Control Techniques Commander SK Quick Start Guide

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Getting Started Guide

Commander SK

Model sizes 2 to 6

AC variable speed drive for 3 phase induction motors

Part Number: 0472-0064-09 Issue: 9

www.controltechniques.com

General Information

The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional operating parameters of the equipment or from mismatching the variable speed drive with the motor.

The contents of this guide are believed to be correct at the time of printing. In the interests of a commitment to a policy of continuous development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or the contents of the guide, without notice.

All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by an information storage or retrieval system, without permission in writing from the publisher.

Drive software version

This product is supplied with the latest software version. If this drive is to be connected to an existing system or machine, all drive software versions should be verified to confirm the same functionality as drives of the same model already present. This may also apply to drives returned from a Control Techniques Service Centre or Repair Centre. If there is any doubt please contact the supplier of the product.

The software version of the drive can be checked by looking at Pr 11.29 and Pr 11.34. This takes the form of xx.yy.zz where Pr 11.29 displays xx.yy and Pr 11.34 displays zz. (e.g. for software version 01.01.00, Pr 11.29 = 1.01 and Pr 11.34 displays 0).

Environmental statement

Control Techniques is committed to minimising the environmental impacts of its manufacturing operations and of its products throughout their life cycle. To this end, we operate an Environmental Management System (EMS) which is certified to the International Standard ISO 14001. Further information on the EMS, our Environmental Policy and other relevant information is available on request, or can be found at www.greendrives.com.

The electronic variable-speed drives manufactured by Control Techniques have the potential to save energy and (through increased machine/process efficiency) reduce raw material consumption and scrap throughout their long working lifetime. In typical applications, these positive environmental effects far outweigh the negative impacts of product manufacture and end-of-life disposal.

Nevertheless, when the products eventually reach the end of their useful life, they must not be discarded but should instead be recycled by a specialist recycler of electronic equipment. Recyclers will find the products easy to dismantle into their major component parts for efficient recycling. Many parts snap together and can be separated without the use of tools, whilst other parts are secured with conventional fasteners. Virtually all parts of the product are suitable for recycling.

Product packaging is of good quality and can be re-used. Large products are packed in wooden crates, while smaller products come in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, these containers can be recycled. Polythene, used on the protective film and bags for wrapping product, can be recycled in the same way. Control Techniques' packaging strategy prefers easily-recyclable materials of low environmental impact, and regular reviews identify opportunities for improvement.

When preparing to recycle or dispose of any product or packaging, please observe local legislation and best practice.

REACH legislation

EC Regulation 1907/2006 on the Registration, Evaluation, Authorisation and restriction of Chemicals (REACH) requires the supplier of an article to inform the recipient if it contains more than a specified proportion of any substance which is considered by the European Chemicals Agency (ECHA) to be a Substance of Very High Concern (SVHC) and is therefore listed by them as a candidate for compulsory authorisation.

For current information on how this requirement applies in relation to specific Control Techniques products, please approach your usual contact in the first instance. Control Techniques position statement can be viewed at:

http://www.controltechniques.com/REACH

Issue Number:9

Software: 01.08.01 onwards

Contents

1 Safety Information .............................................................. 5

2 Product Information ........................................................... 9

2.1 Ratings .................................................................................................... 9

2.2 Typical short term overload limits .......................................................... 10

2.3 Rating Data ...........................................................................................11

2.4 Accessories supplied with the drive ......................................................19

3 Mechanical Installation .................................................... 20

3.1 Fire protection .......................................................................................20

3.2 Removing the terminal covers ............................................................... 21

3.3 Mounting methods ................................................................................. 23

3.4 Mounting brackets ................................................................................. 28

3.5 Enclosure .............................................................................................. 30

3.6 Electrical terminals ................................................................................ 31

4 Electrical Installation ........................................................ 33

4.1 Power connections ................................................................................ 33

4.2 Heatsink fan ..........................................................................................38

4.3 Ground leakage ..................................................................................... 40

4.4 EMC (Electromagnetic compatibility) ....................................................42

4.5 Control terminals I/O specification ........................................................ 43

5 Keypad and Display .......................................................... 48

5.1 Programming keys ................................................................................48

5.2 Control keys ..........................................................................................48

5.3 Selecting and changing parameters ...................................................... 49

5.4 Saving parameters ................................................................................ 50

5.5 Parameter access .................................................................................50

5.6 Security codes ....................................................................................... 50

5.7 Setting drive back to default values ......................................................51

6 Parameters ........................................................................ 52

6.1 Parameter descriptions - Level 1 ..........................................................52

6.2 Parameter descriptions - Level 2 ..........................................................59

6.3 Parameter descriptions - Level 3 ..........................................................69

6.4 Diagnostic parameters .......................................................................... 69

7 Quick start commissioning .............................................. 70

7.1 Terminal control ....................................................................................70

7.2 Keypad control ...................................................................................... 72

8 Diagnostics ....................................................................... 74

9 Options .............................................................................. 77

10 UL listing information ....................................................... 79

10.1 Common UL information ....................................................................... 79

10.2 Power dependant UL information .......................................................... 79

10.3 AC supply specification ......................................................................... 80

10.4 Maximum continuous output current ..................................................... 80

10.5 Safety label ...........................................................................................80

Commander SK Size 2 to 6 Getting Started Guide Issue Number: 9 www.controltechniques.com

Declaration of Conformity

Control Techniques Ltd, The Gro, Newtown. Powys. UK. SY16 3BE

SK2201 SK2202 SK2203 SK2401 SK2402 SK2403 SK2404

SK3201 SK3202 SK3401 SK3402 SK3403

SK3501 SK3502 SK3503 SK3504 SK3505 SK3506 SK3507

SK4201 SK4202 SK4203 SK4401 SK4402 SK4403

SK4601 SK4602 SK4603 SK4604 SK4605 SK4606

SK5401 SK5402 SK5601 SK5602

SK6401 SK6402 SK6601 SK6602

The AC variable speed drive products listed above have been designed and manufactured in

accordance with the following European harmonized standards:

EN 61800-5-1:2007

EN 61800-3:2004

EN 61000-6-2:2005

EN 61000-6-4:2007*

EN 61000-3-2:2006

EN 61000-3-3:2008**

* Applicable to sizes 2 to 4 only. ** Applicable to size 2 only.

These products are for professional use, and power input exceeds 1kW for all models, so no limits

apply.

These products comply with the Low Voltage Directive 2006/95/EC and the Electromagnetic Compatibility Directive 2004/108/EC.

Adjustable speed electrical power drive systems - safety requirements

- electrical, thermal and energy

Adjustable speed electrical power drive systems. EMC product standard including specific test methods

Electromagnetic compatibility (EMC). Generic standards. Immunity standard for industrial environments

Electromagnetic compatibility (EMC). Generic standards. Emission standard for industrial environments

Electromagnetic compatibility (EMC). Limits. Limits for harmonic

current emissions (equipment input current up to and including 16 A

per phase)

Electromagnetic compatibility (EMC). Limits. Limitation of voltage fluctuations and flicker in low-voltage supply systems for equipment with rated current <= 16 A

T. Alexander

Executive VP Technology

Date: 26th May 2009

These electronic drive products are intended to be used with appropriate motors, controllers, electrical protection components and other equipment to form complete end products or systems. Compliance with safety and EMC regulations depends upon installing and configuring drives correctly, including using the specified input filters. The drives must be installed only by professional assemblers who are familiar with requirements for safety and EMC. The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used. Refer to the Technical Data Guide. An EMC Data Sheet is also available giving detailed EMC information.

4 Commander SK Size 2 to 6 Getting Started Guide

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1 Safety Information

WARNING

CAUT ION

NOTE

1.1 Warnings, Cautions and Notes

A Warning contains information, which is essential for avoiding a safety hazard.

A Caution contains information, which is necessary for avoiding a risk of damage to the product or other equipment.

Information

Installation

Safety

Product

Mechanical

A Note contains information which helps to ensure correct operation of the product.

1.2 Electrical safety - general warning

The voltages used in the drive can cause severe electrical shock and/or burns, and could be lethal. Extreme care is necessary at all times when working with or adjacent to the drive.

Specific warnings are given at the relevant places in this Guide.

1.3 System design and safety of personnel

The drive is intended as a component for professional incorporation into complete equipment or system. If installed incorrectly, the drive may present a safety hazard.

The drive uses high voltages and currents, carries a high level of stored electrical energy, and is used to control equipment which can cause injury.

System design, installation, commissioning / start-up and maintenance must be carried out by personnel who have the necessary training and experience. They must read this safety information and this guide carefully.

The STOP and START controls or electrical inputs of the drive must not be relied upon to ensure safety of personnel. They do not isolate dangerous voltages from the output of the drive or from any external option unit. The supply must be disconnected by an approved electrical isolation device before gaining access to the electrical connections.

The drive is not intended to be used for safety-related functions.

Careful consideration must be given to the function of the drive which might result in a hazard, either through its intended behaviour or through incorrect operation due to a fault. In any application where a malfunction of the drive or its control system could lead to or allow damage, loss or injury, a risk analysis must be carried out, and where necessary, further measures taken to reduce the risk - for example, an over-speed protection device in case of failure of the speed control, or a fail-safe mechanical brake in case of loss of motor braking.

Installation

Electrical

Keypad and

Display

Parameters

commissioning

Quick start

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information

UL listing

Commander SK Size 2 to 6 Getting Started Guide 5 Issue Number: 9 www.controltechniques.com

1.4 Environmental limits

Instructions within the supplied data and information within the Commander SK Technical Data Guide regarding transport, storage, installation and the use of the drive

must be complied with, including the specified environmental limits. Drives must not be subjected to excessive physical force.

1.5 Access

Access must be restricted to authorized personnel only. Safety regulations which apply at the place of use must be complied with.

The IP (Ingress Protection) rating of the drive is installation dependant. For further information, refer to the Commander SK Technical Data Guide.

1.6 Fire protection

The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided. For further information, refer to section 3.1 Fire protection on page 20.

1.7 Compliance with regulations

The installer is responsible for complying with all relevant regulations, such as national wiring regulations, accident prevention regulations and electromagnetic compatibility (EMC) regulations. Particular attention must be given to the cross-sectional areas of conductors, the selection of fuses and other protection, and protective ground (earth) connections.

The Commander SK Technical Data Guide contains instructions for achieving compliance with specific EMC standards.

Within the European Union, all machinery in which this product is used must comply with the following directives:

2006/42/EC: Safety of machinery

2004/108/EC: Electromagnetic compatibility

1.8 Motor

Ensure the motor is installed in accordance with the manufacturer's recommendations. Ensure the motor shaft is not exposed.

Standard squirrel cage induction motors are designed for single speed operation. If it is intended to use the capability of a drive to run a motor at speeds above its designed maximum, it is strongly recommended that the manufacturer is consulted first.

Low speeds may cause the motor to overheat because the cooling fan becomes less effective. The motor should be installed with a protection thermistor. If necessary, an electric force vent fan should be used.

The values of the motor parameters set in the drive affect the protection of the motor. The default values in the drive should not be relied upon.

It is essential that the correct value is entered into parameter 06, motor rated current. This affects the thermal protection of the motor.

6 Commander SK Size 2 to 6 Getting Started Guide

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1.9 Mechanical brake control

The brake control functions are provided to allow well co-ordinated operation of an external brake with the drive. While both hardware and software are designed to high standards of quality and robustness, they are not intended for use as safety functions, i.e. where a fault or failure would result in a risk of injury. In any application where the incorrect operation of the brake release mechanism could result in injury, independent protection devices of proven integrity must also be incorporated.

1.10 Adjusting parameters

Some parameters have a profound effect on the operation of the drive. They must not be altered without careful consideration of the impact on the controlled system. Measures must be taken to prevent unwanted changes due to error or tampering.

1.11 Electrical installation

1.11.1 Electric shock risk

The voltages present in the following locations can cause severe electric shock and may be lethal:

• AC supply cables and connections

• DC bus, dynamic brake cables and connections

• Output cables and connections

• Many internal parts of the drive, and external option units

Unless otherwise indicated, control terminals are single insulated and must not be touched.

1.11.2 Isolation device

The AC supply must be disconnected from the drive using an approved isolation device before any cover is removed from the drive or before any servicing work is performed.

1.11.3 STOP function

The STOP function does not remove dangerous voltages from the drive, the motor or any external option units.

1.11.4 Stored charge

The drive contains capacitors that remain charged to a potentially lethal voltage after the AC supply has been disconnected. If the drive has been energized, the AC supply must be isolated at least ten minutes before work may continue.

Normally, the capacitors are discharged by an internal resistor. Under certain, unusual fault conditions, it is possible that the capacitors may fail to discharge, or be prevented from being discharged by a voltage applied to the output terminals. If the drive has failed in a manner that causes the display to go blank immediately, it is possible the capacitors will not be discharged. In this case, consult Control Techniques or their authorized distributor.

1.11.5 Equipment supplied by plug and socket

Special attention must be given if the drive is installed in equipment which is connected to the AC supply by a plug and socket. The AC supply terminals of the drive are connected to the internal capacitors through rectifier diodes which are not intended to give safety isolation. If the plug terminals can be touched when the plug is disconnected from the socket, a means of automatically isolating the plug from the drive must be used (e.g. a latching relay).

Information

Installation

Display

commissioning

information

Safety

Product

Mechanical

Electrical

Keypad and

Parameters

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UL listing

Commander SK Size 2 to 6 Getting Started Guide 7 Issue Number: 9 www.controltechniques.com

1.11.6 Ground leakage current

The drive is supplied with an internal EMC filter capacitor installed. If the input voltage to the drive is supplied through an ELCB or RCD, these may trip due to the ground leakage current. See section 4.3.1 Internal EMC filter on page 40 for further information and how to disconnect the internal EMC capacitor.

1.12 Mechanical installation

1.12.1 Lifting the drive

The weights of the model sizes 4, 5 and 6 are as follows:

Size 4: 30kg (66Ibs)

Size 5: 55kg (121Ibs)

Size 6: 75kg (165Ibs)

Use appropriate safeguards when lifting these models.

8 Commander SK Size 2 to 6 Getting Started Guide

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2 Product Information

Available output

current

Overload limit -

Heavy Duty

Maximum continuous current (above 50% base speed) -

Normal Duty

Maximum continuous current -

Heavy Duty

Motor rated current set in the drive

Heavy Duty

- with high

overload capability

Normal Duty

Overload limit -

Normal Duty

NOTE

2.1 Ratings

Safety Information

Commander SK sizes 2 to 6 are dual rated. The setting of the motor rated current determines

which rating applies - Heavy Duty or Normal Duty. The two ratings are compatible with motors designed to IEC 60034. The following graph illustrates the difference

between Normal Duty and Heavy Duty with respect to continuous current rating and short term overload limits.

Normal Duty Heavy Duty (default)

For applications which use self ventilated induction motors and require a low overload capability (e.g. fans, pumps). Self ventilated induction motors require increased protection against overload due to the reduced

For constant torque applications or applications which require a high overload capability (e.g. cranes, hoists). The thermal protection is set to protect force ventilated induction motors by default.

cooling effect of the fan at low speed. To provide

the correct level of protection the I2t software operates at a level which is speed dependent. This is illustrated in the graph below.

If the application uses a self ventilated motor and increased thermal protection is required for speeds below 50% base speed, then this can be enabled by setting Pr 4.25 = 1.

The speed at which the low speed protection takes effect can be changed by the setting of Pr 4.25.

See Menu 4 in the Commander SK Advanced User Guide for further details.

The protection starts when the motor speed is below 15% of base speed when Pr 4.25 = 0 (default) and below 50% when Pr 4.25 = 1. See Menu 4 in the Commander SK Advanced User Guide for further details.

Information

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Commander SK Size 2 to 6 Getting Started Guide 9 Issue Number: 9 www.controltechniques.com

information

UL listing

Operation of motor I2t protection (It.AC trip) Operation of motor I2t protection (It.AC trip)

Motor total current (Pr 4.01) as a percentage

of motor rated

current

Motor speed as a percentage of base speed

100%

Max. permissible continuous current

100%

I t protection operates in this region

70%

50%15%

Pr = 0 Pr = 1

4.25

Motor total current (Pr 4.01) as a percentage

of motor rated

current

Motor speed as a percentage of base speed

100%

Max. permissible continuous current

100%

I t protection operates in this region

70%

50%

Pr = 0 Pr = 1

4.25

NOTE

Motor I2t protection is fixed as shown below and is compatible with:

Motor I2t protection defaults to be compatible with:

• Forced ventilation induction motors

• Self ventilated induction motors

2.2 Typical short term overload limits

The maximum percentage overload limit changes depending on the induction motor only. Variations in motor rated current, motor rated power factor and motor leakage inductance all result in changes in the maximum possible overload. The exact value for a specific motor can be calculated using the equations detailed in Menu 4 in the Commander SK Advanced User Guide.

Table 2-1 Typical overload limits for size 2 to 5 (peak current)

From cold From 100% full load

Normal Duty overload with motor rated current = drive rated current

Heavy Duty overload with motor rated current = drive rated current

110% for 215s 110% for 5s

150% for 60s 150% for 8s

Table 2-2 Typical overload limits for size 6 (peak current)

From cold From 100% full load

Normal Duty overload with motor rated current = drive rated current

Heavy Duty overload with motor rated current = drive rated current

110% for 165s 110% for 9s

129% for 97s 129% for 15s

Generally the drive rated current is higher than the matching motor rated current allowing a higher level of overload than the default setting. The time allowed in the overload region is proportionally reduced at very low output frequency on some drive ratings.

The maximum overload level which can be attained is independent of the speed.

The output frequency can be increased by 20% during deceleration.

10 Commander SK Size 2 to 6 Getting Started Guide

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2.3 Rating Data

SK 2 4 01

Model number within frame size

Input voltage range:

2 = 200 to 240V 4 = 380 to 480V 5 = 500 to 575V

6 = 500 to 690V

Frame size

Commander SK product range

NOTE

Figure 2-1 Model code explanation

Information

Installation

Safety Information

Product

Mechanical

The nominal motor power kW ratings stated are at 220V, 400V, 575V and 690V. However, the nominal motor power hp ratings stated are at 230V, 460V, 575V and 690V.

Table 2-3 Commander SK2, 200V drive, 3 phase, 200 to 240Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

number

SK2201 4.0 5.0 15.5 3.0 3.0 12.6 18.9

SK2202 5.5 7.5 22 4.0 5.0 17 25.5

SK2203 7.5 10 28 5.5 7.5 25 37.5

Model

number

SK2201 13.4 18.1 20 20

SK2203 24.2 28.3 32 30

Nominal motor

power

kW hp A kW hp A A

Typical full

load input

current*

AA A A Ω kW

100% RMS

output current

Maximum

continuous

input current*

Nominal motor

European input fuse

rating IEC gG

power

USA Input fuse

rating

Class CC <30A

Class J >30A

100% RMS

output current

Minimum

braking resistor

value

18 8.9SK2202 18.2 22.6 25 25

Peak

current

Instantaneous

power rating

* These are Normal Duty values. Refer to Table 2-1 for typical overload limits for Size 2 to 5.

Installation

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Commander SK Size 2 to 6 Getting Started Guide 11 Issue Number: 9 www.controltechniques.com

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UL listing

Table 2-4 Commander SK2, 400V drive, 3 phase, 380 to 480Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

Number

SK2401 7.5 10 15.3 5.5 7.5 13 19.5

SK2402 11 15 21 7.5 10 16.5 24.7

SK2403 15 20 29 11 20 25 34.5

SK2404

Nominal motor

power

kW hp A kW hp A A

100% RMS

output current

Nominal motor

power

15 20 29 43.5

100% RMS

output current

Peak

current

Typ i cal f u ll

Model

Number

SK2401 15.7 17 20 20

SK2402 20.2 21.4 25 25

SK2403 26.6 27.6 32 30

SK2404 26.6 27.6 32 30

load input

current*

AA A A Ω kW

Maximum

continuous

input current*

European input fuse

rating IEC gG

USA Input fuse

rating

Class CC <30A

Class J >30A

Minimum

braking

resistor

value

19 33.1

Instantaneous

power rating

Table 2-5 Commander SK3, 200V drive, 3 phase, 200 to 240Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

Number

SK3201 11 15 42 7.5 10 31 46.5

SK3202

Model

Number

SK3201 35.4 43.1 50 45

SK3202 46.8 54.3 63 60

Nominal motor

power

kW hp A kW hp A A

15 20 54 11 15 42 63

Typ i cal f u ll

load input

current*

AA A A Ω kW

100% RMS

output current

Maximum

continuous

input current*

Nominal motor

European input fuse

rating IEC gG

power

USA Input fuse

rating

Class CC <30A

Class J >30A

100% RMS

output current

Minimum

braking resistor

value

530.3

Peak

current

Instantaneous

power rating

12 Commander SK Size 2 to 6 Getting Started Guide

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Table 2-6 Commander SK3, 400V drive, 3 phase, 380 to 480Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

Number

Nominal motor

power

100% RMS output

current

Nominal motor

power

100% RMS

output current

kW hp A kW hp A A

SK3401 18.5 25 35 15 25 32 48

SK3402 22 30 43 18.5 30 40 60

SK3403

30 40 56 22 30 46 69

Peak

current

Information

Safety Information

Product

Model

Number

Typ ica l

full load

input

current*

Maximum

continuous

input

current*

European input fuse

rating

IEC gG

USA Input fuse

rating

Class CC <30A

Class J >30A

Minimum

braking

resistor value

Instantaneous power

rating

AA A A Ω kW

SK3401 34.2 36.2 40 40

18 35.5SK3402 40.2 42.7 50 45

SK3403 51.3 53.5 63 60

Table 2-7 Commander SK3, 575V drive, 3 phase, 500 to 575Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

Number

Nominal motor

power

100% RMS

output current

Nominal motor

power

100% RMS

output current

kW hp A kW hp A A

SK3501 3.0 3.0 5.4 2.2 2.0 4.1 6.1

SK3502 4.0 5.0 6.1 3.0 3.0 5.4 8.1

SK3503

SK3504

SK3505

SK3506

SK3507

Model

Number

5.5 7.5 8.4 4.0 5.0 6.1 9.1

7.5 10 11 5.5 7.5 9.5 14.2

11 15 16 7.5 10 12 18

15 20 22 11 15 18 27

18.5 25 27 15 20 22 33

Typical full

load input

current*

Maximum

continuous

input current*

European

input fuse

rating IEC gG

USA Input fuse

rating

Class CC <30A

Class J = 30A

Minimum

braking resistor

value

AA A A Ω kW

SK3501 5.0 6.7 8 10

SK3502 6.0 8.2 10 10

SK3503 7.8 11.1 12 15

SK3504 9.9 14.4 16 15

18 50.7

SK3505 13.8 18.1 20 20

SK3506 18.2 22.2 25 25

SK3507 22.2 26 32 30

Peak

current

Instantaneous

power rating

Mechanical

Installation

Electrical

Keypad and

Display

Parameters

commissioning

Quick start

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Commander SK Size 2 to 6 Getting Started Guide 13 Issue Number: 9 www.controltechniques.com

information

UL listing

Table 2-8 Commander SK4, 200V drive, 3 phase, 200 to 240Vac ±10%, 48 to 65Hz units

NOTE

Normal Duty Heavy Duty

Model

number

SK4201 18.5 25 68 15 20 56 84

SK4202 22 30 80 18.5 25 68 102

SK4203

Nominal motor

power

kW hp A kW hp A A

30 40 104 22 30 80 120

100% RMS

output current

Nominal motor power

100% RMS

output current

Peak

current

Typ ica l

Model

number

SK4201 62.1 68.9 100 90 90 160

SK4202 72.1 78.1 100 100 100 160

SK4203 94.5 99.9 125 125 125 200

full load

current*

Maximum

continuous

input

AA A AAA

input

current*

Fuse option 1 Fuse option 2**

European input fuse

rating

IEC gR

USA Input fuse rating Ferraz HSJ

HRC

IEC class

UL class J

Semi-

conductor

IEC class

Minimum

braking

resistor

Instantaneous

value

power rating

530.3

Table 2-9 Commander SK4, 400V drive, 3 phase, 380 to 480Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

number

SK4401 37 50 68 30 50 60 90

SK4402 45 60 83 37 60 74 111

SK4403

Model

number

SK4401 61.2 62.3 80 80 80 160

SK4402 76.3 79.6 110 110 100 200

SK4403 94.1 97.2 125 125 125 200 9 67.6

Nominal motor

power

kW hp A kW hp A A

55 75 104 45 75 96 144

Typ ic al

full load

current*

Maximum

continuous

input

AA AAAA

input

current*

100% RMS

output current

Fuse option 1 Fuse option 2**

European

input fuse

rating

IEC gR

Nominal motor power

USA Input fuse rating Ferraz HSJ

HRC

IEC class

UL class J

100% RMS

output current

Semi-

conductor

IEC class

Minimum

braking resistor

value

11 55.3

Peak

current

Instantaneous

power rating

* These are Normal Duty values.

** Semi conductor fuse in series with HRC fuse or circuit breaker.

The Commander SK size 4 to 6 cannot be used on single-phase supplies due to the halfcontrolled input stage on these drives.

14 Commander SK Size 2 to 6 Getting Started Guide

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Table 2-10 Commander SK4, 575V drive, 3 phase, 500 to 575Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

number

Nominal motor

power

100% RMS

output current

Nominal motor power

100% RMS

output current

Peak current

kW hp A kW hp A A

SK4603 22 30 36 18.5 25 27 40.5

SK4604

SK4605

SK4606

Model

number

SK4603 32.9 35.1

SK4604 39 41

SK4605 46.2 47.9

SK4606 55.2 56.9 80

30 40 43 22 30 36 54

37 50 52 30 40 43 64.5

45 60 62 37 50 52 78

Typ ic al

full load

current*

input

Maximum

continuous

input

current*

AA AAAA

Fuse option 1 Fuse option 2**

European

input fuse

rating

IEC gR

USA Input

fuse rating

Ferraz HSJ

HRC

IEC class

UL class J

Minimum

braking resistor

value

Semi-

conductor

IEC class

125 13 95

Instantaneous

power rating

Table 2-11 Commander SK4, 690V drive, 3 phase, 500 to 690Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

number

Nominal motor

power

kW hp A kW hp A A

SK4601 18.5 25 22 15 20 19 27 SK4602 22 30 27 18.5 25 22 33 SK4603 SK4604 SK4605 SK4606

30 40 36 22 30 27 40.5 37 50 43 30 40 36 54 45 60 52 37 50 43 64.5 55 75 62 45 60 52 78

100% RMS

output current

Nominal motor

power

100% RMS

output current

Peak current

Information

Installation

Display

commissioning

Safety Information

Product

Mechanical

Electrical

Keypad and

Parameters

Quick start

Fuse option 1 Fuse option 2**

European

input fuse

rating

IEC gR

USA Input fuse rating

Ferraz HSJ

HRC

IEC class

UL class J

Semi-

conductor

IEC class

Minimum

braking resistor

value

Instantaneous

power rating

Model

number

Typ ic al

full load

current*

input

Maximum

continuous

input

current*

AA AAAA

SK4601 23 26.5

SK4602 26.1 28.8 40

SK4603 32.9 35.1

SK4604 39 41

SK4605 46.2 47.9

SK4606 55.2 56.9 80

125 13 95

Commander SK Size 2 to 6 Getting Started Guide 15 Issue Number: 9 www.controltechniques.com

Diagnostics Options

information

UL listing

Table 2-12 Commander SK5, 400V drive, 3 phase, 380 to 480Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

number

SK5401 75 100 138 55 100 124 186

SK5402

Nominal motor

power

kW hp A kW hp A A

90 125 168 75 125 156 234

100% RMS

output current

Nominal motor power

100% RMS output

current

Peak current

Typ ica l

Model

number

SK5401 126 131 200 175 160 200

SK5402 152 156 250 225 200 250

full load

input

current*

Maximum

continuous

input

current*

AA AAAA

Fuse option 1 Fuse option 2**

European

input fuse

rating

IEC gR

USA Input

fuse rating

Ferraz HSJ

HRC

IEC class

UL class J

Semi-

conductor

IEC class

Minimum

braking resistor

Instantaneous

value

power rating

786.9

Table 2-13 Commander SK5, 575V drive, 3 phase, 500 to 575Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

number

SK5601 55 75 84 45 60 63 93

SK5602

Model

number

SK5601 75.5 82.6

SK5602 89.1 94.8 125

Nominal motor

power

kW hp A kW hp A A

75 100 99 55 75 85 126

Typ ic al

full load

input

current*

Maximum

continuous

input

current*

AA AAAA

100% RMS

output current

Fuse option 1 Fuse option 2**

European

input fuse

rating

IEC gR

125 100

Nominal motor power

USA Input

fuse rating Ferraz HSJ

HRC

IEC class

UL class J

100% RMS output

current

Semi-

conductor

IEC class

Minimum

braking resistor

160 10 125.4

value

Peak current

Instantaneous

power rating

* These are Normal Duty values. ** Semi conductor fuse in series with HRC fuse or circuit breaker.

16 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

Table 2-14 Commander SK5, 690V drive, 3 phase, 500 to 690Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

number

SK5601 75 100 84 55 75 63 93

SK5602

Nominal motor

power

100% RMS

output current

Nominal motor power

100% RMS output

current

Peak current

kW hp A kW hp A A

90 125 99 75 100 85 126

Information

Safety Information

Product

Fuse option 1 Fuse option 2**

European input fuse

rating

IEC gR

125 100

USA Input fuse rating

Ferraz HSJ

HRC

IEC class

UL class J

Minimum

braking resistor

value

Instantaneous

Semi-

conductor

IEC class

160 10 125.4

power rating

Model

number

Typ ic al

full load

current*

input

Maximum

continuous

input

current*

AA AAAA

SK5601 75.5 82.6

SK5602 89.1 94.8 125

Table 2-15 Commander SK6, 400V drive, 3 phase, 380 to 480Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

number

SK6401 110 150 205 90 150 180 231

SK6402

Model

number

SK6401 224 241 315 300 250 315

SK6402 247 266 315 300 300 350

Nominal motor

power

100% RMS

output current

Nominal motor power

100% RMS

output current

Peak current

kW hp A kW hp A A

132 200 236 110 150 210 270

Typ ic al

full load

current*

input

Maximum

continuous

input

current*

AA AAAA

Fuse option 1 Fuse option 2**

European

input fuse

rating

IEC gR

USA Input fuse rating Ferraz HSJ

HRC

IEC class

UL class J

Semi-

conductor

IEC class

Minimum

braking resistor

value

Instantaneous

5 121.7

power rating

Mechanical

Installation

Electrical

Keypad and

Display

Parameters

commissioning

Quick start

Diagnostics Options

Commander SK Size 2 to 6 Getting Started Guide 17 Issue Number: 9 www.controltechniques.com

information

UL listing

Table 2-16 Commander SK6, 575V drive, 3 phase, 500 to 575Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

number

SK6601 90 125 125 75 100 100 128

SK6602

Nominal motor

power

kW hp A kW hp A A

110 150 144 90 125 125 160

100% RMS

output current

Nominal motor power

100% RMS

output current

Peak current

Typ ic al

Model

number

SK6601 128 138

SK6602 144 156

full load

current*

Maximum

continuous

input

AA AAAA

input

current*

Fuse option 1 Fuse option 2**

European

input fuse

rating

IEC gR

USA Input fuse rating

Ferraz HSJ

200 200 200 200 10 125.4

HRC

IEC class

UL class J

Semi-

conductor

IEC class

Minimum

braking resistor

value

Instantaneous

power rating

Table 2-17 Commander SK6, 690V drive, 3 phase, 500 to 690Vac ±10%, 48 to 65Hz units

Normal Duty Heavy Duty

Model

number

SK6601 110 150 125 90 125 100 128

SK6602

Model

number

SK6601 128 138

SK6602 144 156

Nominal motor

power

kW hp A kW hp A A

132 175 144 110 150 125 160

Typ ic al

full load

current*

Maximum

continuous

input

AA AAAA

input

current*

100% RMS

output current

Fuse option 1 Fuse option 2**

European

input fuse

rating

IEC gR

200 200 200 200 10 125.4

Nominal motor power

USA Input

fuse rating Ferraz HSJ

HRC

IEC class

UL class J

100% RMS

output current

Semi-

conductor

IEC class

Minimum

braking

resistor

value

Peak current

Instantaneous

power rating

* These are Normal Duty values. ** Semi conductor fuse in series with HRC fuse or circuit breaker.

Refer to Table 2-2 for typical overload limits for Size 6.

18 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

2.4 Accessories supplied with the drive

CAUTION

Risk of Electric Shoc k

Power down unit 10min utes

before removing cover

The following accessories are supplied with the drive in the Accessory Kit Box:

Table 2-18 Parts supplied with the drive

Description

UL warning label

Grounding bracket

Through panel mounting gasket

Through panel mounting bracket

Surface mounting brackets

Top surface mounting brackets

Nylon washers

Sealing clips

Grounding clamp

Size 2 Size 3 Size 4 Size 5 Size 6

Information

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Display

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Mechanical

Electrical

Keypad and

Parameters

Ground cable bridge

DC terminal cover grommets

Ferrite ring

Supply and motor connector

M5 nuts

Fan supply connector

IP54 insert

Commander SK Size 2 to 6 Getting Started Guide 19 Issue Number: 9 www.controltechniques.com

commissioning

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UL listing

3 Mechanical Installation

WARNING

Drive

The drive is intended to be mounted in an enclosure which prevents access except by trained and authorized personnel, and which prevents the ingress of contamination. It is designed for use in an environment classified as pollution degree 2 in accordance with IEC 60664-1. This means that only dry, non-conducting contamination is acceptable.

3.1 Fire protection

The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided.

For installation in the USA, a NEMA 12 enclosure is suitable.

For installation outside the USA, the following (based on IEC 62109-1, standard for PV inverters) is recommended.

Enclosure can be metal and/or polymeric, polymer must meet requirements which can be summarized for larger enclosures as using materials meeting at least UL 94 class 5VB at the point of minimum thickness.

Air filter assemblies to be at least class V-2.

The location and size of the bottom shall cover the area shown in Figure 3-1. Any part of the side which is within the area traced out by the 5° angle is also considered to be part of the bottom of the fire enclosure.

Figure 3-1 Fire enclosure bottom layout

The bottom, including the part of the side considered to be part of the bottom, must be designed to prevent escape of burning material - either by having no openings or by having a baffle construction. This means that openings for cables etc. must be sealed with materials meeting the 5VB requirement, or else have a baffle above.

20 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

See Figure 3-2 for acceptable baffle construction. This does not apply for mounting in

Notless tha n 2X

Baffle plates (may be aboveor below bottom of enclosure)

Bottom of fire

enclosure

Not less than 2 times ‘X’

Baffle plates (may be above or

below bottom of enclosure)

Bottom of fire enclosure

Pozi Pz1

an enclosed electrical operating area (restricted access) with concrete floor.

Figure 3-2 Fire enclosure baffle construction

3.2 Removing the terminal covers

To remove a terminal cover, undo the screw and lift the terminal cover off as shown. When replacing the terminal covers, the screws should be tightened with a maximum torque of 0.8Nm (0.6 lb ft) for the control terminal cover and 1Nm (0.7 Ib ft) for the other covers.

Figure 3-3 Removing the control stage terminal cover

Safety Information

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Commander SK Size 2 to 6 Getting Started Guide 21 Issue Number: 9 www.controltechniques.com

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Figure 3-4 Removing the power stage terminal covers

Pozi Pz2

All sizes

Size 3 only

Sizes 4 to 6 only

Figure 3-5 Removing the finger-guard and DC terminal cover break-outs

Place finger-guard on a solid flat surface and hit relevant break-outs with hammer as shown (1). Continue until all required break-outs are removed (2). Remove any sharp edges once break-outs are removed.

22 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

Figure 3-6 Size 4 to 6 finger-guard grommets

Single cable entry grommet

Double cable entry grommet

WARNING

The grommets are available as a kit of four grommets under the following part numbers:

9500-0074 Kit of four single entry grommets

9500-0075 Kit of four double entry grommets

If the break-outs are removed from the finger-guard, then the grommets are required for Commander SK size 4 to 6 to meet the IP20 standard.

Figure 3-7 Removing the terminal cover break-outs

Safety Information

Information

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Mechanical

Installation

Electrical

Keypad and

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Parameters

Grasp the DC terminal cover break-outs with pliers as shown (1) and twist to remove. Continue until all required break-outs are removed. Remove any sharp edges once the break-outs are removed (2). Use the DC terminal cover grommets supplied in the accessory box (Table 2-18 on page 19) to maintain the seal at the top of the drive.

3.3 Mounting methods

The Commander SK can be either surface or through-panel mounted using the appropriate brackets.

If the drive has been used at high load levels for a period of time, the heatsink can reach temperatures in excess of 70°C (158°F). Human contact with the heatsink should be prevented.

Commander SK Size 2 to 6 Getting Started Guide 23 Issue Number: 9 www.controltechniques.com

commissioning

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UL listing

3.3.1 Surface mounting

155mm

(6.102in)

368mm (14.488in)

219mm

(8.622in)

371.6mm (14.630in)

∅

6.5mm

(0.256in)

∅

6.5mm

(0.256in)

21mm (0.827in)

337.5 1.0mm

(13.287 0.039in)

106 1.0mm

4.173 0.039in

24.5mm

(0.965in)

250mm (9.843in)

368mm (14.488in)

260mm (10.236in)

361mm (14.213in)

21mm (0.827in)

97mm

(3.819in)

47mm

(1.850in)

106±1.0mm

(4.173±0.039in)

∅

6.5mm

(0.256in)

327±1.0mm

(12.874±0.039in)

∅

6.5mm

(0.256in)

Figure 3-8 Surface mounting the size 2 drive

Figure 3-9 Surface mounting the size 3 drive

24 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

Figure 3-10 Surface mounting the size 4 drive

310mm (12.205in)

510mm (20.079in)

298mm (11.732in)

258.6 0.5mm

(10.181 0.020in)

528.8

0.5mm

(20.819

0.020in)

546.8mm

(21.528in)

18.4mm (0.724in)

25.7 0.5mm

(1.012 0.020in)

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

258.6 0.5mm

(10.181 0.020in)

25.7 0.5mm

(1.012 0.020in)

839.3

0.5mm

(33.043

0.020in)

310mm (12.205in) 298mm (11.732in)

857.3mm

(33.752in)

820mm (32.283in)

18.4mm (0.72in)

∅

8.5mm

(0.335in)∅8.5mm

(0.335in)

Figure 3-11 Surface mounting the size 5 drive

Safety Information

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Mechanical

Installation

Electrical

Keypad and

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Parameters

Commander SK Size 2 to 6 Getting Started Guide 25 Issue Number: 9 www.controltechniques.com

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UL listing

310mm (12.205in)

18.9mm (0.744in)

1131mm (44.528in)

298mm (11.732in)

1168.8mm (46.016in)

25.7 0.5mm

(1.012 0.020in)

258.6 0.5mm

(10.181 0.020in)

± ±

∅

8.5mm

(0.335in)

∅

8.5mm

(0.335in)

1150.8 ±0.5mm

(45.307 0.020in)

Figure 3-12 Surface mounting the size 6 drive

3.3.2 Through-panel mounting

See the

Commander SK Technical Data Guide.

3.3.3 Mounting with Conduit Boxes

See the Commander SK Technical Data Guide.

26 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

3.3.4 Minimum mounting clearances

Figure 3-13 Minimum mounting clearances

Safety Information

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Mechanical

Installation

Electrical

Keypad and

Display

Drive size

AB C

mm in mm in mm in

2 to 6 30 1.18 30* 1.18* 100 3.94

*This is the minimum spacing between drives measured at the base of the drives where it is mounted against a back plate/flat surface.

Commander SK Size 2 to 6 Getting Started Guide 27 Issue Number: 9 www.controltechniques.com

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UL listing

3.4 Mounting brackets

NOTE

Short section

Long section

Table 3-1 Mounting brackets

Model

size

2x2x1

3x2

5 & 6

To avoid damaging the through-panel mounting bracket when through-panel mounting a size 2, the through-panel mounting bracket should be used to fix the top of the drive to the back plate before the bottom of the drive is fixed to the back plate. The tightening torque should be 4Nm (2.9 Ib ft).

Surface Through-panel

3.4.1 Fitting of the Commander SK mounting brackets on size 4, 5 and 6

Commander SK size 4, 5 and 6 use the same mounting brackets for surface and through-panel mounting.

The mounting bracket has a long section and short section.

Figure 3-14 Size 4, 5 and 6 mounting bracket

Hole

size

6.5mm

(0.256in)

8.5mm

(0.335in)

28 Commander SK Size 2 to 6 Getting Started Guide

The mounting bracket must be installed in the correct orientation with the long section inserted into or attached to the drive and the short section attached to the backplate. Figure 3-15 shows the orientation of the mounting bracket when the drive is surface mounted and through-panel mounted.

www.controltechniques.com Issue Number: 9

Figure 3-15 Orientation of the size 4, 5 and 6 mounting bracket

Short section

Long section

Commander SK size 5 and 6 also requires two top mounting brackets when the drive is surface mounted. The two brackets should be installed to the top of the drive as shown in Figure 3-16.

Figure 3-16 Location of top surface mounting brackets for size 5 and 6

Safety Information

Information

Product

Mechanical

Installation

Electrical

Keypad and

Display

The maximum torque setting for the screws into the drive chassis is 10Nm (7.4 lb ft).

Commander SK Size 2 to 6 Getting Started Guide 29 Issue Number: 9 www.controltechniques.com

Parameters

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information

UL listing

3.5 Enclosure

≥

100mm

(4in)

Enclosure AC supply contactor and fuses or MCB

Locate as required

External controller

Signal cables Plan for all signal cables to be routed at leas t 300mm (12in) from the drive and any power cable

Ensure minimum clearances are maintained for the drive and external EMC filter. Forced or convection air-flow must not be restricted by any obje ct or cabling

≥

100mm

(4in)

Optional braking resistor and overload

Locate optional braking resistor external to cubicle (preferably near to or on top of the cubicle). Locate the overload protection device as required

The external EMC filter can be bookcase mounted (next to the drive) or footprint mounted (with the drive mounted onto the filter).

Note For EMC compliance:

1) When using an external EMC filter, one filter is required for each drive

2) Power cabling must be at least 100mm (4in) from the drive in all directions

Sizes 2 to 6: 30mm (1.181in)

≥

3.5.1 Enclosure layout (size 2 to 6)

Please observe the clearances in the diagram below taking into account any appropriate notes for other devices / auxiliary equipment when planning the installation.

Figure 3-17 Enclosure layout

30 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

3.6 Electrical terminals

Smart / Logic

Stick slot

Serial

communications

port connector

Solutions

Module

connector

AC supply /

motor

connections

Internal EMC filter

Motor

connections

supply

Internal

EMC filter

supply

Motor

connections

Motor

connections

Heatsink fan

supply connections

Power stage label

Power

stage

label

Ground

connections

8mm AF

Solutions Module slot

Display

Power terminals

Control terminals

Ground connections

8mm AF

Pozi Pz 2

T20 Tor x

Pozi Pz 2

Pozi Pz 3

Pozi Pz 2

T20

Tor x

Pozi Pz 2

AC supply / motor connections

Pozi Pz 2

Pozi Pz 3

M10 nut

17mm AF

M10 nut 17mm AF

AC output/

Brake resistor

M10 nut 17mm AF

AC output/

Brake resistor

M10 nut

17mm AF

AC output/

Brake resistor

T20 Tor x

supply

Internal

EMC filter

supply

T20 Tor x

supply

Internal

EMC filter

supply

T20

Tor x

2.5mm

±DC Bus/

Braking

±DC Bus/

Braking

Figure 3-18 Location of power and ground terminals

Safety Information

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Electrical

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Commander SK Size 2 to 6 Getting Started Guide 31 Issue Number: 9 www.controltechniques.com

Parameters

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UL listing

3.6.1 Terminal sizes and torque settings

WARNING

To avoid a fire hazard and maintain validity of the UL Listing, adhere to the specified tightening torques for the power and ground terminals. Refer to the following tables.

Table 3-2 Drive control and relay terminal data

Model Connection type

All Spring terminals

Table 3-3 Drive power terminal data

Model

size

AC terminals

Plug-in terminal

block 1.5Nm

(1.1 lb ft)

Terminal block (M6 screws) 2.5Nm

Torque tolerance ±10%

DC and braking

terminals

Terminal block (M5

screws) 1.5Nm

(1.8 lb ft)

M10 stud

15Nm

(11.1 lb ft)

(1.1 lb ft)

Ground terminals

M5 stud 4.0Nm

(2.9 lb ft)

6.0Nm

(4.4 lb ft)

M10 stud 12Nm

(8.8 lb ft)

32 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

4 Electrical Installation

L1 L2

L2L1 L3 U V W

Optional RFI

filter

Optional

line reactor

Fuses

Mains Supply

Motor

Optional ground

connection

Supply Ground

AC Connections

Thermal overload

protection

device

DC1 DC2

DC Connections

(DC and braking)

+DC

EMC capacitor

connection

Internal

EMC filter

DC1 = DC2 = +

L1 L2

UVW

Optional RFI

filter

Optional

line reactor

Fuses

L3 Mains Supply

Motor

Optional ground

connection

Supply

Ground

AC Connections

BRDC1 DC2

DC Connections

(DC and braking)

+DC

EMC capacitor

connection

Internal

EMC filter

DC1 = DC2 = +

Thermal overload

protection

device

NOTE

4.1 Power connections

4.1.1 AC and DC connections

Figure 4-1 Size 2 power connections Figure 4-2 Size 3 power connections

Safety Information

Information

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Mechanical

Installation

Commander SK Size 2 to 6 Getting Started Guide 33 Issue Number: 9 www.controltechniques.com

An optional internal braking resistor is available for Commander SK size 2. For further information, see the Commander SK Technical Data Guide.

Installation

Electrical

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UL listing

UVW

Motor

Optional ground

connection

+DC BR

Thermal

overload

protection

device

Output connections

Input connections

Mains

Supply

L1 L2

Optional

line reactor

Optional

RFI filter

Fuses

L1 L2 L3

+DC -DC

Internal

EMC filter

Supply ground

4 5 6

Size 6 only: Heatsink fan supply connections

Figure 4-3 Size 4, 5 and 6 power connections

*See section 4.1.3 Ground connections on page 36.

** See section 4.2.2

Heatsink fan supply

on page 38 for more information.

34 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

4.1.2 Starts per hour

CAUT ION

Parameter 200V drive 400V drive

Full power braking time Pr 10.30 0.09 0.02

Full power braking period Pr 10.31 2.0

CAUT ION

Electric starts

With the supply permanently connected the number of electronic motor starts per hour is only limited by motor and drive thermal limits.

Power starts

The number of starts by connection of the AC supply is limited. The start up circuit will allow for three consecutive starts at 3 second intervals on initial power up. Exceeding the rated number of starts per hour, presented in the table below, could result in damage to the start up circuit.

Safety Information

Information

Product

Frame size

Maximum AC line starts per hour evenly spaced

in time

2 to 6 20

Braking resistor overload protection parameter settings Failure to observe the following information may damage the resistor.

The Commander SK software contains an overload protection function for a braking resistor. The braking resistor overload protection Pr 10.30 and Pr 10.31 should be used for SK2. Below are the parameter settings.

For more information on the braking resistor software overload protection, see the Commander SK Advanced User Guide.

If the heatsink mounted braking resistor is to be used at more than half of its average power rating then the drive's cooling fan must be set to full speed by setting Pr 6.45 to On (1).

Braking resistor: High temperatures and overload protection

Braking resistors can reach high temperatures. Locate braking resistors so that damage cannot result. Use cable having insulation capable of withstanding the high temperatures.

It is essential that the braking resistor be protected against overload caused by a failure of the brake control. Unless the resistor has built in protection, the circuit below should be used, where the thermal protection device disconnects the AC supply to the drive.

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Commander SK Size 2 to 6 Getting Started Guide 35 Issue Number: 9 www.controltechniques.com

information

UL listing

Figure 4-4 Typical protection circuit for a braking resistor

Optional RFI filter

Stop

Star t / Reset

Thermal protection device

Braking resistor

Drive

Main contactor power supply

+DC

NOTE

For further information on braking, refer to the Commander SK Technical Data Guide.

For Commander SK size 2 and 3, a single phase supply should be connected between L1 and L2. Please refer to the Commander SK Technical Data Guide for derating information.

4.1.3 Ground connections

On Commander SK size 2, the supply and motor ground connections are made using the grounding bridge that locates at the bottom of the drive.

Figure 4-5 Size 2 ground connections

36 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

On Commander SK size 3, the supply and motor ground connections are made using

Plain washers

Spring washer

M6 bolt

Supply ground

Motor ground

an M6 nut and bolt that locates in the fork protruding from the heatsink between the AC supply and motor output terminals.

Figure 4-6 Size 3 ground connections

Safety Information

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Product

Mechanical

Installation

Electrical

On Commander SK size 4, 5 and 6, the supply and motor ground connections are made using an M10 bolt at the top (supply) and bottom (motor) of the drive.

Figure 4-7 Size 4, 5 and 6 ground connections

The supply and motor ground connections to the drive are connected internally by a copper conductor with a cross-sectional area given below:

Size 4: 19.2mm

Size 5: 60mm

Size 6: 75mm

(0.03in2, or slightly bigger than 6 AWG)

(0.09in2, or slightly bigger than 1 AWG)

(0.12in2, or slightly bigger than 2/0 AWG)

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Commander SK Size 2 to 6 Getting Started Guide 37 Issue Number: 9 www.controltechniques.com

This connection is sufficient to provide the ground (equipotential bonding) connection for the motor circuit under the following conditions:

To standard Conditions

Supply phase conductors having cross-sectional area

IEC 60204-1 & EN 60204-1

NFPA 79

not exceeding:

Size 4: 38.4mm

Size 5: 120mm

Size 6: 150mm

Supply protection device rating not exceeding: Size 4: 200A Size 5: 600A Size 6: 1000A

If the necessary conditions are not met, an additional ground connection must be provided to link the motor circuit ground and the supply ground.

4.2 Heatsink fan

4.2.1 Heatsink fan operation

The Commander SK is ventilated by an internal heatsink mounted fan. The fan housing forms a baffle plate, channelling the air through the heatsink chamber. Thus, regardless of the mounting method (surface or through-panel mounting), the fitting of additional baffle plates is not required.

Ensure the minimum clearances around the drive are maintained to allow air to flow freely.

The heatsink fan on Commander SK size 2 is a dual speed fan and on size 3 to 6, it is a variable speed fan. The drive controls the speed at which the fan runs based on the temperature of the heatsink and the drive's thermal model system. The Commander SK size 3 to 6 is also installed with a single speed fan to ventilate the capacitor bank.

The heatsink fan on the Commander SK size 2 to 5 is supplied internally by the drive. The heatsink fan on the size 6 requires an external +24Vdc power supply.

4.2.2 Heatsink fan supply

The heatsink fan on size 6 requires an external +24Vdc supply. The connections for the heatsink fan supply must be made to the upper terminal connector near to the W phase output on the drive. See Figure 4-8

for the position of the heatsink fan supply connector.

38 Commander SK Size 2 to 6 Getting Started Guide

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Figure 4-8 Location of size 6 heatsink fan supply connections

55 54 53 52 51 50

65 64 63 62 61 60

To the heatsink fan

Pre-wired internally

Not used

24V heatsink fan supply

Upper terminal connector

Lower terminal connector

WARNING

Safety Information

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Mechanical

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Electrical

Figure 4-9 Size 6 heatsink fan supply connections

The heatsink fan supply requirements are as follows:

Nominal voltage: 24Vdc Minimum voltage: 23.5Vdc Maximum voltage: 27Vdc Current drawn: 3.3A Recommended power supply: 24V, 100W, 4.5A

Recommended fuse: 4A fast blow (I

The AC supply to the drive must be installed with suitable protection against overload

t less than 20A2s)

and short circuits. Failure to observe this requirement will cause risk of fire. See section 2.3 Rating Data on page 11 for fuse data.

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Commander SK Size 2 to 6 Getting Started Guide 39 Issue Number: 9 www.controltechniques.com

The drive must be grounded by a conductor sufficient to carry the prospective fault

WARNING

NOTE

WARNING

current in the event of a fault. See also the warning in section 4.3 Ground leakage relating to ground leakage current.

4.3 Ground leakage

The ground leakage current depends upon the internal EMC filter being installed. The drive is supplied with the filter installed. Instructions on removal of the internal EMC filter are given in section 4.3.1 Internal EMC filter on page 40.

With internal EMC filter installed

Size 2 and 3

28mA* AC at 400V, 50Hz 30μA DC with 600V DC bus (10MΩ)

Size 4 to 6

56mA* at 400V, 50Hz 18μA DC with 600V DC bus (33MΩ)

*Proportional to the supply voltage and frequency.

The above leakage currents are just the leakage currents of the drive with the internal EMC filter connected and do not take into account any leakage currents of the motor or motor cables.

With internal EMC filter removed

<1mA

In both cases, there is an internal voltage surge protection device connected to ground. Under normal circumstances this carries negligible current.

When the internal EMC filter is installed, the leakage current is high. In this case, a permanent fixed ground connection must be provided, or suitable measures taken to prevent a safety hazard occurring if the connection is lost.

4.3.1 Internal EMC filter

It is recommended that the internal EMC filter be kept in place unless there is a specific reason for removing it.

On Commander SK size 3, 4, 5 and 6, when used with ungrounded (IT) supplies, the internal EMC filter must be removed unless additional motor ground fault protection is installed or, in the case of size 3 only, the external EMC filter is also used.

For instructions on removal, refer to Figure 4-10.

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Figure 4-10 Removal of the internal EMC filter, size 2 and 3

Loosen/remove screws as shown (1) and (2).

Remove filter (3) and ensure the screws are replaced and re-tightened (4).

Figure 4-11 Removal of the internal EMC filter, size 4, 5 and 6

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Loosen screws (1). Remove EMC filter in the direction shown (2).

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The internal EMC filter reduces radio-frequency emissions into the line power supply. Where the motor cable length is short, it permits the requirements of EN 61800-3:2004 to be met for the second environment. For longer motor cables, the filter continues to provide a useful reduction in emission level, and when used with any length of shielded motor cable up to the limit for the drive, it is unlikely that nearby industrial equipment will be disturbed. It is recommended that the filter be used in all applications unless the

Diagnostics Options

instructions given above require it to be removed or the ground leakage current of 28mA (for sizes 2 and 3) or 56mA (for sizes 4 to 6) is unacceptable.

4.3.2 Use of earth (ground) leakage circuit breakers (ELCB) / residual current device (RCD)

There are three common types of ELCB/RCD:

Typ e AC - detects AC fault currents Typ e A - detects AC and pulsating DC fault currents (provided the DC current

Typ e B - detects AC, pulsating DC and smooth DC fault currents

• Type AC should never be used with drives

• Type A can only be used with single phase drives

• Type B must be used with three phase drives

Commander SK Size 2 to 6 Getting Started Guide 41 Issue Number: 9 www.controltechniques.com

reaches zero at least once every half cycle)

information

UL listing

4.3.3 Further EMC precautions

WARNING

Further EMC precautions are required if more stringent EMC emission requirements apply:

• Operation in the first environment

• Conformity to the generic emission standards

• Equipment which is sensitive to electrical interference operating nearby

In this case it is necessary to use:

The optional external EMC filter A shielded motor cable, with the shield clamped to the grounded metal panel A shielded control cable, with the shield clamped to the grounded metal panel Full instructions are given in the Commander SK Technical Data Guide

A full range of external EMC filters is also available for use with Commander SK.

4.4 EMC (Electromagnetic compatibility)

4.4.1 Grounding hardware

The Commander SK size 2 and 3 are provided with a grounding bracket and grounding clamp. They can be used as cable management bracket/clamp or they can be used to facilitate EMC compliance. They provide a convenient method for direct grounding of cable shields without the use of 'pig tails'. Cable shields can be bared and clamped to the grounding bracket using metal clips or clamps* (not supplied) or cable ties. Note that the shield must in all cases be continued through the cable clamp to the intended terminal on the drive, in accordance with the connection details for the specific signal.

*A suitable clamp is the Phoenix DIN rail mounted SK14 cable clamp (for cables with a maximum outer diameter of 14mm).

Figure 4-12 Fitting the grounding clamp

A faston tab is located on the grounding bracket for the purpose of connecting the drive 0V to ground should the user require to do so.

On Commander SK size 2, the grounding bracket is secured using the power ground terminal of the drive. Ensure that the supply ground connection is secure after fitting/ removing the grounding bracket. Failure to do so will result in the drive not being grounded.

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Figure 4-13 Grounding link bracket in its surface mount position (as supplied)

Grounding link bracket

WARNING

4.5 Control terminals I/O specification

The control circuits are isolated from the power circuits in the drive by basic insulation (single insulation) only. The installer must ensure that the external control circuits are insulated from human contact by at least one layer of insulation (supplementary insulation) rated for use at the AC supply voltage.

If the control circuits are to be connected to other circuits classified as Safety Extra Low Voltage (SELV) (e.g. to personal computer), an additional isolating barrier must be included in order to maintain the SELV classification.

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The above warnings also apply to the PCB edge connector for the optional Solutions Modules. To allow a Solutions Module to be installed to Commander SK, a protective cover must be removed to allow access to the PCB edge connector. See Figure 318 on page 31. This protective cover provides protection from direct contact of the PCB edge connector by the user. When this cover is removed and a Solutions Module installed, the Solutions Module provides the protection from direct contact by the user. If the Solutions Module is then removed, this PCB edge connector becomes exposed. The user is required to provide protection in this case, to protect against direct contact of this PCB edge connector.

Commander SK Size 2 to 6 Getting Started Guide 43 Issue Number: 9 www.controltechniques.com

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Electric shock risk

WARNING

The voltages present in the following locations can cause severe electric shock and may be lethal:

• AC supply cables and connections

• DC and brake cables, and connections

• Output cables and connections

• Many internal parts of the drive, and external option units Unless otherwise indicated, control terminals are single insulated and must not be touched.

User interface terminals can only be considered safe to touch if double insulation is present and the terminals are SELV compliant.

It has come to our attention that not all users are following this advice and that on touching the 0V connection on a size 3 drive an electric shock has been experienced.

The voltage which is present between 0V and ground / earth is due to capacitive coupling between the power and control circuits in the inverter. The stray capacitance between the power and control circuits results in a high frequency leakage current flowing. The current, which flows is dependent on the level of capacitance present. Note that because of the high frequency content it cannot be measured correctly by a DVM.

The size 3 drive has a relatively high capacitance compared to size 2 and the current can cause a painful shock, which is not directly hazardous, but could result in an accident.

The voItage present between the 0V terminal and earth / ground may damage external equipment connected to the drive’s 0V terminal.

On the Commander SK the serial communications port is not double insulated and thus the serial communications 0V is connected directly to the control 0V therefore equipment connected via serial communications can also be affected.

The following precautions should be implemented. This can be easily completed in two ways:

1. Connecting the 0V directly to the triangular grounding bracket supplied with the drive.

2. Connecting the 0V directly to earth / ground using the M5 ground connection.

If it is required for the 0V to remain floating with respect to earth, such as when a 420mA reference is being used, then this connection can be made using a capacitor of 15nF or higher (600Vdc). However, it should be recognized that there is only single isolation, and the appropriate access protection should be facilitated.

The same part is available to order from your drive supplier for the Commander SK if required, the part number is: 9500-0083. It should be connected as shown in Figure 4-

14.

44 Commander SK Size 2 to 6 Getting Started Guide

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Figure 4-14

NOTE

Safety Information

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Mechanical

Installation

See Pr 05 on page 53 (Drive configuration) for terminal connection / set-up diagrams and details.

The digital inputs are positive logic only.

The analog inputs are unipolar. For information on a bipolar input, refer to the Commander SK Advanced User Guide.

T1 0V common

T2 Analog input 1 (A1), either voltage or current (see Pr 16)

Voltage: Current input 0 to 10V: mA as parameter range

Parameter range 4-20, 20-4, 0-20, 20-0, 4-.20, 20-.4, VoLt

Scaling

Input range automatically scaled to Pr 01 Minimum set speed / Pr 02 Maximum set speed

Input impedance 200Ω (current): 100kΩ (voltage)

Resolution 0.1%

0-20: Current input 0 to 20mA (20mA full scale) 20-0: Current input 20 to 0mA (0mA full scale) 4-20: Current input 4 to 20mA with current loop loss (cL1) trip (20mA full scale) 20-4: Current input 20 to 4mA with current loop loss (cL1) trip (4mA full scale) 4-.20: Current input 4 to 20mA with no current loop loss (cL1) trip (20mA full scale) 20-.4: Current input 20 to 4mA with no current loop loss (cL1) trip (4mA full scale) VoLt: 0 to 10V input

T3 +10V reference output

Maximum output current 5mA

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Commander SK Size 2 to 6 Getting Started Guide 45 Issue Number: 9 www.controltechniques.com

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T4 Analog input 2 (A2), either voltage or digital input

WARNING

Voltage: Digital input 0 to +10V: 0 to +24V

Scaling (as voltage input)

Resolution 0.1% Input impedance 100kΩ (voltage): 6k8 (digital input)

Normal threshold voltage (as digital input) +10V (positive logic only)

Status relay - Drive ok (Normally open)

Contact voltage rating

Contact maximum current rating

Contact minimum recommended rating 12V 100mA

Contact isolation 1.5kVac (over voltage category II)

Operation of contact (drive ok - default condition)

Input range automatically scaled to Pr 01 Minimum set speed / Pr 02 Maximum set speed

240Vac 30Vdc

2Aac 240V 4Adc 30V resistive load (2A 35Vdc for UL requirements).

0.3Adc 30V inductive load (L/R=40ms)

OPEN AC supply removed from drive AC supply applied to drive with drive in tripped condition CLOSED AC supply applied to drive with drive in a 'ready to run' or 'running' condition (not tripped)

Provide fuse or over-current protection in status relay circuit.

A flyback diode should be installed across inductive loads connected to the status relay.

B1 Analog voltage output - Motor speed

Voltage output 0 to +10V

Scaling

Maximum output current 5mA

Resolution 0.1%

B2 +24V output

Maximum output current 100mA

0V represents 0Hz/rpm output +10V represents the value in Pr 02 Maximum set speed

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B3 Digital output - Zero speed (or digital input)

NOTE

Voltage range 0 to +24V

Maximum output current 50mA at +24V (current source)

The total available current from the digital output plus the +24V output is 100mA. Terminal B3 can also be configured as a digital input, frequency output or PWM output. Refer to the Commander SK Advanced User Guide for more information.

B4 Digital Input - Enable/Reset*/**

B5 Digital Input - Run Forward**

B6 Digital Input - Run Reverse**

B7 Digital Input - Local/Remote speed reference select (A1/A2)

Logic Positive logic only

Voltage range 0 to +24V

Nominal threshold voltage +10V

Terminal B7 can also be configured as a thermistor input or frequency input. Refer to the Commander SK Advanced User Guide for more information.

If the enable terminal is opened, the drive’s output is disabled and the motor will coast to a stop. The drive will not re-enable for 1.0s after the enable terminal is closed again.

*Following a drive trip, opening and closing the enable terminal will reset the drive. If the run forward or run reverse terminal is closed, the drive will run straight away.

**Following a drive trip and a reset via the stop/reset key, the enable, run forward or run reverse terminals will need to be opened and closed to allow the drive to run. This ensures that the drive does not run when the stop/reset key is pressed.

The enable, run forward and run reverse terminals are level triggered apart from after a trip where they become edge triggered. See * and ** above.

If the enable and run forward or enable and run reverse terminals are closed when the drive is powered up, the drive will run straight away up to a set speed.

If both the run forward and run reverse terminals are closed, the drive will stop under the control of the ramp and stopping modes set in Pr 30 and Pr 31.

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Commander SK Size 2 to 6 Getting Started Guide 47 Issue Number: 9 www.controltechniques.com

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5 Keypad and Display

NOTE

The keypad and display are used for the following:

• Displaying the operating status of the drive

• Displaying a fault or trip code

• Reading and changing parameter values

• Stopping, starting and resetting the drive

Figure 5-1 Keypad and display

on the display indicates if motor map 1 or 2 is selected.

5.1 Programming keys

The MODE key is used to change the mode of operation of the drive.

The UP and DOWN keys are used to select parameters and edit their values. In keypad mode, they are used to increase and decrease the speed of the motor.

5.2 Control keys

The START key is used to start the drive in keypad mode.

The STOP/RESET key is used to stop and reset the drive in keypad mode. It can

also be used to reset the drive in terminal mode.

With USA defaults, the STOP/RESET key will be enabled.

It is possible to change parameter values more quickly. See Chapter 4 Keypad and display in the Commander SK Advanced User Guide for details.

48 Commander SK Size 2 to 6 Getting Started Guide

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5.3 Selecting and changing parameters

NOTE

STATUS MODE

PARAMETER VIEW MODE

Select parameter to view

orPress

Parameter number flashing

PARAMETER EDIT MODE

Change parameter value

orPress

Parameter value flashing

M M

Press and hold for 2s

M M

Parameters

saved

Press and release

Hold for 2s

4 mins

timeout

///

Press and release

MMM

This procedure is written from the first power up of the drive and assumes no terminals have been connected, no parameters have been changed and no security has been set.

Safety Information

Figure 5-2

When in Status mode, pressing and holding the MODE key for 2 seconds will change the display from displaying a speed indication to displaying load indication and vice versa.

Pressing and releasing the MODE key will change the display from status mode to parameter view mode. In parameter view mode, the left hand display flashes the parameter number and the right hand display shows the value of that parameter.

Pressing and releasing the MODE key again will change the display from parameter view mode to parameter edit mode. In parameter edit mode, the right hand display flashes the value in the parameter being shown in the left hand display.

Pressing the MODE key in parameter edit mode will return the drive to the

parameter view mode. If the MODE key is pressed again then the drive will return to

status mode, but if either of the up or down keys are pressed to change the

parameter being viewed before the MODE key is pressed, pressing the MODE key will change the display to the parameter edit mode again. This allows the user to very easily change between parameter view and edit modes while commissioning / starting-up the drive.

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Commander SK Size 2 to 6 Getting Started Guide 49 Issue Number: 9 www.controltechniques.com

Status Modes

Left hand

display

Speed Indications

Display

Mnemonic

Load indications

Display

Mnemonic

Status Explanation

Drive ready

Drive inhibited

Drive has tripped

DC injection

braking

Mains loss See the Commander SK Advanced User Guide.

Drive output frequency in Hz

Motor speed in rpm

Machine speed in customer define units

Load current as a % of motor rated load current

The drive is enabled and ready for a start command. The output bridge is inactive.

The drive is inhibited because there is no enable command, or a coast to stop is in progress or the drive is inhibited during a trip reset.

The drive has tripped. The trip code will be displayed in the right hand display.

DC injection braking current is being applied to the motor.

Explanation

Drive output current per phase in Amps

5.4 Saving parameters

Parameters are automatically saved when the MODE key is pressed when going from parameter edit mode to parameter view mode.

5.5 Parameter access

There are 3 levels of parameter access controlled by Pr 10. This determines which parameters are accessible. See Table 5-1.

The setting of the user security Pr 25 determines whether the parameter access is read only (RO) or read write (RW).

Table 5-1 Parameter access

Parameter access (Pr 10) Parameters accessible

L1 Pr 01 to Pr 10

L2 Pr 01 to Pr 60

L3 Pr 01 to Pr 95

5.6 Security codes

Setting a security code allows view only access to all parameters.

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A security code is locked into the drive when Pr 25 is set to any other value than 0 and

MMMMM

NOTE

then LoC is selected in Pr 10. On pressing the MODE key, Pr 10 is automatically changed from LoC to L1 and Pr 25 will be automatically set to 0 so as not to reveal the security code.

Pr 10 may be changed to L2 or L3 to allow view only access to parameters.

5.6.1 Setting a security code

•Set Pr 10 to L2.

•Set Pr 25 to the desired security code e.g. 5

•Set Pr 10 to LoC.

• Press the MODE key

•Pr 10 will now be reset to L1 and Pr 25 will be reset to 0.

• The security code will now be locked into the drive.

• Security will also be set if the drive is powered down after a security code has been set into Pr 25.

5.6.2 Unlocking a security code

Select parameter to be edited

Press the MODE key, the right hand display will flash 'CodE'

Press the UP key to start entering the set security code. The left hand display will show 'Co' Enter the correct security code

Press the MODE key If the correct security code has been entered, the right hand display will flash and can now be adjusted. If the security code has been entered incorrectly, the left hand display will flash the parameter number. The above procedure should be followed again.

5.6.3 Re-locking security

When a security code has been unlocked and the required parameter changes made, to re-lock the same security code:

•Set Pr 10 to LoC

• Press the STOP/RESET key

5.6.4 Setting security back to 0 (zero) - no security

•Set Pr 10 to L2

• Go to Pr 25

• Unlock security as described above.

•Set Pr 25 to 0

• Press the MODE key.

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If a security code has been lost or forgotten, please contact your local drive centre or distributor

5.7 Setting drive back to default values

•Set Pr 10 to L2

•Set Pr 29 to Eur and press the MODE key. This loads 50Hz default parameters.

•Set Pr 29 to USA and press the MODE key. This loads 60Hz default parameters.

Commander SK Size 2 to 6 Getting Started Guide 51 Issue Number: 9 www.controltechniques.com

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UL listing

6 Parameters

NOTE

Parameters are grouped together into appropriate subsets as follows:

Level 1 Pr 01 to Pr 10: Basic drive set-up parameters Level 2

Pr 11 to Pr 12: Drive operation set-up parameters Pr 15 to Pr 21: Reference parameters Pr 22 to Pr 29: Display / keypad configuration Pr 30 to Pr 33: System configuration Pr 34 to Pr 36: Drive user I/O configuration Pr 37 to Pr 42: Motor configuration (non-standard set-up) Pr 43 to Pr 44: Serial communications configuration Pr 45: Drive software version Pr 46 to Pr 51: Mechanical brake configuration Pr 52 to Pr 54: Fieldbus configuration Pr 55 to Pr 58: Drive trip log Pr 59 to Pr 60: PLC ladder programming configuration Pr 61 to Pr 70: User definable parameter area

Level 3

Pr 71 to Pr 80: User definable parameter set-up Pr 81 to Pr 95: Drive diagnostics parameters These parameters can be used to optimise the set-up of the drive for the application.

6.1 Parameter descriptions - Level 1

No Function Range Defaults Type

01 Minimum set speed 0 to Pr 02 Hz 0.0 RW

Used to set the minimum speed at which the motor will run in both directions. (0V reference or minimum scale current input represents the value in Pr 01).

No Function Range Defaults Type

02 Maximum set speed 0 to 550 Hz Eur: 50.0, USA: 60.0 RW

Used to set the maximum speed at which the motor will run in both directions. If Pr 02 is set below Pr 01, Pr 01 will be automatically set to the value of Pr 02. (+10V reference or full scale current input represents the value in Pr 02).

The output speed of the drive can exceed the value set in Pr 02 due to slip compensation and current limits.

No Function Range Defaults Type

03 Acceleration rate

04 Deceleration rate Eur: 10.0, USA: 33.0

0 to 3200.0 s/100Hz

Eur: 5.0, USA: 33.0

Sets the acceleration and deceleration rate of the motor in both directions in seconds/ 100Hz.

If one of the standard ramp modes is selected (see Pr 30 on page 62), the deceleration rate could be extended automatically by the drive to prevent over voltage (OV) trips if the load inertia is too high for the programmed deceleration rate.

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No Function Range Defaults Type

NOTE

OK Fault

Remote current speed reference input (A1)

+10V reference output

Local voltage speed reference input (A2)

+24V output

Drive Enable/Reset

Run Forward

Run Reverse

Local (A2)/Remote (A1) speed reference select

Remote speed reference input

10k

(2kmin)

+24V

Eur

Remote current speed reference input (A1)

+10V reference output

Local voltage speed reference input (A2)

+24V output

/Stop

Run

Jog

Local (A2)/Remote (A1) speed reference select

Remote speed

reference input

10k

(2kmin)

USA

Analog output (motor speed)

Digital output (zero speed)

Analog output (motor speed)

Digital output (zero speed)

+24V

05 Drive configuration

AI.AV, AV.Pr, AI.Pr, Pr, PAd,

E.Pot, tor, Pid, HVAC

Eur: AI.AV, USA: PAd RW

The setting of Pr 05 automatically sets up the drives configuration.

Safety Information

A change to Pr 05 is set by pressing the MODE key on exit from parameter edit mode. The drive must be disabled, stopped or tripped for a change to take place. If Pr 05 is changed while the drive is running, when the MODE key is pressed on exit from parameter edit mode, Pr 05 will change back to its previous value.

When the setting of Pr 05 is changed, the appropriate drive configuration parameters are set back to their default values.

For example, changing Pr 05 from AI.AV to PAd, means that Pr 11 would change to 0 (un-latched) . In all of the settings below, the status relay is set up as a drive ok relay:

Configuration Description

AI.AV Voltage and current input

AV.P r Voltage input and 3 preset speeds

AI.Pr Current input and 3 preset speeds

Pr 4 preset speeds

PAd Keypad control

E.Pot Electronic motorized potentiometer control

tor Torque control operation

Pid PID control

HVAC Fan and pump control

Figure 6-1 Pr 05 = AI.AV

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Commander SK Size 2 to 6 Getting Started Guide 53 Issue Number: 9 www.controltechniques.com

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Terminal B7 open: Local voltage speed reference (A2) selected.

Terminal B7 closed: Remote current speed reference (A1) selected.

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Figure 6-2 Pr 05 = AV.Pr

Local voltage speed reference input (A1)

+10V reference output

+24V output

Drive Enable/Reset

Run Forward

Run Reverse

+24V

Eur USA

Analog output (motor speed)

Digital output (zero speed)

Reference select

10k

(2kmin)

Local voltage speed

reference input (A1)

+10V reference output

+24V output

/Stop

Run

Jog

+24V

Analog output

(motor speed)

Digital output

(zero speed)

Reference select

10k

(2kmin)

Remote current speed reference input (A1)

+10V reference output

+24V output

Drive Enable/Reset

Run Forward

Run Reverse

Remote speed reference input

+24V

Eur USA

Analog output (motor speed)

Digital output (zero speed)

Reference select

Remote current speed

reference input (A1)

+10V reference output

+24V output

/Stop

Run

Jog

Remote speed reference input

+24V

Analog output

(motor speed)

Digital output

(zero speed)

Reference select

Figure 6-3 Pr 05 = AI.Pr

54 Commander SK Size 2 to 6 Getting Started Guide

T4 B7 Reference selected

00 A1 0 1 Preset 2 1 0 Preset 3 1 1 Preset 4

www.controltechniques.com Issue Number: 9

Figure 6-4 Pr 05 = Pr

+10V reference output

+24V output

Drive Enable/Reset

Run Forward

Run Reverse

+24V

Eur USA

Analog output (motor speed)

Digital output (zero speed)

Reference select

+10V reference output

+24V output

/Stop

Run

Jog

+24V

Analog output (motor speed)

Digital output

(zero speed)

Not used Not used

Reference select

+10V reference output

+24V output

Drive Enable/Reset

+24V

Eur USA

Analog output (motor speed)

Digital output (zero speed)

Not used

+10V reference output

+24V output

Drive Enable/Reset

+24V

Analog output (motor speed)

Digital output

(zero speed)

Not used

Forward/Reverse Forward/Reverse

T4 B7 Reference selected

0 0 Preset 1

0 1 Preset 2

1 0 Preset 3

1 1 Preset 4

Figure 6-5 Pr 05 = PAd

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Commander SK Size 2 to 6 Getting Started Guide 55 Issue Number: 9 www.controltechniques.com

Setting-up a Forward/Reverse terminal in Keypad mode

From the drive’s display:

•Set Pr 71 to 8.23

•Set Pr 61 to 6.33

• Press the Stop/Reset key

Terminal B5 will now be set-up as a Forward/Reverse terminal.

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Figure 6-6 Pr 05 = E.Pot

+10V reference output

+24V output

Drive Enable/Reset

Run Forward

Run Reverse

+24V

Eur USA

Analog output (motor speed)

Digital output (zero speed)

Down

Not used

+10V reference output

+24V output

/Stop

Run

Jog

+24V

Analog output (motor speed)

Digital output

(zero speed)

Down

Not used

Remote current speed reference input (A1)

+10V reference output

Torque reference input (A2)

+24V output

Drive Enable/Reset

Run Forward

Run Reverse

Torque mode select

Remote speed reference input

10k

(2kmin)

+24V

Eur USA

Analog output (motor speed)

Digital output (zero speed)

Remote current speed reference input (A1)

+10V reference output

Torque reference input (A2)

+24V output

/Stop

Run

Jog

Torque mode

select

Remote speed reference input

10k

(2kmin)

+24V

Analog output

(motor speed)

Digital output

(zero speed)

WARNING

When Pr 05 is set to E.Pot, the following parameters are made available for adjustment: Pr 61: Motorized pot up/down rate (s/100%) Pr 62: Motorized pot bipolar select (0 = unipolar, 1 = bipolar) Pr 63: Motorized pot mode: 0 = zero at power-up, 1 = last value at power-up, 2 = zero at power-up and only change when drive is running, 3 = last value at power-up and only change when drive is running.

Figure 6-7 Pr 05 = tor

56 Commander SK Size 2 to 6 Getting Started Guide

When torque mode is selected and the drive is connected to an unloaded motor, the motor speed may increase rapidly to the maximum speed (Pr 02 +20%).

www.controltechniques.com Issue Number: 9

Figure 6-8 Pr 05 = Pid

+10V reference output

+24V output

Drive Enable/Reset

Run Forward

Run Reverse

4-20mA PID feedback input

+24V

Eur USA

Analog output (motor speed)

Digital output (zero speed)

PID feedback input

PID reference input

PID enable

0-10V PID reference input

+10V reference output

+24V output

/Stop

Run

Jog

4-20mA PID feedback input

+24V

Analog output

(motor speed)

Digital output

(zero speed)

PID reference input

PID enable

0-10V PID reference input

PID feedback input

x(-1)

Invert

P Gain

I Gain

PID reference input

PID feedback input

PID enable

Drive healthy

PID high limit

PID low limit

Drive

reference

% to

frequency

conversion

When Pr 05 is set to Pid, the following parameters are made available for adjustment: Pr 61: PID proportional gain Pr 62: PID integral gain Pr 63: PID feedback invert Pr 64: PID high limit (%) Pr 65: PID low limit (%) Pr 66: PID output (%)

Figure 6-9 PID logic diagram

Safety Information

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Figure 6-10 Pr 05 = HVAC terminal configuration

Remote current speed reference input (A1)

+10V reference output

Not used

+24V output

Drive enable / reset

Run reverse

Reference select

Remote speed reference input

Eur + USA

Analog output (motor speed)

Digital output (zero speed)

+24V

Auto run

Hand/Off/Auto

switch

Run forward

H: Contacts made in 'hand' posit ion Keypad control A: Contacts made in 'auto' position Remote current speed reference input

WARNING

NOTE

No Function Range Defaults Type

06 Motor rated current 0 to Drive rated current A Drive rating RW

Enter the motor current rating (taken from the motor name plate).

Pr 06 Motor rated current must be set correctly to avoid a risk of fire in the event of a motor overload.

No Function Range Defaults Type

07 Motor rated speed 0 to 9999 rpm Eur: 1500, USA: 1800 RW

Enter the rated full load speed of the motor (taken from the motor name plate). The motor rated speed is used to calculate the correct slip speed for the motor.

A value of zero entered into Pr 07 means slip compensation is disabled. Slip compensation should be disabled when using Commander SK on a high inertia load, e.g. fan.

If the full load speed of the motor is above 9999rpm, enter a value of 0 in Pr 07. This will

No Function Range Defaults Type

08 Motor rated voltage

disable slip compensation as values >9999 cannot be entered into this parameter.

Enter the motor rated voltage (taken from the motor name plate). This is the voltage applied to the motor at base frequency.

58 Commander SK Size 2 to 6 Getting Started Guide

0 to 240V, 0 to 480V,

0 to 575V, 0 to 690V

www.controltechniques.com Issue Number: 9

Eur: 230/400/575/690

USA: 230/460/575/690

If the motor is not a standard 50 or 60Hz motor, see Pr

NOTE

accordingly.

No Function Range Defaults Type

09 Motor power factor 0 to 1 0.85 RW

39 on page 65

and adjust

Enter the motor rated power factor cos ϕ (taken from the motor name plate).

The power factor value could be automatically changed after a rotating autotune. See Pr 38 on page 65.

No Function Range Defaults Type

10 Parameter access L1, L2, L3, LoC L1 RW

L1: Level 1 access - only the first 10 parameters can be accessed L2: Level 2 access - All parameters from 01 to 60 can be accessed L3: Level 3 access - All parameters from 01 to 95 can be accessed LoC: Used to lock a security code in the drive. See section 5.6 Security codes on

page 50 for further details.

6.2 Parameter descriptions - Level 2

No Function Range Defaults Type

11 Start/Stop logic select 0 to 6 Eur: 0, USA: 4 RW

Pr 11 Ter m ina l B4 Term i na l B5 Term ina l B6 L at c hi n g

0 Enable Run Forward Run Reverse No

1 /Stop Run Forward Run Reverse Yes

2 Enable Run Forward / Reverse No

3 /Stop Run Forward / Reverse Yes

4 /Stop Run Jog* Yes

5 User programmable Run Forward Run Reverse No

6 User Programmable User Programmable User Programmable User Programmable

*Jog can be used without the /Stop input being active.

A change to Pr 11 is set by pressing the MODE key on exit from parameter edit mode. The drive must be disabled, stopped or tripped for a change to take place. If Pr 11 is changed while the drive is running, when the MODE key is pressed on exit from parameter edit mode, Pr 11 will change back to its previous value.

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commissioning

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No Function Range Defaults Type

12 Brake controller enable diS, rEL, d IO, USEr diS RW

diS: Mechanical brake software disabled rEL: Mechanical brake software enabled. Brake control via relay T5 & T6. The digital

output on terminal B3 is automatically programmed as a drive ok output.

d IO: Mechanical brake software enabled. Brake control via digital output B3. The

relay outputs on terminals T5 and T6 are automatically programmed as a drive ok output.

USEr: Mechanical brake software enabled. Brake control to be programmed by user.

The relay and digital output are not programmed. The user should programme the brake control to either the digital output or relay.

Commander SK Size 2 to 6 Getting Started Guide 59 Issue Number: 9 www.controltechniques.com

information

UL listing

The output not programmed to the brake control can be programmed to indicate the

NOTE

WARNING

NOTE

required signal. (See Commander SK Advanced User Guide).

A change to Pr 12 is set by pressing the MODE key on exit from parameter edit mode. The drive must be disabled, stopped or tripped for a change to take place. If Pr 12 is changed while the drive is running, when the MODE key is pressed on exit from parameter edit mode, Pr 12 will change back to its previous value.

Great care should be taken when implementing a brake control set-up, as this may cause a safety issue depending on the application, e.g. crane. If in doubt, contact the supplier of the drive for further information.

Ensure that the brake controller is set-up correctly before the electro-mechanical brake circuit is connected to the drive. Disconnect the electro-mechanical brake circuit before a default is performed.

No Function Range Defaults Type

Not used

No Function Range Defaults Type

15 Jog reference 0 to 400.0 Hz 1.5 RW

Defines the jog speed

No Function Range Defaults Type

16 Analog input 1 mode

0-20, 20-0, 4-20, 20-4,

4-.20, 20-.4, VoLt

4-.20 RW

Determines the input on terminal T2

In the 4-20 or 20-4mA modes (with current loop loss) the drive will trip on cL1 if the input reference is below 3mA. Also, if the drive trips on cL1, the voltage analog input cannot be selected.

If both analog inputs (A1 and A2) are to be set-up as voltage inputs, and if the potentiometers are supplied from the drive’s +10V rail (terminal T3), they must have a resistance >4kΩ each.

No Function Range Defaults Type

17 Enable negative preset speeds OFF or On OFF RW

OFF: Direction of rotation controlled by run forward and run reverse terminals On: Direction of rotation controlled by preset speed values (use run forward

terminal) or keypad reference.

60 Commander SK Size 2 to 6 Getting Started Guide

www.controltechniques.com Issue Number: 9

No Function Range Defaults Type

NOTE

18 Preset speed 1

19 Preset speed 2

20 Preset speed 3

21 Preset speed 4

±550 Hz

(Limited by setting of Pr 02

Maximum set speed)

0.0 RW

Defines preset speeds 1 to 4.

No Function Range Defaults Type

22 Load display units Ld, A Ld RW

Ld: Active current as a % of motor rated active current A: Drive output current per phase in Amps

No Function Range Defaults Type

23 Speed display units Fr, SP, Cd Fr RW

Fr: Drive output frequency in Hz SP: Motor speed in rpm Cd: Machine speed in customer defined units (See Pr 24).

No Function Range Defaults Type

24 Customer defined scaling 0 to 9.999 1.000 RW

Multiplying factor on motor speed (rpm) to give customer defined units.

No Function Range Defaults Type

25 User security code 0 to 999 0 RW

Used to set-up a user security code. See section 5.6 Security codes on page 50.

No Function Range Defaults Type

26 Not used

Safety Information

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Keypad and

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Parameters

No Function Range Defaults Type

27 Power up keypad reference 0, LASt, PrS1 0 RW

0: keypad reference is zero LASt: keypad reference is last value selected before the drive was powered down PrS1: keypad reference is copied from preset speed 1

No Function Range Defaults Type

28 Parameter copying no, rEAd, Prog, boot no RW

no: no action rEAd: program the drive with the contents of the SmartStick Prog: program the SmartStick with the current drive settings boot: SmartStick becomes read only. The contents of the SmartStick will be copied to

the drive every time the drive is powered up.

Before setting boot mode, the current drive settings must be stored in the SmartStick by using Prog mode, otherwise the drive will trip on C.Acc at power-up. Parameter copying is initiated by pressing the MODE key on exit from parameter edit mode after Pr 28 has been set to rEAd, Prog or boot.

If parameter copying is enabled when no SmartStick is installed in the drive, the drive will trip on C.Acc.

Commander SK Size 2 to 6 Getting Started Guide 61 Issue Number: 9 www.controltechniques.com

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The SmartStick can be used to copy parameters between drives of different ratings.

NOTE

WARNING

Certain drive dependant parameters will be stored on the SmartStick but will not be copied to the drive. The drive will trip on C.rtg when being written to by a copied parameter set of a different drive rating. The drive dependant parameters are: Pr 06 Motor rated current, Pr 08 Motor rated voltage, Pr 09 Motor power factor and Pr 37 Maximum switching frequency.

Before the SmartStick /LogicStick is written to using Prog, the SmartStick/LogicStick will need to be inserted into the drive at power up or a reset command performed when the drive has been powered up, otherwise the drive will trip on C.dAt when Prog command executed.

For best motor performance, an autotune should be carried out after parameter copying has taken place.

When copying between drives of different ratings, bit parameters will not be copied.

No Function Range Defaults Type

29 Load defaults no, Eur, USA no RW

no: defaults are not loaded Eur: 50Hz default parameters are loaded USA: 60Hz default parameters are loaded

Default parameters are set by pressing the MODE key on exit from parameter edit mode after Pr 29 has been set to Eur or USA. When default parameters have been set, the display will return to Pr 01 and Pr 10 will be reset to L1.

The drive must be in a disabled, stopped or tripped condition to allow default parameters to be set. If default parameters are set while the drive is running, the display will flash FAIL once before changing back to no.

Disconnect the electro-mechanical brake circuit before a default is performed.

No Function Range Defaults Type

30 Ramp mode select 0 to 3 1 RW

0: Fast ramp selected 1: Standard ramp with normal motor voltage selected 2: Standard ramp with high motor voltage selected 3: Fast ramp with high motor voltage selected

Fast ramp is linear deceleration at programmed rate, normally used when a braking resistor is installed.

Standard ramp is controlled deceleration to prevent DC bus over-voltage trips, normally used when there is no braking resistor installed. If a high motor voltage mode is selected, deceleration rates can be faster for a given inertia but motor temperatures will be higher.

62 Commander SK Size 2 to 6 Getting Started Guide

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When standard ramp mode is used, the output frequency can be increased by 20%

NOTE

Motor thermistor input

NOTE

during deceleration.

No Function Range Defaults Type

31 Stop mode select 0 to 4 1 RW

0: Coast to stop selected 1: Ramp to stop selected 2: Ramp to stop with 1 second DC injection braking 3: DC injection braking with detection of zero speed 4: Timed DC injection braking

See the Commander SK Advanced User Guide.

No Function Range Defaults Type

32 Dynamic V to f select OFF or On OFF RW

OFF: Fixed linear voltage to frequency ratio (constant torque - standard load) On: Voltage to frequency ratio dependant on load current. This gives a higher motor

efficiency.

No Function Range Defaults Type

33 Catch a spinning motor select 0 to 3 0 RW

0: Disabled 1: Detect positive and negative frequencies 2: Detect positive frequencies only 3: Detect negative frequencies only

If the drive is to be configured in fixed boost mode (Pr 41 = Fd or SrE) with catch a spinning motor software enabled, an autotune (see Pr 38 on page 65) must be carried out to measure the motor’s stator resistance beforehand. If a stator resistance is not measured, the drive may trip on OV or OI.AC while trying to catch a spinning motor.

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Parameters

No Function Range Defaults Type

34 Terminal B7 mode select dig, th, Fr, Fr.hr dig RW

dig: Digital input th: Motor thermistor input, connect as per diagram below Fr: Frequency input. See Commander SK Advanced User Guide. Fr.hr: High resolution frequency input. See Commander SK Advanced User Guide.

Figure 6-11

Trip resistance: 3kΩ Reset resistance: 1k8

If Pr 34 is set to th so that terminal B7 is used as a motor thermistor, the functionality of terminal B7 as set-up with Pr 05, drive configuration, will be disabled. Analog reference 2 will no longer be selected as the speed reference. Analog reference 1 should be used.

When Pr 34 is set to th, the mode button will need to be pressed four times to return the drive display to status mode.

Commander SK Size 2 to 6 Getting Started Guide 63 Issue Number: 9 www.controltechniques.com

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No Function Range Defaults Type

NOTE

35 Digital output control (terminal B3)

n=0, At.SP, Lo.SP, hEAL,

Act, ALAr, I.Lt, At.Ld, USEr

n=0 RW

n=0: At zero speed At.SP: At speed Lo.SP: At minimum speed hEAL:Drive ok Act: Drive active ALAr: General drive alarm I.Lt: Current limit active At.Ld: At 100% load USEr: User programmable

This parameter is automatically changed by the setting of Pr 12. When Pr 12 automatically controls the setting of this parameter, this parameter cannot be changed.

A change to Pr 35 is set by pressing the MODE key on exit from parameter edit mode. See the Commander SK Advanced User Guide.

Terminal B3 can also be configured as a digital input, frequency output or PWM output. Refer to the Commander SK Advanced User Guide. for more information.

No Function Range Defaults Type

36 Analog output control (terminal B1) Fr, Ld, A, Por, USEr Fr RW

Fr: Voltage proportional to motor speed Ld: Voltage proportional to motor load A: Voltage proportional to output current Por: Voltage proportional to output power USEr: User programmable

A change to Pr 36 is set by pressing the MODE key on exit from parameter edit mode. See the Commander SK Advanced User Guide..

No Function Range Defaults Type

37 Maximum switching frequency 3, 6, 12 3 RW

3:3kHz 6:6kHz 12: 12kHz

Drive size Voltage rating 3kHz 6kHz 12kHz

2All√√ √

SK320X √√ √

4All√√ 5All√√ 6All√√

SK3401 & SK3402 √√ √

SK3403 √√ √

SK350X √√

See the Commander SK Technical Data Guide for drive derating data.

64 Commander SK Size 2 to 6 Getting Started Guide

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No Function Range Defaults Type

WARNING

NOTE

38 Autotune 0 to 2 0 RW

0: No autotune 1: Non-rotating static autotune 2: Rotating autotune

When a rotating autotune is selected, the drive will accelerate the motor up to 2/3 maximum speed in Pr 02. Once a rotating autotune has been initiated (Pr 38 set to 2) on Commander SK, it must be completed before the drive will operate normally. If the rotating auto-tune is not completed (through the drive being disabled or a trip occuring), the drive will only run at the autotune speed (2/3 rated speed reference) when the drive is asked to run again.

The motor must be at a standstill before a non-rotating autotune is initiated.

Safety Information

Information

Product

Mechanical

Installation

The motor must be at a standstill and unloaded before a rotating autotune is initiated.

No Function Range Defaults Type

39 Motor rated frequency 0.0 to 550.0 Hz Eur: 50.0, USA: 60.0 RW

Enter the motor rated frequency (taken from the motor name plate). This defines the voltage to frequency ratio applied to the motor.

No Function Range Defaults Type

40 Number of motor poles Auto, 2P, 4P, 6P, 8P Auto RW

Auto: Automatically calculates the number of motor poles from the settings of Pr 07

and Pr 39 2P: Set for a 2 pole motor 4P: Set for a 4 pole motor 6P: Set for a 6 pole motor 8P: Set for an 8 pole motor

No Function Range Defaults Type

41 Voltage mode select Ur S, Ur, Fd, Ur A, Ur l, SrE Eur: Ur I, USA: Fd RW

Ur S: Stator resistance is measured each time the drive is enabled and run Ur: No measurement is taken Fd: Fixed boost Ur A: Stator resistance is measured the first time the drive is enabled and run Ur I: Stator resistance measured at each power-up when the drive is enabled and

run SrE: Square law characteristic In all Ur modes, the drive operates in open loop vector mode.

The drive default setting is Ur I mode which means that the drive will carry out an autotune every time the drive is powered-up and enabled. If the load is not going to be stationary when the drive is powered-up and enabled, then one of the other modes should be selected. Not selecting another mode could result in poor motor performance or OI.AC, It.AC or OV trips.

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Commander SK Size 2 to 6 Getting Started Guide 65 Issue Number: 9 www.controltechniques.com

No Function Range Defaults Type

42 Low frequency voltage boost 0.0 to 50.0 % Eur: 3.0, USA: 1.0 RW

Determines the boost level when Pr 41 is set to Fd or SrE.

No Function Range Defaults Type

43 Serial communications baud rate 2.4, 4.8, 9.6, 19.2, 38.4 19.2 RW

2.4: 2400 baud

4.8: 4800 baud

9.6: 9600 baud

19.2: 19200 baud

38.4: 38400 baud

No Function Range Defaults Type

44 Serial comms address 0 to 247 1 RW

Defines the unique address for the drive for the serial interface.

No Function Range Defaults Type

45 Software version 1.00 to 99.99 RO

Indicates the version of software installed to the drive.

Pr 46 to Pr 51 appear when Pr 12 is set to control a motor brake

No Function Range Defaults Type

46 Brake release current threshold

47 Brake apply current threshold 10

0 to 200 %

Defines the brake release and brake apply current thresholds as a % of motor current. If the frequency is >Pr 48 and the current is >Pr 46, the brake release sequence is started. If the current is <Pr 47, the brake is applied immediately.

No Function Range Defaults Type

48 Brake release frequency

49 Brake apply frequency 2.0

0.0 to 20.0 Hz

Defines the brake release and brake apply frequencies. If the current is >Pr 46 and the frequency is > Pr 48, the brake release sequence is started. If the frequency is <Pr 49 and the drive has been commanded to stop, the brake is applied immediately.

No Function Range Defaults Type

50 Pre-brake release delay 0.0 to 25.0 s 1.0 RW

Defines the time between the frequency and load condition being met and the brake being released. The ramp is held during this time.

No Function Range Defaults Type

51 Post brake release delay 0.0 to 25.0 s 1.0 RW

Defines the time between the brake being released and the ramp hold being released.

1.0

66 Commander SK Size 2 to 6 Getting Started Guide

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The brake control functions are provided to allow well co-ordinated operation of an

WARNING

Current

magnitude

Brake release

current threshold

Brake apply

current threshold

+ _

Motor

frequency

Brake release

frequency

Brake apply

frequency

Reference

enabled

Latch

Drive

active

Out

Reset

Pre-brake

release

delay

Post brake

release

delay

Brake

release

Brake

controller

enable

User

programmable

Brake

disabled

Ramp

hold

Pr Brake

release frequency

48:

Pr : Brake release

current threshold

Ramp hold

Pr : Brake apply frequency

Pr :

Pre brake

release delay

Pr : Post brake release delay

Brake release

Output current

Output frequency

Pr :

Brake apply

current threshold

external brake with the drive. While both hardware and software are designed to high standards of quality and robustness, they are not intended for use as safety functions, i.e. where a fault or failure would result in a risk of injury. In any application where the incorrect operation of the brake release mechanism could result in injury, independent protection devices of proven integrity must also be incorporated.

Figure 6-12 Brake function diagram

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Commander SK Size 2 to 6 Getting Started Guide 67 Issue Number: 9 www.controltechniques.com

Figure 6-13 Brake sequence

commissioning

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Pr 52 to Pr 54 appear when a Solutions Module is installed to the drive

No Function Range Defaults Type

52 *Solutions Module dependant 0RW

No Function Range Defaults Type

53 *Solutions Module dependant 0RW

No Function Range Defaults Type

54 *Solutions Module dependant 0RW

*See the Commander SK Advanced User Guide for further information.

No Function Range Defaults Type

55 Last trip

56 Trip before Pr 55

57 Trip before Pr 56

58 Trip before Pr 57

Indicates the last 4 trips of the drive.

No Function Range Defaults Type

59 PLC ladder program enable 0 to 2 0 RW

The PLC ladder program enable is used to start and stop the PLC ladder program.

0: Stop the PLC ladder program 1: Run the PLC ladder program (trip drive if LogicStick is not installed). Any out-of-

range parameter writes attempted will be limited to the maximum/minimum

values valid for that parameter before being written to. 2: Run the PLC ladder program (trip drive if LogicStick is not installed). Any out-of-

range parameter writes attempted will cause the drive to trip. See the Commander SK Advanced User Guide for details on PLC ladder programming.

No Function Range Defaults Type

60 PLC ladder program status -128 to +127 RO

The PLC ladder program status parameter indicates the actual state of the PLC ladder program.

-n: PLC ladder program caused a drive trip due to an error condition while running

rung n. Note that the rung number is shown on the display as a negative

number.

0: LogicStick is installed with no PLC ladder program 1: LogicStick is installed, PLC ladder program is installed but stopped 2: LogicStick is installed, PLC ladder program is installed and running 3: LogicStick is not installed

No Function Range Defaults Type

61 to

Configurable parameter 1 to configurable parameter 10

As source

Pr 61 to Pr 70 and Pr 71 to Pr 80 can be used to access and adjust advanced parameters. Example: It is desired that Pr 1.29 (Skip frequency 1) is to be adjusted. Set one of the parameters Pr 71 to Pr 80 to 1.29, the value of Pr 1.29 will appear in the corresponding parameter from Pr 61 to Pr 70. I.e. if Pr 71 is set to 1.29, Pr 61 will contain the value of Pr 1.29 where it can be adjusted.

0RO

68 Commander SK Size 2 to 6 Getting Started Guide

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Some parameters are only implemented if the drive is disabled, stopped or tripped and

NOTE

the STOP/RESET key is pressed for 1s.

See Commander SK Advanced User Guide for advanced parameter details.

Safety Information

6.3 Parameter descriptions - Level 3

No Function Range Defaults Type

71 to

Pr 61 to Pr 70 set up 0 to Pr 21.51

Set Pr 71 to Pr 80 to the required advanced parameter number to be accessed. The value within these parameters will be displayed in Pr 61 to Pr 70. Pr 61 to Pr 70 can then be adjusted to change the value within a parameter. See Commander SK Advanced User Guide for further details.

6.4 Diagnostic parameters

The following read only (RO) parameters can be used as an aid to fault diagnosis on the drive. See Figure 8-1 Diagnostics logic diagram on page 76.

No Function Range Type

81 Frequency reference selected ±Pr 02 Hz RO 82 Pre-ramp reference ±Pr 02 Hz RO 83 Post-ramp reference ±Pr 02 Hz RO 84 DC bus voltage 0 to Drive maximum Vdc RO 85 Motor frequency ±Pr 02 Hz RO 86 Motor voltage 0 to Drive rating V RO 87 Motor speed ±9999 rpm RO 88 Motor current +Drive maximum A RO 89 Motor active current ±Drive maximum A RO 90 Digital I/O read word 0 to 95 RO 91 Reference enabled indicator OFF or On RO 92 Reverse selected indicator OFF or On RO 93 Jog selected indicator OFF or On RO 94 Analog input 1 level 0 to 100 % RO 95 Analog input 2 level 0 to 100 % RO

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Commander SK Size 2 to 6 Getting Started Guide 69 Issue Number: 9 www.controltechniques.com

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7 Quick start commissioning

Remote current speed reference input (A1)

+10V reference output

Local voltage speed reference input (A2)

+24V output

Drive Enable/Reset

Run Forward

Run Reverse

Local (A2)/Remote (A1) speed reference select

10k

(2kmin)

Eur USA

Analog output (motor speed)

Digital output (zero speed)

Speed

potentiometer

Remote current speed reference input (A1)

+10V reference output

Local voltage speed reference input (A2)

+24V output

/Stop

Run

Jog

Local (A2)/Remote (A1) speed reference select

10k

(2kmin)

Analog output (motor speed)

Digital output

(zero speed)

Speed

potentiometer

T1T2T3T4B1B2B3B4B5B6B7

This procedure is written from default parameter settings as the drive would be delivered from the factory.

For European default settings refer to section 7.1 Terminal control . For USA default settings refer to section 7.2 Keypad control on page 72.

7.1 Terminal control

Figure 7-1 Minimum required control terminal connections

Terminal B7 open: Local voltage speed reference (A2) selected

70 Commander SK Size 2 to 6 Getting Started Guide

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Action Detail

Pr 02

Pr 01

100Hz

Pr 03

Pr 04

Mot X XXXXXXXXX No XXXXXXXXXX kg

IP55 I.cl F C 40 s S1

VHzmin-1kW cosφA 230 400

50 1445 2.20 0.80 8.50

4.90

CN = 14.5Nm 240 415

50 1445 2 .20 0.76 8.50

4.90

CN = 14.4Nm

CTP- VEN 1PHASE 1=0,46A P=110W R.F 32MN

I.E.C 34 1(87)

cos

∅

Ensure:

• The drive enable signal is not given, terminal B4 is open

Before power up

Power up the drive

• The run signal is not given, terminal B5/B6 is open

• The motor is connected to the drive

• The motor connection is correct for the drive Δ or Y

• The correct supply voltage is connected to the drive

Ensure:

• The drive displays:

Safety Information

Information

Product

Enter minimum and maximum speeds

Enter acceleration and deceleration rates

Enter:

• Minimum speed Pr 01 (Hz)

• Maximum speed Pr 02 (Hz)

Enter:

• Acceleration rate Pr 03 (s/100Hz)

• Deceleration rate Pr 04 (s/100Hz)

Enter:

• Motor rated current in Pr 06 (A)

Enter motor nameplate details

• Motor rated speed in Pr 07 (rpm)

• Motor rated voltage in Pr 08 (V)

• Motor rated power factor in Pr 09

• If the motor is not a standard 50/60Hz motor, set Pr 39 accordingly

Ready to autotune

Enable and run the drive

Autotune

Close:

• The Enable and Run Forward or Run Reverse signals

The Commander SK will carry out a non-rotating autotune on the motor. The motor must be stationary to carry out an autotune correctly. The drive will carry out a non-rotating autotune every time it is first started after each power-up. If this will cause a problem for the application, set Pr 41 to the required value.

Autotune complete

When the autotune has been completed, the display will show:

Ready to run

Run The drive is now ready to run the motor.

Increasing and decreasing speed

Turning the speed potentiometer will increase and decrease the speed of the motor.

To stop the motor under ramp control, open either the run

Stopping

forward or run reverse terminal. If the enable terminal is opened while the motor is running, the motor will coast to a stop.

Mechanical

Installation

Electrical

Keypad and

Display

Parameters

commissioning

Quick start

Diagnostics Options

Commander SK Size 2 to 6 Getting Started Guide 71 Issue Number: 9 www.controltechniques.com

information

UL listing

7.2 Keypad control

+10V reference output

+24V output

Drive Enable/Reset

Forward/Reverse

Analog output (motor speed)

Digital output (zero speed)

Not used

NOTE

Figure 7-2 Minimum required control terminal connections

To implement a Forward/Reverse switch from the drive’s display:

•Set Pr 71 to 8.23

•Set Pr 61 to 6.33

• Press the STOP/RESET key Terminal B5 will now be set-up as a Forward/Reverse terminal.

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Action Detail

Pr 02

Pr 01

100Hz

Pr 03

Pr 04

Mot X XXXXXXXXX No XXXXXXXXXX kg

IP55 I.cl F C 40 s S1

VHzmin-1kW cosφA 230 400

50 1445 2.20 0.80 8.50

4.90

CN = 14.5Nm 240 415

50 1445 2.20 0.76 8.50

4.90

CN = 14.4Nm

CTP- VEN 1PHASE 1=0,46A P=110W R.F 32MN

I.E.C 34 1(87)

cos

∅

Ensure:

Before power up

Power up the drive

• The drive enable signal is not given, terminal B4 is open

• The motor is connected to the drive

• The motor connection is correct for the drive Δ or Y

• The correct supply voltage is connected to the drive

Ensure:

• The drive displays:

Safety Information

Information

Product

Enter minimum and maximum speeds

Enter acceleration and deceleration rates

Set keypad control

Enter:

• Minimum speed Pr 01 (Hz)

• Maximum speed Pr 02 (Hz)

Enter:

• Acceleration rate Pr 03 (s/100Hz)

• Deceleration rate Pr 04 (s/100Hz)

Enter:

• PAd into Pr 05

Enter:

• Motor rated current in Pr 06 (A)

Enter motor nameplate details

• Motor rated speed in Pr 07 (rpm)

• Motor rated voltage in Pr 08 (V)

• Motor rated power factor in Pr 09

• If the motor is not a standard 50/60Hz motor, set Pr 39 accordingly

Ready to autotune

Enable and run the drive

Close:

• The enable signal

• Press the START key

The Commander SK will carry out a non-rotating autotune on the motor.

Autotune

Autotune complete

The motor must be stationary to carry out an autotune correctly. The drive will carry out a non-rotating autotune every time it is first started after each power-up. If this will cause a problem for the application, set Pr 41 to the required value.

When the autotune has been completed, the display will show:

Ready to run

Run The drive is now ready to run the motor.

Increasing and decreasing speed

Stopping

Press the UP key to increase the speed

Press the DOWN key to decrease the speed

Press the STOP/RESET key to stop the motor

Mechanical

Installation

Electrical

Keypad and

Display

Parameters

commissioning

Quick start

Diagnostics Options

Commander SK Size 2 to 6 Getting Started Guide 73 Issue Number: 9 www.controltechniques.com

information

UL listing

8 Diagnostics

WARNING

Do not attempt to carry out internal repairs. Return a faulty drive to the supplier for repair.

Trip code Condition Possible cause

UV DC bus under voltage

OV DC bus over voltage

OI.AC**

OI.br**

O.SPd Over speed

tunE

It.AC

O.ht1

O.ht2

O.Ld1*

O.ht3

O.ht4

C.dAt SmartStick data does not exist New/empty SmartStick being read

C.Acc SmartStick read/write fail Bad connection or faulty SmartStick

Drive output instantaneous over current

Braking resistor instantaneous over current

Autotune stopped before completion

It.br

SCL

EEF Internal drive EEPROM trip

t on braking resistor

t on drive output current

IGBT over heat based on drives thermal model

Over heat based on drives heatsink

th Motor thermistor trip Excessive motor temperature

User +24V or digital output overload

Drive over-heat based on drives thermal model

Power module rectifier over temperature.

Analog input 1 current mode,

cL1

current loss

Serial communications loss timeout

Input phase imbalance or input

phase loss

Failure to measure motors stator

resistance

Low AC supply voltage Low DC bus voltage when supplied by an external DC power supply

Deceleration rate set too fast for the inertia of the machine. Mechanical load driving the motor

Insufficient ramp times Phase to phase or phase to ground short circuit on the drives output Drive requires autotuning to the motor Motor or motor connections changed, re-autotune drive to motor

Excessive braking current in braking resistor Braking resistor value too small

Excessive motor speed (typically caused by mechanical load driving the motor)

Run command removed before autotune complete

Excessive braking resistor energy

Excessive mechanical load High impedance phase to phase or phase to ground short circuit at drive output Drive requires re-autotuning to motor

Overheat software thermal model

Heatsink temperature exceeds allowable maximum

Excessive load or short circuit on +24V output

Overheat software thermal model

Power module rectifier temperature exceeds allowable maximum

Input current less than 3mA when 4-20 or 20-4mA modes selected

Loss of communication when drive is under remote control

Possible loss of parameter values (set default parameters (see Pr

One of the input phases has become disconnected from the drive (not dual rated drives)

Motor too small for drive Motor cable disconnected during measurement

29 on page 62))

74 Commander SK Size 2 to 6 Getting Started Guide

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Trip code Condition Possible cause

NOTE

C.rtg SmartStick/drive rating change

Already programmed SmartStick read by a drive of a different rating

O.cL Overload on current loop input Input current exceeds 25mA

HFxx trip Hardware faults

Internal drive hardware fault (see Commander SK Advanced User Guide)

* The Enable/Reset terminal will not reset an O.Ld1 trip. Use the Stop/Reset key.

** These trips cannot be reset for 10 seconds after they occur.

See the Commander SK Advanced User Guide for further information on possible causes of drive trips.

Table 8-1 DC bus voltages

Drive voltage

rating

200V 175 215 390 415

400V 330 425 780 830

575V 435 590 930 990

690V 435 590 1120 1190

UV trip level UV reset level * Braking level OV trip level **

* These are the absolute minimum DC voltages the drives can be supplied by. ** The drive will trip on OV if the DC Bus goes above the OV trip level.

Table 8-2 Alarm warnings/Display indications

Display Condition Solution

OVL.d I x t overload (I = current, t = time) Reduce motor current (Load)

hot Heatsink/IGBT temperature high Reduce ambient temperature or reduce motor current

br.rS Braking resistor overload

AC.Lt Drive is in current limit

FAIL Failed attempt to read stick

See Menu 10 in the Commander SK Advanced User Guide

An attempt was made to read the stick when the drive was not disabled or tripped, or the stick is read only

Safety Information

Information

Product

Mechanical

Installation

Electrical

Keypad and

Display

Parameters

commissioning

Quick start

If no action is taken when an alarm warning appears, the drive will trip on the appropriate fault code.

Commander SK Size 2 to 6 Getting Started Guide 75 Issue Number: 9 www.controltechniques.com

Diagnostics

Options

information

UL listing

Figure 8-1 Diagnostics logic diagram

Analog inputs

Analog input 1 (%)

Analog input 2 (%)

Digital I/O

Read word Pr

Sequencer

Jog

selected

Reverse selected

Reference

enabled

X-1

0Hz

Pre-ramp

reference (Hz)

DC bus

voltage

Motor rated

current

Motor rated

speed

Motor rated

voltage

Motor power

factor

Dynamic V to f

select Switching frequency

Autotune

Motor rated frequency No. of motor poles

Voltage mode select

Voltage boost

Motor control

Acceleration rate Deceleration rate

Ramps

Minimum speed Maximum speed

Speed clamps

Post-ramp

reference

(Hz)

Motor

frequency

Motor

voltage87Motor

speed

rpm

Motor current

Jog

reference

Digital I/O read word Pr

Ter m in al

Binary value for XX B3 1 B4 2 B5 4 B6 8 B7 16

T6/T5 64

Frequency

reference

selected (Hz)

Key

Read-write (RW) parameter

Read-only (RO) parameter

Input terminals

Output terminals

Start/stop

logic select

Brake

controller

enabled

Stop mode

select

Ramp mode select

Motor active

current

Current

measurement

Parameter

access

76 Commander SK Size 2 to 6 Getting Started Guide

Cooling fan control

The cooling fan on a Commander SK size 2 is a dual speed fan and on sizes 3 to 6, it is a variable speed fan. The drive controls the speed at which the fan runs based on the temperature of the drives heatsink and also the drive’s thermal model system. The cooling fan on Commander SK size 6 is a variable speed fan which requires an external +24Vdc power supply.

See section 4.2 Heatsink fan on page 38.

www.controltechniques.com Issue Number: 9

9Options

Option name Function Picture

SmartStick

LogicStick

LogicStick Guard Kitbag

SM-I/O Lite

SM-I/O Timer Additional input/output module with real time clock

SM-I/O 120V

SM-I/O PELV

SM-I/O 24V Protected

SM-I/O 32 Extended I/O Interface

SM-PROFIBUS-DP-V1

SM-DeviceNet DeviceNet adapter for communication

SM-CANopen CANopen adapter for communication

SM-INTERBUS INTERBUS adapter for communication

SM-Ethernet Ethernet adapter for communication

SM-LON Lonworks adapter for communication

SM-EtherCAT EtherCAT adapter for communication

Upload drive parameters to the SmartStick for storage or for easy set-up of identical drives or downloading to replacement drives

The LogicStick plugs into the front of the drive and enables the user to program PLC functions within the drive The LogicStick can also be used as a SmartStick (now supplied with LogicStick Guard)

The LogicStick guard protects the Logicstick when installed to a drive. Available in a bag of 25

Additional input/output module without real time clock

Additional input/output module conforming to IEC 1131-2 120Vac. 6 x digital inputs, 2 x relay outputs

Isolated input/output to NAMUR NE37 specifications (for chemical industry applications)

Additional input/output module with overvoltage protection up to 48V. 2 x analog outputs, 4 x digital inputs/outputs, 3 x digital inputs, 1 x relay output

PROFIBUS-DP-V1 adapter for communication

Safety Information

Information

Product

Mechanical

Installation

Electrical

Keypad and

Display

Parameters

SM-Keypad Plus

SK-Keypad Remote

EMC filters

CT comms cable

CT USB comms cable

Remote panel mounting LCD multilingual text keypad display to IP54 and/or NEMA 12 with additional help key

Remote panel mounting LED display to IP65 and/or NEMA 12 with additional function key

These additional filters are designed to operate together with the drive’s own integral EMC filter in areas of sensitive equipment

Cable with isolation RS232 to RS485 converter. For connecting PC/Laptop to the drive when using CTSoft or SyPTLite

Commander SK Size 2 to 6 Getting Started Guide 77 Issue Number: 9 www.controltechniques.com

commissioning

information

Quick start

Diagnostics

Options

UL listing

Option name Function Picture

Conduit box

AC input line reactors To reduce supply harmonics

CTSoft

SyPTLite

Braking resistor

Top and bottom metal gland plates to allow the drive to comply with the requirements of UL type 1

Software for PC or Laptop which allows the user to commission and store parameter settings

Software for PC or Laptop which allows the user to program PLC functions within the drive

Optional internal braking resistor for Commander SK size 2 (see Commander SK Technical Data Guide for further details).

Details of all the above options can be found at www.controltechniques.com and on the CD supplied with the drive.

78 Commander SK Size 2 to 6 Getting Started Guide

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10 UL listing information

The Control Techniques UL file number is E171230. Confirmation of UL listing can be found on the UL website: www.ul.com.

Safety Information

10.1 Common UL information

Conformity

The drive conforms to UL listing requirements only when the following are observed:

• The drive is installed in a type 1 enclosure, or better, as defined by UL50

• The ambient temperature does not exceed 40°C (104°F) when the drive is operating

• The terminal tightening torques specified in section 3.6.1 Terminal sizes and torque settings on page 32.

Motor overload protection

The drive provides motor overload protection. The default overload protection level is no higher than 150% of full-load current (FLC) of the drive. It is necessary for the motor rated current to be entered into Pr 06 (or Pr 5.07) for the protection to operate correctly. The protection level may be adjusted below 150% if required. The drive also provides motor thermal protection, refer to Pr 4.15, Pr 4.19 and Pr 4.25 in the Commander SK Advanced User Guide.

Overspeed protection

The drive provides overspeed protection. However, it does not provide the level of protection afforded by an independent high integrity overspeed protection device.

10.2 Power dependant UL information

Conformity

The drive conforms to UL listing requirements only when the following is observed:

Fuses

Size 2 to 3

• The correct UL-listed high speed/fast acting fuses (class CC or class J up to 30A and class J above 30A), e.g. Bussman Limitron KTK series, Gould Amp-Trap ATM series or equivalent, are used in the AC supply. The drive does not comply with UL if MCBs are used in place of fuses.

For further details on fusing, refer to section 2.3

Size 4 to 6

• The UL-listed Ferraz HSJ (High speed J class) fuses are used in the AC supply. The drive does not comply with UL if any other fuses or MCBs are used in place of those stated.

For further details on fusing, refer to

Field wiring

Size 2 to 4

• Class 1 60/75°C (140/167°F) copper wire only is used in the installation

Size 5 and 6

• Class 1 75°C (167°F) copper wire only is used in the installation

Field wiring connectors

Sizes 4 to 6

• UL listed wire connectors are used for terminating power circuit field wiring, e.g. Ilsco TA series

section 2.3

Rating Data

on page 11.

Rating Data on page 11.

Information

Product

Mechanical

Installation

Electrical

Keypad and

Display

Parameters

commissioning

Quick start

Diagnostics Options

information

UL listing

Commander SK Size 2 to 6 Getting Started Guide 79 Issue Number: 9 www.controltechniques.com

10.3 AC supply specification

The Commander SK is suitable for use in a circuit capable of delivering not more than 100,000rms symmetrical Amperes at 264Vac rms maximum (200V drives), 528Vac rms maximum (400V drives) or 600Vac rms maximum (575V and 690V drives).

10.4 Maximum continuous output current

The drive models are listed as having the maximum continuous output currents (FLC) shown in Table 10-1, Table 10-2, Table 10-3 and Table 10-4 (see the Commander SK Technical Data Guide for details).

Table 10-1 Maximum continuous output current (200V drives)

Model FLC (A) Model FLC (A)

SK2201 15.5 SK4201 68

SK2202 22 SK4202 80

SK2203 28 SK4203 104

SK3201 42

SK3202 54

Table 10-2 Maximum continuous output current (400V drives)

Model FLC (A) Model FLC (A)

SK2401 15.3 SK4401 68

SK2402 21 SK4402 83

SK2403 29 SK4403 104

SK2404 29 SK5401 138

SK3401 35 SK5402 168

SK3402 43 SK6401 205

SK3403 56 SK6402 236

Table 10-3 Maximum continuous output current (575V drives)

Model FLC (A) Model FLC (A)

SK3501 5.4 SK3505 16

SK3502 6.1 SK3506 22

SK3503 8.4 SK3507 27

SK3504 11

Table 10-4 Maximum continuous output current (690V drives)

Model FLC (A) Model FLC (A)

SK4601 22 SK5601 84

SK4602 27 SK5602 99

SK4603 36 SK6601 125

SK4604 43 SK6602 144

SK4605 52

SK4606 62

10.5 Safety label

The safety label supplied with the connectors and mounting brackets must be placed on a fixed part inside the drive enclosure where it can be seen clearly by maintenance personnel for UL compliance.

The label clearly states “CAUTION Risk of Electric Shock Power down unit 10 minutes before removing cover”.

80 Commander SK Size 2 to 6 Getting Started Guide

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Remote current speed reference input (A1)

+10V reference output

Local voltage speed reference input (A2)

+24V output

Drive Enable/Reset

Run Forward

Run Reverse

Local (A2)/Remote (A1) speed reference select

Remote speed reference input

10k

(2kmin)

+24V

Pr 29 = Eur

Analog output (motor speed)

Digital output (zero speed)

OK Fault

Pr 29 = USA

T3 T4 T5 T6T1 T2

B3 B4 B5 B6B1 B2 B7

0VA1+10V

+10V reference output

+24V output

Drive Enable/Reset

+24V

Analog output

(motor speed)

Digital output (zero speed)

Not used

Forward/Reverse

0472-0064-09

Control Techniques Commander SK Quick Start Guide

Specifications and Main Features

Frequently Asked Questions

User Manual