BONFIGLIOLI ACT 201-07, ACT 201-13, ACT 201-09, ACT 201-11, ACT 201-15 Brief Manual

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ACTIVE

Brief manual Frequency Inverter 230 V / 400 V

0.55 kW ... 30.0 kW

06/05 1

General Information about the Documentation

The present documentation refers to the frequency inverters ACT 201 and ACT 401 series. With their factory settings, both series of devices are suited for a wide range of applications. The modular hardware and software structure enables customerspecific adaptation of the frequency inverters. Applications with high functionality and dynamism requirements can be realized easily.

In order to make it as easy as possible for the user to find his/her way through the

documentation, it is structured according to the customer-specific demands made of the frequency inverter.

Brief Instructions The Brief Instructions describe the basic steps required for mechanical and electrical

installation of the frequency inverter. The guided commissioning supports you in the selection of necessary parameters and the configuration of the frequency inverter by the software.

Operating Instructions The Operating Instructions describe and document all functions of the frequency

inverter. The parameters required for adapting the frequency inverter to specific applications as well as the wide range of additional functions are described in detail.

Application Manual The Application Manual contains additional information facilitating the installation and

commissioning of the frequency inverter, i.e. information on the different issues relating to the specific application realized by the frequency inverter.

Installation Instructions

Complementing the Brief Instructions and the Operating Instructions, the Installation Instructions provide information on how to install and use the additional/optional components.

If you need a copy of the documentation or additional information, contact your

representative of BONFIGLIOLI.

The following pictograms and signal words are used in the documentation:

Danger!

Danger refers to an immediate threat. Non-compliance with the precaution described will result in death, serious injury or material damage.

Warning!

Warning refers to a possible threat. Non-compliance with the warning may result in death, serious injury or material damage.

Caution!

Caution refers to an immediate hazard. Non-compliance may result in personal or material damage.

Attention!

Attention and the related text refer to a possible behavior or an undesired condition which can occur during operation.

Note

Note and the related text provide useful information which supplements the corresponding part of the documentation.

06/052

TABLE OF CONTENTS

TABLE OF CONTENTS............................................................................................................ 2

1 General Safety Instructions and Information on Use.................................................... 4

1.1 General Information ................................................................................................ 4

1.2 Purpose of the Frequency Inverters ........................................................................ 5

1.3 Transport and Storage ............................................................................................. 5

1.4 Handling and Installation ........................................................................................ 5

1.5 Electrical Connection ............................................................................................... 6

1.6 Information on Use.................................................................................................. 6

1.7 Maintenance and Service......................................................................................... 6

2 Scope of Supply.............................................................................................................. 7

2.1 Frequency Inverter (0.55 to 4.0 kW)....................................................................... 7

2.2 Frequency Inverter (5.5 to 15 kW).......................................................................... 8

2.3 Frequency Inverter (18.5 to 30 kW)........................................................................ 9

3 Technical Data.............................................................................................................. 10

3.1 Frequency Inverter 230 V (0.55 to 3.0 kW) .......................................................... 10

3.2 Frequency Inverter 400 V (0.55 to 4.0 kW) .......................................................... 11

3.3 Frequency Inverter 400 V (5.5 to 15.0 kW) .......................................................... 12

3.4 Frequency Inverter 400 V (18.5 up to 30 kW) ...................................................... 13

3.5 Operation diagrams ............................................................................................... 14

4 Mechanical Installation................................................................................................ 15

4.1 Frequency Inverter (0.55 to 4.0 kW)..................................................................... 16

4.2 Frequency Inverter (5.5 to 15 kW)........................................................................ 17

4.3 Frequency Inverter (18.5 to 30 kW)...................................................................... 18

5 Electrical Installation ................................................................................................... 19

5.1 EMC Information.................................................................................................... 20

5.2 Block diagram ........................................................................................................ 21

5.3 Mains Connection .................................................................................................. 22

5.3.1 Frequency Inverter (0.55 to 4.0 kW) ....................................................................... 22

5.3.2 Frequency Inverter (5.5 to 15.0 kW) ....................................................................... 23

5.3.3 Frequency Inverter (18.5 to 30 kW) ........................................................................ 24

5.4 Motor Connection .................................................................................................. 24

5.4.1 Frequency Inverter (0.55 to 4.0 kW) ....................................................................... 25

5.4.2 Frequency Inverter (5.5 to 15 kW) .......................................................................... 26

5.4.3 Frequency Inverter (18.5 to 30 kW) ........................................................................ 27

5.5 Connection of a Brake Resistor ............................................................................. 28

5.5.1 Frequency Inverter (0.55 to 4.0 kW) ....................................................................... 28

5.5.2 Frequency Inverter (5.5 to 15 kW) .......................................................................... 28

5.5.3 Frequency Inverter (18.5 to 30 kW) ........................................................................ 29

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TABLE OF CONTENTS

5.6 Control Terminals .................................................................................................. 29

5.6.1 Relay Output......................................................................................................... 30

5.6.2 Control Terminals – Terminal Diagram..................................................................... 31

5.6.2.1 Configuration 110 – Sensorless Control ............................................................. 31

5.6.2.2 Configuration 410 – Sensorless Field-Oriented Control........................................ 32

5.7 Optional Components ............................................................................................ 33

6 Control Unit KP500 ...................................................................................................... 34

6.1 Actual Value Menu (VAL) ....................................................................................... 35

6.2 Parameter Menu (PARA)........................................................................................ 36

6.3 Controlling the Motor via the Control Unit ............................................................ 37

7 Commissioning of the Frequency Inverter................................................................... 39

7.1 Switching on Mains Voltage .................................................................................. 39

7.2 Setup Using the Control Unit ................................................................................. 39

7.2.1 Configuration ........................................................................................................40

7.2.2 Data Set ............................................................................................................... 40

7.2.3 Motor Type ........................................................................................................... 40

7.2.4 Machine Data ........................................................................................................ 41

7.2.5 Plausibility check ................................................................................................... 41

7.2.6 Parameter identification ......................................................................................... 43

7.2.7 Application data..................................................................................................... 45

7.2.7.1 Acceleration and deceleration........................................................................... 45

7.2.7.2 Set points at multi-functional input ................................................................... 45

7.2.8 Selection of an actual value for display .................................................................... 46

7.3 Check direction of rotation .................................................................................... 46

8 Basic parameters.......................................................................................................... 47

8.1 Menu branch PARA ................................................................................................ 47

8.2 Menu branch VAL ................................................................................................... 50

9 Operational and error diagnosis .................................................................................. 51

9.1 Status message...................................................................................................... 51

9.2 Warning message .................................................................................................. 51

9.3 Fault message ........................................................................................................ 52

06/054

1 General Safety Instructions and Information on Use

Warning! The specifications and instructions contained in the documentation must

be complied with strictly during installation and commissioning. Only qualified staff who has read the documentation and, in particular, the safety instructions carefully is allowed to carry out installation or commissioning work or to operate the frequency inverters. The term „Qualified Staff“ refers to anybody who is familiar with the installation, assembly, commissioning and operation of the frequency inverter and has the proper qualification for the job.

The present documentation was prepared with great care and it was subjected to extensive and repeated reviews. For reasons of clarity, it was not possible to include all details of all the different types of the product in the documentation. Neither was it possible to consider all conceivable installation, operation or maintenance situations. If you require further information or if you meet with specific problems which are not dealt with in sufficient detail in the documentation, contact your local BONFIGLIOLI agent. We would also like to point out that the contents of this documentation do not form part of any previous or existing agreement, assurance or legal relationship. Neither are they intended to supplement or replace such agreements, assurances or legal relationships. The manufacturer's obligations are exclusively specified in the relevant purchase contract. This contract also contains all and any warranty regulations which may apply to the relevant scope of supply. These contractual warranty provisions are neither extended nor limited by the specifications contained in this documentation. The manufacturer reserves the right to correct or amend the specifications, product information and omissions in these operating instructions without notice. The manufacturer shall not be liable for any damage, injuries or costs which may be caused by the aforementioned reasons.

1.1 General Information

Warning! The DC-link circuit of the frequency inverter is charged during operation,

i.e. there is always the risk of contact with high voltage. Frequency inverters are used for driving moving parts and they may become hot at the surface during operation. Any unauthorized removal of the necessary covers, improper use, wrong installation or operation may result in serious injuries or material damage. In order to avoid such injuries or damage, only qualified staff may carry out the transport, installation, setup or maintenance work required. The standards EN 50178, IEC 60364 (Cenelec HD 384 or DIN VDE 0100), IEC 60664-1 (Cenelec HD 625 or VDE 0110-1), BGV A2 (VBG 4) as well as the applicable national regulations must be complied with. The term „Qualified Staff“ refers to anybody who is familiar with the installation, assembly, commissioning and operation of the frequency inverter as well as the possible hazards and has the proper qualification for the job.

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1.2 Purpose of the Frequency Inverters

Warning! The frequency inverters are electrical drive components intended for

installation in industrial plants or machines. Commissioning and start of operation is not allowed until it has been verified that the machine meets the requirements of the EC Machinery Directive 98/37/EEC and EN 60204. In accordance with the CE marking requirements, the frequency inverters comply with the Low Voltage Directive 72/23/EEC as well as EN 50178 / DIN VDE 0160 and EN 61800-2. The user shall be responsible for making sure that the requirements of the EMC Directive 89/336/EEC are met. Frequency inverters are only available at specialized dealers and are exclusively intended for professional use as per EN 61000-3-2. The frequency inverters are also marked with the UL label according to UL508c, which proves that they also meet the requirements of the CSA Standard C22.2-No. 14-95. The technical data, connection specifications and information on ambient conditions are indicated on the name plate and in the documentation and must be complied with in any case. Anyone involved in any kind of work at the device must have read the instructions carefully and understood them before starting the work.

1.3 Transport and Storage

The frequency inverters must be transported and stored in an appropriate way.

During transport and storage the devices must remain in their original packaging. The units may only be stored in dry rooms which are protected against dust and moisture and are exposed to small temperature deviations only. Observe the climatic conditions according to EN 50178 and the marking on the packaging. The units must not be stored for more than one year without connecting them to the rated mains voltage.

1.4 Handling and Installation

Warning! Damaged or destroyed components must not be put into operation

because they may be a health hazard.

The frequency inverters are to be used in accordance with the documentation as well

as the applicable directives and standards. They must be handled carefully and protected against mechanical stress. Do not bend any components or change the isolating distances. Do not touch electronic components or contacts. The devices are equipped with components which are sensitive to electrostatic energy and can easily be damaged if handled improperly. Any use of damaged or destroyed components shall be considered as a non-compliance with the applicable standards. Do not remove any warning signs from the device.

06/056

1.5 Electrical Connection

Warning! Before any assembly or connection work, discharge the frequency

inverter. Verify that the frequency inverter is discharged. Do not touch the terminals because the capacitors may still be charged. Comply with the information given in the operating instructions and on the frequency inverter label.

When working at the frequency inverters, comply with the applicable standards BGV

A2 (VBG 4), VDE 0100 and other national directives. Comply with the electrical installation instructions given in the documentation as well as the relevant directives. Responsibility for compliance with and examination of the limit values of the EMC product norm EN 61800-3 for variable-speed electrical drive mechanisms is with the manufacturer of the industrial plant or machine. The documentation contains information on EMC-conforming installation. The cables connected to the frequency inverters may not be subjected to high-voltage insulation tests unless appropriate circuitry measures are taken before. Otherwise the frequency inverter may be damaged.

1.6 Information on Use

Warning! The frequency inverter may be connected to power supply every 60 s

only. Otherwise the unit may be damaged. For this reason, a jog operation of a mains contactor is not permissible. For commissioning or after an emergency stop, a non-recurrent, direct restart is permissible. After a failure and restoration of the power supply, the motor may start unexpectedly if the Auto-Start function is activated. Before commissioning and the start of the operation fix all covers and check the terminals. Check the additional monitoring and protective devices according to EN 60204 and applicable the safety directives (e.g. Working Machines Act, Accident Prevention Directives etc.). No connection work may be performed, while the system is in operation.

1.7 Maintenance and Service

Warning! Unauthorized opening and improper interventions can lead to personal

injury or material damage. Repairs on the frequency inverters may only be carried out by the manufacturer or persons authorized by the manufacturer. Check protective equipment regularly.

06/05 7

2 Scope of Supply

Thanks to the modular hardware components, the frequency inverters can be

integrated in the automation concept easily. The scope of delivery described can be supplemented by optional components and adapted to the customer-specific requirements. The plug-in type connection terminals enable a safe function and an economical assembly.

2.1 Frequency Inverter (0.55 to 4.0 kW)

ACT 201 (230 V) and ACT 401 (400 V)

Power range 0.55 kW to 4.0 kW

Scope of Supply

Frequency inverter

Terminal strip X1 (Phoenix ZEC 1,5/ST7,5) Plug-in terminals for mains connection and DC linking

Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0) Plug-in terminals for the relay output

Standard fixtures for vertical assembly

Brief Instructions and manuals on CD

Terminal strip X2 (Phoenix ZEC 1,5/ST7,5) Plug-in terminal for brake resistor and motor connection

Control terminals X210A / X210B (Wieland DST85 / RM3.5) Plug-in terminal for connection of the control signals

Note: Please check incoming goods for quality, quantity and nature without

delay. Obvious defects such as exterior damage of the packing and/or the unit must be notified to the sender within seven days for insurance reasons.

06/058

2.2 Frequency Inverter (5.5 to 15.0 kW)

ACT 401 (400 V)

Power range 5.5 kW to 15 kW

Scope of Supply

Frequency inverter

Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0) Plug-in terminals for the relay output

Standard fixtures with fixing bolts (M4x20, M4x60) for vertical assembly

Brief Instructions and manuals on CD

Control terminals X210A / X210B (Wieland DST85 / RM3.5) Plug-in terminal for connection of the control signals

Note: Please check incoming goods for quality, quantity and nature without

delay. Obvious defects such as exterior damage of the packing and/or the unit must be notified to the sender within seven days for insurance reasons.

06/05 9

2.3 Frequency Inverter (18.5 to 30.0 kW)

ACT 401 (400 V)

Power range 18.5 kW to 30 kW

Scope of Supply

Frequency inverter

Terminal strip X10 (Phoenix ZEC 1.5/3ST5.0) Plug-in terminals for the relay output

Standard fixtures with fixing bolts (M4x20, M4x70) for vertical assembly

Brief Instructions and manuals on CD

Control terminals X210A / X210B (Wieland DST85 / RM3.5) Plug-in terminal for connection of the control signals

Note: Please check incoming goods for quality, quantity and nature without

delay. Obvious defects such as exterior damage of the packing and/or the unit must be notified to the sender within seven days for insurance reasons.

06/0510

3 Technical Data

3.1 Frequency Inverter 230 V (0.55 to 3.0 kW)

Type

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

Output, motor side

Recommended shaft output P kW 0.55 0.75 1.1 1.5 2.2 3.0 4) Output current I A 3.0 4.0 5.4 5) 7.0 9.5 12.5

4) 5)

Overload current (60 s) I A 4.5 6.0 7.3 10.5 14.3 16.2 Overload current (1 s) I A 6.0 8.0 8.0 14.0 19.0 19.0 Output voltage U V 3 x 0 ... mains voltage Protection - - Short circuit / earth fault proof Rotary field frequency f Hz 0 ... 1000, depending on switching frequency Switching frequency f kHz 2, 4, 8 (nom. operat. point), 12, 16

Output, brake resistor

min. brake resistor (U

dBC

= 385 V) R Ω 230 160 115 75 55 37

Input, mains side

Mains current 3) , 3ph/PE 1ph/N/PE ; 2ph/PE

I A

3.0

5.4

4.0

7.2

5.5

9.5 2)

7.0

13.2

9.5

16.5 2)

10.5

16.5

2) 4)

Mains voltage U V 184 ... 264 Mains frequency f Hz 45 ... 66 Fuse 3ph/PE

1ph/N/PE ; 2ph/PE

I A

10 16

16 20

20 UL type 250 VAC RK5, 3ph/PE 1ph/N/PE; 2ph/PE

I A

10 15

15 20

Mechanics

Dimensions: HxWxD mm 190x60x175 250x60x175 Weight (approx.) m kg 1.2 1.6 Degree of protection - - IP20 (EN60529) Terminals A

0.2 ... 1.5

Form of assembly - - vertical

Ambient conditions

Energy dissipation (2 kHz switching frequency)

P W 43 53 73 84 115 170

Coolant temperature

°C 0 ... 40 (3K3 DIN IEC 721-3-3)

Storage temperature

°C -25 ... 55

Transport temperature

°C -25 ... 70

Rel. air humidity - % 15 ... 85; not condensing

If required by the customer, the switching frequency may be increased if the output current is reduced at the same time. Comply with the applicable standards and regulations for this operating point.

Output current

Switching frequency

Frequency inverter nominal power

2 kHz 4 kHz 8 kHz 12 kHz 16 kHz

0.55 kW 3.0 A 3.0 A 3.0 A 2.5 A 2.0 A

0.75 kW 4.0 A 4.0 A 4.0 A 3.4 A 2.7 A

1.1 kW 5.5 A 2) 5.5 A

2) 5)

5.4 A

2) 5)

4.5 A

2) 5)

3.7 A 5)

1.5 kW 7.0 A 7.0 A 7.0 A 5.9 A 4.8 A

2.2 kW 9.5 A 2) 9.5 A 2) 9.5 A 2) 8.0 A 2) 6.5 A

3.0 kW

2) 4)

12.5 A

1) 5)

12.5 A

1) 5)

10.5 A

1) 5)

8.5 A 5)

1) Three-phase connection requires a commutating choke.

One- and two-phase connection requires a commutating choke.

Mains current with relative mains impedance 1% (see chapter„Electrical installation“)

Maximum output current is 9.5 A for one- and two-phase connection.

5)’

Switching frequency is reduced in thermal limit range

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3.2 Frequency Inverter 400 V (0.55 to 4.0 kW)

Type

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

Output, motor side

Recommended shaft output P kW 0.55 0.75 1.1 1.5 1.85 2.2 3.0 4.0 Output current I A 1.8 2.4 3.2 3.8 3) 4.2 5.8 7.8 9.0

Overload current (60 s) I A 2.7 3.6 4.8 5.7 6.3 8.7 11.7 13.5 Overload current (1 s) I A 3.6 4.8 6.4 7.6 8.4 11.6 15.6 18.0 Output voltage U V 3 x 0 ... mains voltage Protection - - Short circuit / earth fault proof Rotary field frequency f Hz 0 ... 1000, depending on switching frequency Switching frequency f kHz 2, 4, 8 (nom. operat. point), 12, 16

Output, brake resistor

Min. brake resistor (U

dBC

= 770 V) R Ω 930 634 462 300 300 220 148 106

Input, mains side

Mains current 2) 3ph/PE I A 1.8 2.4 2.8 1)3.3 1) 4.2 5.8 6.8 1) 7.8 1) Mains voltage U V 320 ... 528 Mains frequency f Hz 45 ... 66 Fuses 3ph/PE I A 6 10 UL type 600 VAC RK5, 3ph/PE I A 6 10

Mechanics

Dimensions: HxWxD mm 190x60x175 250x60x175 Weight (approx.) m kg 1.2 1.6 Degree of protection - - IP20 (EN60529) Terminals A

0.2 ... 1.5

Form of assembly - - vertical

Ambient conditions

Energy dissipation (2 kHz switching frequency)

P W 40 46 58 68 68 87 115 130

Coolant temperature

°C 0 ... 40 (3K3 DIN IEC 721-3-3)

Storage temperature

°C -25 ... 55

Transport temperature

°C -25 ... 70

Rel. air humidity - % 15 ... 85, not condensing

If required by the customer, the switching frequency may be increased if the output current is reduced at the same time. Comply with the applicable standards and regulations for this operating point.

Output current

Switching frequency

Frequency inverter nominal power

2 kHz 4 kHz 8 kHz 12 kHz 16 kHz

0.55 kW 1.8 A 1.8 A 1.8 A 1.5 A 1.2 A

0.75 kW 2.4 A 2.4 A 2.4 A 2.0 A 1.6 A

1.1 kW 3.2 A 1) 3.2 A 1) 3.2 A 1) 2.7 A 1) 2.2 A

1.5 kW 1) 3.8 A 3.8 A 3) 3.8 A 3) 3.2 A 3) 2.6 A 3)

1.85 kW 4.2 A 4.2 A 4.2 A 3.5 A 2.9 A

2.2 kW 5.8 A 5.8 A 5.8 A 4.9 A 3.9 A

3.0 kW 7.8 A 1) 7.8 A 1) 7.8 A 1) 6.6 A 1) 5.3 A

4.0 kW 9.0 A 1) 9.0 A

1) 3)

9.0 A

1) 3)

7.6 A

1) 3)

6.1 A

1) Three-phase connection requires a commutating choke.

Mains current with relative mains impedance 1% (see chapter„Electrical installation“)

Switching frequency is reduced in thermal limit range

06/0512

3.3 Frequency Inverter 400 V (5.5 to 15.0 kW)

Type

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

Output, motor side

Recommended shaft output P kW 5.5 7.5 9.2 11.0 15.0 Output current I A 14 18 22 3) 25 32 Overload current (60 s) I A 21.0 26.3 30.3 37.5 44.5 Overload current (1 s) I A 28.0 33.0 33.0 50.0 64.0 Output voltage U V 3 x 0 ... mains voltage Protection - - Short circuit / earth fault proof Rotary field frequency f Hz 0 ... 1000, depending on switching frequency Switching frequency f kHz 2, 4, 8 (nom. operat. point), 12, 16

Output, brake resistor

Min. brake resistor (U

dBC

= 770 V) R Ω 80 58 48 48 32

Input, mains side

Mains current 2) 3ph/PE I A 14.2 15.8 1) 20.0 1) 26.0 28.2 1) Mains voltage U V 320 ... 528 Mains frequency f Hz 45 ... 66 Fuses 3ph/PE I A 16 25 35 UL type 600 VAC RK5, 3ph/PE I A 20 30 40

Mechanics

Dimensions HxWxD mm 250x100x200 250x125x200 Weight (approx.) m kg 3.0 3.7 Degree of protection - - IP20 (EN60529) Terminals A mm

0.2 ... 6 0.2 ... 16

Form of assembly - - vertical

Ambient conditions

Energy dissipation (2 kHz switching frequency)

P W 145 200 225 240 310

Coolant temperature Tn °C 0 ... 40 (3K3 DIN IEC 721-3-3) Storage temperature TL °C -25 ... 55 Transport temperature TT °C -25 ... 70 Rel. air humidity - % 15 ... 85, not condensing

If required by the customer, the switching frequency may be increased if the output current is

reduced at the same time. Comply with the applicable standards and regulations for this operating point.

Output current

Switching frequency

Frequency inverter nominal power

2 kHz 4 kHz 8 kHz 12 kHz 16 kHz

5.5 kW 14.0 A 14.0 A 14.0 A 11.8 A 9.5 A

7.5 kW 18.0 A 1) 18.0 A 1) 18.0 A 1) 15.1 A 1) 12.2 A

9.2 kW 1) 23.0 A 22.7 A

22.0 A

18.5 A 3) 15.0 A

11 kW 25.0 A 25.0 A 25.0 A 21.0 A 17.0 A 15 kW 32.0 A 1) 32.0 A 1) 32.0 A 1) 26.9 A 1) 21.8 A

1) Three-phase connection requires a commutating choke.

Mains current with relative mains impedance 1% (see chapter„Electrical installation“)

Switching frequency is reduced in thermal limit range

06/05 13

3.4 Frequency Inverter 400 V (18.5 up to 30 kW)

Type

ACT 401 -27 -29 -31

Motor-side output

Recommended motor shaft output P kW 18.5 22 30 Output current I A 40.0 45.0 60.0 Overload current (60 s) I A 60.0 67.5 90.0 Overload current (1 s) I A 80.0 90.0 120.0 Output voltage U V 3 x 0 ... mains voltage Protection - - Short circuit / earth fault proof Rotary field frequency f Hz 0 ... 1000, depending on switching frequency Switching frequency f kHz 2, 4, 8 (nom. operat. point)

Brake resistor output

Min. brake resistor (U

dBC

= 770 V) R Ω 24 16

Mains-side input

Mains current 2) 3ph/PE I A 42.0 50.0 58.0 1) Mains voltage U V 320 ... 528 Mains frequency f Hz 45 ... 66 Fuses 3ph/PE I A 50 50 63 UL type 600 VAC RK5, 3ph/PE I A 40 50 60

Mechanical

Dimensions HxWxD mm 250x200x290 Weight (approx.) m kg 8 Degree of protection - - IP20 (EN60529) Terminals A mm

up to 25

Form of assembly - - vertical

Environmental conditions

Energy dissipation (2 kHz switching frequency)

P W 420 470 750

Coolant temperature T

°C 0 ... 40 (3K3 DIN IEC 721-3-3) Storage temperature TL °C -25 ... 55 Transport temperature TT °C -25 ... 70 Rel. air humidity - % 15 ... 85, not condensing

Depending on the customer-specific requirements, an increase of the switching frequency is permissible if the output current is reduced. Comply with the applicable standards and regulations for this operating point.

Output current

Switching frequency

Frequency inverter nominal power

2 kHz 4 kHz 8 kHz

18.5 kW 40.0 A 40.0 A 40.0 A 22 kW 45.0 A 45.0 A 45.0 A 30 kW 60.0 A 1) 60.0 A 1) 60.0 A 1)

1) Three-phase connection requires a commutating choke.

Mains current with relative mains impedance 1% (see chapter "Electrical installation")

06/0514

3.5 Operation diagrams

The technical data of the frequency inverters refer to the nominal point which was

selected to enable a wide range of applications. A functionally and efficient dimensioning (derating) of the frequency inverters is possible based on the following diagrams.

Site altitude

100

3000

1000

2000 4000

3000

1000

2000

4000

Power reduction (Derating), 5%/1000 m above sea level, h = 4000 m

max

max. coolant temperature,

3.3 °C/1000 m above sea level,

Mounting altitude in m above sea level Mounting altitude in m above sea level

Output current in %

Coolant temperature in °C

Coolant temperature

100

0 10

40 50 55

Power reduction (Derating)

2.5%/K upper 40 °C, T = 55 °C

max

Output current in

Coolant temperature in °C

Mains voltage

100

0 400

420

440

460

480

reduction of output current at constant power (Derating

)

0.22%/ V upper 400 V, U = 480 V

max

utput current in

Mains voltage in V

06/05 15

4 Mechanical Installation

The frequency inverters of degree of protection IP20 are designed, as a standard, for

installation in electrical cabinets.

• During installation, both the installation and the safety instructions as well as the device specifications must be complied with.

Warning! To avoid serious physical injuries or major material damage, only

qualified persons are allowed to work on the devices.

Warning! During assembly, make sure that no foreign particles (e.g. filings, dust,

wires, screws, tools) can get inside the frequency inverter. Otherwise there is the risk of short circuits and fire. The frequency inverters comply with protection class IP20 only if the covers and terminals are mounted properly. The units may only be used if these requirements are met.

Caution! Mount the devices with sufficient clearance to other components so that

the cooling air can circulate freely. Avoid soiling by grease and air pollution by dust, aggressive gases, etc.

06/0516

4.1 Frequency Inverter (0.55 to 4.0 kW)

The frequency inverter is mounted in a vertical position on the assembly panel by

means of the standard fittings. The following illustration shows the different mounting possibilities.

Standard installation

a a2

x 100 mm

≥

Assembly is effected by inserting the long side of the fixing plate in the heat sink and

screwing it to the mounting plate. The dimensions of the device and the installation dimensions are those of the standard device without optional components and are given in millimeters.

Dimensions in mm Installation dimensions in mm

Frequency inverter

a b c a1 a2 b1 c1

0.55 kW ... 1.1 kW

190 60 175 210 ... 230 255 30 130

ACT 201

1.5 kW ... 3.0 kW

250 60 175 270 ... 290 315 30 130

0.55 kW ... 1.5 kW

190 60 175 210 ... 230 255 30 130

ACT 401

1.85 kW ... 4.0 kW

250 60 175 270 ... 290 315 30 130

06/05 17

4.2 Frequency Inverter (5.5 to 15 kW)

The frequency inverter is mounted in a vertical position on the assembly panel by

means of the standard fittings. The following illustration shows the standard fitting.

Standard installation

a1 a2

x 100 mm

≥

fixing bracket bottom (fixing with screws )

M4x60

fixing bracket top (fixing with screws )

M4x20

Assembly is done by screwing the two fixing brackets to the heat sink of the

frequency inverter and the assembly panel. The frequency inverters are provided with fixing brackets, which are fitted using four thread-cutting screws. The dimensions of the device and the installation dimensions are those of the standard device without optional components and are given in millimeters.

Dimensions in mm Installation dimensions in mm

Frequency inverter

a b c a1 a2 b1 c1

5.5 kW ... 9.2 kW

250 100 200 270 ... 290 315 12 133

11.0 kW ... 15.0 kW

250 125 200 270 ... 290 315 17.5 133

06/0518

4.3 Frequency Inverter (18.5 to 30 kW)

The frequency inverter is mounted in a vertical position on the assembly panel by

means of the standard fittings. The following illustration shows the standard fitting.

Standard installation

x 100 mm

≥

fixing bracket top (fixing with screws )

M4x20

fixing bracket bottom (fixing with screws )

M4x70

Assembly is done by screwing the two fixing brackets to the heat sink of the frequency

inverter and the assembly panel. The frequency inverters are provided with fixing brackets, which are fitted using four thread-cutting screws. The dimensions of the device and the installation dimensions are those of the standard device without optional components and are given in millimeters.

Dimensions in mm Installation dimensions in mm

Frequency inverter

a b c a1 a2 b1 c1

18.5 kW ... 30 kW

250 200 290 270 … 290 315 20 165

06/05 19

5 Electrical Installation

The electrical installation must be carried out by qualified staff according to the

general and regional safety and installation directives. For a safe operation of the frequency inverter it is necessary that the documentation and the device specifications be complied with during installation and commissioning. In the case of special applications, you may also have to comply with further guidelines and instructions.

Danger! When the frequency inverter is disconnected from power supply, the

mains, DC-link voltage and motor terminals may still be live for some time. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.

The connecting cables must be protected externally, considering the maximum

voltage and current values of the fuses. The mains fuses and cable cross-sections are to be selected according to EN 60204-1 and DIN VDE 0298 Part 4 for the nominal operating point of the frequency inverter. According to UL/CSA, the frequency inverter is suitable for operation at a supply network of a maximum of 480 VAC which delivers a maximum symmetrical current of 5000 A (effective value) if protected by fuses of class RK5. Only use copper cables with a temperature range of 60/75 °C.

Warning! The frequency inverters are to be grounded properly, i.e. large

connection area and with good conductivity. The leakage current of the frequency inverters may be > 3.5 mA. According to EN 50178 a permanent connection must be provided. The protective conductor cross-section required for grounding the fixing plate must be at least 10 mm², or a second protective conductor must be installed electrically parallel to the first one. In these applications, the cross-section must correspond to the recommended cross-section of the wire.

Connection conditions

− The frequency inverter is suited for connection to the public or industrial supply mains according to the technical data. If the transformer output of the supply mains is ≤ 500 kVA, the optional mains commutation choke is only necessary for the frequency inverters identified in the technical data. The other frequency inverters are suitable for connection without a mains commutating choke with relative mains impedance ≥ 1%.

− It must be checked, based on the specifications of EN 61000-3-2, if the devices can be connected to the public supply means without taking additional measures. The frequency inverters ≤ 9.2 kW with integrated EMC filter comply with the emission limits of the product standard EN 61800-3 up to a motor cable length of 10 m, without additional measures being required. Increased requirements in connection with the specific application of the frequency inverter are to be met by means of optional components. Commutating chokes and EMC filters are optionally available for the series of devices.

− Operation on unearthed mains (IT mains) is admissible after disconnection of the Y capacitors in the interior of the device.

− Interference-free operation with residual-current device is guaranteed at a tripping current ≥ 30 mA if the following points are observed:

− Pulse-current and alternating-current sensitive residual current devices (Type

A to EN 50178) in the case of a connection of frequency inverters with onephase power supply (L1/N)

− All-current sensitive residual current devices (Type B to EN 50178) in the case

of a connection of frequency inverters with two-phase (L1/L2) or three-phase (L1/L2/L3) power supply.

− Use EMC filters with reduced leakage current or, if possible, do not use EMC

filters at all.

− The length of the shielded motor cable is ≤ 10 m and there are no additional

capacitive components between the mains or motor cables and PE.

06/0520

5.1 EMC Information

The frequency inverters are designed according to the requirements and limit values

of product norm EN 61800-3 with an interference immunity factor (EMI) for operation in industrial applications. Electromagnetic interference is to be avoided by expert installation and observation of the specific product information.

Measures

• Install the frequency inverters and commutating chokes on a metal mounting

panel. Ideally, the mounting panel should be galvanized.

• Provide proper equipotential bonding within the system or the plant. Plant components such as control cabinets, control panels, machine frames, etc. must be connected by means of PE cables.

• Connect the frequency inverter, the commutating choke, external filters and other components to an earthing point via short cables.

• Keep the cables as short as possible, make sure that cables are installed properly using appropriate cable clamps, etc.

• Contactors, relays and solenoids in the electrical cabinet are to be provided with suitable interference suppression components.

Mains connection The length of the mains supply cable is not limited. However, it must be installed separate from the control, data and motor cables.

DC link connection

The frequency inverters are to be connected to the same mains potential or a common direct voltage source. Cables longer than 300 mm are to be shielded. The shield must be connected to the mounting panel on both sides.

Control Connection

The control and signal cables must be kept physically separate from the power cables. The shield of the control cables is to be connected to ground potential properly, i.e. with good conductivity, on both sides. Analog signal lines are to be connected to the shield potential on one side.

Motor and brake resistor

The shield of the motor cable is to be connected to ground potential properly on both sides. On the motor side use a metal compression gland. On the frequency inverter side an appropriate shield clamp is to be used. The signal cable used for monitoring the motor temperature must be kept separate from the motor cable. Connect the shield of this line on both sides. If a brake resistor is used, the connection cable must also be shielded, and the shield is to be connected to earth potential on both sides.

Attention! The frequency inverters meet the requirements of the low-voltage direc-

tive 73/23/EEC and the requirements of the EMC directive 89/336/EEC. The EMC product standard EN 61800-3 relates to the drive system. The documentation provides information on how the applicable standards can be complied if the frequency inverter is a component of the drive system. The declaration of conformity is to be issued by the supplier of the drive system.

06/05 21

5.2 Block diagram

+10 V / 4 mA

MFI1

GND 10 V

X210A

+20 V / 180 mA

GND 20 V

S4IND

X210B

2 3

S3OUT

S3IND

S2IND

S1IND

S5IND

S6IND

GND 20 V

MFO1

S1OUT

CPU

L2 L3L1

Rb1

Rb2

U, I

B C

D E

Relay connection S3OUT

Change-over contact, response time approx. 40 ms, 240 V AC / 5 A, 24 V DC / 5 A

(ohmic)

Digital input S1IND

Digital signal, controller enable signal, response time approx. 16 ms (on), 10 µs (off),

max

= 30 V, 10 mA at 24 V, PLC compatible

Digital input S2IND ... S6IND

Digital signal: response time approx. 16 ms, U

max

= 30 V, 10 mA at 24 V, PLC com-

patible, frequency signal: 0...30 V, 10 mA at 24 V, f

max

= 150 kHz

Digital output S1OUT

Digital signal, 24 V, I

max

= 40 mA,

PLC compatible, overload and short-circuit proof

Multi-function output MFO1

Analog signal: 24 V, I

max

= 40 mA, pulse-width modulated, f

PWM

= 116 Hz

Digital signal: 24 V, I

max

= 40 mA,

frequency signal: 0...24 V, I

max

= 40 mA, f

max

= 150 kHz,

PLC compatible, overload and short-circuit proof

Multi-function input MFI1

Analog signal: resolution 12 Bit, 0...10 V (Ri = 70 kΩ), 0...20 mA (Ri = 500 Ω), digital signal: response time approx. 16 ms, U

max

= 30 V, 4 mA at 24 V,

PLC compatible

06/0522

5.3 Mains Connection

The mains fuses and cable cross-sections are to be selected according to EN 60204-1

and DIN VDE 0298 Part 4 for the nominal operating point of the frequency inverter. According to UL/CSA, approved Class 1 copper lines with a temperature range of 60/75°C and matching mains fuses are to be used for the power cables. The electrical installation is to be done according to the device specifications and the applicable standards and directives.

Caution! The control, mains and motor lines must be kept physically separate from

one another. The cables connected to the frequency inverters may not be subjected to high-voltage insulation tests unless appropriate circuitry measures are taken before.

5.3.1 Frequency Inverter (0.55 to 4.0 kW)

The mains connection of the frequency inverter is via plug-in terminal X1. Degree of protection IP20 (EN60529) is only guaranteed if terminal X1 is plugged in.

Danger! Switch off power supply before connecting or disconnecting the keyed

plug-in terminal X1. Dangerous voltage may be present at the mains terminals and the DC terminals even after the frequency inverter has been disconnected safely from power supply. Wait for some minutes until the DC link capacitors have discharged before starting the work.

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is discharged.

Mains power connection 0.55 kW to 4.0 kW

1ph / 230V AC

L2 L3L1

3ph / 230V AC 3ph / 400V AC

L2 L3L1

L3 PE

2ph / 230V AC

L1 L2 PE

550 W … 1.1 kW

Phoenix ZEC 1,5/ .. ST7,5

0.2 … 1.5 mm AWG 24 … 16

0.25 … 1.5 mm AWG 22 … 16

2ph / 230V AC

L1 L2 L3L1

1ph / 230V AC

L1 L2

1.5 kW … 3.0 kW

3ph / 230V AC 3ph / 400V AC

L1 L2

L3 PE

1.5 kW … 3.0 kW 1.5 kW … 4.0 kW

With a mains current above 10 A, the mains power connection 230 V 1ph/N/PE and the mains power connection 230 V 2ph/N/PE are to be done on two terminals.

06/05 23

5.3.2 Frequency Inverter (5.5 to 15.0 kW)

Danger! Switch off power supply before connecting or disconnecting the

mains cable to terminal X1 Dangerous voltage may be present at the mains terminals and the DC terminals even after the frequency inverter has been disconnected safely from power supply. Wait for some minutes until the DC link capacitors have discharged before starting the work.

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is discharged.

Mains power connection 5.5 kW to 15.0 kW

0.2 … 6 mm AWG 24 … 10

5.5 kW … 9.2 kW WAGO Line 745 / 6qmm / RM7,5

0.2 … 6 mm AWG 24 … 10

0.25 … 4 mm AWG 22 … 12

0.25 … 4 mm AWG 22 … 16

L2 L3L1

L3 PE

3ph / 400V AC

0.2 … 16 mm AWG 24 … 6

11 kW … 15 kW WAGO Line 745 / 16qmm / RM10+1

0.2 … 16 mm AWG 24 … 6

0.25 … 10 mm AWG 22 … 8

06/0524

5.3.3 Frequency Inverter (18.5 to 30 kW)

Danger! Switch off power supply before connecting or disconnecting the mains

cable to terminal X1 Dangerous voltage may be present at the mains terminals and the DC terminals even after the frequency inverter has been disconnected safely from power supply. Wait for some minutes until the DC link capacitors have discharged before starting the work.

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is discharged.

Mains power connection 18.5 kW to 30 kW

0.5 … 35 mm AWG 20 … 2

18.5 kW … 30 kW PHOENIX MKDSP 25/ 6-15,00-

0.5 … 25 mm AWG 20 … 4

1.00 … 25 mm AWG 18 … 4

1.5 … 25 mm

AWG 16

… 4

L2 L3L1

L3 PE

3ph / 400V AC

5.4 Motor Connection

The connection of the motor and the brake resistor to the frequency inverter is to be

done using shielded cables. The shield is to be connected to PE potential properly, i.e. with good conductivity, on both sides. The control, mains and motor lines must be kept physically separate from one another. The user must comply with the applicable limits stipulated in the relevant national and international directives as regards the application, the length of the motor cable and the switching frequency.

Permissible length of motor cable without output filter

Frequency inverter unshielded cable shielded cable

0.55 kW … 4.0 kW 50 m 25 m

5.5 kW … 15.0 kW 100 m 50 m

18.5 kW … 30.0 kW 150 m 50 m

The specified lengths of the motor cables must not be exceeded if no output filter is

installed. Upon request, we will check if longer motor cables can be used after taking appropriate technical measures, e.g. use of low-capacitance cables and output filters.

Note: The frequency inverters ≤ 9.2 kW with integrated EMC filter comply with the

emission limits stipulated in EN 61800-3 if the motor cable is not longer than 10 m. Customer-specific requirements can be met by means of an optional filter.

06/05 25

5.4.1 Frequency Inverter (0.55 to 4.0 kW)

The connection of the motor and the brake resistor to the frequency inverter is to be done via plug-in terminal X2. Degree of protection IP20 (EN60529) is only guaranteed if terminal X2 is connected.

Danger! Switch off power supply before connecting or disconnecting the

keyed plug-in terminal X2. Dangerous voltage may be present at the motor terminals and the terminals of the brake resistor even after the frequency inverter has been disconnected safely from power supply. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is discharged.

Motor power connection 0.55 kW to 4.0 kW

Phoenix ZEC 1,5/ .. ST7,5

0.2 … 1.5 mm AWG 24 … 16

0.25 … 1.5 mm AWG 22 … 16

Star connection

Delta connection

Rb2

Rb1

06/0526

5.4.2 Frequency Inverter (5.5 to 15 kW)

The connection of the motor to the frequency inverter is to be done via terminal X2.

Danger! Switch off power supply before connecting or disconnecting the

motor cables to terminal X2. Dangerous voltage may be present at the motor terminals and the terminals of the brake resistor even after the frequency inverter has been disconnected safely from power supply. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is discharged.

Motor power connection 5.5 kW to 15 kW

Star connection

Delta connection

5.5 kW … 9.2 kW WAGO Line 745 / 6qmm / RM7,5

0.2 … 6 mm AWG 24 … 10

0.25 … 4 mm AWG 22 … 12

0.25 … 4 mm

AWG

22 … 1

11 kW … 15 kW WAGO Line 745 / 16qmm / RM10+1

0.2 … 16 mm AWG 24 … 6

0.25 … 10 mm AWG 22 … 8

0.25 … 10 mm

AWG

22 …

Rb2

Rb1

06/05 27

5.4.3 Frequency Inverter (18.5 to 30 kW)

The connection of the motor to the frequency inverter is to be done via terminal X2.

Danger! Switch off power supply before connecting or disconnecting the

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is discharged.

Motor power connection 18.5 kW to 30 kW

Delta connection

0.5 … 35 mm AWG 20 … 2

18.5 kW … 30 kW PHOENIX MKDSP 25/ 6-15,00-F

0.5 … 25 mm AWG 20 … 4

1.00 … 25 mm AWG 18 … 4

1.5 … 25 mm

AWG 16

… 4

Rb2

Rb1

06/0528

5.5 Connection of a Brake Resistor

Connection of a brake resistor is done via terminal X2.

Danger! Switch off power supply before connecting or disconnecting the brake

resistor cables to terminal X2. Dangerous voltage may be present at the motor terminals and the terminals of the brake resistor even after the frequency inverter has been disconnected safely from power supply. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is discharged.

Caution! The brake resistor must be equipped with a temperature switch. The

temperature switch must disconnect the frequency inverter from mains supply if the brake resistor is overloaded.

5.5.1 Frequency Inverter (0.55 to 4.0 kW)

Degree of protection IP20 (EN60529) is only guaranteed if terminal X2 is connected.

Connection of brake resistor with temperature switch

V WU

Rb2Rb1

Rb1 Rb2

5.5.2 Frequency Inverter (5.5 to 15 kW)

Connection of brake resistor with temperature switch

Rb1 Rb2

V WU

Rb2Rb1

06/05 29

5.5.3 Frequency Inverter (18.5 to 30 kW)

Connection of brake resistor with temperature switch

Rb1 Rb2

V WU

Rb2Rb1

5.6 Control Terminals

The control and software functionality can be freely configured to ensure a reliable

and economical operation. The operating instructions describe the factory settings of the standard connections in the relevant

Configuration 30 as well as the software

parameters to be set up.

Caution! Switch off power supply before connecting or disconnecting the keyed

control inputs and outputs. Otherwise, components may be damaged.

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is discharged.

Control Terminals

0.14 … 1.5 mm AWG 30 … 16

Wieland DST85 / RM3,5

0.14 … 1.5 mm AWG 30 … 16

0.25 … 1.0 mm AWG 22 … 18

0.25 … 0.75 mm AWG 22 … 20

0.2 … 0.3 Nm

1.8 … 2.7 lb-in

06/0530

Control terminal X210A Ter. Description 1 Voltage output 20 V, I

max

=180 mA 1) 2 Ground / GND 20 V 3 Digital input S1IND, U

max

=30 V, 10 mA at 24 V, PLC compatible,

response time approx. 16ms (on), 10 µs (off)

4 Digital input EM-S2IND, U

max

=30 V, 10 mA at 24 V, PLC compatible,

response time approx. 16 ms

5 Digital input EM-S3IND, U

max

=30 V, 10 mA at 24 V, PLC compatible,

response time approx. 16 ms

6 Digital input S4IND, U

max

= 30 V, 10 mA at 24 V, PLC compatible,

frequency signal: 0...30 V, 10 mA at 24 V, f

max

= 150 kHz

7 Digital input S5IND, U

max

= 30 V, 10 mA at 24 V, PLC compatible,

frequency signal: 0...30 V, 10 mA at 24 V, f

max

= 150 kHz

Control terminal X210B Ter. Description 1 Digital input S6IND, U

max

=30 V, 10 mA at 24 V, PLC compatible,

response time approx. 16 ms 2 Ground / GND 20 V 3 Digital output S1OUT, U=24 V, I

max

=40 mA, overload and short-circuit proof

4 Multi-function output MFO1,

analog signal: U=24 V, I

max

=40 mA, pulse-width modulated, f

PWM

=116 Hz

digital signal: U=24 V, I

max

=40 mA, overload and short-circuit proof,

frequency signal: 0...24 V, I

max

=40 mA, f

max

=150 kHz

5 Reference output 10 V, I

max

=4 mA

6 Multi-function input MFI1,

analog signal: resolution 12 Bit, 0...+10 V (Ri = 70 kΩ), 0...20 mA (Ri = 500 Ω),

digital signal: response time approx. 16 ms, U

max

= 30 V, 4 mA at 24 V,

PLC compatible 7 Ground / GND 10 V

The power supply at terminal X210A.1 may be loaded with a maximum current of I

max

= 180 mA. The maximum current available is reduced by the digital

output S1OUT and multifunctional output MFO1.

5.6.1 Relay Output

By default, the freely programmable relay output is linked to the monitoring function

(factory setting). The logic link to various functions can be freely configured via the software parameters. Connection of the relay output is not absolutely necessary for the function of the frequency inverter.

Relay Output

1 2 3

0.2 … 1.5 mm AWG 24 … 16

Phoenix ZEC 1,5/3ST5,0

0.2 … 1.5 mm AWG 24 … 16

0.25 … 1.5 mm AWG 22 … 16

0.25 … 1.5 mm

WG 22 … 16

S3OUT

X10

Control terminal X10 Ter. Description 1 ... 3 Relay output, floating change-over contact, response time approx. 40 ms,

max. contact load, make contact 5 A / 240 V AC, 5 A (ohmic) / 24 V DC max. contact load, break contact 3 A / 240 V AC, 1 A (ohmic) / 24 V DC

06/05 31

5.6.2 Control Terminals – Terminal Diagram

The control hardware and the software of the frequency inverter are freely

configurable to a great extent. Certain functions can be assigned to the control terminals, and the internal logic of the software modules can be freely selected.

In these brief instructions, the sensor-less control and the sensor-less field oriented

control are described in Configuration 110 and Configuration 410, respectively

5.6.2.1 Configuration 110 – Sensorless Control

Configuration 110 contains the functions for variable-speed control of a 3-phase

machine in a wide range of standard applications. The motor speed is set according to the selected ratio of the reference frequency to the necessary voltage.

Control terminal X210A X210A.1 Supply voltage +20V X210A.2 Ground 20 V X210A.3 Controller release / error acknowl-

edgment X210A.4 Start of clockwise operation X210A.5 Start of anticlockwise operation X210A.6 Data set change-over 1 X210A.7 Data set change-over 2

Control terminal X210B X210B.1 Motor thermal contact X210B.2 Ground 20 V X210B.3 Operating message X210B.4 Analog signal of actual frequency X210B.5 Supply voltage +10V

Reference value potentiometer X210B.6 Reference speed 0 ...+10 V

GND 20 V S1OUT

MFO1A +10 V/ 4 mA MFI1A GND 10 V

1 2 3 4 5 6 7

X210A

+20 V/180 mA GND 20 V

S1IND S2IND

S3IND S4IND S5IND

S6IND

X210B

1 2 3 4 5 6 7

X210B.7 Ground 10 V

06/0532

5.6.2.2 Configuration 410 – Sensorless Field-Oriented Control

Configuration 410 contains the functions for sensorless, field-oriented control of a 3-

phase machine. The current motor speed is determined from the present currents and voltages in combination with the machine parameters. Separate control of torque and flux-forming current enables high drive dynamism at a high load moment.

Control terminal X210A X210A.1 Supply voltage +20V X210A.2 Ground 20 V X210A.3 Controller release / error acknowl-

edgment X210A.4 Start of clockwise operation X210A.5 Start of anticlockwise operation X210A.6 Data set change-over 1 X210A.7 Data set change-over 2

Control terminal X210B X210B.1 Motor thermal contact X210B.2 Ground 20 V X210B.3 Operating message X210B.4 Analog signal of actual frequency X210B.5 Supply voltage +10V

Reference value potentiometer X210B.6 Reference speed 0 ...+10 V

GND 20 V S1OUT

MFO1A +10 V/4 mA MFI1A GND 10 V

1 2 3 4 5 6 7

X210A

+20 V/180 mA GND 20 V

S1IND S2IND

S3IND S4IND S5IND

S6IND

X210B

1 2 3 4 5 6 7

X210B.7 Ground 10 V

06/05 33

5.7 Optional Components

Thanks to the modular hardware components, the frequency inverters can be

integrated in the automation concept easily. The standard and optional modules are recognized during the initialization, and the controller functionality is adjusted automatically. For the information required for installation and handling of the optional modules, refer to the corresponding documentation.

Danger! The hardware modules at slots B and C may only be assembled and

disassembled after the frequency inverter has been disconnected safely from power supply. Wait for some minutes until the DC link capacitors have discharged before starting the work.

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is discharged.

Hardware modules

Control Unit KP500 Connection of the optional control unit KP500 or an interface adapter KP232.

Communication module CM

Plug-in section for connection to various communication protocols: CM-232: RS232 interface CM-485: RS485 interface CM-PDP: Profibus-DP interface CM-CAN: CANopen interface

Extension module EM

Slot for customer-specific adaptation of the control inputs and outputs to various applications: EM-ENC: extended speed sensor evaluation EM-RES: resolver evaluation EM-IO: analog and digital inputs and outputs EM-SYS: system bus

(system bus in combination with CM-CAN communication module upon request)

Attention! If two optional components with CAN-Protocol controller are installed,

the system bus interface in the EM extension module is deactivated!

06/0534

6 Control Unit KP500

The optional KP500 control unit is a practical tool for controlling the frequency inverter

and setting and displaying the frequency inverter parameters. The control unit is not absolutely necessary for the operation of the frequency inverter and can be plugged on when required.

Keys

RUN Used for starting the drive and opening the CTRL menu.

Press the RUN key to open the motor potentiometer function.

STOP Used for opening the CTRL menu, stopping the drive and acknowledging

faults

� � Used for navigating in the menu structure and selecting parameters.

Increasing/decreasing of parameter values.

ENT Used for opening parameters or switching to another menu within the menu

structure. Confirmation of the selected function or the set parameter.

ESC Used for aborting parameters or switching back to the previous menu within

the menu structure. Canceling the function or resetting the parameter value.

FUN Used for switching over the key function, access to special functions.

Display

Three-digit 7-segment display to show the parameter number

One-digit 7-segment display for display of the active data record, direction of rotation etc.

Display of the selected menu branch:

VAL Display actual values PARA Select parameters and adjust parameter values. CTRL Select a function for adjustment and/or display via the control unit:

SEtUP guided commissioning CtrL motor potentiometer and jog function

Status and operating messages:

WARN Warning about a critical operating behavior FAULT Message indicating that the unit was switched off due to a fault RUN Flashing: signals readiness for operation

Lights up: signals that the unit is operating and the output stage is enabled REM Active remote control via interface connection F Function switch-over with the FUN key

Five-digit 7-segment display for display of parameter value and sign

Physical unit of the parameter value displayed

Active acceleration or deceleration ramp

Current direction of rotation of the drive

06/05 35

6.1 Actual Value Menu (VAL)

In the VAL menu branch, the control unit displays a variety of actual values,

depending on the configuration selected and the options installed. The parameters and basic software functions linked to the corresponding actual value are documented in the operating instructions.

ENT

ESC

ENT

ESC

Use the arrow keys to select the required number from the actual values displayed in numerical order. In the current record, the record-related actual value parameters are displayed, including the corresponding data record number. The seven-segment display shows data record 0 if the actual values in the four data sets are identical.

Keys

� + � Display the actual value parameter upon switch-on. FUN , � Display last actual value parameter (highest number). FUN , � Display first actual value parameter (lowest number).

Use the ENT key to select the parameter. The parameter is displayed including its current value, unit and the active data record.

During commissioning, operation and error analysis, it is possible to monitor each actual value parameter specifically. Some of the actual value parameters are arranged in the four available data records. If the parameter values in the four data records are identical, the actual value is displayed in data record 0. If the actual values in the four data records are different, diFF is displayed in data record 0.

Keys

� , �

Switch to another of the data set in the case of related actual values.

FUN , � Determine maximum value and display it permanently. FUN , � Determine minimum value and display it permanently.

FUN , ENT

Display of mean value of the actual value during the monitoring

period.

Use the ENT key to save the selected actual value as a parameter displayed at

switch-on. The message SEt (with parameter number) is displayed for a short time. When the frequency inverter is switched on the next time, this actual

value will be displayed automatically.

After saving the parameter, you can monitor and display the value again. Use the ESC key to switch to the parameter selection of the VAL menu branch.

06/0536

6.2 Parameter Menu (PARA)

The parameters to be configured during the guided commissioning were selected

from common applications and can be supplemented as required by further settings in the PARA menu branch. The parameters and basic software functions linked to the corresponding actual value are documented in the operating instructions.

ENT

ESC

ENT

ESC

Use the arrow keys to select the required number from the parameters displayed in numerical order. The parameter number is displayed with the active data set (flashes). In the current data set, the related parameters are displayed, including the corresponding data set number. The seven-segment display shows data set 0 if the parameter values in the four data sets are identical.

Keys

� + � Change to the last parameter edited. FUN , � Display of last parameter (highest number). FUN , � Display of first parameter (lowest number).

Use the ENT key to select the parameter. The parameter is displayed including its value, unit and the active data set. If settings are edited in data set 0, the parameter values are changed in the four data sets.

Use the arrow keys to adjust the parameter value or to select an operation mode. The adjustment possibilities you have depend on the parameter. Keep the arrow keys pressed for a while to change the displayed values quickly. If you release the keys again, the speed at which the values change is reduced again. If the parameter value starts to flash, the speed at which the values change is reset to the initial value again.

Keys

� + � Set parameter to factory setting. FUN , � Set parameter to highest value. FUN , � Set parameter to smallest value.

FUN , ENT

Change of the data set in the case of data set related

parameters.

Use the ENT key to save the parameter. For a short time, the message SEt

including the parameter number and the data set is displayed. To leave the parameter unchanged, press the ESC key.

Messages

Err1: EEPrO Parameter has not been saved.

Err2: StOP

Parameter can only be read (i.e. not edited) when the unit is in operation.

Err3: Error Other error

After saving the parameter, you can edit the value again or return to the

parameter selection menu by pressing the ESC key.

06/05 37

6.3 Controlling the Motor via the Control Unit

The control unit enables controlling the connected motor in accordance with the

selected operation mode of parameter

Local/Remote 412.

Note: In order to be able to control the drive via the control unit, the digital

controller input S1IND must be connected and set to "High-Signal" in order to enable the output stage.

Warning! Switch off power supply before connecting and disconnecting control

terminal S1IND. When the frequency inverter is disconnected from power supply, dangerous voltage may still be present at the mains, DC link voltage and motor terminals for some time. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.

• The unit may only be connected with the power supply switched off.

• Verify that the frequency inverter is de-energized.

: When the RUN key was pressed, the drive was in operation already.

The CTRL menu branch can be accessed via the navigation

within the menu structure. The CtrL function contains subfunctions which are displayed according to the operating point of the frequency inverter. Press the RUN key at any point in the menu structure to switch to the motorpoti function Pot or the internal reference value int if the drive is already in operation.

Motor potentiometer function Pot

Use the arrow keys to adjust the output frequency of the frequency inverter from the

Minimum Frequency 418 to the

Maximum Frequency 419. The acceleration corresponds to

the factory settings (2 Hz/s) for parameter

Ramp Keypad-

Motorpoti

473. The parameters Acceleration (Clockwise) 420

and

Deceleration (Clockwise) 421 are considered in the case

of low acceleration values.

06/0538

Internal reference value int

The drive is in operation, i.e. output signals are present at the frequency inverter and the current actual value is displayed. Press an arrow key to switch to the motor potentiometer function Pot. The current frequency value is taken over in the motor potentiometer function Pot.

JOG frequency JOG

This function is useful for manual setup and positioning of a machine. The frequency of the output signal is set to the entered value if the FUN key is pressed.

• Press FUN key to switch from the internal reference value int or the motor potentiometer function Pot to the

JOG-

Frequency

489.

• Keep the FUN key pressed and press the arrow keys to

adjust the required frequency. (The frequency value last adjusted is saved as the

JOG-

Frequency

489.)

• Release the FUN key to stop the drive.

(The display returns to the previous function Pot or int.)

Key functions

ENT

Reversal of the direction of rotation independent of the control signal on the terminals Clockwise S2IND or Anticlockwise S3IND.

ESC Cancel function and return to the menu structure.

FUN

Switch from internal set point int or rather motor potentiometer function Pot to JOG frequency; the drive starts. Release the key to switch to the sub-function and stop the drive.

RUN Start drive; alternative to control signal S2IND or S3IND STOP Stop drive; alternative to control signal S2IND or S3IND

Attention! If you press the ENT key, the direction of rotation is changed

independent of the signal on the terminals Clockwise S2IND or Anticlockwise S3IND. If the

Minimum Frequency 418 has been set to 0.00 Hz, the direction

of rotation of the motor changes as soon as the sign of the reference

frequency value changes.

06/05 39

7 Commissioning of the Frequency Inverter

7.1 Switching on Mains Voltage

After completion of the installation work, make sure to check all control and power

connections again before switching on the mains voltage. If all electrical connections are correct, make sure that the frequency inverter is not released (control input S1IND open). After power-up, the frequency inverter carries out a self-test and the relay output (X10) reports "Fault". After a few seconds, the self-test is complete; the relay (X10) picks up and signals "no fault ". If the unit is in "as-delivered" condition or after resetting the unit to the factory settings, the guided commissioning procedure is started automatically. On the control unit, the "SetUP" menu from the menu branch CTRL is displayed.

7.2 Setup Using the Control Unit

The guided commissioning of the frequency inverter determines all parameter

settings relevant to the required application. The available parameters were selected based on known standard drive applications. This facilitates the selection of the important parameters. After successful completion of the SETUP routine, the actual value

Actual Frequency 241 from the VAL menu branch is displayed on the control

unit. Now, the user should check whether further parameters are relevant for the application.

Note: The guided commissioning contains the function for parameter identifi-

cation. The parameters are determined by way of measurement and set accordingly. In the case of higher requirements as regards the accuracy of the speed/torque control, you should carry out the guided commissioning procedure once again under operating conditions because part of the machine data depends on the operating temperature.

When the unit is in "as-delivered" condition, the guided

commissioning procedure is started automatically. After successful commissioning, the guided commissioning can be carried out again later via the sub-menu CTRL.

• Use the ENT key to switch to the CTRL sub-menu.

• In the CTRL sub-menu, select the menu item "SEtUP" and

confirm by pressing the ENT key.

• Use the ENT key to select parameter Configuration 30.

The available configurations are displayed automatically depending on the selected

Control Level 28.

• Use the arrow keys to enter the number of the required configuration. (for a description of the configurations, refer to the following chapter)

If the setup was changed, the hardware and software functionality will be configured. The message "SEtUP" is displayed again. Confirm this message by pressing the ENT key in order to continue the commissioning procedure.

• Switch to the next parameter.

• After initialization, confirm the selected configuration by

pressing the ENT key.

• Continue the guided commissioning procedure according to the following chapters.

ENT

06/0540

7.2.1 Configuration

The software of the frequency inverter offers several configuration options. These

differ with respect to the way in which the drive is controlled. Parameter

Configuration 30 determines the assignment and basic function of the control inputs

and outputs as well as the software functions. Analog and digital inputs can be combined and complemented by optional communication protocols as further reference value sources. In these brief instructions, the sensor-less control and the sensor-less field oriented control are described in Configuration 110 and Configuration 410, respectively.

Configuration 110, sensorless control

Configuration 110 contains the functions for variable-speed control of a 3-phase machine in a wide range of standard applications. The motor speed is set according to the V/f characteristic in accordance with the voltage/frequency ratio.

Configuration 410, sensorless field-oriented control

Configuration 410 contains functions for sensorless, field-oriented control of a 3-phase machine. The current motor speed is determined from the present currents and voltages in combination with the machine parameters. In this configuration, parallel connection of several 3-phase motors is possible to a limited extent only.

7.2.2 Data Set

Data set change-over enables the selection of one of four data sets for storing parameter settings. The default setting dS0 is recommended. If data set 0 is selected (factory setting), the parameter values saved in data set 0 are copied to data sets 1 to

4. In this way, all values determined during the guided commissioning are saved in all

data sets. The frequency inverter uses data set 1 as the active data set. For more information, refer to the operating instructions.

Data Set Setup

Parameter dS Function 0 All data sets (DS0) 1 Data set 1 (DS1) 2 Data set 2 (DS2) 3 Data set 3 (DS3) 4 Data set 4 (DS4)

7.2.3 Motor Type

The properties of the control functions and methods to be set vary depending on the motor which is connected. The parameter

Motor type 369 offers a range of motor

variants with the corresponding table values. The verification of the entered rated values and the guided commissioning are carried out on the basis of the parameterized motor type. The selection of motor types varies depending on the requirements of the different control methods. In instructions the functionality and operating performance are described for 3-phase motors.

Caution! Polling and presetting of parameter values depends on the operation mode

selected for parameter

Motor type 369.

If the motor type is not entered correctly, the drive may be damaged.

06/05 41

Operation mode Function 0 - Unknown The motor is not a standard type. 1 - Asynchronous Three-phase asynchronous motor, squirrel cage 2 - Synchronous Three-phase synchronous motor 3 - Reluctance Three-phase reluctance motor 10 - Transformer Transformer with three primary windings

When the motor type is specified, the machine data must be entered. This is described

in the following chapter. The data are polled in accordance with the table below.

7.2.4 Machine Data

The machine data to be entered during the guided commissioning procedure are indicated on the type plate or the data sheet of the motor. The factory settings of the machine parameters are based on the nominal data of the frequency inverter and the corresponding four-pole three-phase motor. The entered and calculated machine data are checked for plausibility during the guided commissioning procedure. The user should verify the factory-set rated data of the three-phase motor. U

FUN, IFUN, PFUN

are rated values of the frequency inverter.

Parameter Settings No. Description Min. Max. Fact. sett.

370 Rated Voltage 0.17⋅U

FUN

2⋅U

FUN

371 Rated Current 0.01⋅I

FUN

10⋅o ⋅ I

FUN

372 Rated Speed 96 min-1 60 000 min-1 nN 374 Rated Cosinus Phi 0.01 1.00 cos (ϕ)N 375 Rated Frequency 10.00 Hz 1000.00 Hz 50.00 376 Rated Mech. Power 0.01⋅P

FUN

10⋅P

FUN

• Use the arrow keys to select the required parameter and edit the parameter

value.

• Use the ENT key to confirm the selected parameter and the parameter values

entered.

Attention! The rated data of the motor are to be entered according to the

specifications on the rating plate for the motor connection type used (star or delta connection). If the data entered deviate from the rating plate, the parameters will not be identified correctly.

7.2.5 Plausibility check

After the machine data (and the speed sensor data, if applicable) have been entered, the calculation or examination of the parameters is started automatically. The display changes over to "CALC" for a short time. If the verification of the machine data is successful, the guided commissioning procedure continues with the identification of the parameters. Verification of the machine data should only be skipped by experienced users. The configurations contain complex control processes which depend to a large degree on the correctness of the machine parameters entered.

06/0542

The warning and error messages displayed during the verification process have to be observed. If a critical condition is detected during the guided commissioning, it is displayed by the control unit. Depending on the deviation from the expected parameter value, either a warning or an error message is displayed.

− To ignore the warning or error messages, press the ENT key. The guided

commissioning is continued. However, it is recommended that the data be checked and corrected if necessary.

− To correct the entered parameter values after the warning or error message,

press the ESC key. Use the arrow keys to switch to the parameter value which is to be corrected.

Warning Messages Code Measures / Remedy

SA000

No warning message present. This message can be read out via an optional communication module.

SA001

The value of the parameter

Rated Voltage 370 is out of the rated voltage

range of the frequency inverter. The maximum reference voltage is indicated on the nameplate of the frequency inverter.

SA002

The calculated efficiency is in the limit range for a three-phase motor. Check the values entered for the parameters

Rated Voltage 370, Rated

Current

371 and Rated Mech. Power 376.

SA003

The value entered for parameter

Rated Cosinus Phi 374 is outside of the

normal range (0.6 to 0.95). Check the value.

SA004

The calculated slip for an asynchronous motor is in the limit range. Check the values entered for parameters

Rated Speed 372 and Rated

Frequency

375.

If an error message is displayed, the rated values must be checked and corrected.

The guided commissioning procedure is repeated until the rated values have been entered correctly. Aborting the guided commissioning procedure by pressing ESC key should only be done be expert users because it may be possible that rated values have not been entered or determined correctly.

Error Messages Code Measures / Remedy SF000 No error message exists

SF001

The value entered for parameter

Rated Current 371 is too low. Correct the

value.

SF002

The value for parameter

Rated Current 371 is too high, referred to

parameters

Rated Mech. Power 376 and Rated Voltage 370. Correct the

values.

SF003

The value entered for parameter

Rated Cosinus Phi 374 is wrong (greater

than 1 or smaller than 0.3). Correct the value.

SF004

The calculated slip frequency is negative. Correct the values entered for parameters

Rated Speed 372 and Rated Frequency 375.

SF005

The calculated slip frequency is too high. Correct the values entered for parameters

Rated Speed 372 and Rated

Frequency

375.

SF006

The calculated total output of the drive is lower than the rated power. Correct the value entered for parameter

Rated Mech. Power 376.

SF007

The set configuration is not supported by the guided commissioning. For parameter

Configuration 30, select one of the configurations described in

these operating instructions.

06/05 43

7.2.6 Parameter identification

In addition to the parameterized rated data, the selected configuration demands knowledge of further machine data not stated on the rating plate of the three-phase machine. In addition to entering the rated motor parameters or as an alternative, the required machine data can also be measured during the guided commissioning process. The machine data are measured while the drive is at a standstill. The measured values are entered in the parameter automatically either directly or after the calculation. The procedure and the duration of the parameter identification depend on the type of machine connected and the device. After checking the machine data entered, the guided commissioning switches to the parameter identification. Confirm the display "PAidE" by pressing the ENT key. During the parameter identification, the connected load is measured.

The safety functions of the frequency inverter avoid a release of the power unit if no signal is present at digital input S1IND. If a signal was already applied at the beginning of the guided commissioning, the "FUF" message is not displayed.

Note: The parameter identification feature of the frequency inverter requires

the presence of a signal at digital input S1IND for release of the power unit.

Warning! Verify that the keyed control inputs and outputs are free of power before

connecting or disconnecting. When the frequency inverter is disconnected from power supply, the mains, DC-link voltage and motor terminals may still be live for some time. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is discharged.

Confirm the final "rEAdY" message by pressing the ENT key. Canceling the operation with the ESC key or withdrawing the release signal S1IND results in an incomplete take-over of the values.

Note: In the case of higher requirements as regards the accuracy of the

speed/torque control, you should carry out the guided commissioning procedure once again under operating conditions because part of the machine data depends on the operating temperature. During this procedure, confirm the machine data already entered.

After completion of the parameter identification, warning messages may be displayed. Depending on the warning message code, the following instructions should be followed and the measures indicated should be taken.

06/0544

Warning Messages Code Measures / Remedy

SA0021 The stator resistance is very high. The following causes are possible:

− The motor cable cross-section is not sufficient.

− The motor cable is too long.

− The motor cable is not connected correctly.

− The contacts are not in a proper condition (corrosion).

SA0022 The rotor resistance is very high. The following causes are possible:

− The motor cable cross-section is not sufficient.

− The motor cable is too long.

− The motor cable is not connected correctly.

− The contacts are not in a proper condition (corrosion).

SA0041 The slip speed was not determined correctly. Check the values entered for

parameters

Rated Speed 372 and Rated Frequency 375.

SA0042 The slip speed was not determined correctly. Check the values entered for

parameters

Rated Speed 372 and Rated Frequency 375.

SA0051 The machine data for star connection were entered, the motor, however, is

connected in delta. For star operation, change the motor cable connection. For delta operation, check the entered rated motor values. Repeat the parameter identification

SA0052 The machine data for delta connection were entered, the motor, however,

is connected in star. For delta operation, change the motor cable connection. For star operation, check the entered rated motor values. Repeat the parameter identification

SA0053 A phase asymmetry was measured. Check the cables at the terminals of

the motor and the frequency inverter for proper connection and check the contacts for corrosion.

After completion or during the parameter identification, error messages may be displayed. Depending on the error code, the following instructions should be followed and the measures indicated should be taken.

Error Messages Code Measures / Remedy

SF0011 The main inductance measurement has failed because the motor has a

high slip. Correct the rated motor values in parameters 370, 371, 372, 374, 375 and 376. Carry out the guided commissioning once again. In case an error message is displayed again, enter the value 110 for parameter

Configuration 30 (sensorless regulation according to U/f-

characteristic) if value 410 was set so far. Carry out the guided commissioning once again.

SF0012 The leakage inductance measurement has failed because the motor has a

Configuration 30 (sensorless regulation according to U/f-

characteristic) if value 410 was set so far. Carry out the guided commissioning once again.

SF0021 The measurement of the stator resistance did not deliver a plausible value.

Check the cables at the terminals of the motor and the frequency inverter for proper connection and check the contacts for corrosion and safe contact. Repeat the parameter identification

SF0022 The measurement of the rotor resistance did not deliver a plausible value.

Check the cables at the terminals of the motor and the frequency inverter for proper connection and check the contacts for corrosion and safe contact. Repeat the parameter identification

06/05 45

7.2.7 Application data

With the frequency inverter, a great variety of different drive applications can be

realized. The parameter settings required for this often require the verification of other parameters. The parameters polled during the guided commissioning procedure were selected from standard applications. After completion of commissioning, further parameters can be set in the PARA menu branch.

7.2.7.1 Acceleration and deceleration

The settings define how fast the output frequency changes after a reference value change or a start, stop or brake command.

Parameter Settings No. Description Min. Max. Fact. sett.

420 Acceleration (Clockwise) 0.00 Hz/s 999.99 Hz/s 5.00 Hz/s 421 Deceleration (Clockwise) 0.00 Hz/s 999.99 Hz/s 5.00 Hz/s

Attention! The deceleration of the drive is monitored in the default parameter

setting

Operation Mode 670 for the Voltage Controller. The

deceleration ramp can be extended in the case of an increase in the DC link voltage during regenerative operation and/or during the braking process.

7.2.7.2 Set points at multi-functional input

The multi-functional input MFI1 can be parameterized for a reference value signal in

Operation Mode 452. Operation mode 3 should only be selected by expert users for

drive control via

Fixed Frequency 1 480 and Fixed Frequency 2 481.

Operation mode Function 1 - Voltage Input Voltage signal (MFI1A), 0V ... 10V

2 - Current Input Current signal (MFI1A), 0mA ... 20mA 3 - Digital Input Digital signal (MFI1D), 0V ...24V

Confirm the "End" display by pressing the ENT key. The guided commissioning of the frequency inverter is terminated via a reset and the initialization of the frequency inverter. The relay output X10 signals a fault.

After successful initialization of the frequency inverter, the factory-set parameter

Actual Frequency 241 is displayed. If a signal is present at digital inputs S1IND

(controller release) and S2IND (start clockwise operation) or at digital inputs S1IND (controller release) and S3IND (start of anti-clockwise operation), the drive is accelerated to the adjusted

Minimum Frequency 418 (default value 3.50 Hz).

06/0546

7.2.8 Selection of an actual value for display

After commissioning, the value of parameter Actual Frequency 241 is displayed at the control unit KP500. If another actual value is to be displayed after a restart, make the following settings:

• Use the arrow keys to select the actual value to be displayed as from now.

• Use the ENT key to display the value of the parameter.

• Press the ENT key again. "SEt" is displayed for confirmation.

As from now, the selected actual value is displayed after each restart. If the parameter settings were made via the optional control software or in the PARA menu branch of the control unit, the display of the selected actual value must be activated manually. Use the ESC key to switch to the selection of the actual value for display again.

7.3 Check direction of rotation

Warning! Dangerous voltage may be present at the motor terminals and the

terminals of the brake resistor even after the frequency inverter has been disconnected from power supply. Wait for some minutes until the DC link capacitors have discharged before starting to work at the unit.

• The unit may only be connected with the power supply switched off.

• Make sure that the frequency inverter is de-energized.

To check if the reference value and the actual direction of rotation of the drive

correspond to one another, proceed as follows:

• Operate the drive at low speed, i.e. specify a reference value of approx. 10%.

• Release the frequency inverter briefly {signal at digital inputs S1IND (controller

release) and S2IND (start of clockwise operation) or S1IND (controller release) and S3IND (start of anti-clockwise operation)}.

• Check if the motor shaft turns in the required direction.

In case the sense of rotation is wrong, exchange two motor phases, e.g. U and V at the terminals of the frequency inverter. The mains-side connection of the frequency inverter does not affect the sense of rotation of the drive. In addition to checking the drive, the corresponding actual values and operating messages can be read out by means of the control unit.

Note: The commissioning of the frequency inverter is complete and can be

complemented by further settings in the PARA menu. The set parameters have been selected in such a way that they are sufficient for commissioning in most applications. The other settings which are relevant to the application can be checked according to the operating instructions.

06/05 47

8 Basic parameters

8.1 Menu branch PARA

The parameters displayed in the PARA menu branch are partly set via the guided

commissioning. The parameters documented in the brief instructions are complemented by the information given in the operating instructions.

Control Level 28 - The brief instructions describe the parameters in control level 1.

The parameters of the higher control levels 2 or 3 are described in the operating instructions and should be set up by expert operators only.

Setting: 1 ... 3

Configuration 30 - The basic function of the control inputs and outputs as well as

the assignment of the software modules is selected by the configuration. The selection is made during the guided commissioning.

110 - sensor-less control with U/f characteristic for speed regulation

in a great number of standard applications

Setting:

410 - sensor-less, field-oriented control, for applications with a high

functionality and dynamics

Program(ming) 34 - The factory settings of all parameters is restored or a fault

message is acknowledged (alternative to signal at digital input S1IND).

4444 Activate factory settings

Setting:

123 Acknowledge fault message

Motor type 369 – Setting of connected motor or transformer. The verification of the

entered rated values and the guided commissioning are carried out on the basis of the parameterized motor type.

0 - Unknown The motor is not a standard type.

1 - Asynchronous Three-phase asynchronous motor, squirrel cage 2 - Synchronous Three-phase synchronous motor 3 - Reluctance Three-phase reluctance motor

Setting:

10 - Transformer Transformer with three primary windings

Rated Voltage 370 - enter the voltage indicated on the type plate of the

asynchronous motor. Setting: 60.0 V ... 800.0 V

Rated Current 371 - enter the rated current indicated on the type plate of the

asynchronous motor. Setting:

0.01⋅I

FIN

... 10⋅o⋅I

FIN

Rated Speed 372 – Enter the motor speed (at rated frequency) indicated on the type

plate of the asynchronous motor. Setting: 96 min

-1

... 60000 min-1

Rated Cosinus Phi 374 – enter the cos (ϕ) value indicated on the type plate of the

asynchronous motor. Setting: 0.01 ... 1.00

Rated Frequency 375 – Enter the rated frequency (at parameterized rated speed)

indicated on the type plate of the asynchronous motor. Setting: 10.00 ... 1000.00

06/0548

Rated Mech. Power 376 - enter the power (in kW) indicated on the type plate of the

asynchronous motor. Setting:

0.1⋅P

FIN

... 10⋅P

FIN

Switching Frequency 400 - The rated operating point of the frequency inverter is

defined at a switching frequency of 2 kHz. Higher switching frequencies require a reduction of the output current (see technical data). Setting: 2 kHz, 4 kHz, 8 kHz, 12 kHz, 16 kHz

Min. Switching Frequency 401 – defines the minimum value the switching frequency

is reduced automatically in the case of a thermal overload of the frequency inverter. Setting: 2 kHz, 4 kHz, 8 kHz, 12 kHz, 16 kHz

Minimum Frequency 418 - the start command entered via the control unit or digital

inputs S2IND, S3IND results in an acceleration of the drive to the minimum frequency. Setting: 0.00 Hz ... 999.99 Hz

Maximum Frequency 419 - The speed range of the drive is limited by the maximum

output frequency of the frequency inverter. Setting: 0.00 Hz ... 999.99 Hz

Acceleration (Clockwise) 420, Deceleration (Clockwise) 421 - the ramps define

how fast the output frequency is changed after a start, stop or brake command or when the reference value is changed. Setting: 0.00 Hz/s ... 9999.99 Hz/s ...

Operation Mode 452 (for multi-function input); the set point at input MFI1 can be

adjusted according to the connected signal source.

1 - voltage signal, 0 V ... 10 V (factory setting)

2 - current signal, 0 mA ... 20 mA

Setting:

3 - digital fixed frequency change-over, 0 V ... 24 V, digital input

Fixed Frequency 1 480, Fixed Frequency 2 481 - change-over between the two

fixed frequencies is effected via the fixed frequency change over function of the multi-function input MFI1

Operation Mode 452 (multi-function input on setting 3). Via the data set change-

over S4IND, S5IND, the fixed frequency in one of the four data sets can be selected. Up to 8 fixed frequencies can be parameterized and selected via the control of the digital inputs. Setting: -999.99 Hz ... 999.99 Hz

Op. Mode Digital Output 1 530, Op. Mode Digital Output 3 532 - various control

and monitoring functions can be assigned to the digital output S1OUT and the relay output S3OUT.

0 - switched off

2 - run signal, drive turning/not turning message

3 - fault message

11 - Warning

41 - trigger electro-mechanical brake

Setting:

1xx - inverted operation mode (LOW active)

06/05 49

Analog Operation 553 - output MFO1 supplies a pulse width modulated signal (0 V

... 10 V) which is proportional to an actual value.

7 -

actual frequency, 0 Hz ...

Maximum Frequency 419

20 - active current, 0 A ... I

FIN

30 -

active power P

wirk

, 0 kW ... Rated Mech. Power 376

50 - effective current, 0 A ... I

FIN

Setting:

52 - machine voltage, 0 V ... 1000 V

Motor Temp. Operation Mode. 570 - monitoring the motor temperature protects the

drive system. Connect a suitable sensor to digital input S6IND.

0 - thermo-contact switched off

1 - thermo-contact warning message

2 - thermo-contact error switch-off

3 - Thermo-contact error switch-off after 1 min

4 - Thermo-contact error switch-off after 5 min

Setting:

5 - Thermo-contact error switch-off after 10 min

Operation Mode 645 (for synchronization) - synchronization to a rotating drive is

useful in some applications such as pumps and fans or after acknowledgement of an error switch-off. If synchronization to the motor speed is not possible, the function is quit and a fault message is issued.

0 - switched off

Setting:

10 - synchronization switched on, quick synchronization

Operation Mode 651 - automatic startup of the drive is permissible only in

accordance with VDE 0113 (Section 5.4, 5.5), VDE 0100 Part 227 and the national regulations. Make sure that automatic startup does not result in any dangerous situation.

0 - switched off, control signal at S1IND, S2IND or S3IND

Setting:

1 - automatic startup, control signal at S1IND, S2IND or S3IND

Operation Mode 670 - the DC link voltage, which increases due to generatoric

operation and/or deceleration operations, is limited by means of the voltage controller or an external braking resistor in order to avoid an error switch-off due to overvoltage.

0 - switched off, limited by connected brake resistor

Setting:

1 - overvoltage controller, controlled deceleration ramps

The following parameters are displayed in addition to the basic parameters in

configuration 410.

Integral Time 1 722 - the control behavior of configuration 410 is to be adapted,

depending on the mechanical moment of inertia, via the integral time of the speed controller. The lower the value is, the more dynamic the behavior. The increase in inherent instability of the system is proportional to the reduction of the integral time. Setting: 0 ... 60000 ms

Current Limit 728 - the speed and torque can be controlled separately in

configuration 410. The torque is limited to the rated torque if the current limit is the same as the

Rated Current 371 of the motor.

Setting:

0.0 A ... o⋅I

FIN

FIN, UFIN, PFIN

: nominal values of frequency inverter, o: overload capacity of the frequency

inverter

06/0550

8.2 Menu branch VAL

The actual values in the VAL menu branch facilitate operation and error diagnosis.

R.m.s. Current 211 - effective output current (motor current) of the frequency

inverter calculated from the measurement in the three motor phases. Display:

0.0 A ... o⋅I

FIN

Output Voltage 212 - output voltage of the frequency inverter modulated depending

on the operating point of the motor. Display: 0.0 V ... U

FIN

Active Power 213 - calculated power of the asynchronous motor at the current

operating point. Product of machine voltage, current and cosine phi Display: 0.0 kW ... P

FIN

Actual Speed 240 - speed of the asynchronous machine calculated using the

machine model and the current load point. Display: 0.00 min

-1

... 60000 min-1 ...

Actual Frequency 241 - the current output frequency of the frequency inverter or

actual frequency of the drive calculated from the machine model. Display: 0.00 Hz ... 999.99 Hz

Current Error 259 - the cause which resulted in an error switch-off and the

corresponding error code are displayed. The current error is used for error diagnosis. Display: F0000 ... F9999

Warnings 269 - if a critical condition is detected, this condition is indicated by the

field WARN. The warning code can be read out via parameter 269. Display: A0000 ... A9999

Last Error 310 - the fault message is displayed immediately when a fault occurs.

The frequency inverter will try to acknowledge some errors automatically, other errors will be reset via digital input S1IND. The last error code is saved for error diagnosis. Display: F0000 ... F9999

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9 Operational and error diagnosis

The operation of the frequency inverter and the connected load is continuously

monitored. The operating and error diagnosis documented in the brief instructions are complemented by the information given in the operating instructions.

9.1 Status message

The green and red light-emitting diodes give information about the operating point of

the frequency inverter. If the operating unit has been attached, the status reports are additionally displayed by the display elements RUN, WARN and FAULT.

Status display

green LED red LED Display Description off off - No power supply on on - Initialization and self-test flashes off RUN flashes Ready for operation, no output signal on off RUN Operational message

on flashes

RUN on +

WARN flashes

Operational message, current

Warning 269

flashes flashes

RUN flashes + WARN flashes

Ready for operation, current

Warning 269

off flashes FAULT flashes

Last Error 310 of the frequency inverter

off on FAULT

Last Error 310, acknowledge error

9.2 Warning message

The code which can be read out via parameter

Warnings 269 can be composed of

several messages. For example, code A0088 signals the individual warning messages A0008 + A0080.

Warning messages

Code Meaning A0000 No warning message available. A0001 Frequency inverter overloaded, warning code (A0002 or A0004) A0002 Frequency inverter overloaded (60 s), check load behavior. A0004 Short-term overload (1 s), check motor and application parameters. A0008 Max. heat sink temperature reached, check cooling and fan. A0010 Max. inside temperature reached, check cooling and fan. A0020 Speed reference value is limited by a controller. A0080 Max. motor temperature reached, check motor and sensor. A0100 Mains phase failure, check mains fuses and supply cable. A0400 Limit frequency reached; output frequency is limited. A4000 DC link voltage has reached the type-specific minimum.

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9.3 Fault message

The error code saved after a fault in parameter

Last Error 310 facilitates

troubleshooting and error diagnosis. The error code consists of the error group FXX and the code number XX. The error message is to be acknowledged via the keys of

the control unit and digital input S1IND. Error messages Code Meaning F00 00 No fault has occurred. Overload 02 Frequency inverter overloaded (60 s), check load behavior

F01

03 Short-term overload (1 s), check motor and application parameters Heat sink 00 Heat sink temperature too high, check cooling and fan.

F02

01 Temperature sensor defective or ambient temperature too low. Inside temperature 00 Inside temperature too high, check cooling and fan.

F03

01 Inside temperature too low, check electrical cabinet heating. Motor connection

Motor temperature too high or sensor defective, check connection S6IND.

F04

03 Phase failure, check motor and wiring. Output current 00 Overloaded, check load situation and ramps. 03 Short circuit or earth fault, check motor and wiring. 05 Asymmetric motor current, check motor and wiring.

06 Motor phase current too high, check motor and wiring.

F05

07 Message from phase monitoring, check motor and wiring. DC link voltage

DC link voltage too high, check deceleration ramps and connected brake resistor

01 DC link voltage too low, check mains voltage. 02 Power failure, check mains voltage and circuit 03 Phase failure, check mains fuses and circuit. 04 Mains voltage UDC too high on switch-on, check voltage. 05 Mains voltage BC too high on switch-on, check voltage.

F07

06 Mains voltage MC too high on switch-on, check voltage. Electronics voltage 01 Electronics voltage too low, check control terminals.

F08

04 Electronics voltage too high, check wiring of control terminals. Output frequency 00 Output frequency too high, check control signals and settings.

F11

Max. frequency achieved by control, check deceleration ramps and

connected brake resistor. Motor connection 00 Earth fault on output, check motor and wiring.

F13

10 Minimum current monitoring, check motor and wiring. Control connection 01 Reference value signal on multifunctional input 1 faulty, check signal.

F14

07 Overcurrent on multifunctional input 1, check signal.

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BONFIGLIOLI ACT 201-07, ACT 201-13, ACT 201-09, ACT 201-11, ACT 201-15 Brief Manual

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