by a flashing code of indication H1. Precondition: • All inverter modules are fully connected. • The first drive is already fully commissioned into operation. Note: The CARD menu can only be selected if the drive is not active! Save data set to SMARTCARD Step 1 Action Note Presentation Connect the KEYPAD to the inverter module of the first drive, insert a SMARTCARD and switch on the power. CARD 2 Select the CARD menu. = load/save with SMARTCARD CARD start enter 3 Choose WRITE. = Save data set CARD start enter 4 Choose ALL and start the save operation with the start/enter key. stop return = Complete data set is saved CARD start enter stop return 5 READY appears. = Save operation completed without error By this procedure you have written your data set to a SMARTCARD. CDA3000 Operation Manual 4-12 CARD 4 Commissioning Download data set from SMARTCARD to next inverter Step 1 Action Note Presentation Connect the KEYPAD to the inverter module of the next drive, insert the SMARTCARD with the desired data set and switch on the power. 1 CARD 2 Select the CARD menu. = load/save with SMARTCARD CARD start enter 3 Choose READ. = Load data set 2 CARD start enter 4 Choose ALL and start the load operation with the start/enter key. stop return = Complete data set is loaded CARD 3 start enter stop return 5 READY appears. = Load operation completed without error Repeat this procedure on each of the other drives. Note: CARD 4 Data set is automatically stored in inverter module. 5 A CDA3000 Operation Manual 4-13 DE EN FR IT ES FR 4 Commissioning 4.6.2 Serial commissioning with DRIVEMANAGER Precondition: • All inverter modules are fully connected. • The first drive is already fully commissioned into operation. • A PC with installed DRIVEMANAGER user software (V3.1 or higher) is connected. Step Save data set from device to file 1 2 3 4a 4b 5 Download data set from file into device Remember to save the setting. 6 7 Action Comment Connect your PC to the inverter Use a standard serial cable (9-pin Dmodule of the first drive and switch SUB, socket/pin) e.g. LUST accessory on the power to the inverter. CCD-SUB90x . Automatically links to the connected Start DRIVEMANAGER. inverter module. If the connection fails, check the settings in the Tools > Options menu and try again by way of icon. Save the current data set with icon, either in the parameter database (directory: c:/../userdata) of the DRIVEMANAGER or on a floppy disk (a:/). With icon the current data set of the connected device is always saved. Give the file a name of your choice. Disconnect from all devices with icon Connect your PC to the inverter module of the next drive and switch on the power to the inverter. With icon establish a link between the DRIVEMANAGER and the newly connected device. With icon load the data set The data set is stored in the device as saved in step 4 into the user data set 1. device. With icon select the main window. Save the setting with button -> Repeat steps 4 ... 7 on each of the other drives. For more information refer to the DRIVEMANAGER Manual. CDA3000 Operation Manual 4-14 4 Commissioning 4.7 Operation with KEYPAD KP200 The KEYPAD can be plugged directly into the inverter module ( X4). Overview of KEYPAD KP200 SM ART CARD (1) (2) (1) SMARTCARD chipcard to save and transfer settings (2) 3-digiti display, e.g. for parameter number (3) Current menu (4) 5-digit display for parameter name and value (5) Acceleration or braking ramp active (6) Bar graph display, 10-character (5) (3) (4) VAL 1 2 Hz (6) stop return start enter start enter Call up menu branches or parameters; Save changes; Start in “Control drive” mode stop return Quit menu branches; Cancel changes; Stop in “Control drive” mode 3 4 Select menu, subject area or parameter; Increase setting Select menu, subject area or parameter; Reduce setting Table 4.3 Menu structure Operating and display elements of the KEYPAD KP200 VAL Actuals • select • display CTRL PARA Subject area • select Drive • control Capacity indicator CARD A SMARTCARD • read • write Parameter • Write protection • select • change Initial commissioning Figure 4.5 Functions of the menus CDA3000 Operation Manual 5 The KEYPAD KP200 has a user-friendly menu structure which is identical to that of the KP100 for the SMARTDRIVE VF1000 inverters and the MASTERCONTROL SERVOCONTROLLERS. 4-15 DE EN FR IT ES FR 4 Commissioning Example of parameter setting (PARA menu) • The parameters in the PARA menu are grouped into subject areas according to their functions, in order to provide a clearer overview. • Only the parameters to which the current user level permits access can be changed. PARA 1. Select PARA menu. start enter stop return 2. Select desired subject area with cursor keys and confirm with start/enter. PARA start enter stop return PARA 3. Select desired parameter with cursor keys (user level 1-MODE = 2). start enter stop return 4. The current value is displayed, with the last character flashing. Switch to the next character using the down key. Use the up key to change the flashing character. The fifth character at the extreme left indicates the preceding sign: (–) = minus. The last character can be entered as an exponent. Save new value with start/enter or cancel (without saving) with stop/return. CDA3000 Operation Manual 4-16 start enter PARA 0...9 PARA 4 Commissioning CARD MENU Read from/write to SMARTCARD: • In this menu inverter settings can be saved to the SMARTCARD and transferred to other inverter modules. • In every storage operation all parameters are always saved to the SMARTCARD. For read operations, either all parameters or only parameters from one subject area (per read operation) can be read-in. Function READ > ALL READ > _27RS WRITE LOCK UNLOCK Meaning Read all parameters from SMARTCARD Parameters from subject area, e.g. B. _27RS (reference structure) Store all parameters on the SMARTCARD Write-protect the SMARTCARD Cancel the write protection 1 2 3 4 5 A CDA3000 Operation Manual 4-17 DE EN FR IT ES FR 4 Commissioning 4.8 Operation with DRIVEMANAGER Precondition: • DRIVEMANAGER user software version V3.1 or higher installed on the PC. X4 H1 H2 H3 X4 RS232 3mm ax. RS232 D RIV E M AN AG ER ! ACHTUNG Kondensatorentladezeit >3 Min. Betriebsanleitung beachten! WARNING capacitor disscharge time >3 minutes. Pay attention to the operation manual! ATTENTION temps de decharge du condensteur >3 min. observer le mode dèmploi! CCD-SUB90X X2 X3 X1 Figure 4.6 Inverter module connection to PC/DRIVEMANAGER The key functions Icon Function Menu Change setting of active device Active device > Change settings Print parameter data set Active device > Print settings Digital scope Active device > Monitoring > Quickly changing digital scope values Control drive Active device > Open-loop control > Basic operation modes Connect to device Communication > Connect > Single device Bus initialization, change setting Communication> Bus configuration Disconnect all devices Communication > Disconnect Save data set of active device to file Active device > Save device settings to Data set transfer from file to active device Active device > Load device settings from For more information refer to the DRIVEMANAGER Manual. CDA3000 Operation Manual 4-18 4 Commissioning 4.9 Parameter list (selection) Name Unit Function Factory setting 1 Subject area User-defined_11UA Any parameters can be inserted into this subject area using the DRIVEMANAGER (V3.0 or higher). The number is limited to 14. * In the factory setting the parameters listed here are inserted. 01-MODE - User level of KP200 2 150-SAVE - Save setting in device READY 152 -ASTER - Preset terminal assignment DRV_1 180 -FISA0 - Function selector of ISA00 off 181 -FISA1 - Function selector of ISA01 off 242 -FOS02 - Function selector of OSD02 off 270-FFIX1 Hz Fixed frequency characteristic data set CDS1 20 301 -FMIN1 Hz CDS1: Minimum frequency 0 303 -FMAX1 Hz CDS1: Maximum frequency 50 330-MOPTC - Type of PTC evaluation off 590 -ACCR1 Hz/s CDS1: Acceleration ramp 20 592 -DECR1 Hz/s CDS1: Braking ramp 20 594 -STPR1 Hz/s CDS1: Stop ramp 20 95-ERR1 h Your setting Last error - 2 3 4 Subject area Initial commissioning _15FC 150-SAVE - Back-up device setup READY 152 -ASTER - Preset terminal assignment DRV_1 Subject area Fixed frequencies_27FF 270-FFIX1 Hz Fixed frequency 20 5 Subject area Frequency limits_30OL 301 -FMIN1 Hz CDS1: Minimum frequency 0 303 -FMAX1 Hz CDS1: Maximum frequency 50 Subject area Motor protection _33MO 330-MOPTC - Type of motor PTC evaluation OFF A Subject area Driving profile generator _59DP 590 -ACCR1 * For more information refer to the DRIVEMANAGER MANUAL. Hz/s CDS1: Acceleration ramp 20 592 -DECR1 Hz/s CDS1: Deceleration ramp 20 594 -STPR1 Hz/s CDS1: Stop ramp 20 Subject area Encoder evaluation _79EN 790-ECLNC CDA3000 Operation Manual Pulses Lines per revolution of encoder per rev 4-19 1024 DE EN FR IT ES FR 4 Commissioning Name Unit Function Factory setting Subject area Analog inputs _18IA 180 -FISA0 Settings3) for analog input ISA00: OFF = Not active 0-10V = Voltage input 0...10 V PM10V = Voltage input -10 V...+10 V 0-20 = Current input 0...20 mA 4-20 = Current input 4...20 mA OFF Subject area Driving sets_60TB 601-FFTB1 Hz Table frequency 2 10 602-FFTB2 Hz Table frequency 3 15 603-FFTB3 Hz Table frequency 4 20 1) Setting dependent on device. 2) Setting dependent on motor. 3) Selection, not complete CDA3000 Operation Manual 4-20 Your setting 1 5 Diagnosis/Fault rectification 5.1 LEDs ........................................................................5-1 5.2 Error messages .......................................................5-2 2 Helpline ..................................................................... 5-3 Service/support ........................................................ 5-3 5.1 LEDs 5.3 User errors in KEYPAD operation .............................5-4 5.4 User errors in SMARTCARD operation .......................5-4 5.5 Errors in power switching ......................................5-4 5.6 Reset ........................................................................5-5 At the top right of the inverter module there are three status LEDs colored red (H1), yellow (H2) and green (H3). Device status H1 H2 H3 Red LED (H1) - ● Ready (ENPO set) ❍ ● ● In service/Auto-tuning active ❍ ✳ ● Warning Error ● ✳ (flash code) 4 Yellow LED (H2) Green LED (H3) - Power on 3 ● /✳ ❍ 5 ● ● ❍ LED off, ● LED on, ✳ LED flashing A CDA3000 Operation Manual 5-1 DE EN FR IT ES FR 5 Diagnosis/Fault rectification 5.2 Error messages If a fault occurs in operation it is indicated by a flash code from LED H1 (red) on the inverter module. The code indicates the type of error. If a KP200 is connected the KP200 indicates the error type as an abbreviation. Flash code of red LED H1 Display KEYPAD 1x E-CPU Collective error 2x E-OFF Undervoltage shut-off Check power supply. Also occurs briefly in response to normal power-off. 3x E-OC Current overloadshut-off 4x E-OV 5x E-OLM 6x E-OLI Device safety shut-off Device overloaded: Check dimensioning. Possibly use a larger device. 7x E-OTM Motor temperature too high Motor PTC correctly connected? Parameter MOPTC correctly set(type of motor PTC evaluation)? Motor overloaded? Allow motor to cool down. Check dimensioning. 8x E-OTI Inverter overheating Ambient temperature too high: Improve ventilation in switch cabinet. Load too high during driving/braking: Check dimensioning. Possibly use a braking resistor. Explanation Voltage overload shut-off Motor protectionshut-off Cause/Remedy Power-off, remove all control signals, power-on. If error recurs, inform LUST Service.1) Short-circuit, ground fault: Check cabling of connections, check motor coil, check neutral conductor and grounding (see also section 3, Installation). Device setup not correct: Check parameters of control loops. Check ramp setting. Voltage overload from mains: Check mains voltage. Restart device. Voltage overload resulting from feedback from motor (regenerative operation): Slow down braking ramps. If not possible, use a braking resistor. Motor overloaded (after I x t monitoring): Slow down process cycle rate if possible. Check motor dimensioning. 1) For more information refer to CDA3000 Application Manual Table 5.1 CDA3000 Operation Manual Error messages 5-2 5 Diagnosis/Fault rectification Helpline If you need further assistance, our specialists at the LUST helpline will be glad to help. You can reach us: 1 Mon.-Thur.: 8 a.m. - 4.30 p.m.Tel. +49 (0) 64 41/9 66-180 Fri.: 8 a.m. - 4 p.m. Fax: +49 (0) 64 41/9 66-177 Tel. +49 (0) 64 41/9 66-180 E-mail: helpline@lust-tec.de 2 Service/support If you search for further support in service case, we - the specialists of the LUST-service center - would like to help you. 3 You can reach us: Mon.-Thur.: 8 a.m. - 4.30 p.m.Tel. +49 (0) 6441/966-171 Fri.: 8 a.m. - 4 p.m. Fax: +49 (0) 441/966-211 Tel. +49 (0) 6441/966-171 E-mail: service@lust-tec.de 4 5 A CDA3000 Operation Manual 5-3 DE EN FR IT ES FR 5 Diagnosis/Fault rectification 5.3 User errors in KEYPAD operation Error Cause ATT1 Parameter cannot be changed at current user level or is not editable. Select user level 1-MODE higher. ATT2 Motor must not be controlled via the CTRL menu. Cancel start signal from a different control location. ATT3 Motor must not be controlled via the CTRL menu because of error state. Reset error. ATT4 New parameter value impermissible Change value. ATT5 New parameter value too high Reduce value. ATT6 New parameter value too low Increase value. ATT7 Card must not be read in current state. Reset start signal. ERROR Invalid password Enter correct password. Table 5.2 5.4 User errors in SMARTCARD operation KEYPAD user error: Reset with Start/Enter Error Meaning Errors in power switching SMARTCARD write-protected ERR92 Error in plausibility check ERR93 SMARTCARD not readable, wrong inverter type ERR94 SMARTCARD not readable, parameter not compatible ERR96 Connection to SMARTCARD broken ERR97 SMARTCARD DATA invalid (checksum) ERR98 Insufficient memory on SMARTCARD ERR99 Selected area not present on SMARTCARD, no parameters transferred to SMARTCARD Use different SMARTCARD SMARTCARDerror: Reset with Stop/Return Error Power on. Inverter module shows no response (LEDs off). CDA3000 Operation Manual Remedy ERR91 Table 5.3 5.5 Remedy Cause If switching is too frequent, the device protects itself by means of high-resistance isolation from the system. 5-4 Remedy After a rest phase of a few minutes the device is ready to start once again. 5 Diagnosis/Fault rectification 5.6 Reset The reset function is divided into two areas with differing effects. Parameter reset restores to the last value stored in the device. Device reset restores the entire data set to factory setting (delivery defaults). Parameter reset with KEYPAD If you are in the setup mode of a parameter and press the two cursor keys simultaneously, the parameter you are currently editing will be reset to the last setting stored (= saved with parameter 150-SAVE). Factory setting with KEYPAD Press both cursor keys simultaneously during inverter module power-up to reset all parameters to their factory defaults and the system is reinitialized. Factory setting with DRIVEMANAGER In the “Active device” menu, the “Reset to factory setting” option can be used to restore the delivery defaults of the device. 1 2 3 4 Note: The factory setting causes application data set 1 (traction and lifting drive, DRV_1) to be loaded. Check the terminal assignment and functionality of the inverter module in this operation mode, or load your own user data set. 5 A CDA3000 Operation Manual 5-5 DE EN FR IT ES FR 5 Diagnosis/Fault rectification CDA3000 Operation Manual 5-6 1 A Appendix 2 A.1 Current capacity of inverter modules .................... A-2 A.2 Technical data ........................................................ A-5 A.3 Ambient conditions ................................................ A-8 A.4 Project planning notes, Cold plate ........................ A-9 A.5 Project planning notes for multimotor operation .................................................... A-10 A.6 through use of a line choke ................................. A-12 A.7 Line filter .............................................................. A-14 A.8 UL approbation ..................................................... A-15 A.9 Layouts of all sizes .............................................. A-16 3 4 5 A CDA3000 Operation Manual A-1 DE EN FR IT ES FR A.1 Current capacity of inverter modules The maximum permissible inverter output current and the peak current are dependent on the mains voltage, the motor cable length, the power stage switching frequency and the ambient temperature. If the conditions change, the maximum permissible current capacity of the inverter modules also changes. Refer to the following graphs and tables. I IN (1) Continuous (2) Intermittent* > 5 Hz rotating field frequency Inverter modules 0.37 to 15 kW I/IN = 1.8 (for 30 s at 4 kHz) I/IN = 1.8 (for 30 s at 8 kHz) I/IN = 1.8 (for 30 s at 16 kHz) Inverter modules 22 to 90 kW I/IN = 1.5 (for 60 s at 4 kHz) I/IN = 1.5 (for 60 s at 8 kHz) (3) Intermittent* 0 to 5 Hz rotating field frequency Inverter modules 0.37 to 15 kW I/IN = 1.8 (for 30 s at 4 kHz) I/IN = 1.25-1.8 (for 30 s at 8 kHz) Inverter modules 22 to 90 kW I/IN = 1.5 (for 60 s at 4 kHz) I/IN = 1-1.5 (for 60 s at 8 kHz) (4) Pulse mode Inverter modules 0.37 to 15 kW I/IN = approx. 2.2 (at 4, 8, 16 kHz) Inverter modules 22 to 90 kW I/IN = approx. 1.8 (at 4, 8 kHz) (3) (4) 2 (2) 1 (1) 5 25 40 45 50 f [Hz] *Intermittent IN > Ieff I eff = 1 n 2 -- ⋅ Σ I ⋅t T i=1 i i Inverter modules for 230 V systems Rec. 4-pole Inverter module standard motor [kW] Switching frequency of power stage [kHz] Rated current [A] Peak current for Peak current for intermittent intermittent mode mode 0 to 5 Hz [A] > 5 Hz [A] CDA32.004,Cx.x1) 0.75 4 8 16 4 4 3 7.2 7.2 5.4 7.2 7.2 5.4 CDA32.006,Cx.x1) 1.1 4 8 16 5.5 5.5 4.3 9.9 9.9 7.7 9.9 9.9 7.7 CDA32.008,Cx.x1) 1.5 4 8 16 7.1 7.1 5.5 12.8 12.8 8 12.8 12.8 9.9 Peak current for 30 s with inverter module 0.75 to 15 kW Peak current for 60 s with inverter module 22 to 90 kW Cooling air temperature: 45 °C at power stage switching frequency 4 kHz 40 °C at power stage switching frequency 8, 16 kHz 1) With heat sink HS3... or additional cooling surface CDA3000 Operation Manual A-2 Mains voltage 1 x 230 V -20 % +15 % Motor cable length 10 m Mounting height 1000 m above MSL End-to-end mounting Inverter modules for 400/460 V systems: Rec. 4-pole Inverter module standard motor [kW] CDA34.003,Cx.x 0.75 Rated current IN[A] Switching frequency of power stage [kHz] Rated current IN[A] 4 8 16 2.2 2.2 1.0 2.2 2.2 1.0 4 4 1.1 4 4 1.8 7.4 7.4 4.3 7.4 7.4 4.3 at 400V2) at 460V3) Peak current for Peak current for intermittent intermittent mode mode 0 to 5 Hz [A] > 5 Hz [A] CDA34.005,Cx.x1) 1.5 4 8 16 4.1 4.1 2.4 4.1 3.6 - CDA34.006,Cx.x1) 2.2 4 8 16 5.7 5.7 2.6 5.7 5.7 - 10.3 10.3 4.7 10.3 10.3 4.7 CDA34.008,Wx.x 3.0 4 8 16 7.8 7.8 5 7.8 7.8 - 14 14 7.8 14 14 9 CDA34.010,Wx.x 4.0 4 8 16 10 10 6.2 10 8.8 - 18 16.5 7.8 18 18 11 CDA34.014,Wx.x 5.5 4 8 16 14 14 6.6 14 12.2 - 25 21 9.2 25 21 11.9 CDA34.017,Wx.x 7.5 4 8 16 17 17 8 17 13.5 - 31 21.2 9.2 31 31 14.4 CDA34.024,Wx.x 11 4 8 16 24 24 15 24 24 - 43 40 22 43 43 27 CDA34.032,Wx.x 15 4 8 16 32 32 20 32 28 - 58 40 22 58 58 36 CDA34.045,Wx.x 22 4 8 45 45 45 39 68 54 68 68 CDA34.060,Wx.x 30 4 8 60 60 60 52 90 71 90 90 CDA3000 Operation Manual A-3 1 2 3 4 5 A DE EN FR IT ES FR Rec. 4-pole Inverter module standard motor [kW] Switching frequency of power stage [kHz] Rated current IN[A] at 400V2) Rated current IN[A] at 460V3) Peak current for Peak current for intermittent intermittent mode mode 0 to 5 Hz [A] > 5 Hz [A] CDA34.072,Wx.x 37 4 8 72 72 72 62 112 78 112 112 CDA34.090,Wx.x 45 4 8 90 90 90 78 135 104 135 135 CDA34.110,Wx.x 55 4 8 110 110 110 96 165 110 165 165 CDA34.143,Wx.x 75 4 8 143 143 143 124 215 143 215 215 CDA34.170,Wx.x 90 4 8 170 170 170 147 255 212 255 255 110 4 210 210 255 300 132 4 250 250 255 300 CDA34.250,Wx.x Peak current for 30 s with inverter module 0.75 to 15 kW Peak current for 60 s with inverter module 22 to 132 kW 2) Mains voltage 3 x 400 V ±10 % 3) Mains voltage 3 x 460 V ±10 % Motor cable length 10 m Mounting height 1000 m above MSL End-to-end mounting Cooling air temperature: 45 °C at power stage switching frequency 4 kHz (CDA34.003 - 34.032) 40 °C at power stage switching frequency 8, 16 kHz Cooling air temperature:40 °C at power stage switching frequency 4 kHz (CDA34.045 - 34.250) 1) With heat sink HS3... or additional cooling surface CDA3000 Operation Manual A-4 CDA34.003 CDA34.005 CDA34.006 Technical data CDA32.008 Designation CDA32.006 CDA32.004 to CDA34.006 CDA32.004 A.2 Technical data 0.75 kW 1.1 kW 1.5 kW 0.75 kW 1.5 kW 2.2 kW Output, motor side Recommended rated power with 4-pole Standard motor 1 2 Voltage 3 x 0 ... 230 V 3 x 0 ... 400/460 V Continuous current (RMS) (IN) 4.0 A 5.5 A 7.1 A 2.2 A 4.1 A 5.7 A Peak current 1.8 x IN for 30 s 7.2 A 9.9 A 12.8 A 4.0 A 7.4 A 10.3 A Rotating field frequency 0 ... 400 Hz Switching frequency of power stage 4, 8, 16 kHz 3 Input, mains side 1 x 230 V -20 % +15 % Mains voltage Device connected load 1.7 kVA Asymmetry of mains voltage Frequency Power loss at Power stage clock frequency 2.3 kVA 4 3 x 460 V -25 % +10 % 3.0 kVA 1.6 kVA 3.0 kVA 4.2 kVA - ±3 % max. 50/60 Hz ±10 % 50/60 Hz ±10 % 4 kHz 48 W 75 W 95 W 55 W 80 W 106 W 8/16 kHz 55 W 82 W 105 W 70 W 112 W 148 W – – 1.6 kW at 360 Ω 5 Braking chopper power electronics Peak braking power with int. braking resistor (only with version CDA34 ..., Wx.x, BR) Minimum ohmic resistance of an externally installed braking resistor CDA3000 Operation Manual - - 100 Ω 56 Ω A 180 Ω A-5 DE EN FR IT ES FR CDA34.014 CDA34.017 CDA34.024 CDA34.032 CDA34.045 CDA34.060 Technical data CDA34.010 Designation CDA34.008 CDA34.008 to CDA34.060 3.0 kW 4.0 kW 5.5 kW 7.5 kW 11 kW 15 kW 22 kW 30 kW Output, motor side Recommended rated power with 4-pole Standard motor Voltage 3 x 0 ... 400/460 V Continuous current (RMS) (IN) 7.8 A 10 A 14 A 17 A 24 A 32 A 45 A 60 A Peak current 1.8 x IN for 30 s 14 A 18 A 25 A 31 A 43 A 58 A 68 A 90 A Rotating field frequency 0 ... 400 Hz 0 ... 200 Hz Switching frequency of power stage 4, 8, 16 kHz 4, 8 kHz Input, mains side Mains voltage Device connected load 3 x 460 V -25 % +10 % 5.7 kVA 7.3 kVA 10.2 kVA 12.4 kVA 17.5 kVA 23,3 kVA Asymmetry ±3 % max. Frequency 50/60 Hz ±10 % Power loss at Power stage4 kHz clock frequency 8/16 kHz 135 W 162 W 172 W 207 W 210 W 268 W 255 W 325 W 315 W 400 W 400 W 510 W 32.8 kVA 43.8 kVA 777 W 933 W 1010 W 1220 W Braking chopper power electronics Peak braking power with int. braking resistor (only with version CDA34 ..., Wx.x, BR) Minimum ohmic resistance of an externally installed braking resistor CDA3000 Operation Manual 6.0 kW at 90 Ω 6.0 kW at 90 Ω 6.0 kW at 90 Ω - 81 Ω 47 Ω 22 Ω 18 Ω A-6 CDA34.110 CDA34.143 CDA34.170 CDA34.250 CDA34.250 Technical data CDA34.090 Designation CDA34.072 CDA34.072 to CDA34.250 37 kW 45 kW 55 kW 75 kW 90 kW 110 kW 132 kW Output, motor side Recommended rated power with 4-pole Standard motor 2 Voltage 3 x 0 ... 400/460 V Continuous current (RMS) (IN) 72 A 90 A 110 A 143 A 170 A 210 A 250 A Peak current for 60 s 108 A 135 A 165 A 214 A 255 A 300 A 300 A Rotating field frequency 3 0 ... 200 Hz Switching frequency of power stage 4, 8 kHz 4 kHz Input, mains side 4 3 x 460 V -25 % +10 % Mains voltage Device connected load 52.5 kVA 65.6 kVA 80 kVA Asymmetry of mains voltage 104 kVA 124 kVA 145 kVA 173 kVA ±3 % max. Frequency Power loss at Power stage clock frequency 1 5 50/60 Hz ±10 % 4 kHz 1270 W 1510 W 1880 W 2450 W 2930 W 3405 W 4043 W 8 kHz 1530 W 1820 W 2290 W 2970 W 3550 W - - A Braking chopper power electronics Minimum ohmic resistance of an externally installed braking resistor CDA3000 Operation Manual 13 Ω 12 Ω 10 Ω 5.6 Ω A-7 DE EN FR IT ES FR A.3 Ambient conditions Characteristic Temperature range in operation -10 ...45 ° C (BG1 ... BG5) 0 ... 40 ° C (BG6 ... BG8) with power reduction to 55 ° C in storage -25 ... +55 °C in transit -25 ... +70 °C Relative air humidity Mechanical strength to IEC 68-2-6 Protection in stationary use in transit 15 ... 85 %, condensation not permitted Vibration: 0.075 mm in frequency range 10 ... 58 Hz Shock: 9.8 m/s2 in frequency range >58 ... 500 Hz Vibration: 3.5 mm in frequency range 5 ... 9 Hz Shock: 9.8 m/s2 in frequency range >9 ... 500 Hz Device IP20 (NEMA 1) Cooling method Cold plate: IP20 Push-through heat sink: IP54 (3 ...15 kW) Touch protection VBG 4 Mounting height up to 1000 m above MSL, above 1000 m above MSL with power reduction 1% per 100 m, max. 2000 m above MSL Voltage stress of the motor winding typical slew rate 3 - 6 kV/µs Note: CDA3000 Operation Manual Inverter module If a rotating field frequency of > 200/400 Hz is required, inverter modules with special firmware for high-frequency motors must be ordered. Detailed order data see in order catalogue CDA3000. A-8 A.4 Project planning notes, Cold plate Subject 1 Project planning notes Thermal connection to cooler • Evenness of contact surface = 0.05 mm Roughness of contact surface = roughness factor 6.3 • Coat area between inverter module (“cold plate” backing plate) and cooler with heat transfer compound (coat thickness 30-70µ). • The temperature in the middle of the inverter module backing plate must not exceed 85 °C. Distribution of power loss Active cooling surface Size Power Heat sink Housing BG 1/2 BG 3 BG 4 BG 5 0.37 to 2.2 kW 3 to 4 kW 5.5 to 7.5 kW 11 to 15 kW approx. 65% approx. 70% approx. 75% approx. 80% approx. 35% approx. 30% approx. 25% approx. 20% Size Power [kW] BG 1 BG 2 BG 3 BG 4 BG 5 0.37 to 0.75 kW 1.1 to 2.2 kW 3 to 4 kW 5.5 to 7.5 kW 11 to 15 kW a b H B Device basic area [mm] 3 Active cooling surface [mm] B H a b 70 70 100 150 200 193 218 303 303 303 50 90 120 65 80 165 200 260 215 300 4 5 Thermal resistance Rth Size Power [kW] Thermal resistance between active cooling surface and cooler Rth [K/W] BG 1 BG 2 BG 3 BG 4 BG 5 0.37 to 0.75 kW 1.1 to 2.2 kW 3 to 4 kW 5.5 to 7.5 kW 11 to 15 kW 0.05 0.05 0.03 0.02 0.015 Cooler Heat transfer compound CDA3000 backing plate Note: CDA3000 Operation Manual 2 For size 3 (BG3) and above an active cooling surface or cooler is required. The usual mounting surface or a position on the machine housing is not adequate. A-9 A DE EN FR IT ES FR A.5 Project planning notes for multimotor operation Subject Project planning notes Current configuration of inverter module The sum total of the motor currents must be less than the rated output current of the inverter module Σ of motor currents, (IM1 + IM2 + IMn ) < Iinverter Motor control method Multi-motor operation is only permitted with the VFC motor control method. Motor choke A motor output choke must always be used. The motor choke limits the du/dt and thus the leakage currents, and protects again switching voltage overload resulting from switching of the motor inductance. Motor cable length The total length of the overall motor cable is produced by adding the individual lengths per motor. Motor protection In multi-motor operation the parallel-connected motors cannot be protected by the inverter module. As a result, depending on application the motor protection should be provided by means of external motor circuit-breakers or thermistor protective relays. All motors have the same power output In this application the torque characteristics of all motors remain roughly equal. The motors have different power outputs If the motor outputs are very different, problems may occur on startup and at low speeds. This is because of the high stator resistance of small motors and the resultant high voltage drop on the stator coil. In practice: With a power ratio of around 1:4 between the motors, the starting torque of the smallest motor is still approx. 70% of the nominal torque. If the torque of approx. 70% is not sufficient, a larger motor must be used. If all the motors are started together, the small motor will start up later, because the slip frequency is higher. Speed proportionality Differing motor output speeds can only be attained by using motors with differing nominal speeds, e.g. 1440 rpm and 2880 rpm. The speed ratio of approx. 1:2 is maintained during the speed change. The accuracy depends on the slip and thus on the load. Connecting individual motors When connecting motors, ensure that the connection current is not higher than the inverter peak current. It is advantageous if the inverter load is >40%. This 40% base load backs up the output voltage of the inverter module at the moment of connection of the motor. During connection the motor must not be run in the field weakening range, since the connected motor would otherwise have to run at reduced runup torque. CDA3000 Operation Manual A-10 A.5.1 Engineering note „Motor contactor“ In order to prevent an unexpected starting it is necessary to avoid a dangerous motion at access to the machine according to EN1037 - thus to provide galvanic separation with a motor contactor in the cable between inverter and motor. 1 Basically the switching in the motor cable must always be made in deenergized condition, otherwise there will be problems of burnt contacts and a switching off due to overvoltage or overcurrent. To guarantee a deenergized switching, it is necessary that the contacts of the motor contactor are closed before enabling the power stage of the inverter. In the opposite case it is necessary that the contacts are closed until the power stage is switched-off. 2 This will be reached by planning corresponding safety time for the switching of the motor contactor during control sequence or by using the special software function of CDA3000 inverter. Software function „Switching of motor contactor“: Step Example for the digital output OSD01 (terminal plug X2-16/17) Action 1 3 Adjust one of the digital outputs of the inverter to function „ENMO“. • choose in subject area _240D parameter 241_FOS01 • adjust parameter 241_FOS01 to „ENMO“ 4 • memorize the adjustment • choose parameter 247_TENMO in subject area _240D 2 Adjust the necessary delay time at parameter 247_TENMO. • choose parameter 247_TENMO applied to your application (factory setting = 300 ms) 5 • value area = 0 ... 2000 ms A CDA3000 Operation Manual A-11 DE EN FR IT ES FR Example for the digital output OSD01: f [Hz] 0 t STR (Start/Stop) 1 0 e.g. OSD01 (ENMO) 1 0 power stage 1 0 TENMO TENMO Attention: A corresponding driver relay has to be used between the digital output and the motor contactor. A.6 through use of a line choke Line chokes are required: • Where the drive controller is used in applications with disturbance variables corresponding to environment class 3, as per EN 61000-2-4 and above (hostile industrial environment). • With a dc-link between multiple inverter moduls. Characteristics of environment class 3 include: • Mains voltage fluctuations > + 10% UN • Short-time interruptions between 10 ms and 60 s • Voltage asymmetry > 3% Environment class 3 typically applies where: • a major part of the load is supplied by power converters (dc choppers or soft-start equipment). • welding machines are present. • induction or arc furnaces are present. • large motors are started frequently. • loads fluctuate rapidly. CDA3000 Operation Manual A-12 Mains load (example) Without line choke With line choke 4 kW inverter, mains impedance 0.6 mH Change 4 kW inverter, Without line choke mains impedance compared to 6 mH with line choke Voltage distortion (THD)1) 99 % Mains current amplitude 18.9 A 9.7 A -48 % Mains current effective 8.5 A 6.23 A -27 % Commutation notches referred to the mains voltage 28 V 8V -70% Nominal life 2 to 3 times nominal life +100 to 200 % Life of the DC-link capacitors 33 % -67 % 2 3 1) THD = Total Harmonic Distortion (U5 ...U41) Table A.1 1 Change in system load resulting from insertion of a line choke with 4% short-circuit voltage based on the example of a 4 kW inverter CDA34.010 4 Mains voltage asymmetry (example) Asymmetry of mains voltage Without line choke With line choke 4 kW inverter, mains impedance 0.6 mH 4 kW inverter, mains impedance 6 mH 0% +3 % -3 % 0% +3 % -3 % Mains current amplitude 18.9 A 25.4 A 25.1 A 9.7 A 10.7 A 11 A Mains current effective 8.5 A 10.5 A 10.2 A 6.2 A 6.7 A 6.8 A Table A.2 Effect of the line choke with asymmetrical mains voltage based on the example of a 4 kW inverter CDA34.010 5 A Recommended: The example shows that the benefits of a line choke with 4 % short-circuit voltage are multi-faceted. We therefore recommend that you use a line choke as a matter of course. CDA3000 Operation Manual A-13 DE EN FR IT ES FR A.7 Line filter Details concerning the subject "Electromagnetic Compatibility" can be found in chapter 3.2. Permissible motor cable length with internal radio interference suppression filter 4 kHz power stage cycle frequency Drive controller With integrated line filter 8 kHz power stage cycle frequency With integrated line filter 16 kHz power stage cycle frequency With integrated line filter Industrial area Living area Industrial area Living area Industrial area Living area CDA32.004 1) 1) 20 10 25 10 CDA32.006 25 10 20 10 25 10 CDA32.008 25 10 20 10 25 10 CDA34.003 10 10 25 10 1) 1) CDA34.005 10 10 25 10 25 1) CDA34.006 10 10 25 10 25 1) CDA34.008 25 10 25 10 25 1) CDA34.010 25 10 25 10 CDA34.014 CDA34.017 1) 1) Table A.3 CDA3000 Operation Manual 10 10 25 25 25 1) 10 2) 25 1) 10 2) 25 1) Permissible motor cable length with integrated line filter in compliance with standard 61800-3 A-14 Explanation on Table A.3 Living area: Limit values acc. to EN61800-3 (first environment), limited availability. Maximum permissible motor cable length at which the emitted interference (>9 kHz) is below the permitted limit values. Measurements were only performed for 10 (15 m). Industrial area: Limit values acc. to EN61800-3 (first environment), limited availability. Maximum permissible motor cable length at which the emitted interference (>9 kHz) is below the permitted limit values. Measurements were only performed for 25 m. 1) For 10 m and/or 25 m the emitted interference was beyond the specified limit values. However, this does not mean that the line filter is ineffective, but only that it has no optimal effect over the entire frequency band. An external line filter must therefore be used in order to comply with the standard. 2) For compliance with the standard a power choke (uK=4%) has to be connected additionally. Measuring method: The permissible motor cable length was determined according to the standard (specified measuring method). 1 2 3 4 5 A CDA3000 Operation Manual A-15 DE EN FR IT ES FR A.8 UL approbation Measures to maintain UL approbation 1. Switch cabinet mounting with IP54 protection and pollution degree 2 is mandatory. 2. The devices are only usable in systems with surge strength class III. 3. Only UL approved fuses and circuit-breakers may be used. CDA32.xxx : Mains fuses min. 250 V H or K5 CDA34.xxx : Mains fuses min. 600 V H or K5 4. The devices are usable in systems with a maximum current capacity of 5000 A. 5. The connecting cables (mains power, motor and control cables) must be UL approved. CDA32.xxx : Min. 300 V cables (mains/motor), Cu 75° C min. CDA34.xxx : Min. 600 V cables (mains/motor), Cu 75° C min. Tightening torque of Tightening torque of grounding lead terminals mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals as mains/motor terminals 6 ... 8 Nm 6 ... 8 Nm 0.5 ... 0.6 Nm 0.5 ... 0.6 Nm 0.5 ... 0.6 Nm 0.5 ... 0.6 Nm 0.5 ... 0.6 Nm 0.5 ... 0.6 Nm 0.5 ... 0.6 Nm 0.5 ... 0.6 Nm 0.5 ... 0.6 Nm 0.5 ... 0.6 Nm 1.2 ... 1.5 Nm 1.2 ... 1.5 Nm 6 ... 8 Nm 6 ... 8 Nm 6 ... 8 Nm 15 ... 20 Nm 15 ... 20 Nm Table A.4 CDA3000 Operation Manual Device Wire cross-section Mains fuse CDA32.004 CDA32.006 CDA32.008 CDA34.003 CDA34.005 CDA34.006 CDA34.008 CDA34.010 CDA34.014 CDA34.017 CDA34.024 CDA34.032 CDA34.045 CDA34.060 CDA34.072 CDA34.090 CDA34.110 AWG 16 N/M AWG 14 N/AWG 16 M AWG 14 N/AWG 16 M AWG 16 N/M AWG 16 N/M AWG 16 N/M AWG 14 N/M AWG 14 N/M AWG 12 N/M AWG 12 N/M AWG 10 N/M AWG 8 N/M AWG 6 N/M AWG 6 N/M AWG 4 N/M AWG 2 N/M AWG 1 N/M 10 A 10 A 20 A 10 A 10 A 10 A 15 A 15 A 20 A 25 A 30 A 50 A 50 A 63 A 80 A 100 A 125 A Cable cross-sections - mains (N), motor (M) A-16 Attention: The inverter modules can typically be overloaded with 1.5 x IN for 60 s (1.8 x IN for 30 s). The effective inverter capacity utilization (Ieff. ≤ IN) must never be greater than IN (rated current). 1 Minimum cross-section of the grounding lead to DIN VDE 0100 Part 540 Cross-section Grounding lead (PE) cross section of at least 10 mm² or lay a second electrical conductor parallel to the existing grounding lead, because the operational leakage current is > 3.5 mA. PE conductor with cross-section of mains power cable - see VDE 0100 Part 540 Mains power cable <10 mm² Mains power cable >10 mm² Table A.5 2 PE mains connection 3 Minimum cross-section of the grounding lead A.9 Layouts of all sizes H1 H2 H3 X7 X4 H1 H2 H3 BG3+4 4 X7 BG5 X4 ! ACHTUNG Kondensatorentladezeit >3 Min. Betriebsanleitung beachten! WARNING capacitor disscharge time >3 minutes. Pay attention to the operation manual! ATTENTION temps de decharge du condensteur >3 min. observer le mode dèmploi! H1 H2 H3 BG1+2 ! ACHTUNG Kondensatorentladezeit >3 Min. Betriebsanleitung beachten! WARNING capacitor disscharge time >3 minutes. Pay attention to the operation manual! ATTENTION temps de decharge du condensteur >3 min. observer le mode dèmploi! X7 X4 U U V V W W L+ L+ RB RB L- L- L1 N L2 L3 L3 Figure A.1 CDA3000 Operation Manual X3 X6 A X3 V ! ACHTUNG Kondensatorentladezeit >3 Min. Betriebsanleitung beachten! WARNING capacitor disscharge time >3 minutes. Pay attention to the operation manual! ATTENTION temps de decharge du condensteur >3 min. observer le mode dèmploi! 5 X2 W L+ X1 RB X6 X2 X3 L- L1 L2 L3 L1 L- RB L+ U V W L2 L3 X1 CDA32.XXX CDA34.XXX X1 U X6 X2 Layout of CDA3000 inverter moduls, sizes 1 to 5 A-17 DE EN FR IT ES FR Terminal Explanation X1 Power connections X2 Control connections X3 Motor PTC connection X4 PC/KP200 connection (RS232 interface) X6 UM-xxx module connection X7 CM-xxx module connection VAL Hz BG8 start enter stop return H1 H2 H3 X7 X4 U X6 V W RB X2 L+ X3 LL1 L2 L3 VAL Hz VAL Hz start enter stop return start enter stop return H1 H2 H3 X7 X6 X4 X2 X7 X4 BG7 X6 BG6 X2 X3 X1 X3 L1 L2 L3 L+ L- RB U X1 L1 L2 L3 L+ L- RB U V W Figure A.2 Layout of CDA3000 inverter moduls, sizes 6 to 8 CDA3000 Operation Manual A-18 V W Hinweis zur EN 61000-3-2 DE Notes on EN 61000-3-2 EN (rückwirkende Netzbelastung durch Oberwellen) Unsere Frequenzumrichter und Servo-regler sind im Sinne der EN61000 "professionelle Geräte", so dass sie bei einer Nennanschlußleistung ≤1kW in den Geltungsbereich der Norm fallen.Beim direkten Anschluß von Antriebsgeräten ≤1kW an das öffentliche Niederspannungsnetz sind entweder Maßnahmen zur Einhaltung der Norm zu treffen oder das zuständige Energieversorgungsunter-nehmen muß eine Anschlußge-nehmigung erteilen. Sollten Sie unsere Antriebsgeräte als eine Komponente in ihrer Maschine/ Anlage einsetzen, dann ist der Geltungsbereich der Norm für die komplette Maschine/ Anlage zu prüfen. (limits for harmonic current emissions) Our frequency inverters and servocontrollers are "professional devices" in the sense of the European Standard EN 61000, and with a rated power of ≤1kW obtained in the scope of this standard. Direct connection of drive units ≤1kW to the public low-voltage grid only either by means of measurements for keeping the standard or via an authorization of connection from the responsible public utility. In case our drive units are used as a component of a machinery/ plant, so the appropriate scope of the standard of the machinery/plant must be checked. Remarque concernant EN 61000-3-2 FR Riferimento ad EN 61000-3-2 IT (valeurs limites pour courants d'harmonique) Dans l'esprit de EN61000, nos convertisseurs de fréquence et régulateurs automatiques sont des "appareils professionnels". Par conséquent ils tombent sous l'application de la norme lorsque la puissance de raccordement nominale ≤1kW. Lorsque des appareils d'entraînement sont raccordés directement au réseau public basse tension, il convient de prendre des mesures pour respecter la norme ou l'entreprise de distribution d'électricité compétente doit délivrer une autorisation de branchement. Si vous deviez utiliser nos appareils de branchement comme composants dans votre machine ou votre installation, il convient dans ce cas de vérifier le domaine d'application de l'ensemble de la machine ou de l'installation. (carico di rete retroattivo tramite armoniche) I nostri invertitori di frequenza e servoregolatori sono degli "apparecchi professionali" ai sensi della EN61000 così da ricadere nel campo di validità della norma con una potenza nominale di collegamento di ≤1kW. Nel caso di collegamento diretto di azionamenti da ≤1kW alla rete pubblica di bassa tensione devono essere applicati dei provvedimenti per il rispetto della norma oppure ottenere un permesso di allacciamento da parte dell'ente di energia competente. Doveste usare i nostri apparecchi di azionamento come componenti della vostra macchina o del vostro impianto, controllare il campo di validità della norma per l'intera macchina o l'impianto. Lust Antriebstechnik GmbH Gewerbestrasse 5-9 • 35633 Lahnau • Germany Tel. +49 64 41 / 9 66-0 • Fax +49 64 41 / 9 66-137 www.lust-antriebstechnik.de • info@lust-tec.de D RIVET RONICS Lust DriveTronics GmbH Heinrich-Hertz-Str. 18 • 59423 Unna • Germany Tel. +49 23 03 / 77 9-0 • Fax +49 23 03 / 77 9-3 97 www.lust-drivetronics.de • info@lust-drivetronics.de ID no.: 0840.00B.5-00 • 09/2005 Technische Änderungen vorbehalten. We reserve the right to make technical changes.
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