BERGES ACP SLV 6000 User Manual

BERGES

Operating manual

SLV

ACP

BERGES Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]

Program Code Summary (Level 1 and 2)

·Level 1 – accesses only basic operator parameters.

·Level 2 – accesses all parameters in Level 1 and Level 2.

·Level 3 – accesses all parameters in Level 1, Level 2 and Level 3.

For more information consult Section 5 and publication “ACP 6000 – Option”.

	PARAMETER		DESCRIPTION	DATA RANGE	FACTORY	ACCESS	SEE	CUSTOMER
	NUMBER	NAME			SETTING	LEVEL	PAGE	SETTING
	01	MODEL	Model Number	0–65000	(1)	1	47
	02	RVLVL	Software Revision	0–640	(1)	2	47
	03	IRAT	Rated Current	2–200 A	(1)	2	47
	05	SERNO	Serial Number	0–65000		2	47
	06	REP	Repair Date	0–65000		2	47
	07	FLT3	Last Fault	–		1	48
	08	FLT2	2nd Fault	–		2	48
	09	FLT1	1st Fault	–		2	48
	12	FOUT	Output Frequency	0–400 Hz		1	48
	13	VOUT	Output Voltage	0–100%		1	48
	14	IOUT	Output Current	0–650 A		1	48
	15	LOAD	Drive Load	0–200%		1	48
	16	TORQ	Load Torque	0–200%		1	48
	17	TEMP	Inverter Temp	2–105 °C		1	48
	18	TIME1	Total Run Time	0–65000 h		2	48
	19	TIME2	Power On Hours	0–65000 h		2	48
	1B	FLUX	Magnetizing Current	0–100%		2	48
	21	MODE	Input Mode	0–36	13	1	49
	24	FSEL	Reference Select	0–19	0	2	49
	27	TLSEL	Torque Limit Select	0–6	0	2	51
	31	FMIN	Minimum Frequency	0.01–400.00 Hz	0.00 Hz	1	51
	32	FMAX	Maximum Frequency	20.00–400.00 Hz	50.00 Hz	1	51
	33	F2	Preset Frequency 2 (Jog)	0.00–400.00 Hz	5.00 Hz	1	51
	34	F3	Preset Frequency 3	0.00–400.00 Hz	20.00 Hz	2	51
	35	F4	Preset Frequency 4	0.00–400.00 Hz	40.00 Hz	2	51
	36	F5	Preset Frequency 5	0.00–400.00 Hz	60.00 Hz (2)	2	51
	37	F6	Preset Frequency 6	0.00–400.00 Hz	0.00 Hz (2)	2	51
	38	F7	Preset Frequency 7	0.00–400.00 Hz	0.00 Hz (2)	2	51
	39	FTL	Minimum Frequency in Torque Limit	0.00–400.00 Hz	10.00 Hz	2	52
	41	RSEL	Ramp Selector	0–7	0	2	52
	42	ACC1	Acceleration Ramp 1	0.10–600.00 s	3.00 s	1	52
	43	DEC1	Deceleration Ramp 1	0.10–600.00 s	3.00 s	1	52
	44	ACC2	Acceleration Ramp 2	0.10–600.00 s	1.00 s	2	52
	45	DEC2	Deceleration Ramp 2	0.10–600.00 s	1.00 s	2	52
	46	DECTL	Torque Limit Response Time	0.10–30.00 s	1.00 s	2	53
	47	DCBRK	DC Brake Time	0.00–5.00 s	0.20 s	2	53
	48	DCVLT	DC Brake Voltage	0.00–15.00%	(1)	2	53

(1)Default value is model dependant.

(2)Parameter adjustable while the drive is in the run mode.

30.10.97	Operating manual
05_GB	ACP 6000SLV — 0.75–55

	BERGES			Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]
	PARAMETER			DESCRIPTION	DATA RANGE	FACTORY	ACCESS	SEE	CUSTOMER
	NUMBER	NAME				SETTING	LEVEL	PAGE	SETTING
	51	VSEL	V/Hz Characteristic Selector		0–6	0	2	53
	52	BOOST		Torque Boost	0.00–20.00%	(1)	1	54
	53	FKNEE		V/Hz Knee Frequency	26.00–640.00 Hz	50.00 Hz	2	54
	54	SKBND	Skip Frequency Hysteresis Band		0.20–20.00 Hz	1.00 Hz	2	54
	55	SK1		Skip Frequency 1	0.00–400.00 Hz	0.00 Hz	2	54
	56	SK2		Skip Frequency 2	0.00–400.00 Hz	0.00 Hz	2	54
	57	SK3		Skip Frequency 3	0.00–400.00 Hz	0.00 Hz	2	54
	58	SK4		Skip Frequency 4	0.00–400.00 Hz	0.00 Hz	2	54
	59	MVOLT		Rated Motor Voltage	370–480 V	400 V	2	55
	5B	IMAG	Rated Magnetizing Current		15.00–80.00%	0.00%	2	55
	61	LTLF		Load Torque Limit FWD	5–200%	150%	2	56
	62	LTLR		Load Torque Limit REV	5–200%	150%	2	56
	63	RTLF	Regenerative Torque Limit FWD		5–110%	80%	2	56
	64	RTLR	Regenerative Torque Limit REV		5–110%	80%	2	56
	65	SLIP		Slip Compensation	0.00–10.00%	0.00%	1	56
	66	STAB		Current Stability	0–6	2	2	56
	67	TOL		Timed Overload Trip Point	0–100%	0%	1	57
	68	NRST		Restart Number	0–8	0	2	57
	69	DRST		Restart Delay	0.00–60.00 s	0.00 s	2	58
	6A	TOLC	Timed Overload Characteristic		0–7	0	2	58
	70	MCAL		Meter Calibration	0–255	Set to	1	58
						10 VDC (2)
	71	METER		Analog Meter Output	0–8	1	1	58
	72	ST1		Auxiliary Output 1	0–11	6	2	59
	73	ST2		Auxiliary Output 2	0–11	3	2	59
	74	ST3		Auxiliary Output 3	0–11	7	2	59
	75	STR		Auxiliary Relay (Fault)	0–11	1	1	59
	77	MOL	Motor Overload Input Function		0–1	0	2	60
	81	PRGNO		Special Program Number	0–65000	0	2	61
	82	START		Inverter Start Options	0–7	0	2	62
	83	PWM	Carrier Frequency Selector		0–8	1	2	62
	84	DISP		Display Option Full Setting	0–65000	0	2	63
	85	UNITS		Display Units	6-digit	RPM 1	2	63
	86	LANG		Display Language	0–3	0	2	64
	87	ACODE		Security Access Code	0–999	0	2	64
	88	FRO	Frequency Reference Output		0–1	0	2	65
	A2	RATIO		Master Slave Speed Ratio	0.00–200.00%	100.00% (2)	2	65
	B1	OPTNO		Option Board Number	0–6	0	2	65
	Cx	CNTLx		Event Control (1–9)	Binary (8)	0 (3)	2
	Ex	ECNTx		Event Counts (1–9)	0–65535	0 (3)	2

NOTES:

Level 1 Parameters shown shaded.

See Section 5 for parameters accessible in Level 3 (SIO control).

(1)Default value is model dependant.

(2)Parameter adjustable while the drive is in the run mode.

(3)Consult BERGES for specific implementation instructions.

Operating manual	30.10.97
ACP 6000SLV — 0.75–55	05_GB

BERGES Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]

30.10.97	Operating manual
05_GB	ACP 6000SLV — 0.75–55

BERGES Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]

Operating manual	30.10.97
ACP 6000SLV — 0.75–55	05_GB

BERGES Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]

Table of contents

			Page
1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 2
	1.0	Safety and operating instructions for drive converters . . . . . . . . . . . . . . . . . . . .	. . 2
	1.1	Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 5
	1.2	Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 5
	1.3	Control Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 5
	1.4	ACP Series Control Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 6
	1.5	ACP Inverter Input/Output Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 10
	1.6	AC Inverter Fundamentals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 10
	1.7	Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 11
2 Installation and enclosure dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			. 12
	2.1	General Rules for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 12
	2.2	Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 14
	2.3	Input AC Line Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 22
	2.3.1	Mains power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 23
	2.3.2	Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 24
	2.3.3	EMC Ordinance (EMC Directive, 89/336 EEC) . . . . . . . . . . . . . . . . . . . . . . . . . .	. 24
	2.3.4	Using mains filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 26
	2.3.5	Interference suppression measures/EMC (electromagnetic compatibility) . . . . .	. 26
	2.4	Line Fuse or Circuit Breaker Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 28
	2.5	Wiring Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 28
	2.6	Reducing Current Surges and Voltage Transients . . . . . . . . . . . . . . . . . . . . . . .	. 29
	2.7	Function and Use of Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 30
	2.8	Environmental Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 33
3 Control Functions and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			. 35
	3.1	General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 35
	3.2	Digital Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 35
	3.3	Operation Mode (STOP and RUN modes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 36
	3.4	Program Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 37
	3.5	Status (LED) Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 37
	3.6	Description of Displays (Operating Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 38
	3.7	Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 41
	3.8	Quick-Start – Running the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 42
	3.9	Programming Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 44
4 Level 1 and 2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			. 45
	4.1	Program Code Summary (Level 1 and 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 45
	4.2	Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 47
	4.3	Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 47
5	Level 3 parameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. 66
	5.1	Program Code Summary (Level 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 66
	5.2	Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 66
	5.3	Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 67
6	Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. 72
	6.1	Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 72
	6.2	Options and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 74
	6.3	Application Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 75
7	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. 77
	7.1	Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 77
	7.2	Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 78
	7.3	Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 80

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05_GB	ACP 6000SLV — 0.75–55

BERGES Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]

1 General information

Explanation of symbols and notes

Work safety symbol

You will find this symbol next to all work safety notes in this operating manual if there is a risk of injury or death for persons involved. Pay attention to these notes and observe particular caution in such cases. Also pass on all work safety instructions to other users.

Voltage warning

This symbol is shown wherever particular caution is necessary owing to occurring or applied voltages (e.g. DC voltages up to 650 V) and where special precautionary measures have to be taken. The inverter must always be isolated from the mains when working on it.

	Caution note
	This note is shown in all parts of this operating manual to which particular attention must be
ATTENTION!
	paid to ensure that the guidelines, specifications, notes and the correct sequence of work
	will be obeyed and to prevent damage or destruction of the inverter and/or systems.

1.0Safety and operating instructions for drive converters

1. General

In operation, drive converters, depending on their degree of protection, may have live, unisolated, and possibly also moving or rotating parts, as well as hot surfaces.

In case of inadmissible removal of the required covers, of improper use, wrong installation or maloperation, there is the danger of serious personal injury and damage to property.

For further information, see documentation.

All operations serving transport, installation and commissioning as well as maintenance are to be carried out by skilled technical personnel (Observe IEC 364 or CENELEC HD 384 or DIN VDE 0100 and IEC 664 or DIN/VDE 0110 and national accident prevention rules!).

For the purposes of these basic safety instructions, “skilled technical personnel” means persons who are familiar with the installation, mounting, commissioning and operation of the product and have the qualifications needed for the performance of their functions.

We draw attention to the fact that no liability can be assumed for damage and malfunctions resulting from failure to observe the operating manual.

Technical amendments of illustrations and data given in this operating manual are reserved in the interest of improving the unit and its functions.

2. Intended use

The application of the drive converter described in this operating manual exclusively serves the purpose of continuously variable speed control of three-phase motors.

Drive converters are components designed for inclusion in electrical installations or machinery.

The drive converters are designed for installation in a switchgear cabinet (applies only to units of protection class IP 00/IP 21) and for permanent connection.

The operator of the system is solely liable for damage resulting from improper use of the drive converter.

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BERGES Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]

Only items expressly approved by BERGES (e.g. mains filter, choke, external braking choppers and braking resistors etc.) may be used as accessories.

The installer of the system is liable for any damage resulting from the use of accessories that have not been approved expressly by BERGES. Please consult us in case of doubt.

In case of installation in machinery, commissioning of the drive converters (i.e. the starting of normal operation) is prohibited until the machinery has been proved to conform to the provisions of the directive 89/392/EEC (Machinery Safety Directive – MSD). Account is to be taken of EN 60204.

Commissioning (i.e. the starting of normal operation) is admissible only where conformity with the EMC directive (89/336/EEC) has been established.

The drive converters meet the requirements of the low-voltage directive 73/23/EEC. They are subject to the harmonized standards of the series prEN 50178/DIN VDE 0160 in conjunction with EN 60439-1/DIN VDE 0660, part 500, and EN 60146/DIN VDE 0558.

The technical data as well as information concerning the supply conditions shall be taken from the rating plate and from the documentation and shall be strictly observed.

3. Transport, storage

The instructions for transport, storage and proper use shall be complied with.

Damage established after delivery must be notified to the transport company immediately. Where necessary, the supplier must also be notified before the damaged drive converter is put into operation.

The climatic conditions shall be in conformity with prEN 50178.

4. Installation

The installation and cooling of the appliances shall be in accordance with the specifications in the pertinent documentation.

The drive converters shall be protected against excessive strains. In particular, no components must be bent or isolating distances altered in the course of transportation or handling. No contact shall be made with electronic components and contacts.

Drive converters contain electrostatic sensitive components which are liable to damage through improper use. Electric components must not be mechanically damaged or destroyed (potential health risks).

5. Electrical connection

When working on live drive converters, the applicable national accident prevention rules (e.g. VBG 4) must be complied with.

The electrical installation shall be carried out in accordance with the relevant requirements (e.g. cross-sectional areas of conductors, fusing, PE connection). For further information, see documentation.

Instructions for the installation in accordance with EMC requirements, like screening, earthing, location of filters and wiring, are contained in the drive converter documentation. They must always be complied with, also for drive converters bearing a CE marking. Observance of the limit values required by EMC law is the responsibility of the manufacturer of the installation or machine.

6. Operation

The components of the power section and certain elements of the control section are connected to the voltage mains when the drive converter is connected to the mains voltage.

Touching these components involves mortal danger!

Always isolate the drive converter from the mains supply before performing any work on the electrical or mechanical part of the system.

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05_GB	ACP 6000SLV — 0.75–55

BERGES Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]

Isolate the drive converter from the mains before removing the terminal cover or the housing (e.g. by removing or deactivating on-site fuses or by deactivating a master switch isolating all poles etc.).

After disconnection of the drive converters from the voltage supply, live appliance parts and power terminals must not be touched immediately because of possibly energized capacitors. In this respect, the corresponding signs and markings on the drive converter must be respected. After switching off the mains voltage, wait for at least 5 minutes before beginning work on or in the drive converter. Dangerous voltages are still present as long as the “BUS CHG” lamp is still lit. In the event of malfunctions, the discharge time of 5 minutes may be exceeded substantially.

The drive converter contains protective facilities that deactivate it in the event of malfunctions, whereby the motor is de-energized and comes to a standstill (so-called “coasting” of the motor is possible depending on the rotating mass of the type of drive involved). Standstill of the motor can, however, also be produced by mechanical blockage. Voltage fluctuations, and particularly mains power failures, may also lead to deactivation. In certain circumstances, the drive may start up automatically once the cause of the fault has been remedied. As a result of this, certain systems may be damaged or destroyed and there may be a risk for operators working on the system. Installations which include drive converters shall be equipped with additional control and protective devices in accordance with the relevant applicable safety requirements, e.g. Act respecting technical equipment, accident prevention rules etc. Changes to the drive converters by means of the operating software are admissible.

The motor may be stopped during operation by disabling it or by deactivating the setpoint, whereby the drive converter and motor may remain live. If inadvertent startup of the motor must be excluded to protect operating personnel, electronic interlocking by disabling the motor or by deactivating the setpoint is inadequate. This is why the drive converter must be isolated from the mains voltage.

During operation, all covers and doors shall be kept closed.

Measuring instruments must be connected and disconnected only in de-energized condition.

Unauthorized conversions or modifications on or in the drive converter and its components and accessories will render all warranty claims void.

When installing an option board, observe the installation specification valid for this board.

Please contact BERGES if conversions or modifications are necessary, particularly if electrical components are involved.

7. Maintenance and servicing

The manufacturer’s documentation shall be followed.

KEEP SAFETY INSTRUCTIONS IN A SAFE PLACE!

Before you read on, please check whether technical changes are attached in the annex to this operating manual!

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BERGES Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]

1.1Preface

	This manual contains the specifications, installation instructions, description of operation and
	troubleshooting procedure for the ACP 6000 AC inverter. Before installing the drive, read this
	manual carefully to ensure correct installation and maximum performance. The information
	contained in this manual is current for versions fitted with drive software series 4.43 (02-RVLVL).
	Display Language
	With the parameter 86-LANG you can select the display language, see page 64.
HINT!

1.2Inspection

A.Upon receipt of the product, unpack the AC inverter and carefully inspect for any damage sustained in transit (depression in the enclosure, damage to parts, missing parts).

B.Next remove the AC Inverter cover, if supplied, and inspect for any loose screws, nuts or connectors.

C.Read the technical data plate and verify the correct power size for the application and note the input voltage and current required for the inverter.

D.If the inverter is to be stored for a long period of time, repack the inverter and store in a clean dry place, free from direct sunlight or corrosive fumes, and in a location where the ambient temperature will not be less than -20 °C nor more than 60 °C.

1.3Control Identification Number

Asystematic numbering system is used to define all models by input voltage rating, power rating, and enclosure type. This model number appears both on the shipping carton label and the technical data label on the enclosure. A model number code is also accessible in the Level 1 programming mode (Refer page 47, 01-MODEL).

ACP 6007-5A

ACP

6

007-5

A

BERGES inverter type:

Input volts:

6

= 400 V AC

460 V AC

KW:

007-5

= 7.5 kW

Housing:

A

= IP 00

C = IP 21/IP 54

Example Control Identification Number

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05_GB	ACP 6000SLV — 0.75–55

BERGES Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]

The different power ratings available and code for each rating are as follows:

CODE	KW	PS	3 ´ 400 V
6000-7	0.75	1.0	X
6001-5	1.5	2.0	X
6002-2	2.2	3.0	X
6003-0	3.0	4.0	X
6004-0	4.0	5.0	X
6005-5	5.5	7.5	X
6007-5	7.5	10.0	X
6011-0	11.0	15.0	X
6015-0	15.0	20.0	X
6022-0	22.0	30.0	X
6030-0	30.0	40.0	X
6037-0	37.0	50.0	X
6045-0	45.0	60.0	X
6055-0	55.0	75.0	X

Table 1.3

1.4ACP Series Control Specifications

		MODEL SERIES	ACP 6000	SEE
				PAGE
	Applicable	Horsepower (PS)	1–75.	–
	Motor Output
		Kilowatt (kW)	0.75–55.	10
	Inverter Output	Capacity (kVA)	1.5–135.0.	10
	Ratings
		Continuous Amps (A)	2–121.	10
		Output Voltage	3 ´ 7.0–460 VAC.	–
		(Source limited)
		Frequency Range	Programmable 0.1–400 Hz.	51, 62
		Overload Capacity at	150% for 60 Seconds;	57, 58
		40 °C Ambient	120% for 90 Seconds.
		Running Torque	More than 100% (Programmable) + autoboost.	54
		Efficiency at Rated	Greater than 95%.	–
		Outputs
	Inverter Input	Input Voltage	±10% at 400–460 V.	10, 22
	Ratings	(3Æ inputs all 3-wire)
		Input Current at	2.2–152.8 A.	10
		Maximum Rated Output
		(AC amperes)
		KVA at 50/60 Hz	1.8–122.0.	10
		Input Frequency	50/60 Hz ±10%.	–
		Phase Imbalance	2% maximum.	22
	Control	Control System	Sine weighted Pulse Width Modulation with	–
	Specifications		Application Specific Integrated Circuit.
		Frequency Range	4000:1; 0.1–400 Hz (Programmable).	51, 62

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		MODEL SERIES	ACP 6000	SEE
				PAGE
	Control	Frequency Command	0–10 VDC or 0–2 VDC (100 kW),	30, 49
	Specifications	Selections	4–20 mA (237 W),
			0–1 kHz or 0–10 kHz pulse train,
			Ext. Potentiometer,
			Digital Keypad,
			RS 485 Serial Communication Link.
		Frequency Resolution	0.01 Hz.	–
		Frequency Stability	Analog +0.2%,	–
			0–1 kHz pulse train +0.4%,
			0–10 kHz pulse train +0.1%,
			Keypad +0.1%,
			RS 485 Port +0.1%.
		V/Hz Ratio	Programmable using FKNEE function	54
			(0.01 Hz resolution)
			400 VAC output models – 0.72 to 17.69.
		Acceleration/Deceleration	Programmable – 0.1 to 600 seconds to maximum	52
		Ramps	frequency (primary and alternate available).
		Minimum Frequency	Programmable – 0.5 to 400 Hz (0.01 Hz increments).	51
		Maximum Frequency	Programmable – 20 to 400 Hz (0.01 Hz increments).	51
		Torque Limit	Four Quadrant Programmable –	51, 56
			5 to 200% torque (motoring mode);
			5 to 110% torque (regenerative mode);
			Individual program settings for FWD run, FWD regen,
			REV run, and REV regen.
		Torque Limit Deceleration	Programmable – 0.1 to 30 Seconds.	53
		Rate
		Minimum Frequency in	Programmable – 0.5 to 400 Hz.	52
		Torque Limit
		Torque Boost	Programmable to suit requirements plus Autoboost.	53, 54
		Dynamic Braking	30–200% of drive rating (10 sec. max.) standard.	–
			Consult BERGES for model specific data. Additional
			capacity available by adding external DB kits.
		Adjustments	Over 100 parameters can be monitored with over 80	–
			user adjustments.
		PWM Frequencies	Two settings available.	62
		Agency Listing	, UL® and CUL® Listed.	–
	Protection	Charge Indicator	Indicates the presence of potentially lethal bus voltage.	31
	Features
		Ground Fault	All models fully protected.	–
		Output Short Circuit	All models fully protected.	–
		(Line-to-Line)
		Electronic Motor Overload	Programmable Inverse Time Overload Trip.	57, 58
		Overvoltage Trip Level	763 VDC.	–
		(on DC bus)
		Undervoltage Trip Level	395 VDC.	–
		(on DC bus)

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		MODEL SERIES		ACP 6000	SEE
					PAGE
	Protection		Torque Limit	4-Quadrant – Independently Programmable.	51, 56
	Features
		Program Lockout		User definable security access code.	64
		Line Start Lockout		Prevents automatic start-up when line power is	62
				applied (defeatable by programming).
		Overtemperature		Drive will shutdown if heat sink temperature exceeds	–
				rating.
			DB Failure	Drive will sense circuit failure and shutdown.	–
		Error/Fault Messages		19 fault codes, 6 warning displays.	77
			Fault Storage	Last three (3) faults stored. Most recent displayed.	48
		Line Transient Limit		2 kV Maximum (less than 40 microsecond duration).	–
		External MOL Contact		Compatible with NC fault contact.	60
	Operating	Operating Controls		1. Keypad: Forward, Reverse, Jog, Stop, Program,	35
	Features			Shift, Enter, Local/Remote and Up/Down Arrows.
				2. Terminal strip: See typical connection diagrams	32
				(Page 72).
				3. RS 485 Serial Input/Output (SIO) Link.	66
			LED Indicators	Forward, Reverse, Jog, Stop, Bus Charged and CPU	37
				active.
			Display	2-lines of 16 characters, Super-Twist alphanumeric	38, 63, 64
				for all modes of operation.
				Programmable to display in English, French, Spanish
				or German.
				Any engineering units such as RPM, FPM, and GPM
				are supported.
			Auxiliary Relay	Programmable as Fault Relay or to signal one of	33, 59
				eleven conditions.
	Programming	Programming Levels		Level 1 – Operator;	45, 66
				Level 2 – Engineer;
				Level 3 – Engineer with SIO.
		Parameter Block 00		Model #, software revision, rated current, heat sink	–
			Drive Data	temperature trip point, mfg. serial #, repair date code,
				and fault log.
		Parameter Block 10		Output frequency, voltage, motor current, motor load,	–
			Status	torque, drive temperature, elapsed time since power
				applied, and total hours of operation.
		Parameter Block 20		Definition of the LOCal/REMote keypad button in	–
			Control	reference to the keypad, terminal strip, and the SIO
				link. Also, various speed and torque references are
				contained within this block.
		Parameter Block 30		Various speed setpoints of the inverter.	–
			Frequencies
		Parameter Block 40		Ramp time selections (the time from start to	–
			Ramps	maximum frequency FMAX or from FMAX to stop).
		Parameter Block 50		V/Hz curves, boost, minimum frequency at full	–
		Voltage/Frequency		voltage, and skip frequencies.
			Characteristics

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BERGES

Berges electronic · D–51709 Marienheide-Rodt · Tel. [phone] · Fax [phone]

MODEL SERIES

ACP 6000

SEE

PAGE

Programming

Parameter Block 60

Torque limit setpoints, slip compensation, overload

–

Torque Limit

trip point, and auto-restart parameters.

Parameter Block 70

METer output, open collector output, and fault relay

–

I/0 Definition

definitions.

Parameter Block 80

Storage and Retrieval of standard or custom

–

Program Options

programs, complete reset to factory settings, auto-

restart, line start-lockout, PWM selection, display of

engineering units, alternate display languages, and

customer access code storage.

Parameter Block 90

BAUD or communication rate, slave address,

–

RS 485 Serial Link

watchdog timer and retrieval of SIO generated fault

Options

codes.

Parameter Block A0

Speed Ratio and various parameters relative to the

–

Option Parameters

calibration of option cards (WPC).

Parameter Block B0

Option Board Identification and various parameters

–

Option Parameters

relative to the calibration of option cards (WPC).

Parameter Block C0

Used with program sequencer to control drive

–

Event Control Bytes

operation.

Parameter Block E0

Used with program sequencer to control drive

–

Event Count Bytes

operation.

Construction

IP 00, IP 21, IP 54

IP 54 standard thru 37 kW.

–

Mounting

IP 00 and IP 21

In separate enclosure free from dust, liquids and

12

Location

corrosive fumes.

IP 54

Indoor or Outdoor protected from direct sunlight.

12, 33

Ambient

Operating Temperature

IP 00 – 0 °C to 50 °C;

–

Conditions

IP 21/IP 54 – 0 °C to 40 °C.

Storage Temperature

-20 °C to +60 °C.

–

Humidity

90% RH or less, noncondensing.

–

Vibration

0.6 G Maximum.

–

Elevation

Below 1000 m without derating.

–

Table 1.4

DIMENSIONS/WEIGHT

Type

6000-7

6001-5

6002-2

6003-0

6004-0

6005-5

6007-5

6011-0

6015-0

6022-0

6030-0

6037-0

6045-0

6055-0

Dimensions (IP 00)

mm

221 ´ 301 ´ 135

229 ´ 441 ´ 203

356 ´

406 ´733 ´298

(W ´ H ´ D)

619 ´ 298

Weight (IP 00)

kg

5,5

11,5

35,0

39,0

Dimensions (IP 54)

mm

227 ´ 307 ´ 142

229 ´ 449 ´ 210

365 ´

417 ´

(W ´ H ´ D)

619 ´ 306

733 ´ 306

Weight (IP 54)

kg

6,0

12,5

44,0

51,0

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1.5ACP Inverter Input/Output Ratings

AC RATINGS BY MODEL NUMBERS

		Input ratings				Maximum motor ratings
		Continuous			Continuous		1 min at 40 °C (2)
Inverter type	KW	KVA (5)	A		KVA	A (1)	KVA	A
6000-7	0.75	1.8	2.2		1.6	2.0	2.4	3.0
6001-5	1.5	3.4	4.3		2.9	3.7	4.4	5.6
6002-2	2.2	4.9	6.2		4.4	5.5	6.6	8.3
6003-0	3.0	5.5	7.0		4.9	7.0	7.4	10.5
6004-0	4.0	8.6	10.8		7.2	9.0	10.8	13.5
6005-5	5.5	12.8	16.0		10.4	13.0	15.5	19.5
6007-5	7.5	17.7	22.2		14.3	18.0	21.5	27.0
6011-0	11.0	24.7	31.0		19.1	24.0	28.7	36.0
6015-0	15.0	30.2	37.9		23.9	30.0	35.9	45.0
6022-0	22.0	45.3	56.8		35.9	45.0	53.8	67.5
6030-0	30.0	61.4	77.1		48.6	61.0	72.9	91.5
6037-0	37.0	75.5	94.7		59.8	75.0	89.6	112.5
6045-0	45.0	90.0	112.0		71.0	90.0	106.4	133.5
6055-0	55.0	111.0	134.0		88.0	110.0	131.5	165.0
			Table 1.5

NOTES:

1)Value stored in parameter 03-IRAT. Wire size must be selected based upon 60/75 °C copper wire insulation rating.

2)For chassis models (IP 00), ratings are for 1 minute at +50 °C (40 °C external ambient when enclosed).

3)Control rated for 110% of motor rating (Continuous).

4)Motor thermal overload relay rating – 1.1 ´ continuous motor nameplate amps (necessary only in multimotor applications).

5)If the kVA rating of the power source exceeds ten times this value, the use of an isolation transformer or a line inductor is recommended.

1.6AC Inverter Fundamentals

The principal of operation of the ACP or any AC Inverter, is to provide both an adjustable voltage and an adjustable frequency to the AC motor. The ACP automatically maintains the required volts/hertz ratio, allowing the AC motor to run at its optimum efficiency and providing rated torque capability throughout the motor’s speed range.

The basic formula that relates the output frequency to motor speed is:

NS =	60 × f
	P
NS = Synchronous Speed (RPM) f = Frequency (Hertz)			P = Number of pairs of poles.
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For Induction Motors:

Motor RPM = Synchronous Speed–Motor Slip (RPM).

The number of pairs of poles of a particular motor, and the amount of slip for a given load torque, are set by the motor’s design and manufacturer.

1.7Description of Operation

The primary functional blocks of the inverter are outlined in Figure 1.7.

The ultimate goal of any inverter is to accept fixed voltage and frequency from a power source and convert this power into variable voltage and frequency to control a three phase AC induction motor. The ACP 6000 does this and much more. It allows the user to interface into the very powerful electronics necessary to provide variable speed control of the motor, in a very friendly fashion.

Signals can be introduced to the terminal strip for full or partial control of the inverter. The powerful serial input output (SIO) link is available for total communication and programming. The keypad provides total control of programming and drive operation.

LINE INPUTS	PRE-CHARGE	DC BUS
			MOTOR
	RECTIFIER	DC	OUTPUTS
		BRAKE
			INVERTER BRIDGE

M 3~

	TEMPERATURE	POWER SUPPLY	VOLTAGE	CURRENT	DRIVER ELECTRONICS
	MEASUREMENT	AND MONITOR	MEASUREMENT	MEASUREMENT
		RAMP	CURRENT	PWM-
		GENERATOR	CONTROL	GENERATOR
		CONTROL		U/F-
	SIGNAL	FUNCTIONS		CHARACTERISTIC
	CONDITIONING
		CONTROL		DIAGNOSIS
		AND PARAMETER
		BLOCK
					CPU
	SERIAL	KEYPAD AND DISPLAY		OPTION BOARD
	LINK (SIO)

Figure 1.7

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2 Installation and enclosure dimensions

2.1General Rules for Installation

Improper installation of the inverter will greatly effect its life. Be sure to observe the following points when selecting a mounting location:

A.Mount the unit vertically and do not restrict the airflow to the heat sink fins on the back of the controller. The fan and fins allow cooling of internal components. Any air restriction could greatly reduce the life of the inverter, as well as resulting in nuisance overtemperature trips.

B.If the inverter has to be installed in a different position, external cooling is required for full capacity utilization.

C.The ACP inverter generates heat, and therefore there must be a sufficient amount of free space around the unit (see Figure 2.1). If the unit is accommodated in a housing together with a different unit, the prescribed minimum distances must be observed so that adequate ventilation can be ensured.

Figure 2.1

D.Do not install the inverter in a place subjected to high temperature, high humidity, or excessive vibration (consult Table 1.4 for temperature, humidity and maximum vibration limits).

E.Do not mount the ACP near heat generating equipment, or in direct sunlight.

F.BERGES inverters are generally designed so that they can be operated at ambient temperatures of 0 °C to +50 °C (IP 00) or 0 °C to 40 °C (IP 21/54) and at a relative humidity of up to 90%.

The occurrence of condensate must be avoided!

G.Please contact BERGES if the above values are exceeded. Therefore, when installing the unit, you must ensure that a heat buildup is prevented. In certain circumstances, the internal air circulation does not suffice when installing the unit in a control cabinet with a small volume.

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H. The units should never be installed in the proximity of corrosive or flammable gases,

		conductive dust or large magnetic and electric fields.
	I.	Pay close attention during installation to ensuring that no objects (such as drilling swarf,
		wire or anything else) fall into the unit. Otherwise, a device fault cannot be excluded, even
		after longer periods of operation.
ATTENTION!	J.	Do not use wire end ferrules for the control terminals. The terminals are designed

so that the wires can be inserted in the terminals after twisting the individual wires.

K. Line starting

ACP is designed to provide controlled starting and stopping of AC motors by use of the keypad or external contacts connected to the control terminal strip. ACP may also be started by applying AC power to terminals L1, L2 and L3. The inverter has line-start-lock- out as a standard feature, to prevent automatic starting when line power is applied. This provision can be defeated by appropriate programming. The inverter may be started once every two minutes in this mode.

The safety of the operating personnel must be guaranteed in all operating states. Please refer to the safety instructions in chapter 1.0, page 2. The mains voltage must be switched off before opening or working on the device. Dangerous voltages are present as long as the charge indicator lamp is still lit.

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2.2Dimensional Data

The following pages show the dimensional data for the IP 00, IP 21 and IP 54 ACP inverters.

ACP 6000 – 0.75...4.0 kW (IP 21/IP 54)

227

200	142
14	3
14

307 280

BERGES

22

7

80

42

38

77

Figure 2.2.1

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ACP 6000 – 0.75...4.0 kW (IP 00)

221

	200	135
10	10	3

301 280

22

7

80

42

38

77

Figure 2.2.2

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ACP 6000 – 5.5...15.0 kW (IP 21/IP 54)

229

200

210

15	14

449 419

BERGES

9

29

119

49	51
	102
	Figure 2.2.3
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ACP 6000 – 5.5...15.0 kW (IP 00)

229

200

203

14

11

441 419

9

29

119

49 51

102

Figure 2.2.4

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ACP 6000 – 22...30 kW (IP 21/IP 54)

365

327

306

9 21

619 600

BERGES

10

35

220

75	89
	178
	Figure 2.2.5
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ACP 6000 – 22...30 kW (IP 00)

356

327

298

9 14

619 600

10

Figure 2.2.6

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ACP 6000 – 37...55 kW (37 kW = IP 21 or IP 54; 45...55 kW = only IP 21)

417

378

306

21

12

733 711

BERGES

12

35

220

75	89
	178
	Figure 2.2.7
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ACP 6000 – 37...55 kW (IP 00)

406

378

298

14

12

733 711

12

Figure 2.2.8

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