Bell & Gossett P2001487 User Manual
INSTRUCTION MANUAL
P2001487
REV 0
®
TECHNOLOGIC
Pump Controller
Safety
Safety
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains input power. Installation, start
up, and maintenance should be performed by qualified
personnel only. Failure to perform installation, start up,
and maintenance by qualified personnel could result in
death or serious injury.
High Voltage
Frequency converters are connected to hazardous mains
voltages. Extreme care should be taken to protect against
shock. Only trained personnel familiar with electronic
equipment should install, start, or maintain this equipment.
WARNING
UNINTENDED START!
When the frequency converter is connected to AC mains,
the motor may start at any time. The frequency
converter, motor, and any driven equipment must be in
operational readiness. Failure to be in operational
readiness when the frequency converter is connected to
AC mains could result in death, serious injury,
equipment, or property damage.
Unintended Start
When the frequency converter is connected to the AC
mains, the motor may be started by means of an external
switch, a serial bus command, an input reference signal, or
a cleared fault condition. Use appropriate cautions to
guard against an unintended start.
WARNING
DISCHARGE TIME!
Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is
not powered. To avoid electrical hazards, disconnect AC
mains, any permanent magnet type motors, and any
remote DC-link power supplies, including battery
backups, UPS and DC-link connections to other
frequency converters. Wait for the capacitors to fully
discharge before performing any service or repair work.
The amount of wait time is listed in the Discharge Time
table. Failure to wait the specified time after power has
been removed before doing service or repair could result
in death or serious injury.
Voltage [V] Minimum waiting time [minutes]
4715
200-240 1.1-3.7 kW 5.5-45 kW
380-480 1.1-7.5 kW 11-90 kW
525-600 1.1-7.5 kW 11-90 kW
525-690 1.1-7.5 kW 11-90 kW
High voltage may be present even when the warning LED
indicator lights are off.
Discharge Time
Symbols
The following symbols are used in this manual.
WARNING
Indicates a potentially hazardous situation which could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which can
result in minor or moderate injury. It can also be used to
alert against unsafe practices.
CAUTION
Indicates a situation that could result in equipment
or property-damage-only accidents.
NOTE
Indicates highlighted information to regard with
attention to avoid mistakes or operate equipment at less
than optimal performance.
Approvals
The frequency converter complies with UL508C thermal
memory retention requirements. For more information
refer to 2.4.5 Motor Thermal Protection.
NOTE
Imposed limitations on the output frequency
(due to export control regulations):
From software version 3.92 the output frequency of the
frequency converter is limited to 590 Hz.
Safety
Contents
Contents
1 Introduction
1.1 Purpose of the Manual
1.2 Additional Resources
1.3 Product Overview
1.4 Internal Frequency Converter Controller Functions
1.5 Frame Sizes and Power Ratings
2 Installation
2.1 Installation Site Check List
2.2 Frequency Converter and Motor Pre-installation Check List
2.3 Mechanical Installation
2.3.1 Cooling 8
2.3.2 Lifting 9
2.3.3 Mounting 9
2.3.4 Tightening Torques 9
2.4 Electrical Installation
2.4.1 Requirements 12
2.4.2 Earth (Grounding) Requirements 12
4
6
6
6
6
7
8
8
8
8
10
2.4.2.1 Leakage Current (>3.5 mA) 13
2.4.2.2 Grounding Using Shielded Cable 13
2.4.3 Motor Connection 13
2.4.3.1 Motor Connection for A2 and A3 14
2.4.3.2 Motor Connection for A4 and A5 15
2.4.3.3 Motor Connection for B1 and B2 15
2.4.3.4 Motor Connection for C1 and C2 15
2.4.4 AC Mains Connection 16
2.4.5 Control Wiring 16
2.4.5.1 Access 17
2.4.5.2 Control Terminal Types 17
2.4.5.3 Wiring to Control Terminals 18
2.4.5.4 Using Screened Control Cables 19
2.4.5.5 Control Terminal Functions 19
2.4.5.6 Jumper Terminals 12 and 27 19
2.4.5.7 Terminal 53 and 54 Switches 20
2.4.6 Serial Communication 20
3 Start Up and Functional Testing
3.1 Pre-start
3.1.1 Safety Inspection 22
3.2 Applying Power
22
22
24
1
Contents
3.3 Basic Operational Programming
3.4 Asynchronous Motor Setup
3.5 PM Motor Setup
3.6 Automatic Motor Adaptation
3.7 Check Motor Rotation
3.8 Local-control Test
3.9 System Start Up
3.10 Acoustic Noise or Vibration
4 User Interface
4.1 Local Control Panel
4.1.1 LCP Layout 29
4.1.2 Setting LCP Display Values 30
4.1.3 Display Menu Keys 30
4.1.4 Navigation Keys 31
4.1.5 Operation Keys 31
4.2 Back Up and Copying Parameter Settings
4.2.1 Uploading Data to the LCP 32
24
25
25
26
27
27
28
28
29
29
31
4.2.2 Downloading Data from the LCP 32
4.3 Restoring Default Settings
4.3.1 Recommended Initialisation 32
4.3.2 Manual Initialisation 32
5 About Frequency Converter Programming
5.1 Introduction
5.2 Programming Example
5.3 Control Terminal Programming Examples
5.4 International/North American Default Parameter Settings
5.5 Parameter Menu Structure
5.5.1 Quick Menu Structure 37
5.5.2 Main Menu Structure 39
5.6 Remote Programming with MCT 10 Set-up Software
6 Application Set-Up Examples
6.1 Introduction
6.2 Application Examples
32
33
33
33
34
35
36
43
44
44
44
7 Status Messages
7.1 Status Display
7.2 Status Message Definitions
8 Warnings and Alarms
2
48
48
48
51
Contents
8.1 System Monitoring
8.2 Warning and Alarm Types
8.3 Warning and Alarm Definitions
9 Basic Troubleshooting
9.1 Start Up and Operation
10 Specifications
10.1 Power-dependent Specifications
10.1.3 Mains Supply 3 x 525-690 V AC 73
10.2 General Technical Data
10.3 Fuse Specifications
10.3.1 Branch Circuit Protection Fuses 81
10.3.2 UL and cUL Branch Circuit Protection Fuses 83
10.3.3 Substitute Fuses for 240 V 85
10.4 Connection Tightening Torques
Index
51
51
51
60
60
63
63
76
81
85
86
3
1
Introduction
1Introduction
Illustration 1.1 Exploded View Frame Size A
1 LCP 10 Motor output terminals 96 (U), 97 (V), 98 (W)
2 RS-485 serial bus connector (+68, -69) 11 Relay 2 (01, 02, 03)
3 Analog I/O connector 12 Relay 1 (04, 05, 06)
4 LCP input plug 13 Brake (-81, +82) and load sharing (-88, +89) terminals
5 Analog switches (A53), (A54) 14 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable strain relief/PE ground 15 USB connector
7 Decoupling plate 16 Serial bus terminal switch
8 Grounding clamp (PE) 17 Digital I/O and 24 V power supply
9 Shielded cable grounding clamp and strain relief 18 Control cable cover plate
Table 1.1 Legend to Illustration 1.1
4
Introduction
1 1
Illustration 1.2 Exploded View Frame Sizes B and C
1 LCP 11 Relay 2 (04, 05, 06)
2Cover 12Lifting ring
3 RS-485 serial bus connector 13 Mounting slot
4 Digital I/O and 24 V power supply 14 Grounding clamp (PE)
5 Analog I/O connector 15 Cable strain relief / PE ground
6 Cable strain relief/PE ground 16 Brake terminal (-81, +82)
7 USB connector 17 Load sharing terminal (DC bus) (-88, +89)
8 Serial bus terminal switch 18 Motor output terminals 96 (U), 97 (V), 98 (W)
9 Analog switches (A53), (A54) 19 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
Table 1.2 Legend to Illustration 1.2
5
1
Introduction
1.1 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and start up of the frequency converter.
2 Installation provides requirements for mechanical and
electrical installation, including input, motor, control and
serial communications wiring and control terminal
functions. 3 Start Up and Functional Testing provides
detailed procedures for start up, basic operational
programming, and functional testing. The remaining
chapters provide supplementary details. These details
include user interface, detailed programming, application
examples, start-up troubleshooting, and specifications.
1.2 Additional Resources
1.4 Internal Frequency Converter Controller
Functions
Illustration 1.3 is a block diagram of the frequency
converter's internal components. See Table 1.3 for their
functions.
Other resources are available to understand advanced
frequency converter functions and programming.
The Programming Guide provides greater detail on
•
working with parameters and many application
examples.
The Design Guide is intended to provide detailed
•
capabilities and functionality to design motor
control systems.
Optional equipment is available that may change
•
some of the procedures described. Reference the
instructions supplied with those options for
specific requirements.
1.3 Product Overview
A frequency converter is an electronic motor controller
that converts AC mains input into a variable AC waveform
output. The frequency and voltage of the output are
regulated to control the motor speed or torque. The
frequency converter can vary the speed of the motor in
response to system feedback, such as changing
temperature or pressure for controlling fan, compressor, or
pump motors. The frequency converter can also regulate
the motor by responding to remote commands from
external controllers.
In addition, the frequency converter monitors the system
and motor status, issues warnings or alarms for fault
conditions, starts and stops the motor, optimizes energy
efficiency, and offers many more control, monitoring, and
efficiency functions. Operation and monitoring functions
are available as status indications to an outside control
system or serial communication network.
Illustration 1.3 Frequency Converter Block Diagram
Area Title Functions
Three-phase AC mains power
•
1Mains input
2Rectifier
3DC bus
4DC reactors
5 Capacitor bank
6Inverter
7 Output to motor
supply to the frequency
converter
The rectifier bridge converts
•
the AC input to DC current to
supply inverter power
Intermediate DC-bus circuit
•
handles the DC current
Filter the intermediate DC
•
circuit voltage
Prove line transient protection
•
Reduce RMS current
•
Raise the power factor
•
reflected back to the line
Reduce harmonics on the AC
•
input
Stores the DC power
•
Provides ride-through
•
protection for short power
losses
Converts the DC into a
•
controlled PWM AC waveform
for a controlled variable
output to the motor
Regulated three-phase output
•
power to the motor
6
Introduction
Area Title Functions
Input power, internal
•
processing, output, and motor
current are monitored to
provide efficient operation
and control
8 Control circuitry
Table 1.3 Legend to Illustration 1.3
User interface and external
•
commands are monitored and
performed
Status output and control can
•
be provided
1.5 Frame Sizes and Power Ratings
References to frames sizes used in this manual are defined in Table 1.4.
1 1
Volts [V]A2A3 A4 A5B1B2B3B4C1C2C3C4
200-240 0.25-2.2 3.0-3.7 0.25-2.2 0.25-3.7 5.5-11 15 5.5-11 15-18.5 18.5-30 37-45 22-30 37-45
380-480 0.37-4.0 5.5-7.5 0.37-4.0 0.37-7.5 11-18.5 22-30 11-18.5 22-37 37-55 75-90 45-55 75-90
525-600 n/a 0.75-7.5 n/a 0.75-7.5 11-18.5 22-30 11-18.5 22-37 37-55 75-90 45-55 75-90
525-690 n/a 1.1-7.5 n/a n/a n/a 11-30 n/a n/a n/a 37-90 45-55 n/a
Single phase
200-240 n/a 1.1 n/a 1.1 1.5-5.5 7.5 n/a n/a 15 22 n/a n/a
380-480 n/a n/a n/a n/a 7.5 11 n/a n/a 18.5 37 n/a n/a
Table 1.4 Frames Sizes and Power Ratings
Frame Size [kW]
7
2
Installation
2 Installation
2.1 Installation Site Check List
The frequency converter relies on the ambient air
•
for cooling. Observe the limitations on ambient
air temperature for optimal operation
Ensure that the installation location has sufficient
•
support strength to mount the frequency
converter
Keep the manual, drawings, and diagrams
•
accessible for detailed installation and operation
instructions. It is important that the manual is
available for equipment operators.
Locate equipment as near to the motor as
•
possible. Keep motor cables as short as possible.
Check the motor characteristics for actual
tolerances. Do not exceed
300 m (1000 ft) for unshielded motor
•
leads
150 m (500 ft) for shielded cable.
•
Ensure that the ingress protection rating of the
•
frequency converter is suitable for the installation
environment. IP55 (NEMA 12) or IP66 (NEMA 4)
enclosures may be necessary.
CAUTION
Ingress protection
IP54, IP55 and IP66 ratings can only be guaranteed if
the unit is properly closed.
Ensure that all cable glands and unused
•
holes for glands are properly sealed.
Ensure that the unit cover is properly closed
•
Ensure that the frequency converter output
•
current rating is equal to or greater than motor
full load current for peak motor performance
Motor size and frequency converter
power must match for proper overload
protection
If frequency converter rating is less than
motor, full motor output cannot be
achieved
2.3 Mechanical Installation
2.3.1 Cooling
To provide cooling airflow, mount the unit to a
•
solid flat surface or to the optional back plate
(see 2.3.3 Mounting)
Top and bottom clearance for air cooling must be
•
provided. Generally, 100-225 mm (4-10 in) is
required. See Illustration 2.1 for clearance
requirements
Improper mounting can result in over heating
•
and reduced performance
Derating for temperatures starting between 40 °C
•
(104 °F) and 50 °C (122 °F) and elevation 1000 m
(3300 ft) above sea level must be considered. See
the equipment Design Guide for detailed
information.
CAUTION
Device damage through contamination
Do not leave the frequency converter uncovered.
2.2 Frequency Converter and Motor Preinstallation Check List
Compare the model number of unit on the
•
nameplate to what was ordered to verify the
proper equipment
Ensure each of the following are rated for same
•
voltage:
Mains (power)
Frequency converter
Motor
8
Installation
2
2
Illustration 2.2 Proper Mounting with Back Plate
Item A in Illustration 2.2 and Illustration 2.3 is a back plate
properly installed for required airflow to cool the unit.
Illustration 2.1 Top and Bottom Cooling Clearance
Enclosure A2-A5 B1-B4 C1, C3 C2, C4
a/b [mm] 100 200 200 225
Table 2.1 Minimum Airflow Clearance Requirements
2.3.2 Lifting
Check the weight of the unit to determine a safe
•
lifting method
Ensure that the lifting device is suitable for the
•
task
If necessary, plan for a hoist, crane, or forklift with
•
the appropriate rating to move the unit
For lifting, use hoist rings on the unit, when
•
provided
2.3.3 Mounting
Mount the unit vertically
•
The frequency converter allows side by side
•
installation
Ensure that the strength of the mounting location
•
will support the unit weight
Mount the unit to a solid flat surface or to the
•
optional back plate to provide cooling airflow
(see Illustration 2.2 and Illustration 2.3)
Improper mounting can result in over heating
•
and reduced performance
Use the slotted mounting holes on the unit for
•
wall mounting, when provided
Illustration 2.3 Proper Mounting with Railings
Item#Description
1Back plate
Table 2.2 Legend to Illustration 2.3
NOTE
Back plate is needed when mounted on railings.
2.3.4 Tightening Torques
See 10.4 Connection Tightening Torques for proper
tightening specifications.
9
2
Installation
2.4 Electrical Installation
This section contains detailed instructions for wiring the frequency converter. The following tasks are described.
Wiring the motor to the frequency converter output terminals
•
Wiring the AC mains to the frequency converter input terminals
•
Connecting control and serial communication wiring
•
After power has been applied, checking input and motor power; programming control terminals for their intended
•
functions
Illustration 2.4 shows a basic electrical connection.
Illustration 2.4 Basic Wiring Schematic Drawing
* Terminal 37 is an option
10
Installation
2
2
Illustration 2.5 Typical Electrical Connection
1 PLC 6 Min. 200 mm (7.9 in) between control cables, motor and mains
2 Frequency converter 7 Motor, 3-phase and PE
3 Output contactor (Generally not recommended) 8 Mains, 3-phase and reinforced PE
4 Earth (grounding) rail (PE) 9 Control wiring
5 Cable insulation (stripped) 10
Table 2.3 Legend to Illustration 2.5
Equalising min. 16 mm
2
(0.025 in)
11
2
Installation
2.4.1 Requirements
WARNING
EQUIPMENT HAZARD!
Rotating shafts and electrical equipment can be
hazardous. All electrical work must conform to national
and local electrical codes. It is strongly recommended
that installation, start up, and maintenance be
performed only by trained and qualified personnel.
Failure to follow these guidelines could result in death or
serious injury.
CAUTION
WIRING ISOLATION!
Run input power, motor wiring and control wiring in
three separate metallic conduits or use separated
shielded cable for high frequency noise isolation. Failure
to isolate power, motor and control wiring could result
in less than optimum frequency converter and associated
equipment performance.
For your safety, comply with the following requirements.
Electronic controls equipment is connected to
•
hazardous mains voltage. Extreme care should be
taken to protect against electrical hazards when
applying power to the unit.
Run motor cables from multiple frequency
•
converters separately. Induced voltage from
output motor cables run together can charge
equipment capacitors even with the equipment
turned off and locked out.
Overload and Equipment Protection
An electronically activated function within the
•
frequency converter provides overload protection
for the motor. The overload calculates the level of
increase to activate timing for the trip (controller
output stop) function. The higher the current
draw, the quicker the trip response. The overload
provides Class 20 motor protection. See
8 Warnings and Alarms for details on the trip
function.
All frequency converters must be provided with
•
short-circuit and over-current protection. Input
fusing is required to provide this protection, see
Illustration 2.6. If not factory supplied, fuses must
be provided by the installer as part of installationinstallation. See maximum fuse ratings in
10.3 Fuse Specifications.
Illustration 2.6 Frequency Converter Fuses
Item#Description
1Fuses
2Ground
Table 2.4 Legend to Illustration 2.6
Wire Type and Ratings
All wiring must comply with local and national
•
regulations regarding cross-section and ambient
temperature requirements.
Xylem recommends that all power connections
•
be made with a minimum 75 °C rated copper
wire.
See 10.1 Power-dependent Specifications for
•
recommended wire sizes.
2.4.2 Earth (Grounding) Requirements
WARNING
GROUNDING HAZARD!
For operator safety, it is important to ground the
frequency converter properly in accordance with national
and local electrical codes as well as instructions
contained within this document. Ground currents are
higher than 3.5 mA. Failure to ground the frequency
converter properly could result in death or serious injury.
NOTE
It is the responsibility of the user or certified electrical
installer to ensure correct grounding (earthing) of the
equipment in accordance with national and local
electrical codes and standards.
12
Installation
2
Follow all local and national electrical codes to
•
ground electrical equipment properly
Proper protective grounding for equipment with
•
ground currents higher than 3.5 mA must be
established, see 2.4.2.1 Leakage Current (>3.5 mA)
A dedicated ground wire is required for input
•
power, motor power and control wiring
Use the clamps provided with the equipment for
•
proper ground connections
Do not ground one frequency converter to
•
another in a “daisy chain” fashion
Keep the ground wire connections as short as
•
possible
Using high-strand wire to reduce electrical noise
•
is recommended
Follow motor manufacturer wiring requirements
•
2.4.2.1 Leakage Current (>3.5 mA)
Follow national and local codes regarding protective
earthing of equipment with a leakage current > 3.5 mA.
Frequency converter technology implies high frequency
switching at high power. This will generate a leakage
current in the earth connection. A fault current in the
frequency converter at the output power terminals might
contain a DC component which can charge the filter
capacitors and cause a transient earth current. The earth
leakage current depends on various system configurations
including RFI filtering, screened motor cables, and
frequency converter power.
EN/IEC61800-5-1 (Power Drive System Product Standard)
requires special care if the leakage current exceeds 3.5 mA.
Earth grounding must be reinforced in one of the
following ways:
Earth ground wire of at least 10 mm2
•
Two separate earth ground wires both complying
•
with the dimensioning rules
See EN 60364-5-54 § 543.7 for further information.
Using RCDs
Where residual current devices (RCDs), also known as earth
leakage circuit breakers (ELCBs), are used, comply with the
following:
Use RCDs of type B only which are capable of
detecting AC and DC currents
Use RCDs with an inrush delay to prevent faults
due to transient earth currents
Dimension RCDs according to the system configuration and environmental considerations
2.4.2.2 Grounding Using Shielded Cable
Earthing (grounding) clamps are provided for motor wiring
(see Illustration 2.7).
Illustration 2.7 Grounding with Shielded Cable
2.4.3 Motor Connection
WARNING
INDUCED VOLTAGE!
Run output motor cables from multiple frequency
converters separately. Induced voltage from output
motor cables run together can charge equipment
capacitors even with the equipment turned off and
locked out. Failure to run output motor cables separately
could result in death or serious injury.
For maximum wire sizes see 10.1 Power-dependent
•
Specifications
Comply with local and national electrical codes
•
for cable sizes
Motor wiring knockouts or access panels are
•
provided at the base of IP21 and higher
(NEMA1/12) units
Do not install power factor correction capacitors
•
between the frequency converter and the motor
Do not wire a starting or pole-changing device
•
between the frequency converter and the motor
Connect the 3-phase motor wiring to terminals
•
96 (U), 97 (V), and 98 (W)
Ground the cable in accordance with grounding
•
instructions provided
Torque terminals in accordance with the
•
information provided in 10.4 Connection
Tightening Torques
2
13
2
Installation
Follow motor manufacturer wiring requirements
•
Illustration 2.8, Illustration 2.9 and Illustration 2.10 represent
mains input, motor, and earth grounding for basic
frequency converters. Actual configurations vary with unit
types and optional equipment.
Illustration 2.10 Motor, Mains and Earth Wiring for Frame
Sizes B, C and D
Illustration 2.8 Motor, Mains and Earth Wiring for Frame Size
A
Illustration 2.9 Motor, Mains and Earth Wiring for Frame Sizes
B, C and D Using Shielded Cable
2.4.3.1 Motor Connection for A2 and A3
Follow these drawings step by step for connecting the
motor to the frequency converter.
1. Connect the motor earthwire to terminal 99,
place motor U, V and W wires in plug and
tighten.
14
Illustration 2.11 Motor Connection for A2 and A3
Installation
2
2.
Mount cable clamp to ensure 360° connection
between chassis and screen, note the outer
insulation of the motor cable is removed under
the clamp.
2.4.3.3 Motor Connection for B1 and B2
1. Terminate the motor earth
2. Place motor U, V and W wires in terminal and
tighten
3. Ensure that the outer insulation of the motor
cable is removed under the EMC clamp
2
Illustration 2.12 Cable Clamp Mounting
2.4.3.2 Motor Connection for A4 and A5
1. Terminate the motor earth
2. Place motor U, V and W wires in terminal and
tighten
3. Ensure that the outer insulation of the motor
cable is removed under the EMC clamp
Illustration 2.14 Motor Connection for B1 and B2
2.4.3.4 Motor Connection for C1 and C2
1. Terminate the motor earth
2. Place motor U, V and W wires in terminal and
tighten
3. Ensure that the outer insulation of the motor
cable is removed under the EMC clamp
Illustration 2.13 Motor Connection for A4 and A5
15
2
Installation
Illustration 2.15 Motor Connection for C1 and C2
2.4.4 AC Mains Connection
Size wiring based upon the input current of the
•
frequency converter. For maximum wire sizes see
10.1 Power-dependent Specifications.
Comply with local and national electrical codes
•
for cable sizes.
Connect 3-phase AC input power wiring to
•
terminals L1, L2, and L3 (see Illustration 2.16).
Depending on the configuration of the
•
equipment, input power will be connected to the
mains input terminals or the input disconnect.
Ground the cable in accordance with grounding
•
instructions provided in 2.4.2 Earth (Grounding)
Requirements
All frequency converters may be used with an
•
isolated input source as well as with ground
reference power lines. When supplied from an
isolated mains source (IT mains or floating delta)
or TT/TN-S mains with a grounded leg (grounded
delta), set 14-50 RFI Filter to OFF. When off, the
internal RFI filtercapacitors between the chassis
and the intermediate circuit are isolated to avoid
damage to the intermediate circuit and to reduce
earth capacity currents in accordance with IEC
61800-3.
The electronic thermal relay in the frequency converter has
received UL-approval for single motor protection, when
1-90 Motor Thermal Protectionis set for ETR Trip and
1-24 Motor Current is set to the rated motor current (see
motor name plate).
For thermal motor protection it is also possible to use the
MCB 112 PTC Thermistor Card option. This card provides
ATEX certificate to protect motors in explosion hazardous
areas, Zone 1/21 and Zone 2/22. When 1-90 Motor Thermal
Protection is set to [20] ATEX ETR is combined with the use
of MCB 112, it is possible to control an Ex-e motor in
explosion hazardous areas. Consult the programming
guide for details on how to set up the frequency converter
for safe operation of Ex-e motors.
2.4.5 Control Wiring
Isolate control wiring from high power
•
components in the frequency converter.
If the frequency converter is connected to a
•
thermistor, for PELV isolation, optional thermistor
control wiring must be reinforced/double
insulated. A 24 V DC supply voltage is
recommended.
Illustration 2.16 Connecting to AC Mains
16
Installation
2
2.4.5.1 Access
Remove access cover plate with a screw driver.
•
See Illustration 2.17.
Or remove front cover by loosening attaching
•
screws. See Illustration 2.18.
Illustration 2.17 Control Wiring Access for A2, A3, B3, B4, C3
and C4 Enclosures
2.4.5.2 Control Terminal Types
Illustration 2.19 shows the removable frequency converter
connectors. Terminal functions and default settings are
summarized in Table 2.6.
2
Illustration 2.18 Control Wiring Access for A4, A5, B1, B2, C1
and C2 Enclosures
See Table 2.5 before tightening the covers.
Frame IP20 IP21 IP55 IP66
A3/A4/A5 - - 2 2
B1/B2 - * 2.2 2.2
C1/C2/C3/C4 - * 2.2 2.2
* No screws to tighten
- Does not exist
Illustration 2.19 Control Terminal Locations
Connector 1 provides four programmable digital
•
inputs terminals, two additional digital terminals
programmable as either input or output, a 24 V
DC terminal supply voltage, and a common for
optional customer supplied 24 V DC voltage
Connector 2 terminals (+)68 and (-)69 are for an
•
RS-485 serial communications connection
Connector 3 provides two analog inputs, one
•
analog output, 10 V DC supply voltage, and
commons for the inputs and output
Connector 4 is a USB port available for use with
•
the frequency converter
Also provided are two Form C relay outputs that
•
are in various locations depending upon the
frequency converter configuration and size
Some options available for ordering with the unit
•
may provide additional terminals. See the manual
provided with the equipment option.
See 10.2 General Technical Data for terminal ratings details.
Table 2.5 Tightening Torques for Covers (Nm)
17
Installation
2
Terminal Description
Digital Inputs/Outputs
Default
Terminal Parameter
12, 13 - +24 V DC 24 V DC supply
18 5-10 [8] Start
19 5-11 [0] No
32 5-14 [0] No
33 5-15 [0] No
27 5-12 [2] Coast
29 5-13 [14] JOG
20 - Common for digital
39 -
42 6-50 Speed 0 -
50 - +10 V DC 10 V DC analog
53 6-1 Reference Analog input.
54 6-2 Feedback
55 -
61 -
68 (+) 8-3 RS-485 Interface. A
69 (-) 8-3
Setting Description
operation
operation
operation
inverse
Analog Inputs/Outputs
High Limit
Serial Communication
voltage. Maximum
output current is 200
mA total for all 24 V
loads. Useable for
digital inputs and
external transducers.
Digital inputs.
Selectable for digital
input and output.
Default setting is
input.
inputs and 0 V
potential for 24 V
supply.
Common for analog
output
Programmable analog
output. The analog
signal is 0-20 mA or
4-20 mA at a
maximum of 500
supply voltage. 15 mA
maximum commonly
used for potenti-
ometer or thermistor.
Selectable for voltage
or current. Switches
A53 and A54 select
mA or V.
Common for analog
input
Integrated RC-Filter
for cable screen. ONLY
for connecting the
screen when experi-
encing EMC problems.
control card switch is
provided for
termination resistance.
Terminal Description
Digital Inputs/Outputs
Default
Terminal Parameter
01, 02, 03 5-40 [0] [0] Alarm Form C relay output.
04, 05, 06 5-40 [1] [0] Running
Table 2.6 Terminal Description
Setting Description
Relays
Usable for AC or DC
voltage and resistive
or inductive loads.
2.4.5.3 Wiring to Control Terminals
Control terminal connectors can be unplugged from the
frequency converter for ease of installation, as shown in
Illustration 2.20.
Illustration 2.20 Unplugging Control Terminals
Ω
1. Open the contact by inserting a small screwdriver
into the slot above or below the contact, as
shown in Illustration 2.21.
2. Insert the bared control wire into the contact.
3. Remove the screwdriver to fasten the control wire
into the contact.
4. Ensure the contact is firmly established and not
loose. Loose control wiring can be the source of
equipment faults or less than optimal operation.
See 10.1 Power-dependent Specifications for control terminal
wiring sizes.
See 6 Application Set-Up Examples for typical control wiring
connections.
18
Installation
2
Illustration 2.21 Connecting Control Wiring
2.4.5.4 Using Screened Control Cables
Correct screening
The preferred method in most cases is to secure control
and serial communication cables with screening clamps
provided at both ends to ensure best possible high
frequency cable contact.
If the earth potential between the frequency converter and
the PLC is different, electric noise may occur that will
disturb the entire system. Solve this problem by fitting an
equalizing cable next to the control cable. Minimum cable
cross section: 16 mm
2
.
Illustration 2.24 Twisted-pair Cables
1
Min. 16 mm
2 Equalizing cable
Table 2.8 Legend to Illustration 2.24
Alternatively, the connection to terminal 61 can be
omitted:
Illustration 2.25 Twisted-pair Cables without Terminal 61
1
Min. 16 mm
2 Equalizing cable
Table 2.9 Legend to Illustration 2.25
2
2
2
Illustration 2.22 Correct Screening
1
Min. 16 mm
2Equalizing cable
Table 2.7 Legend to Illustration 2.22
50/60 Hz ground loops
With very long control cables, ground loops may occur. To
eliminate ground loops, connect one end of the screen-toground with a 100 nF capacitor (keeping leads short).
Illustration 2.23 50/60 Hz Ground Loops
Avoid EMC noise on serial communication
This terminal is connected to earth via an internal RC link.
Use twisted-pair cables to reduce interference between
conductors. The recommended method is shown in
Illustration 2.24:
2
2.4.5.5 Control Terminal Functions
Frequency converter functions are commanded by
receiving control input signals.
Each terminal must be programmed for the
•
function it will be supporting in the parameters
associated with that terminal. See Table 2.6 for
terminals and associated parameters.
It is important to confirm that the control
•
terminal is programmed for the correct function.
See 4 User Interface for details on accessing
parameters and 5 About Frequency Converter
Programming for details on programming.
The default terminal programming is intended to
•
initiate frequency converter functioning in a
typical operational mode.
2.4.5.6 Jumper Terminals 12 and 27
A jumper wire may be required between terminal 12 (or
13) and terminal 27 for the frequency converter to operate
when using factory default programming values.
Digital input terminal 27 is designed to receive a
•
24 V DC external interlock command. In many
19
2
Installation
applications, the user wires an external interlock
device to terminal 27
When no interlock device is used, wire a jumper
•
between control terminal 12 (recommended) or
13 to terminal 27. This provides in internal 24 V
signal on terminal 27
No signal present prevents the unit from
•
operating
When the status line at the bottom of the LCP
•
reads AUTO REMOTE COASTING or Alarm 60
External Interlock is displayed, this indicates that
the unit is ready to operate but is missing an
input signal on terminal 27.
When factory installed optional equipment is
•
wired to terminal 27, do not remove that wiring.
2.4.5.7 Terminal 53 and 54 Switches
Analog input terminals 53 and 54 can select
•
either voltage (0 to 10 V) or current (0/4-20 mA)
input signals
Remove power to the frequency converter before
•
changing switch positions
Set switches A53 and A54 to select the signal
•
type. U selects voltage, I selects current.
The switches are accessible when the LCP has
•
been removed (see Illustration 2.26).
WARNING
Some option cards available for the unit may cover these
switches and must be removed to change switch
settings. Always remove power to the unit before
removing option cards.
Terminal 53 default is for a speed reference signal
•
in open loop set in 16-61 Terminal 53 Switch
Setting
Terminal 54 default is for a feedback signal in
•
closed loop set in 16-63 Terminal 54 Switch Setting
Illustration 2.26 Location of Terminals 53 and 54 Switches
2.4.6 Serial Communication
RS-485 is a two-wire bus interface compatible with multidrop network topology, i.e. nodes can be connected as a
bus, or via drop cables from a common trunk line. A total
of 32 nodes can be connected to one network segment.
Repeaters divide network segments. Note that each
repeater functions as a node within the segment in which
it is installed. Each node connected within a given network
must have a unique node address, across all segments.
Terminate each segment at both ends, using either the
termination switch (S801) of the frequency converters or a
biased termination resistor network. Always use screened
twisted pair (STP) cable for bus cabling, and always follow
good common installation practice.
Low-impedance earth (ground) connection of the screen at
every node is important, including at high frequencies.
Thus, connect a large surface of the screen to earth
(ground), for example with a cable clamp or a conductive
cable gland. It may be necessary to apply potentialequalizing cables to maintain the same earth (ground)
potential throughout the network. Particularly in installations with long cables.
To prevent impedance mismatch, always use the same
type of cable throughout the entire network. When
connecting a motor to the frequency converter, always use
screened motor cable.
20
Installation
2
Cable Screened twisted pair (STP)
Impedance
Max. cable
length [m]
Table 2.10 Cable Information
120
Ω
1200 (including drop lines)
500 station-to-station
2
21
3
Start Up and Functional Tes...
3 Start Up and Functional Testing
3.1 Pre-start
3.1.1 Safety Inspection
WARNING
HIGH VOLTAGE!
If input and output connections have been connected improperly, there is potential for high voltage on these terminals.
If power leads for multiple motors are improperly run in same conduit, there is potential for leakage current to charge
capacitors within the frequency converter, even when disconnected from mains input. For initial start up, make no
assumptions about power components. Follow pre-start procedures. Failure to follow pre-start procedures could result
in personal injury or damage to equipment.
1. Input power to the unit must be OFF and locked out. Do not rely on the frequency converter disconnect switches
for input power isolation.
2. Verify that there is no voltage on input terminals L1 (91), L2 (92), and L3 (93), phase-to-phase and phase-toground,
3. Verify that there is no voltage on output terminals 96 (U), 97 (V), and 98 (W), phase-to-phase and phase-to-ground.
4. Confirm continuity of the motor by measuring ohm values on U-V (96-97), V-W (97-98), and W-U (98-96).
5. Check for proper grounding of the frequency converter as well as the motor.
6. Inspect the frequency converter for loose connections on terminals.
7. Record the following motor-nameplate data: power, voltage, frequency, full load current, and nominal speed. These
values are needed to program motor nameplate data later.
8. Confirm that the supply voltage matches voltage of frequency converter and motor.
CAUTION
Before applying power to the unit, inspect the entire installation as detailed in Table 3.1. Check mark those items when
completed.
Inspect for Description
Auxiliary equipment
Cable routing
Control wiring
Cooling clearance
EMC considerations
Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside
•
on the input power side of the frequency converter or output side to the motor. Ensure that they
are ready for full speed operation.
Check function and installation of any sensors used for feedback to the frequency converter
•
Remove power factor correction caps on motor(s), if present
•
Ensure that input power, motor wiring and control wiring are separated or in three separate metallic
•
conduits for high frequency noise isolation
Check for broken or damaged wires and loose connections
•
Check that control wiring is isolated from power and motor wiring for noise immunity
•
Check the voltage source of the signals, if necessary
•
The use of shielded cable or twisted pair is recommended. Ensure that the shield is terminated
•
correctly
Measure that top and bottom clearance is adequate to ensure proper air flow for cooling
•
Check for proper installation regarding electromagnetic compatibility
•
☑
22
Start Up and Functional Tes...
3
Inspect for Description
Environmental consider-
ations
Fusing and circuit
breakers
Earthing (Grounding)
Input and output power
wiring
Panel interior
Switches
Vibration
Table 3.1 Start Up Check List
See equipment label for the maximum ambient operating temperature limits
•
Humidity levels must be 5-95% non-condensing
•
Check for proper fusing or circuit breakers
•
Check that all fuses are inserted firmly and in operational condition and that all circuit breakers are
•
in the open position
The unit requires an earth wire (ground wire) from its chassis to the building earth (ground)
•
Check for good earth connections (ground connections) that are tight and free of oxidation
•
Earthing (grounding) to conduit or mounting the back panel to a metal surface is not a suitable
•
earth (ground)
Check for loose connections
•
Check that motor and mains are in separate conduit or separated screened cables
•
Inspect that the unit interior is free of dirt, metal chips, moisture, and corrosion
•
Ensure that all switch and disconnect settings are in the proper positions
•
Check that the unit is mounted solidly or that shock mounts are used, as necessary
•
Check for an unusual amount of vibration
•
☑
3
23
Start Up and Functional Tes...
3.2 Applying Power
3
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains. Installation, start-up and
maintenance should be performed by qualified
personnel only. Failure to comply could result in death
or serious injury.
WARNING
UNINTENDED START!
When the frequency converter is connected to AC mains,
the motor may start at any time. The frequency
converter, motor, and any driven equipment must be in
operational readiness. Failure to comply could result in
death, serious injury, equipment, or property damage.
1. Confirm that the input voltage is balanced within
3%. If not, correct input voltage imbalance before
proceeding. Repeat this procedure after the
voltage correction.
2. Ensure that optional equipment wiring, if present,
matches the installation application.
3. Ensure that all operator devices are in the OFF
position. Panel doors should be closed or cover
mounted.
4. Apply power to the unit. DO NOT start the
frequency converter at this time. For units with a
disconnect switch, turn to the ON position to
apply power to the frequency converter.
settings recommended are intended for start up and
checkout purposes. Application settings may vary. See
4 User Interface for detailed instructions on entering data
through the LCP.
Enter data with power ON, but before operating the
frequency converter.
1. Press [Main Menu] twice on the LCP.
2. Use the navigation keys to scroll to parameter
group 0-** Operation/Display and press [OK].
Illustration 3.1 Main Menu
3. Use navigation keys to scroll to parameter group
0-0* Basic Settings and press [OK].
NOTE
If the status line at the bottom of the LCP reads AUTO
REMOTE COASTING or Alarm 60 External Interlock is
displayed, this indicates that the unit is ready to operate
but is missing an input signal on terminal 27. See for
details.
3.3 Basic Operational Programming
3.3.1 Required Initial Frequency Converter
Programming
NOTE
If the wizard is run, ignore the following.
Frequency converters require basic operational
programming before running for best performance. Basic
operational programming requires entering motornameplate data for the motor being operated and the
minimum and maximum motor speeds. Enter data in
accordance with the following procedure. Parameter
Illustration 3.2 Operation/Display
4. Use navigation keys to scroll to 0-03 Regional
Settings and press [OK].
Illustration 3.3 Basic Settings
5. Use navigation keys to select [0] International or
[1] North America as appropriate and press [OK].
(This changes the default settings for a number
of basic parameters. See 5.4 International/North
24
Start Up and Functional Tes...
3
American Default Parameter Settings for a
complete list.)
6. Press [Quick Menu] on the LCP.
7. Use the navigation keys to scroll to parameter
group Q2 Quick Setup and press [OK].
Illustration 3.5 Motor Setup
3
3.5 PM Motor Setup
Illustration 3.4 Quick Menus
8. Select language and press [OK].
9. A jumper wire should be in place between
control terminals 12 and 27. If this is the case,
leave 5-12 Terminal 27 Digital Input at factory
default. Otherwise select No Operation. For
frequency converters with an optional Xylem
bypass, no jumper wire is required.
10. 3-02 Minimum Reference
11. 3-03 Maximum Reference
12. 3-41 Ramp 1 Ramp Up Time
13. 3-42 Ramp 1 Ramp Down Time
14.
3-13 Reference Site. Linked to Hand/Auto* Local
Remote.
3.4 Asynchronous Motor Setup
Enter the motor data in parameters 1-20/1-21 to 1-25. The
information can be found on the motor nameplate.
1. 1-20 Motor Power [kW] or 1-21 Motor
Power [HP]
1-22 Motor Voltage
1-23 Motor Frequency
1-24 Motor Current
1-25 Motor Nominal Speed
CAUTION
Do only use PM motor with fans and pumps.
Initial Programming Steps
1.
Activate PM motor operation 1-10 Motor
Construction, select [1) PM, non salient SPM
2. Make sure to set 0-02 Motor Speed Unit to [0] RPM
Programming motor data
After selecting PM motor in 1-10 Motor Construction, the
PM motor-related parameters in parameter groups 1-2*
Motor Data, 1-3* Adv. Motor Data and 1-4* are active.
The information can be found on the motor nameplate
and in the motor data sheet.
Following parameters must be programmed in the listed
order
1. 1-24 Motor Current
2. 1-26 Motor Cont. Rated Torque
3. 1-25 Motor Nominal Speed
4. 1-39 Motor Poles
5. 1-30 Stator Resistance (Rs)
Enter line to common stator winding resistance
(Rs). If only line-line data are available, divide the
line-line value with 2 to achieve the line to
common (starpoint) value.
It is also possible to measure the value with an
ohmmeter, which will also take the resistance of
the cable into account. Divide the measured
value by 2 and enter the result.
6. 1-37 d-axis Inductance (Ld)
Enter line to common direct axis inductance of
the PM motor.
If only line-line data are available, divide the lineline value with 2 to achieve the line-common
(starpoint) value.
It is also possible to measure the value with an
inductancemeter, which will also take the
inductance of the cable into account. Divide the
measured value by 2 and enter the result.
25
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