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Page 1

User Guide

www.emersonclimate.com/CommercialScroll

CSD100

Model size 4 to 6

Variable Speed AC drive for permanent magnet motors

Part Number: 0478-0107-03 Issue: 3

Page 2

Original Instructions

For the purposes of compliance with the EU Machinery Directive 2006/42/EC:

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 firmware version

This product is supplied with the latest firmware version. If this drive is to be connected to an existing system or machine, all drive firmware 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 Service Centre or Repair Centre. If there is any doubt please contact the supplier of the product.

The firmware version of the drive can be checked by looking at Pr 11.029.

CSD100 Software version

This product is supplied with the latest software version. The software version can be verified in Pr 00.056 {20.003}.

Page 3

How to use this guide

NOTE

1 Safety information

2 Product information

3 Mechanical installation

4 Electrical installation

5 Getting started

Compressor specific functions

7 Running the motor

8 Optimization

9 NV media card operation

10 CT MODBUS RTU

11 Technical data

12 Diagnostics

13 UL listing information

This user guide provides complete information for installing and operating the drive from start to finish. The information is in logical order, taking the reader from receiving the drive through to fine tuning the performance.

There are specific safety warnings throughout this guide, located in the relevant sections. In addition, Chapter 1 Safety information contains general safety information. It is essential that the warnings are observed and the information considered when working with or designing a system using the drive.

This map of the user guide helps to find the right sections for the task you wish to complete, but for specific information, refer to Contents on page 4:

Page 4

Contents

1 Safety information .................................7

1.1 Warnings, Cautions and Notes .............................7

1.2 Electrical safety - general warning ........................7

1.3 System design and safety of personnel ................7

1.4 Environmental limits ..............................................7

1.5 Access ...................................................................7

1.6 Compliance with regulations .................................7

1.7 Motor .....................................................................7

1.8 Adjusting parameters ............................................7

1.9 Electrical installation ..............................................7

2 Product information ..............................8

2.1 Introduction ...........................................................8

2.2 Model number .......................................................9

2.3 Ratings ................................................................10

2.4 Operating modes .................................................12

2.5 Drive features ......................................................12

2.6 Nameplate description ........................................13

2.7 Options ................................................................13

2.8 Items supplied with the drive ...............................15

3 Mechanical installation .......................16

3.1 Safety information ...............................................16

3.2 Planning the installation ......................................16

3.3 Terminal cover removal .......................................17

3.4 Installing / removing option modules and

keypads ...............................................................21

3.5 Dimensions and mounting methods ....................23

3.6 Enclosure for standard drives .............................27

3.7 Enclosure design and drive ambient

temperature .........................................................29

3.8 Heatsink fan operation ........................................29

3.9 Enclosing standard drive for high

environmental protection .....................................29

3.10 External EMC filter ..............................................32

3.11 Electrical terminals ..............................................33

3.12 Routine maintenance ..........................................34

4 Electrical installation ...........................37

4.1 Power connections ..............................................37

4.2 AC supply requirements ......................................40

4.3 Ratings ................................................................40

4.4 Output circuit and motor protection .....................42

4.5 Ground leakage ...................................................43

4.6 EMC (Electromagnetic compatibility) ..................43

4.7 Communications connections .............................51

4.8 Control connections ............................................51

4.9 CSD100 specific Input/Output and control ..........52

4.10 SAFE TORQUE OFF (STO) ...............................56

5 Getting started .................................... 58

5.1 Understanding the display .................................. 58

5.2 Keypad operation ............................................... 58

5.3 Menu structure ................................................... 60

5.4 Menu 0 ............................................................... 61

5.5 Advanced menus ............................................... 61

5.6 Saving parameters ............................................. 62

5.7 Parameter access level and security ................. 62

5.8 Displaying parameters with non-default

values only ......................................................... 63

5.9 Displaying destination parameters only ............. 63

5.10 Communications ................................................ 63

6 Compressor specific functions ......... 65

6.1 Menu 0 - compressor specific parameters ......... 65

6.2 Detailed compressor function descriptions ........ 67

6.3 Compressor protection ....................................... 77

6.4 System control ................................................... 82

6.5 Parameter descriptions ...................................... 87

7 Running the motor .............................. 88

7.1 Quick start connections ...................................... 88

8 Optimization ........................................ 92

8.1 Motor thermal protection .................................... 92

9 NV Media Card Operation .................. 93

9.1 Introduction ........................................................ 93

9.2 NV Media Card support ...................................... 93

9.3 Transferring data ................................................ 94

9.4 Data block header information ........................... 95

9.5 NV Media Card parameters ............................... 95

9.6 NV Media Card trips ........................................... 96

10 CT MODBUS RTU ................................ 97

10.1 MODBUS RTU ................................................... 97

10.2 Slave address .................................................... 97

10.3 MODBUS registers ............................................. 97

10.4 Data encoding .................................................... 98

10.5 Function codes ................................................... 98

10.6 Exceptions ........................................................ 101

10.7 CRC ................................................................. 101

11 Technical data ................................... 102

11.1 Drive technical data .......................................... 102

11.2 Optional external EMC filters ........................... 109

4 CSD100 User Guide

Issue Number: 3

Page 5

12 Diagnostics ........................................111

12.1 Status modes (Keypad and LED status) ...........111

12.2 Trip indications ..................................................111

12.3 Identifying a trip / trip source .............................112

12.4 Compressor specific diagnostics ......................113

12.5 Trips, Sub-trip numbers ....................................117

12.6 Internal / Hardware trips ....................................136

12.7 Alarm indications ...............................................137

12.8 Status indications ..............................................137

12.9 Displaying the trip history ..................................137

12.10 Behaviour of the drive when tripped .................138

13 UL listing information .......................139

CSD100 User Guide 5 Issue Number: 3

Page 6

Declaration of Conformity

Control Techniques Ltd

The Gro

Newtown

Powys

SY16 3BE

This declaration applies to CSD100 variable speed drive products, comprising model numbers as shown below:

CSD100-bbbbbbbbb Valid characters:

04400240A

bbbbbbbbb

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

05400300A 06200500A, 06200580A, 06400380A,

06500220A, 06500270A

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

Moteurs Leroy-Somer

Usine des Agriers

Boulevard Marcellin Leroy

CS10015

16915 Angoulême Cedex 9

France

These products comply with the requirements of the Restriction of Hazardous Substances Directive 2011/65/EU, the Low Voltage Directive 2006/95/EC and the Electromagnetic Compatibility Directive 2004/108/ EC.

T. Alexander

Control Techniques Vice President, Technology

Newtown

Date: 10th December 2014

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 User Guide. An EMC Data Sheet is also available giving detailed EMC information.

EN 61000-3-2:2006

EN 61000-3-3:2008

EN 61000-3-2:2006 Applicable where input current <16 A. No limits apply for professional equipment where input power >1 kW.

Electromagnetic compatibility (EMC), Limits, Limits for harmonic current emissions (equipment input current <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

6 CSD100 User Guide

Issue Number: 3

Page 7

Safety

WARNING

CAUTION

NOTE

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Compressor

specific functions

Running the

motor

Optimization

NV Media Card

Operation

CT MODBUS

RTU

Technical

data

Diagnostics

UL listing

information

1 Safety information

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.

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 User Guide.

1.3 System design and safety of

The drive is intended as a component for professional incorporation into complete equipment or a 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.

Close attention is required to the electrical installation and the system design to avoid hazards either in normal operation or in the event of equipment malfunction. 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 User Guide carefully.

The STOP and SAFE TORQUE OFF functions of the drive 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.

With the sole exception of the SAFE TORQUE OFF function, none of the drive functions must be used to ensure safety of personnel, i.e. they must not be used for safety-related functions.

Careful consideration must be given to the functions of the drive which might result in a hazard, either through their intended behavior 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.

The SAFE TORQUE OFF function may be used in a safety-related application. The system designer is responsible for ensuring that the complete system is safe and designed correctly according to the relevant safety standards.

personnel

1.5 Access

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

1.6 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 or other protection, and protective ground (earth) connections.

This User Guide contains instruction 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.

1.7 Motor

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

1.8 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.

1.9 Electrical installation

1.9.1 Electric shock risk

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

AC supply cables and connections 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.

1.9.2 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.

1.4 Environmental limits

Instructions in this User Guide regarding transport, storage, installation and use of the drive must be complied with, including the specified environmental limits. Drives must not be subjected to excessive physical force.

CSD100 User Guide 7 Issue Number: 3

Page 8

Safety

CSD100

OEM controller

Start/Stop and Stator heating control*

Speed reference command(rpm)

CSD100 condition (alerts/trips/lockouts)

Motor

Power

Condenser

Evaporator

Expansion

Valve

Fan

Condenser Pressure

(Pc)

Evaporator Pressure

(Pe)

Discharge

Temperature

Full OEM control mode

Pc**

Pe**

Pc and Pe**

Discharge Line Temperature

Defrost control

Compressor

*Note Start/Stop and Stator

heating control can be via digital

input (Pr18.016 bit 8=0)or via

fieldbus (Pr18.016 bit 8=1)

**See description of ‘Envelope

control’ on next page

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Compressor

specific functions

Running the

motor

Optimization

NV Media Card

Operation

CT MODBUS

RTU

Technical

data

Diagnostics

2 Product information

2.1 Introduction

Variable speed compressor drive

The CSD100 delivers maximum machine performance with sensorless permanent magnet motor control, for dynamic and efficient machine operation.

Features

• Universal high performance drive for sensorless permanent magnet motors.

• Onboard IEC 61131-3 programmable automation

• 485 serial communications interface

• Single channel SAFE TORQUE OFF (STO) input

Optional features

• Select up to three option modules

• NV Media Card for parameter copying and data storage

•Keypad

• EMC filter

• Input line reactor The CSD100 compressor drive is designed to be used in the configuration shown below.

Figure 2-1 Full OEM control mode

UL listing

information

Compressor functionality provided by the dedicated CSD100 software

The dedicated CSD100 compressor related functionality includes:

• Soft start

The initial start of the compressor, where the motor is accelerated to a predetermined dwell speed.

• Locked rotor

During a mechanical failure of compressor or associated system, a condition can occur where the motor cannot turn even with maximum current, this is the locked rotor condition. It is detected by the software during soft start if the estimating motor speed is below 20% of the soft-start dwell speed.

• Motor phase loss detection

The drive will detect and trip if a phase connection to the motor is missing during soft-starting. After 5 minutes the trip is automatically reset and the soft-start can begin once more. The system will lockout after 10 trips within 24 hours [the count of trips is reset on lockout].

• Reverse rotation

Reverse rotation of the compressor can occur if the motor has been miss-wired (phase order error). The software detects this condition by monitoring the torque profile during soft start. This is only checked on the first soft start after power up.

8 CSD100 User Guide

Issue Number: 3

Page 9

Safety

Optional Build

Identification Label

Derivative Electrical Specifications

CSD1

00300

CSD100 Product Line

Frame Size:

Voltage Rating:

Current Rating:

Current rating x 10

Drive Format:

A - AC in AC out

Customer Code

A B 1 00

Customer Code:

06 = 50 Hz 07 = 60 Hz

Reserved:

Conformal Coating:

0 = Standard

IP / NEMA Rating:

1 = IP21 / NEMA 1

Brake Transistor:

Cooling:

A = Air

Reserved

Documentation

Documentation:

0 - Supplied separately 1 - English

2 - 200 V (200 - 240

- 400 V (380 - 480

- 575 V (500 - 575

± 10 %) 4 ±±10 %) 510%)

Not used

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Compressor

specific functions

Running the

motor

Optimization

NV Media Card

Operation

CT MODBUS

RTU

Technical

data

Diagnostics

UL listing

information

• Envelope control

The compressor has a speed envelope in which normal operation takes place. Envelope control is used to keep the compressor operating within this envelope. The software function receives both the condenser and evaporator pressures and limits the speed reference to keep the compressor operating within its envelope. If operation outside the outer envelope is detected, a trip will occur to protect the compressor.

• Resonance avoidance

This is to avoid running at motor speeds that cause mechanical resonance effects.

• Defrost cycle

During this mode of operation the compressor motor is changed to a defined speed for a period of time. This is to raise the temperature of the evaporator and defrost it.

• Oil boost

If the compressor is running at a speed that is insufficient to guarantee lubrication (for a defined time) oil boost mode is entered. During oil boost the motor speed is increased for a period of time to ensure the compressor is correctly lubricated.

• Lost rotor trip prevent

The drive automatically reduces the compressor speed under conditions where the speed error is greater than expected to avoid nuisance trips.

• Controlled shut down

A controlled shut down avoids compressor issues that would be caused by simply turning off the power. During a controlled shut down, the motor decelerates to a defined speed for a dwell time and then slows to zero speed at a controlled rate.

• Anti short cycling

Excessive short duration cycles can cause damage to the compressor and system. The short-cycle prevention scheme detects if there have been too many short-cycles. It will alert the user and impose a restart lockout time to prevent further short-cycles.

• Discharge Line Temperature

The drive monitors the level of the discharge line temperature sensor and trips if it is outside of the permitted range.

• Stator Heating

This function feeds DC current through the motor stator windings in order to heat the compressor while the compressor is not spinning.

• Field-bus communications watchdog timer

This function may be used to protect the system from a long term loss of field-bus communications.

• Alert log

The last 20 alerts occurring within the last 7 days are logged for diagnostic purposes

2.2 Model number

The way in which the model numbers for the CSD100 range are formed is illustrated below:

Figure 2-2 Model number

CSD100 User Guide 9 Issue Number: 3

Page 10

Safety

Available output

current

Motor continuous current (above 50% base speed)

Motor rated current set in the drive

Overload limit

NOTE

Motor total

current (Pr 04.001)

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 = 004.025

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Compressor

specific functions

Running the

motor

Optimization

NV Media Card

Operation

CT MODBUS

2.3 Ratings

Ratings are compatible with motors designed to IEC60034. The graph aside illustrates the relationship between continuous current rating and short term overload limits.

RTU

Technical

data

Diagnostics

UL listing

information

To provide the correct level of protection the I

t software operates at a level which is speed dependent. This is illustrated in the graph below.

The speed at which the low speed protection takes effect can be changed by the setting of Low Speed Thermal Protection Mode (04.025). The protection starts when the motor speed is below 15 % of base speed when Pr 04.025 = 0 (default) and below 50 % when Pr 04.025 = 1.

Operation of motor I2t protection

Motor I

t protection is fixed as shown below.

10 CSD100 User Guide

Issue Number: 3

Page 11

Safety

NOTE

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Compressor

specific functions

Running the

motor

Optimization

NV Media Card

Operation

CT MODBUS

RTU

Technical

data

Diagnostics

UL listing

information

The continuous current ratings given are for maximum 40 °C (104 °F), 1000 m altitude and 3.0 kHz switching. Derating is required for higher switching frequencies, ambient temperature >40 °C (104 °F) and high altitude. For further information, refer to Chapter 11 Technical data on page 102.

Table 2-1 200 V drive ratings (200 V to 240 V ±10 %)

Maximum permissible continuous output

Nominal rating

Model

current (A) for the following ambient

temperatures

kW hp (40°C) (60°C)

Frame size 6

06200500 11 15 50 27 06200580 15 20 58 43

Table 2-2 400 V drive ratings (380 V to 480 V ±10 %)

Maximum permissible continuous output

Model

Nominal rating

current (A) for the following ambient

temperatures

kW hp (40°C) (60°C)

Frame size 4 04400240 11 15 24 15 Frame size 5 05400300 15 20 30 24 Frame size 6 06400380 18.5 25 38 38

Table 2-3 575 V drive ratings (500 V to 575 V ±10 %)

Maximum permissible continuous output

Model

Nominal rating

current (A) for the following ambient

temperatures

kW hp (40°C) (60°C)

Frame size 6

06500220 11 15 22 06500270 15 20 27 24

2.3.1 Typical short term overload limits

The maximum percentage overload limit changes depending on the selected motor. Variations in motor characteristics can 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 Parameter Reference Guide.

Typical values are shown in the table below for RFC-S.

Table 2-4 Typical overload limits

Operating mode RFC from cold RFC from 100 %

Overload with motor rated current = drive rated current 110 % for 165 s 110 % for 9 s

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.

CSD100 User Guide 11 Issue Number: 3

Page 12

Safety

15 14

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Compressor

specific functions

Running the

motor

Optimization

NV Media Card

Operation

CT MODBUS

RTU

Technical

data

Diagnostics

UL listing

information

2.4 Operating modes

The CSD100 drive is designed to operate in the following mode:

1. RFC - S Without position feedback sensor (Sensorless)

2.4.1 RFC- S mode

Without position feedback sensor (Sensorless)

RFC-S sensorless mode provides closed loop control without the need for position feedback by using current, voltages and key motor parameters to estimate the motor speed.

2.5 Drive features

Figure 2-3 Features of the drive

Key

1. Keypad connection 5. Option module slot 1 9. Control connections 13. DC bus -

2. Rating label 6. Option module slot 2 10. Communications port 14. Motor connections

3. Identification label 7. Option module slot 3 11. NV media card slot 15. AC supply connections

4. Status LED 8. Relay connections 12. DC bus + 16. Ground connections

12 CSD100 User Guide

Issue Number: 3

Page 13

Safety

Refer to

User Guide

Model

Frame

size

Voltage

Current

rating

Drive format

CSD1-054 00300 A

Approvals

Input

voltage

Output

voltage

Power rating

Customer and date code

Serial number

Input

frequency

No.of phases & Typical input current

Rated output current

15/15 kW

STDN39

Patents: www.ctpatents.info Designed in UK. / Made in UK

Key to approvals

CE approval Europe

C Tick approval Australia

UL / cUL approval

USA &

Canada

RoHS compliant Europe

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

2.6 Nameplate description

See Figure 2-3 for location of rating labels.

Figure 2-4 Typical drive rating labels

Compressor

specific functions

Running the

motor

Optimization

NV Media Card

Operation

CT MODBUS

RTU

Technical

data

Diagnostics

UL listing

information

Refer to Figure 2-2 Model number on page 9 for further information relating to the labels.

2.7 Options

Figure 2-5 Options available with the drive

1. Keypad

2. Option module slot 1

3. Option module slot 2

CSD100 User Guide 13 Issue Number: 3

4. Option module slot 3

5. CT Comms cable

6. NV media card

Page 14

Safety

WARNING

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Compressor

specific functions

Running the

motor

Optimization

NV Media Card

Operation

CT MODBUS

RTU

Technical

data

Diagnostics

UL listing

information

Be aware of possible live terminals when inserting or removing the NV media card.

All standard option modules are color-coded in order to make identification easy. All modules have an identification label on top of the module. Standard option modules can be installed to any of the available option slots on the drive. The following tables shows the color-code key and gives further details on their function.

Table 2-5 Option module identification (standard modules)

Typ e

Option

module

Color Name Further Details

Profibus option

PROFIBUS adapter for communications with the drive

DeviceNet option

DeviceNet adapter for communications with the drive

CANopen option

CANopen adapter for communications with the drive

Fieldbus

Purple SI-PROFIBUS

Medium Grey SI-DeviceNet

Light Grey SI-CANopen

Extended I/O

Increases the I/O capability by adding the following combinations:

Automation

(I/O expansion)

Orange SI-IO

• Digital I/O

• Digital Inputs

• Analog Inputs (differential or single ended)

• Analog Output

• Relays

Table 2-6 Keypad identification

Type Keypad Name Further Details

HOA-Keypad

LCD keypad option

Keypad with a LCD display

Keypad

HOA-Keypad RTC

LCD keypad option

Keypad with a LCD display and real time clock

14 CSD100 User Guide

Issue Number: 3

Page 15

Safety

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

Compressor

specific functions

Running the

motor

Optimization

NV Media Card

Operation

CT MODBUS

RTU

Technical

data

Diagnostics

UL listing

information

2.8 Items supplied with the drive

The drive is supplied with a copy of the Getting Started Guide, a safety information booklet, the Certificate of Quality and an accessory kit box including the items shown in Table 2-7.

Table 2-7 Parts supplied with the drive

Description Size 4 Size 5 Size 6

Control connectors

x 1 x 1

Relay connector

x 1

24 V power supply connector

x 1

Grounding bracket

x 1

Surface mounting brackets

x 2 x 2 x 2

Grounding clamp

DC terminal cover grommets

Terminal nuts

Supply and motor connector

Finger guard grommets

x 1 x 1 x 1

x 2

M6 x 11

x 1 x 1 x 1

x 3 x 2

CSD100 User Guide 15 Issue Number: 3

Page 16

Safety

WARNING

NOTE

information

Product

information

Mechanical installation

Electrical

installation

Getting started

Compressor

specific functions

Running the

motor

Optimization

NV Media Card

Operation

CT MODBUS

RTU

Technical

data

Diagnostics

UL listing

information

3 Mechanical installation

This chapter describes how to use all mechanical details to install the drive. The drive is intended to be installed in an enclosure. Key features of this chapter include:

• Through-hole mounting

• High IP as standard or through-panel mounting

• Enclosure sizing and layout

• Option module installing

• Terminal location and torque settings

3.1 Safety information

Follow the instructions

The mechanical and electrical installation instructions must be adhered to. Any questions or doubt should be referred to the supplier of the equipment. It is the responsibility of the owner or user to ensure that the installation of the drive and any external option unit, and the way in which they are operated and maintained, comply with the requirements of the Health and Safety at Work Act in the United Kingdom or applicable legislation and regulations and codes of practice in the country in which the equipment is used.

Competence of the installer

The drive must be installed by professional assemblers who are familiar with the 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.

3.2.3 Cooling

The heat produced by the drive must be removed without its specified operating temperature being exceeded. Note that a sealed enclosure gives much reduced cooling compared with a ventilated one, and may need to be larger and/or use internal air circulating fans.

For further information, refer to section 3.6 Enclosure for standard drives on page 27.

3.2.4 Electrical safety

The installation must be safe under normal and fault conditions. Electrical installation instructions are given in Chapter 4 Electrical installation on page 37.

Enclosure

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.

3.2 Planning the installation

The following considerations must be made when planning the installation:

3.2.1 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 dependent. For further information, refer to section 3.9 Enclosing standard drive for high environmental protection on page 29.

3.2.2 Environmental protection

The drive must be protected from:

• Moisture, including dripping water or spraying water and

condensation. An anti-condensation heater may be required, which must be switched off when the drive is running.

• Contamination with electrically conductive material

• Contamination with any form of dust which may restrict the fan, or

impair airflow over various components

• Temperature beyond the specified operating and storage ranges

• Corrosive gasses

During installation it is recommended that the vents on the drive are covered to prevent debris (e.g. wire off-cuts) from entering the drive.

16 CSD100 User Guide

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Page 17

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WAR NING

WARNING

AC / Motor

terminal cover

Control terminal

cover

Control / AC /

Motor terminal cover

DC terminal

cover

Control

terminal cover

AC / Motor

terminal cover

DC terminal

cover right

DC terminal

cover left

DC terminal

cover

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3.2.5 Electromagnetic compatibility

Variable speed drives are powerful electronic circuits which can cause electromagnetic interference if not installed correctly with careful attention to the layout of the wiring.

Some simple routine precautions can prevent disturbance to typical industrial control equipment. If it is necessary to meet strict emission limits, or if it is known that electromagnetically sensitive equipment is located nearby, then full precautions

must be observed. In-built into the drive, is an internal EMC filter, which reduces emissions under certain conditions. If these conditions are exceeded, then the use of an external EMC filter may be required at the drive inputs, which must be located very close to the drives. Space must be made available for the filters and allowance made for carefully segregated wiring. Both levels of precautions are covered in section 4.6 EMC (Electromagnetic compatibility) on page 43.

3.2.6 Hazardous areas

The drive must not be located in a classified hazardous area unless it is installed in an approved enclosure and the installation is certified.

3.3 Terminal cover removal

Isolation device

The AC and / or DC power 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.

Stored charge

The drive contains capacitors that remain charged to a potentially lethal voltage after the AC and / or DC power supply has been disconnected. If the drive has been energized, the power 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.

3.3.1 Removing the terminal covers

Figure 3-1 Location and identification of terminal covers

CSD100 User Guide 17 Issue Number: 3

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1. Control / AC / Motor terminal cover

2. DC terminal cover

On size 4 drives, the Control / AC / Motor terminal cover must be removed before removal of the DC terminal cover. When replacing the terminal covers, the screws should be tightened to a maximum torque of 1 N m (0.7 lb ft).

Figure 3-3 Removing the size 5 terminal covers

1. Control terminal cover

2. DC terminal cover right

On size 5 drives, the Control terminal cover must be removed before removal of the DC terminal cover right. When replacing the terminal covers, the screws should be tightened to a maximum torque of 1 N m (0.7 lb ft).

18 CSD100 User Guide

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CSD100 User Guide 19 Issue Number: 3

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3.3.2 Removing the finger-guard and DC terminal cover break-outs

Figure 3-5 Removing the finger-guard break-outs

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A: All sizes. B: Size 5 only. C: Size 6 only. D: Size 7 only Place finger-guard on a flat solid surface and hit relevant break-outs with

hammer as shown (1). Continue until all required break-outs are removed (2). Remove any flash / sharp edges once the break-outs are removed.

20 CSD100 User Guide

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3.4 Installing / removing option modules and keypads

Power down the drive before installing / removing the option module. Failure to do so may result in damage to the product.

Figure 3-6 Installation of a standard option module

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Installing the first option module

Option module slots must be used in the following order: slot 3, slot 2 and slot 1 (refer to Figure 2-3 Features of the drive on page 12 for slot numbers).

• Move the option module in direction shown (1).

• Align and insert the option module tab in to the slot provided (2), this is highlighted in the detailed view (A).

• Press down on the option module until it clicks into place.

Installing the second option module

• Move the option module in direction shown (3).

• Align and insert the option module tab in to the slot provided on the already installed option module (4), this is highlighted in the detailed view (B).

• Press down on the option module until it clicks into place. Image (5) shows two option modules fully installed.

Installing the third option module

• Repeat the above process. The drive has the facility for all three option module slots to be used at the same time, image (6) shows the three option modules installed.

CSD100 User Guide 21 Issue Number: 3

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Figure 3-7 Removal of a standard option module

• Press down on the tab (1) to release the option module from the drive housing, the tab is highlighted in the detailed view (A).

• Tilt the option module towards you as shown (2).

• Totally remove the option module in direction shown (3).

Figure 3-8 Installation and removal of the HOA-Keypad

Diagnostics

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To install, align the keypad and press gently in the direction shown until it clicks into position. To remove, reverse the installation instructions.

The keypad can be installed / removed while the drive is powered up and running a motor, providing that the drive is not operating in keypad mode.

22 CSD100 User Guide

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WAR NING

Æ 6.5 mm (0.26 in) x 4 holes

106 mm (4.17 in)

375 mm

(14.76 in)

8mm

(0.32 in)

53 mm

(2.09 in)

53 mm

(2.09 in)

124 mm (4.88 in)

391 mm (15.39 in)

365 mm (14.37 in)

200 mm (7.87 in)

9mm

(0.35 in)

NOTE

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3.5 Dimensions and mounting methods

The drive can be either surface or through-panel mounted using the appropriate brackets. The following drawings show the dimensions of the drive and mounting holes for each method to allow a back plate to be prepared.

The Through-panel mounting kit is not supplied with the drive and can be purchased separately, below are the relevant part numbers:

Size CT part number

4 3470-0056 5 3470-0067 6 3470-0055

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.

Many of the drives in this product range weigh in excess of 15 kg (33 lb). Use appropriate safeguards when lifting these models. A full list of drive weights can be found in section 11.1.19 Weights on page 104.

3.5.1 Surface mounting

Figure 3-9 Surface mounting the size 4 drive

The outer holes in the mounting bracket are to be used for surface mounting. See Table 3-1 for further information.

CSD100 User Guide 23 Issue Number: 3

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Safety

106 mm (4.17 in)

9mm

(0.35 in)

8mm

(0.32 in)

375 mm (14.76 in)

143 mm (5.63 in)

391 mm (15.39 in)

365 mm (14.37 in)

202 mm (7.95 in)

Æ 7.0 mm (0.28 in)

NOTE

376 mm

(14.80 in)

196.0 mm (7.72 in)

6.0 mm

(0.24 in)

Æ7.0 mm

(0.27 in)

7.0 mm

(0.28 in)

227 mm (8.94 in)

210 mm (8.27 in)

389 mm

(15.32 in)

365 mm

14.37 in

NOTE

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Figure 3-10 Surface mounting the size 5 drive

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The outer holes in the mounting bracket are to be used for surface mounting. See Table 3-1 for further information.

Figure 3-11 Surface mounting the size 6 drive

The outer holes in the mounting bracket are to be used for surface mounting. See Table 3-1 for further information.

24 CSD100 User Guide

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Safety

106 mm (4.17 in)

15 mm

(0.59 in)

394 mm (15.51 in)

401 mm (15.79 in)

124 mm (4.88 in)

134 mm (5.28 in)

68 mm

(2.68 in)

68 mm

(2.68 in)

118 mm (4.65 in)

168 mm (6.61 in)

67 mm

(2.64 in)

59 mm

(2.32 in)

59 mm

(2.32 in)

106 mm (4.17 in)

157 mm (6.18 in)

359 mm (14.13 in)

169 mm (6.65 in)

26 mm (1.02 in)

167 mm (6.58 in)

26 mm (1.02 in)

393 mm (15.47 in)

137 mm (5.47 in)

Æ6.5 mm (0.3 in)

(x 4 holes)

Æ5.0 mm (0.20 in)

(x 4 holes)

143 mm (5.63 in)

409 mm (16.10 in)

365 mm (14.37 in)

135 mm (5.32 in)

67 mm (2.64 in)

17 mm

(0.66 in)

53 mm (2.1 in) 53 mm (2.1 in)

78.5 mm (3.09 in) 78.5 mm (3.09 in)

68 mm (2.67 in)

Radius 1.0 mm

(0.04 in)

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3.5.2 Through-panel mounting

Figure 3-12 Through panel mounting the size 4 drive

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Figure 3-13 Through panel mounting the size 5 drive

CSD100 User Guide 25 Issue Number: 3

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Safety

196 mm (7.72 in)

Ø7.0 mm (0.276 in)98 mm (3.86 in)

101 mm (3.98 in)

202 mm (7.95 in)

101 mm (3.98 in)

Radius 1.0 mm

(0.04 in)

98 mm (3.86 in)

26 mm (1.02 in)

120 mm (4.73 in)

(1.02 in)

227 mm (8.94)

131 mm (5.16 in)

412 mm (16.22 in)

210 mm (8.27 in)

96 mm (3.78 in)

365 mm (14.37 in)

356 mm (14.02 in)

399 mm (15.71)

264 mm (10.39 in)

21 mm (0.83 in)

167 mm (6.58 in)

Æ 5.0 mm (0.20 in)

26 mm (1.02 in)

NOTE

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Figure 3-14 Through panel mounting the size 6 drive

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The outer holes plus the hole located in the center of the bracket are to be used for through panel mounting.

Table 3-1 Mounting brackets

Frame size Surface Qty Through-panel Qty

4 x 2

Hole size: 5.2 mm (0.21 in)

Hole size: 6.5 mm (0.26 in) Hole size: 6.5 mm (0.26 in)

5 x 2

Hole size: 6.5 mm (0.26 in) Hole size: 6.5 mm (0.26 in)

6 x 2

Hole size: 5.2 mm (0.21 in)

x 3

x 2

x 3

Hole size: 6.5 mm (0.26 in) Hole size: 6.5 mm (0.26 in)

26 CSD100 User Guide

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x 2

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Safety

100 mm

(4 in)

Enclosure

AC supply contactor and fuses or MCB

Locate as required

External controller

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

Ensure minimumc learances are maintained for the drive and external EMCf ilter. Forced or convection air-flow must not be restricted by any object or cabling

100mm

(4in)

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

Siz

e4to6

> 30mm (1.18 in)

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 (4 in) from the drive in all directions

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3.6 Enclosure for standard drives

3.6.1 Enclosure layout

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

Figure 3-15 Enclosure layout

CSD100 User Guide 27 Issue Number: 3

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intText

–()

-----------------------------------

NOTE

392.4

5.5 40 30–()

---------------------------------

2HD–

HD+

--------------------------

7.135 2 2× 0.6×()–

20.6+

-----------------------------------------------------

3kP

intText

–

---------------------------

-------

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3.6.2 Enclosure sizing

1. Add the dissipation figures from section on page 102 for each drive that is to be installed in the enclosure.

2. If an external EMC filter is to be used with each drive, add the dissipation figures from section 11.2.1 EMC filter ratings on page 110 for each external EMC filter that is to be installed in the enclosure.

3. If the braking resistor is to be mounted inside the enclosure, add the average power figures from for each braking resistor that is to be installed in the enclosure.

4. Calculate the total heat dissipation (in Watts) of any other equipment to be installed in the enclosure.

5. Add the heat dissipation figures obtained above. This gives a figure in Watts for the total heat that will be dissipated inside the enclosure.

Calculating the size of a sealed enclosure

The enclosure transfers internally generated heat into the surrounding air by natural convection (or external forced air flow); the greater the surface area of the enclosure walls, the better is the dissipation capability. Only the surfaces of the enclosure that are unobstructed (not in contact with a wall or floor) can dissipate heat.

Calculate the minimum required unobstructed surface area A enclosure from:

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Figure 3-16 Enclosure having front, sides and top panels free to

dissipate heat

Insert the following values:

40 °C

int

30 °C

ext

k 5.5 P 392.4 W

The minimum required heat conducting area is then:

UL listing

information

Where:

Unobstructed surface area in m2 (1 m2 = 10.9 ft2)

Maximum expected temperature in

ext

C outside the enclosure Maximum permissible temperature in oC inside the

int

enclosure

P Power in Watts dissipated by all heat sources in the

enclosure

k Heat transmission coefficient of the enclosure material

2/o

in W/m

Example

To calculate the size of an enclosure for the following:

• Two drives operating at the Normal Duty rating

• External EMC filter for each drive

• Braking resistors are to be mounted outside the enclosure

• Maximum ambient temperature inside the enclosure: 40°C

• Maximum ambient temperature outside the enclosure: 30°C

For example, if the power dissipation from each drive is 187 W and the power dissipation from each external EMC filter is 9.2 W.

Total dissipation: 2 x (187 + 9.2) =392.4 W

Power dissipation for the drives and the external EMC filters can be obtained from Chapter 11 Technical data on page 102.

The enclosure is to be made from painted 2 mm (0.079 in) sheet steel

2/o

having a heat transmission coefficient of 5.5 W/m

C. Only the top,

front, and two sides of the enclosure are free to dissipate heat.

The value of 5.5 W/m

/ºC can generally be used with a sheet steel enclosure (exact values can be obtained by the supplier of the material). If in any doubt, allow for a greater margin in the temperature rise.

= 7.135 m

(77.8 ft2) (1 m2 = 10.9 ft2)

Estimate two of the enclosure dimensions - the height (H) and depth (D), for instance. Calculate the width (W) from:

Inserting H = 2m and D = 0.6 m, obtain the minimum width:

=1.821 m (71.7 in)

If the enclosure is too large for the space available, it can be made smaller only by attending to one or all of the following:

• Using a lower PWM switching frequency to reduce the dissipation in the drives

• Reducing the ambient temperature outside the enclosure, and/or applying forced-air cooling to the outside of the enclosure

• Reducing the number of drives in the enclosure

• Removing other heat-generating equipment

Calculating the air-flow in a ventilated enclosure

The dimensions of the enclosure are required only for accommodating the equipment. The equipment is cooled by the forced air flow.

Calculate the minimum required volume of ventilating air from:

Where:

V Air-flow in m T

Maximum expected temperature in °C outside the

ext

enclosure

Maximum permissible temperature in °C inside the

int

enclosure

P Power in Watts dissipated by all heat sources in the

enclosure

per hour (1 m3/hr = 0.59 ft3/min)

k Ratio of

Where:

is the air pressure at sea level

is the air pressure at the installation

Typically use a factor of 1.2 to 1.3, to allow also for pressure-drops in dirty air-filters.

28 CSD100 User Guide

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Safety

31.3× 323.7× 40 30–

---------------------------------------

IP21

(NEMA1)

IP65 (sizes 3 to 8) or IP55 (size 9 and 10)

(NEMA 12) enclosure

Drive with high IP insert installed

Gasket

seal

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Example

To calculate the size of an enclosure for the following:

• Three drives operating at the Normal Duty rating

• External EMC filter for each drive

• Braking resistors are to be mounted outside the enclosure

• Maximum ambient temperature inside the enclosure: 40 °C

• Maximum ambient temperature outside the enclosure: 30 °C

For example, dissipation of each drive: 101 W and dissipation of each external EMC filter: 6.9 W (max).

Total dissipation: 3 x (101 + 6.9) = 323.7 W Insert the following values:

40 °C

int

30 °C

ext

k 1.3 P 323.7 W

Then:

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3.9 Enclosing standard drive for high environmental protection

An explanation of environmental protection rating is provided in section

11.1.9 IP / UL Rating on page 103.

The standard drive is rated to IP21 pollution degree 2 (dry, nonconductive contamination only) (NEMA 1). However, it is possible to configure the drive to achieve IP65 rating (NEMA 12) at the rear of the heatsink for through-panel mounting (some current derating is required). Refer to Table on page 102.

This allows the front of the drive, along with various switchgear, to be housed in a high IP enclosure with the heatsink protruding through the panel to the external environment. Thus, the majority of the heat generated by the drive is dissipated outside the enclosure maintaining a reduced temperature inside the enclosure. This also relies on a good seal being made between the heatsink and the rear of the enclosure using the gaskets provided.

Figure 3-17 Example of IP65 (NEMA 12) through-panel layout

UL listing

information

= 126.2 m

/hr (74.5 ft3 /min) (1 m3/ hr = 0.59 ft3/min)

3.7 Enclosure design and drive ambient temperature

Drive derating is required for operation in high ambient temperatures Totally enclosing or through panel mounting the drive in either a sealed

cabinet (no airflow) or in a well ventilated cabinet makes a significant difference on drive cooling.

The chosen method affects the ambient temperature value (T should be used for any necessary derating to ensure sufficient cooling

for the whole of the drive. The ambient temperature for the four different combinations is defined

below:

1. Totally enclosed with no air flow (<2 m/s) over the drive

= T

rate

2. Totally enclosed with air flow (>2 m/s) over the drive

rate

3. Through panel mounted with no airflow (<2 m/s) over the drive

rate

4. Through panel mounted with air flow (>2 m/s) over the drive

rate

Where:

ext

int

rate

+ 5 °C

int

= T

int

= the greater of T

= Temperature outside the cabinet

= Temperature inside the cabinet

= Temperature used to select current rating from tables in

Chapter 11 Technical data on page 102.

+5 °C, or T

ext

or T

ext

int

) which

rate

int

The main gasket should be installed as shown in Figure 3-18. On drive sizes 4 and 5, in order to achieve the high IP rating at the rear

of the heatsink it is necessary to seal a heatsink vent by installing the high IP insert as shown in Figure 3-20 and Figure 3-21.

3.8 Heatsink fan operation

The drive 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 mounting method (surface mounting or through-panel mounting), the installing 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 all sizes 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 maximum speed at which the fan operates can be limited in Pr 06.045. This could incur an output current derating. Refer to section 3.12.2 Fan removal procedure on page 35 for information on fan removal. The size 6 and 7 is also installed with a variable speed fan to ventilate the capacitor bank.

CSD100 User Guide 29 Issue Number: 3

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Safety

Drive

Gasket

Enclosure rear wall

Through panel

securing bracket

Enclosure rear wall

Through panel securing bracket

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Figure 3-18 Installing the gasket

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Figure 3-20 Installation of high IP insert for size 4

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To seal the space between the drive and the backplate, use two sealing brackets as shown in Figure 3-19. The sealing brackets are included in the accessories kitbox supplied with the drive.

Figure 3-19 Through panel mounting

1. To install the high IP insert, firstly place a flat head screwdriver into the slot highlighted (1).

2. Pull the hinged baffle up to expose the ventilation hole, install the high IP insert into the ventilation hole in the heatsink (2).

3. Ensure the high IP insert is securely installed by firmly pressing it into place (3).

4. Close the hinged baffle as shown (1).

To remove the high IP insert, reverse the above instructions. The guidelines in Table 3-2 should be followed.

30 CSD100 User Guide

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Figure 3-21 Installation of high IP insert for size 5

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When designing an IP65 (NEMA 12) enclosure (Figure 3-17 Example of IP65 (NEMA 12) through-panel layout on page 29), consideration should be made to the dissipation from the front of the drive.

Table 3-3 Power losses from the front of the drive when through-

panel mounted

Frame size Power loss

4 ≤75 W 5 ≤100 W 6 ≤100 W

1. To install the high IP insert, firstly place a flat head screwdriver into the slot highlighted (1).

2. Pull the hinged baffle up to expose the ventilation holes, install the high IP inserts into the ventilation holes in the heatsink (2).

3. Ensure the high IP inserts are securely installed by firmly pressing them into place (3).

4. Close the hinged baffle as shown (1).

To remove the high IP insert, reverse the above instructions.

Table 3-2 Environment considerations

Environment High IP insert Comments

Clean Not installed Dry, dusty (non-conductive) Installed Dry, dusty (conductive) Installed IP65 compliance Installed

Regular cleaning

recommended

A current derating must be applied to the drive if the high IP insert is installed. Derating information is provided in section 11.1.1 Power and current ratings on page 102.

Failure to do so may result in nuisance tripping.

CSD100 User Guide 31 Issue Number: 3

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V1 W1

Netz / Line

Last/Load

V2 W2

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3.10 External EMC filter

The external EMC filter details for each drive rating are provided in the table below

Table 3-4 External EMC filter data

Model CT part number

200 V

06200500 to 06200580 4200-2300 6.5 14.3

400 V

04400240 4200-0252 4.1 9.04 05400300 4200-0402 5.5 12.13 06400380 4200-4800 6.7 14.8

575 V

06500220 to 06500270 4200-3690 7.0 15.4

The external EMC filters for size 4, 5 and 6 can be footprint or bookcase mounted, see Figure 3-22 and Figure 3-23. Mount the external EMC filter following the guidelines in section 4.6.5 Compliance with generic emission standards on page 48.

Figure 3-22 Footprint mounting the EMC filter Figure 3-23 Bookcase mounting the EMC filter

Weight

kg Ib

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Figure 3-24 Size 4 to 6 external EMC filter

V: Ground stud X: Threaded holes for footprint mounting of the drive Y: Footprint mounting hole diameter Z: Bookcase mounting slot diameter. CS: Cable size

Table 3-5 Size 4 external EMC filter dimensions

CT part

number

4200-0252

ABCDEHWVXYZCS

395 mm

(15.55 in)

425 mm

(16.73 in)

100 mm

(3.94 in)

60 mm

(2.36 in)

33 mm

(1.30 in)

437 mm (17.2 in)

123 mm (4.84 in)

M6 M6

6.5 mm

(0.26 in)

6.5 mm

(0.26 in)

6 mm

(10 AWG)

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Table 3-6 Size 5 external EMC filter dimensions

CT part number

4200-0402

ABCDEHWVXYZCS

395 mm

(15.55 in)

425 mm

(16.73 in)

106 mm (4.17 in)

60 mm

(2.36 in)

33 mm

(1.30 in)

Table 3-7 Size 6 external EMC filter dimensions

CT part number

ABCDEHWVXYZCS

4200-2300

4200-3690

392 mm

(15.43 in)

420 mm

(16.54 in)

180 mm (7.09 in)

60 mm

(2.36 in)

33 mm

(1.30 in)

4200-4800

3.11 Electrical terminals

3.11.1 Location of the power and ground terminals

Figure 3-25 Locations of the power and ground terminals

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437 mm (17.2 in)

434 mm

(17.09 in)

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143 mm (5.63 in)

210 mm (8.27 in)

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data

6.5 mm

(0.26 in)

6.5 mm

(0.26 in)

Diagnostics

6.5 mm

(0.26 in)

6.5 mm

(0.26 in)

UL listing

information

10 mm

(8 AWG)

2.5 mm

(14 AWG)

16 mm

(6 AWG)

Key

1. Control terminals 4. Ground connections 7. DC bus -

2. Relay terminals 5. AC power terminals 8. DC bus +

3. Additional ground connection 6. Motor terminals

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3.11.2 Terminal sizes and torque settings

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 3-8 Drive control and relay terminal data

Model Connection type Torque setting

All Plug-in terminal block 0.5 N m (0.4 lb ft)

Table 3-9 Drive power terminal data

CSD100 frame size

Recommended Maximum Recommended Maximum

0.7 N m (0.5 lb ft) 0.8 N m (0.6 lb ft) 2.0 N m (1.4 Ib ft) 2.5 N m (1.8 Ib ft)

1.5 N m (1.1 lb ft) 1.8 N m (1.3 lb ft) 2.0 N m (1.4 Ib ft) 5.0 N m (3.7 Ib ft)

6.0 N m(4.4 Ib ft) 8.0 N m(6.0 Ib ft) 6.0 N m(4.4 Ib ft) 8.0 N m(6.0 Ib ft)

Table 3-10 Plug-in terminal block maximum cable sizes

Model size Terminal block description Max cable size

All

4 6 way AC power connector

AC and motor terminals Ground terminal

Plug-in terminal block T20 Torx (M4) / M4 Nut (7 mm AF)

Plug-in terminal block M5 Nut (8 mm AF)

M6 Nut (10 mm AF) M6 Nut (10 mm AF)

11 way control connectors

2 way relay connector

1.5 mm

2.5 mm

3 way AC power connector

3 way motor connector

2 way low voltage power

24 V supply connector

1.5 mm

Technical

data

6 mm

8 mm

Diagnostics

(16 AWG)

(12 AWG)

(10 AWG)

(8 AWG)

(16 AWG)

UL listing

information

Table 3-11 External EMC filter terminal data

CT part

number

4200-0252 4200-0402 4200-2300 4200-3690

Max cable

size

16 mm

(6 AWG)

16 mm

(6 AWG)

Power

connections

Max torque Ground stud size Max torque

1.8 N m

(1.4 lb ft)

2.3 N m

(1.70 Ib ft)

Ground

connections

5.0 N m

(3.7 lb ft)

5.0 N m

(3.7 lb ft)

3.12 Routine maintenance

The drive should be installed in a cool, clean, well ventilated location. Contact of moisture and dust with the drive should be prevented. Regular checks of the following should be carried out to ensure drive / installation reliability are maximized:

Environment

Ambient temperature Ensure the enclosure temperature remains at or below maximum specified

Dust

Moisture Ensure the drive enclosure shows no signs of condensation

Enclosure

Enclosure door filters Ensure filters are not blocked and that air is free to flow

Electrical

Screw connections Ensure all screw terminals remain tight Crimp terminals Ensure all crimp terminals remains tight – check for any discoloration which could indicate overheating Cables Check all cables for signs of damage

Ensure the drive remains dust free – check that the heatsink and drive fan are not gathering dust. The lifetime of the fan is reduced in dusty environments.

34 CSD100 User Guide

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3.12.1 Real time clock battery replacement

Those keypads which have the real time clock feature contain a battery to ensure the clock works when the drive is powered down. The battery has a long life time but if the battery needs to be replaced or removed, follow the instructions below.

Low battery voltage is indicated by

Figure 3-26 HOA-Keypad RTC (rear view)

Figure 3-26 above illustrates the rear view of the HOA-Keypad RTC.

1. To remove the battery cover insert a flat head screwdriver into the slot as shown (1), push and turn anti-clockwise until the battery cover is released.

2. Replace the battery (the battery type is: CR2032).

3. Reverse point 1 above to replace battery cover.

low battery symbol on the keypad display.

Ensure the battery is disposed of correctly.

3.12.2 Fan removal procedure

Figure 3-27 Removal of the size 4 and 5 heatsink fan

1. Ensure the fan cable is disconnected from the drive prior to attempting fan removal.

2. Press the two tabs (1) inwards to release the fan from the drive frame.

3. Using the central fan tab (2), withdraw the fan assembly from the drive housing.

Replace the fan by reversing the above instructions.

If the drive is surface mounted using the outer holes on the mounting bracket, then the heatsink fan can be replaced without removing the drive from the backplate.

CSD100 User Guide 35 Issue Number: 3

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Figure 3-28 Removal of the size 6 heatsink fan

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A: Press the tabs (1) inwards to release the fan assembly from the underside of the drive. B: Use the tabs (1) to withdraw the fan by pulling it away from the drive. C: Depress and hold the locking release on the fan cable lead as shown (2). D: With the locking release depressed (2), take hold of the fan supply cable and carefully pull to separate the connectors.

36 CSD100 User Guide

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WARNING

L1 L2

L2L1 L3 U V W

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Motor

Optional ground

connection

Supply

Ground

AC Connections

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4 Electrical installation

Many cable management features have been incorporated into the product and accessories, this chapter shows how to optimize them. Key features include:

• SAFE TORQUE OFF function

• Internal EMC filter

• EMC compliance with shielding / grounding accessories

• Product rating, fusing and cabling information

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 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.

Isolation device

The AC and / or DC power 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.

STOP function

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

4.1 Power connections

4.1.1 AC connections

Figure 4-1 Size 4 power connections

SAFE TORQUE OFF function

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

Stored charge

The drive contains capacitors that remain charged to a potentially lethal voltage after the AC and / or DC power supply has been disconnected. If the drive has been energized, the AC and / or DC power 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.

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).

Permanent magnet motors

Permanent magnet motors generate electrical power if they are rotated, even when the supply to the drive is disconnected. If that happens then the drive will become energized through its motor terminals. If the motor load is capable of rotating the motor when the supply is disconnected, then the motor must be isolated from the drive before gaining access to any live parts.

See Figure 4-4 for further information on ground connections.

CSD100 User Guide 37 Issue Number: 3

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Safety

L1 L2

L2L1 L3 U V W

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Motor

Optional ground

connection

Supply

Ground

AC Connections Motor Connections

L1 L2

L2L1

UVW

Optional EMC

filter

Optional

line reactor

Fuses

Mains

Supply

Motor

Optional ground

connection

Supply Ground

AC Connections

Motor Connections

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Electrical

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Figure 4-2 Size 5 power connections

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Figure 4-3 Size 6 power connections

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The upper terminal block (1) is used for AC supply connection. The lower terminal block (2) is used for the Motor connection. See Figure 4-5 for further information on ground connections.

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4.1.2 Ground connections

Electrochemical corrosion of grounding terminals

Ensure that grounding terminals are protected against corrosion i.e. as could be caused by condensation.

Size 4

On size 4, the supply and motor ground connections are made using the M4 studs located either side of the drive near the plug-in power connector. Refer to Figure 4-4 for additional ground connection.

Figure 4-4 Size 4 ground connections

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Figure 4-6 Size 6 ground connections

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1. Ground connection studs.

2. Additional ground connection.

Size 5

On size 5, the supply and motor ground connections are made using the M5 studs located near the plug-in power connector. Refer to Figure 4-5 for additional ground connection.

Figure 4-5 Size 5 ground connections

1. Ground connection studs.

2. Additional ground connection.

Size 6

On a size 6, the supply and motor ground connections are made using the M6 studs located above the supply and motor terminals. Refer to Figure 4-6 below.

The ground loop impedance must conform to the requirements of local safety regulations.

The drive must be grounded by a connection capable of carrying the prospective fault current until the protective device (fuse, etc.) disconnects the AC supply.

The ground connections must be inspected and tested at appropriate intervals.

Table 4-1 Protective ground cable ratings

Input phase

conductor size

Minimum ground conductor size

Either 10 mm2 or two conductors of the

≤ 10 mm

same cross-sectional area as the input phase conductor (an additional ground connection is provided on sizes 3, 4 and 5 for this purpose).

> 10 mm

> 16 mm

> 35 mm

and ≤ 16 mm

and ≤ 35 mm216 mm

The same cross-sectional area as the input

phase conductor

Half of the cross-sectional area of the input phase conductor

CSD100 User Guide 39 Issue Number: 3

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100

----------

-------

2π f I

------------

×=

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4.2 AC supply requirements

Voltage:

200 V drive: 200 V to 240 V ±10 % 400 V drive: 380 V to 480 V ±10 %

575 V drive: 500 V to 575 V ±10 % Number of phases: 3 Maximum supply imbalance: 2 % negative phase sequence (equivalent

to 3 % voltage imbalance between phases). Frequency range: 45 to 66 Hz For UL compliance only, the maximum supply symmetrical fault current

must be limited to 100 kA

4.2.1 Supply types

All drives are suitable for use on any supply type i.e TN-S, TN-C-S, TT and IT.

• Supplies with voltage up to 600 V may have grounding at any

potential, i.e. neutral, centre or corner (“grounded delta”)

• Supplies with voltage above 600 V may not have corner grounding

Drives are suitable for use on supplies of installation category III and lower, according to IEC60664-1. This means they may be connected permanently to the supply at its origin in a building, but for outdoor installation additional over-voltage suppression (transient voltage surge suppression) must be provided to reduce category IV to category III.

Operation with IT (ungrounded) supplies:

Special attention is required when using internal or external EMC filters with ungrounded supplies, because in the event of a ground (earth) fault in the motor circuit the drive may not trip and the filter could be over-stressed. In this case, either the filter must not be used (removed), or additional independent motor ground fault protection must be provided. For instructions on removal, refer to section 4.6.2 Internal EMC filter on page 45. For details of ground fault protection contact the supplier of the drive.

A ground fault in the supply has no effect in any case. If the motor must continue to run with a ground fault in its own circuit then an input isolating transformer must be provided and if an EMC filter is required it must be located in the primary circuit.

Unusual hazards can occur on ungrounded supplies with more than one source, for example on ships. Contact the supplier of the drive for more information.

4.2.2 Supplies requiring line reactors

Input line reactors reduce the risk of damage to the drive resulting from poor phase balance or severe disturbances on the supply network.

Where line reactors are to be used, reactance values of approximately 2 % are recommended. Higher values may be used if necessary, but may result in a loss of drive output (reduced torque at high speed) because of the voltage drop.

For all drive ratings, 2 % line reactors permit drives to be used with a supply unbalance of up to 3.5 % negative phase sequence (equivalent to 5% voltage imbalance between phases).

Severe disturbances may be caused by the following factors, for example:

• Power factor correction equipment connected close to the drive.

• Large DC drives having no or inadequate line reactors connected to

the supply.

• Across the line (DOL) started motor(s) connected to the supply such

that when any of these motors are started, the voltage dip exceeds

20 %. Such disturbances may cause excessive peak currents to flow in the

input power circuit of the drive. This may cause nuisance tripping, or in extreme cases, failure of the drive.

Drives of low power rating may also be susceptible to disturbance when connected to supplies with a high rated capacity.

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CSD drive model sizes have an internal DC choke so they do not require AC line reactors except for cases of excessive phase unbalance or extreme supply conditions.

When required, each drive must have its own reactor(s). Three individual reactors or a single three-phase reactor should be used.

Reactor current ratings

The current rating of the line reactors should be as follows: Continuous current rating:

Not less than the continuous input current rating of the drive

Repetitive peak current rating:

Not less than twice the continuous input current rating of the drive

4.2.3 Input inductor calculation

To calculate the inductance required (at Y%), use the following equation:

Where:

I = drive rated input current (A) L = inductance (H) f = supply frequency (Hz) V = voltage between lines

4.3 Ratings

The input current is affected by the supply voltage and impedance.

Typical input current

The values of typical input current are given to aid calculations for power flow and power loss.

The values of typical input current are stated for a balanced supply.

Maximum continuous input current

The values of maximum continuous input current are given to aid the selection of cables and fuses. These values are stated for the worst case condition with the unusual combination of stiff supply with bad balance.

The value stated for the maximum continuous input current would only be seen in one of the input phases. The current in the other two phases would be significantly lower.

The values of maximum input current are stated for a supply with a 2 % negative phase-sequence imbalance and rated at the supply fault current given in Table 4-2 .

Table 4-2 Supply fault current used to calculate maximum input current

Model Symmetrical fault level

All 100

UL listing

information

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Fuses

The AC supply to the drive must be installed with suitable protection against overload and short-circuits. Table 4-3 shows recommended fuse ratings. Failure to observe this requirement will cause risk of fire.

Table 4-3 AC Input current and fuse ratings (200 V)

Maximum

continuous

input current

Model

Typical input

current

AAA A A A A

06200550 06200580

42 49

48 64 56 85 70

Table 4-4 AC Input current and fuse ratings (400 V)

Maximum

continuous

input current

Model

Typical input

current

AAA A A A A

04400240 05400300 06400380

22 26 32

24 35 32 32 30 30 29 58 40 40 35 35 36 67 63 63 40 60

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Fuse rating

IEC gG Class CC or Class J

Nominal Maximum Nominal Maximum

63 63

Fuse rating

IEC gG Class CC or Class J

Nominal Maximum Nominal Maximum

Diagnostics

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information

Table 4-5 AC Input current and fuse ratings (575 V)

Maximum

continuous

input current

Model

Typical input

current

AAA A A A A

06500220 06500270

22 26

24 41 40 40 30 30 29 50 50 63 35 50

Ensure all cables used suit local wiring regulations.

The nominal cable sizes below are only a guide. The mounting and grouping of cables affects their current-carrying capacity, in some cases smaller cables may be acceptable but in other cases a larger cable is required to avoid excessive temperature or voltage drop. Refer to local wiring regulations for the correct size of cables.

Table 4-6 Cable ratings (200 V)

Cable size (IEC)

Model

Input Output Input Output

Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum

06200500 06200580

16 25

Maximum

overload input

current

IEC gG Class CC or Class J

Nominal Maximum Nominal Maximum

Fuse rating

Cable size (UL)

AWG

16 25 3 3

Table 4-7 Cable ratings (400 V)

Model

Cable size (IEC)

Input Output Input Output

Cable size (UL)

AWG

Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum

04400240 05400300 06400380

666 6 666 6

10 25 10 25

8888

6363

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Table 4-8 Cable ratings (575 V)

Cable size (IEC)

Model

Input Output Input Output

Nominal Maximum Nominal Maximum Nominal Maximum Nominal Maximum

06500220 06500270

10 8 8

PVC insulated cable should be used.

Cable sizes are from IEC60364-5-52:2001 table A.52.C with correction factor for 40°C ambient of 0.87 (from table A52.14) for cable installation method B2 (multicore cable in conduit).

Installation class (ref: IEC60364-5-52:2001)

B1 - Separate cables in conduit. B2 - Multicore cable in conduit. C - Multicore cable in free air. Cable size may be reduced if a different installation method is used, or if the ambient temperature is lower.

The nominal output cable sizes assume that the motor maximum current matches that of the drive. Where a motor of reduced rating is used the cable rating may be chosen to match that of the motor. To ensure that the motor and cable are protected against overload, the drive must be programmed with the correct motor rated current. A fuse or other protection must be included in all live connections to the AC supply.

Fuse types

The fuse voltage rating must be suitable for the drive supply voltage.

Ground connections

The drive must be connected to the system ground of the AC supply. The ground wiring must conform to local regulations and codes of practice.

For information on ground cable sizes, refer to Table 4-1 Protective ground cable ratings on page 39.

4.3.1 Main AC supply contactor

The recommended AC supply contactor type for size 4, 5 and 6 is AC1.

4.4 Output circuit and motor protection

The output circuit has fast-acting electronic short-circuit protection which limits the fault current to typically no more than five times the rated output current, and interrupts the current in approximately 20 µs. No additional short-circuit protection devices are required.

The drive provides overload protection for the motor and its cable. For this to be effective, Rated Current (Pr 05.007) must be set to suit the motor.

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4.4.1 Cable types and lengths

Since capacitance in the motor cable causes loading on the output of the drive, ensure the cable length does not exceed the values given in Table 4-9, Table 4-10 and Table 4-11.

Use 105 °C (221 °F) (UL 60/75 °C temp rise) PVC-insulated cable with copper conductors having a suitable voltage rating, for the following power connections:

• AC supply to external EMC filter (when used)

• AC supply (or external EMC filter) to drive

• Drive to motor

• Drive to braking resistor

Table 4-9 Maximum motor cable lengths (200 V drives)

200 V Nominal AC supply voltage

Maximum permissible motor cable length for each of

Model

kHz3 kHz4 kHz6 kHz8 kHz

06200500 06200580

300 m

(984 ft)

Table 4-10 Maximum motor cable lengths (400 V drives)

Maximum permissible motor cable length for each of

Model

kHz3kHz4kHz6kHz8kHz12kHz16kHz

04400240 05400300

06400380

200 m (660 ft)

300 m

(984 ft)

Table 4-11 Maximum motor cable lengths (575 V drives)

Maximum permissible motor cable length for each of

Model

kHz3kHz4kHz6kHz8kHz12kHz16kHz

06500270 06500270

300 m

(984 ft)

the following switching frequencies

200 m

(660 ft)

150 m

(490 ft)

100 m

(330 ft)

400 V Nominal AC supply voltage

the following switching frequencies

150 m

(330 ft)

200 m

(660 ft)

575 V Nominal AC supply voltage

150 m

(330 ft)

100 m

(330 ft)

100 m

(330 ft)

the following switching frequencies

200 m

(660 ft)

150 m

(490 ft)

100 m

(330 ft)

75 m

(245 ft)

75 m

(245 ft)

75 m

(245 ft)

75 m

(245 ft)

kHz

50 m

(165 ft)

50 m

(165 ft)

50 m

(165 ft)

50 m

(165 ft)

UL listing

information

kHz

37 m

(120 ft)

Rated Current (Pr 05.007) must be set correctly to avoid a risk of fire in the event of motor overload.

There is also provision for the use of a motor thermistor to prevent overheating of the motor, e.g. due to loss of cooling.

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Normal capacitance

Shield or armour separated from the cores

High capacitance

Shield or armour close to the cores

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4.4.2 High-capacitance / reduced diameter cables

The maximum cable length is reduced from that shown in section

4.4.1 Cable types and lengths on page 42 if high capacitance or reduced

diameter motor cables are used.

Most cables have an insulating jacket between the cores and the armor

or shield; these cables have a low capacitance and are recommended.

Cables that do not have an insulating jacket tend to have high

capacitance; if a cable of this type is used, the maximum cable length is

half that quoted in the tables, (Figure 4-7 shows how to identify the two

types).

Figure 4-7 Cable construction influencing the capacitance

The maximum motor cable lengths specified in Section 4.4.1 Cable

types and lengths , are shielded and contain four cores. Typical

capacitance for this type of cable is 130 pF/m (i.e. from one core to all

others and the shield connected together).

4.4.3 Motor winding voltage

The PWM output voltage can adversely affect the inter-turn insulation in

the motor. This is because of the high rate of change of voltage, in

conjunction with the impedance of the motor cable and the distributed

nature of the motor winding.

For normal operation with AC supplies up to 500 Vac and a standard

motor with a good quality insulation system, there is no need for any

special precautions. In case of doubt the motor supplier should be

consulted. Special precautions are recommended under the following

conditions, but only if the motor cable length exceeds 10 m:

• AC supply voltage exceeds 500 V

• DC supply voltage exceeds 670 V

• Operation of 400 V drive with continuous or very frequent sustained braking

• Multiple motors connected to a single drive

For multiple motors, the precautions given in section on page 43 should be followed.

For the other cases listed, it is recommended that an inverter-rated motor be used taking into account the voltage rating of the inverter. This has a reinforced insulation system intended by the manufacturer for repetitive fast-rising pulsed voltage operation.

Users of 575 V NEMA rated motors should note that the specification for inverter-rated motors given in NEMA MG1 section 31 is sufficient for motoring operation but not where the motor spends significant periods braking. In that case an insulation peak voltage rating of 2.2 kV is recommended.

If it is not practical to use an inverter-rated motor, an output choke (inductor) should be used. The recommended type is a simple iron-cored component with a reactance of about 2 %. The exact value is not critical. This operates in conjunction with the capacitance of the motor cable to increase the rise-time of the motor terminal voltage and prevent excessive electrical stress.

4.4.4 Output contactor

If the cable between the drive and the motor is to be interrupted by a contactor or circuit breaker, ensure that the drive is disabled before the contactor or circuit breaker is opened or closed. Severe arcing may occur if this circuit is interrupted with the motor running at high current and low speed.

A contactor is sometimes required to be installed between the drive and motor for safety purposes.

The recommended motor contactor is the AC3 type. Switching of an output contactor should only occur when the output of

the drive is disabled. Opening or closing of the contactor with the drive enabled will lead to:

1. OI ac trips (which cannot be reset for 10 s)

2. High levels of radio frequency noise emission

3. Increased contactor wear and tear The Drive Enable terminal (T31) when opened provides a SAFE

TORQUE OFF function. This can in many cases replace output contactors.

For further information see section 4.10 SAFE TORQUE OFF (STO) on page 56.

4.5 Ground leakage

The ground leakage current depends upon whether the internal EMC filter is installed or not. The drive is supplied with the filter installed. Instructions for removing the internal filter are given in section

4.6.2 Internal EMC filter on page 45.

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

4.5.1 Use of residual current device (RCD)

There are three common types of ELCB / RCD:

1. AC - detects AC fault currents

2. A - detects AC and pulsating DC fault currents (provided the DC current reaches zero at least once every half cycle)

3. 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

Only type B ELCB / RCD are suitable for use with 3 phase inverter drives.

If an external EMC filter is used, a delay of at least 50 ms should be incorporated to ensure spurious trips are not seen. The leakage current is likely to exceed the trip level if all of the phases are not energized simultaneously.

4.6 EMC (Electromagnetic compatibility)

The requirements for EMC are divided into three levels in the following three sections:

Section4.6.3, General requirements for all applications, to ensure reliable operation of the drive and minimise the risk of disturbing nearby equipment. The immunity standards specified in Chapter 11 Technical data on page 102 will be met, but no specific emission standards are applied. Note also the special requirements given in Surge immunity of control circuits - long cables and connections outside a building on page 50 for increased surge immunity of control circuits where control wiring is extended.

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Section 4.6.4, Requirements for meeting the EMC standard for power drive systems, IEC61800-3 (EN 61800-3:2004).

Section 4.6.5, Requirements for meeting the generic emission standards for the industrial environment, IEC61000-6-4, EN 61000-6-

4:2007. The recommendations of section 4.6.3 will usually be sufficient to avoid

causing disturbance to adjacent equipment of industrial quality. If particularly sensitive equipment is to be used nearby, or in a nonindustrial environment, then the recommendations of section 4.6.4 or section 4.6.5 should be followed to give reduced radio-frequency emission.

In order to ensure the installation meets the various emission standards described in:

• The EMC data sheet available from the supplier of the drive

• The Declaration of Conformity at the front of this manual

• Chapter 11 Technical data on page 102 The correct external EMC filter must be used and all of the guidelines in

section 4.6.3 General requirements for EMC on page 47 and section

4.6.5 Compliance with generic emission standards on page 48 must be followed.

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Figure 4-8 Installation of grounding clamp (size 3 and 4)

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Table 4-12 Drive and EMC filter cross reference

Model CT Part number

200 V

06200500 to 06200580 4200-2300

400 V

04400240 4200-0252

05400300 4200-0402

06400380 4200-4800

575 V

06500220 to 06500270 4200-3690

High ground leakage current

When an EMC filter is used, a permanent fixed ground connection must be provided which does not pass through a connector or flexible power cord. This includes the internal EMC filter.

The installer of the drive is responsible for ensuring compliance with the EMC regulations that apply in the country in which the drive is to be used.

4.6.1 Grounding hardware

The drive is supplied with a grounding bracket and grounding clamp 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 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 14 mm).

• See Figure 4-8 to Figure 4-10 for details on installing the grounding

clamp.

• See Figure 4-11 for details on installing the grounding bracket.

Loosen the ground connection nuts and slide the grounding clamp in the direction shown. Once in place, the ground connection nuts should be tightened with a maximum torque of 2 N m (1.47 lb ft).

Figure 4-9 Installation of grounding clamp (size 5)

Loosen the ground connection nuts and slide the grounding clamp down onto the pillars in the direction shown. Once in place, the ground connection nuts should be tightened with a maximum torque of 2 N m (1.47 lb ft).

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Figure 4-10 Installation of grounding clamp (size 6)

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4.6.2 Internal EMC filter

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

If the drive is used with ungrounded (IT) supplies, the internal EMC filter must be removed unless additional motor ground fault protection is installed. For instructions on removal refer to section 4.6.2. For details of ground fault protection contact the supplier of the drive.

The internal EMC filter reduces radio-frequency emission into the line power supply. Where the motor cable is short, it permits the requirements of EN 61800-3:2004 to be met for the second environment

- see section 4.6.4 Compliance with EN 61800-3:2004 (standard for

Power Drive Systems) on page 48 and section 11.1.25 Electromagnetic compatibility (EMC) on page 108. For longer motor cables the filter

continues to provide a useful reduction in emission levels, 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 instructions given above require it to be removed. See Figure 4-12 or Figure 4-14 on page 46 for details of removing and installing the internal EMC filters.

The supply must be disconnected before removing the internal EMC filter.

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The grounding clamp is secured using the provided 2 x M4 x 10 mm fasteners. The fasteners should be tightened with the maximum torque of 2 N m (1.47 Ib ft).

Figure 4-11 Installation of grounding bracket (all sizes)

Figure 4-12 Removal of the size 4 internal EMC filter

To electrically disconnect the Internal EMC filter, remove the screw as highlighted above (1).

Loosen the ground connection nuts and slide the grounding bracket in the direction shown. Once in place, the ground connection nuts should be tightened with a maximum torque of 2 N m (1.47 lb ft).

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

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Figure 4-13 Removal of the size 5 internal EMC filter

Remove the three M5 terminal nuts (1). Lift away the cover (2) to expose the M4 Torx internal EMC filter removal screw. Finally remove the M4 Torx internal EMC filter removal screw (3) to electrically disconnect the internal EMC filter.

Figure 4-14 Removal of the size 6 internal EMC filter

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To electrically disconnect the Internal EMC filter, remove the screw as highlighted above (1).

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Optional

ground

connection

External controller

If the control circuit 0V is to be grounded, this should be done at the system controller only to avoid injecting noise currents into the 0V circuit

Metal backplate

Grounding bar

If ground connections are made using a separate cable, they should run parallel to the appropriate power cable to minimise emissions

Use four core cable to

connect the motor to the drive.

The ground conductor in the motor cable must be connected

directly to the earth terminal of

the drive and motor. It must not be connected directly to the power earth busbar.

The incoming supply ground should be connected to a single power ground bus bar or low impedance earth terminal inside the cubicle. This should be used as a common 'clean' ground for all components inside the cubicle.

3 phase AC supply

Optional EMC filter

Metal backplate safety bonded to power ground busbar

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4.6.3 General requirements for EMC

Ground (earth) connections

The grounding arrangements should be in accordance with Figure 4-15, which shows a single drive on a back-plate with or without an additional enclosure.

Figure 4-15 shows how to configure and minimise EMC when using unshielded motor cable. However shielded cable is a better option, in which case it should be installed as shown in section 4.6.5 Compliance with generic emission standards on page 48.

Figure 4-15 General EMC enclosure layout showing ground connections

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Do not place sensitive (unscreened) signal circuits in a zone extending 300 mm (12”) all around the Drive, motor cable, input cable from EMC filter and unshielded braking resistor cable (if used)

300 mm

(12 in)

NOTE

CAUTION

≥

100 mm

(4 in)

≥

100 mm

(4 in)

Do not modify the filter wires

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Cable layout

Figure 4-16 indicates the clearances which should be observed around the drive and related ‘noisy’ power cables by all sensitive control signals / equipment.

Figure 4-16 Drive cable clearances

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Where a filter is not required, follow the guidelines given in section

4.6.3 General requirements for EMC on page 47.

The second environment typically includes an industrial lowvoltage power supply network which does not supply buildings used for residential purposes. Operating the drive in this environment without an external EMC filter may cause interference to nearby electronic equipment whose sensitivity has not been appreciated. The user must take remedial measures if this situation arises. If the consequences of unexpected disturbances are severe, it is recommended that the guidelines in Section 4.6.5 Compliance with generic emission standards be adhered to.

Refer to section 11.1.25 Electromagnetic compatibility (EMC) on page 108 for further information on compliance with EMC standards and definitions of environments.

Detailed instructions and EMC information are given in the EMC Data Sheet which is available from the supplier of the drive.

4.6.5 Compliance with generic emission standards

The following information applies to frame sizes 3 to 8. Use the recommended filter and shielded motor cable. Observe the

layout rules given in Figure 4-17.

Figure 4-17 Supply and ground cable clearance (sizes 4, 5 and 6)

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Any signal cables which are carried inside the motor cable (i.e. motor thermistor, motor brake) will pick up large pulse currents via the cable capacitance. The shield of these signal cables must be connected to ground close to the motor cable, to avoid this noise current spreading through the control system.

4.6.4 Compliance with EN 61800-3:2004 (standard

for Power Drive Systems)

Meeting the requirements of this standard depends on the environment that the drive is intended to operate in, as follows:

Operation in the first environment

Observe the guidelines given in section 4.6.5 Compliance with generic emission standards on page 48. An external EMC filter will always be

required.

Operation in the second environment

In all cases a shielded motor cable must be used, and an EMC filter is required for all drives with a rated input current of less than 100 A.

The drive contains an in-built filter for basic emission control. In some cases feeding the motor cables (U, V and W) once through a ferrite ring can maintain compliance for longer cable lengths.

For longer motor cables, an external filter is required. Where a filter is required, follow the guidelines in Section 4.6.5 Compliance with generic emission standards .

This is a product of the restricted distribution class according to IEC 61800-3

In a residential environment this product may cause radio interference in which case the user may be required to take adequate measures.

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Sensitive signal cable

≥

300 mm

(12 in)

Ensure direct metal contact at drive and filter mounting points (any paint must be removed).

Motor cable shield (unbroken) electrically connected to and held in place by grounding clamp.

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Figure 4-18 Sensitive signal circuit clearance

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Connect the shield of the motor cable to the ground terminal of the motor frame using a link that is as short as possible and not exceeding 50 mm (2 in) long.

A complete 360

termination of the shield to the terminal housing of the

motor is beneficial. From an EMC consideration it is irrelevant whether the motor cable

contains an internal (safety) ground core, or if there is a separate external ground conductor, or where grounding is through the shield alone. An internal ground core will carry a high noise current and therefore it must be terminated as close as possible to the shield termination.

Figure 4-20 Grounding the motor cable shield

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Avoid placing sensitive signal circuits in a zone 300 mm (12 in) in the area immediately surrounding the power module. Ensure good EMC grounding.

Figure 4-19 Grounding the drive, motor cable shield and filter

If the control wiring is to exit the enclosure, it must be shielded and the shield(s) clamped to the drive using the grounding bracket as shown in Figure 4-21. Remove the outer insulating cover of the cable to ensure the shield(s) make direct contact with the bracket, but keep the shield(s) intact until as close as possible to the terminals.

Alternatively, wiring may be passed through a ferrite ring, part number 3225-1004.

Figure 4-21 Grounding of signal cable shields using the

grounding bracket

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From the Drive

To the motor

Back-plate

Enclosure

Isolator

Coupling bar

From the Drive

To the motor

(If required)

Signal from plant Signal to drive

0V 0V

30V zener diode e.g. 2xBZW50-15

Signal from plant Signal to drive

0V 0V

2 x 15V zener diode e.g. 2xBZW50-15

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4.6.6 Variations in the EMC wiring

Interruptions to the motor cable

The motor cable should ideally be a single length of shielded or armored cable having no interruptions. In some situations it may be necessary to interrupt the cable, as in the following examples:

• Connecting the motor cable to a terminal block in the drive enclosure

• Installing a motor isolator / disconnect switch for safety when work is

done on the motor

In these cases the following guidelines should be followed.

Terminal block in the enclosure

The motor cable shields should be bonded to the back-plate using uninsulated metal cable-clamps which should be positioned as close as possible to the terminal block. Keep the length of power conductors to a minimum and ensure that all sensitive equipment and circuits are at least 0.3 m (12 in) away from the terminal block.

Figure 4-22 Connecting the motor cable to a terminal block in the

enclosure

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In applications where they may be exposed to high-energy voltage surges, some special measures may be required to prevent malfunction or damage. Surges may be caused by lightning or severe power faults in association with grounding arrangements which permit high transient voltages between nominally grounded points. This is a particular risk where the circuits extend outside the protection of a building.

As a general rule, if the circuits are to pass outside the building where the drive is located, or if cable runs within a building exceed 30 m, some additional precautions are advisable. One of the following techniques should be used:

1. Galvanic isolation, i.e. do not connect the control 0 V terminal to ground. Avoid loops in the control wiring, i.e. ensure every control wire is accompanied by its return (0 V) wire.

2. Shielded cable with additional power ground bonding. The cable shield may be connected to ground at both ends, but in addition the ground conductors at both ends of the cable must be bonded together by a power ground cable (equipotential bonding cable) with

cross-sectional area of at least 10 mm

, or 10 times the area of the signal cable shield, or to suit the electrical safety requirements of the plant. This ensures that fault or surge current passes mainly through the ground cable and not in the signal cable shield. If the building or plant has a well-designed common bonded network this precaution is not necessary.

3. Additional over-voltage suppression - for the analog and digital inputs and outputs, a zener diode network or a commercially available surge suppressor may be connected in parallel with the input circuit as shown in Figure 4-24 and Figure 4-25.

If a digital port experiences a severe surge its protective trip may operate (I/O Overload trip). For continued operation after such an event, the trip can be reset automatically by setting Pr 10.034 to 5.

Figure 4-24 Surge suppression for digital and unipolar inputs and

outputs

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Using a motor isolator / disconnect-switch

The motor cable shields should be connected by a very short conductor having a low inductance. The use of a flat metal coupling-bar is recommended; conventional wire is not suitable.

The shields should be bonded directly to the coupling-bar using uninsulated metal cable-clamps. Keep the length of the exposed power conductors to a minimum and ensure that all sensitive equipment and circuits are at least 0.3 m (12 in) away.

The coupling-bar may be grounded to a known low-impedance ground nearby, for example a large metallic structure which is connected closely to the drive ground.

Figure 4-23 Connecting the motor cable to an isolator /

disconnect switch

Surge immunity of control circuits - long cables and connections outside a building

The input/output ports for the control circuits are designed for general use within machines and small systems without any special precautions.

These circuits meet the requirements of EN 61000-6-2:2005 (1 kV surge) provided the 0 V connection is not grounded.

Figure 4-25 Surge suppression for analog and bipolar inputs and

outputs

Surge suppression devices are available as rail-mounting modules, e.g. from Phoenix Contact:

Unipolar TT-UKK5-D/24 DC Bipolar TT-UKK5-D/24 AC

These devices are not suitable for encoder signals or fast digital data networks because the capacitance of the diodes adversely affects the signal. Most encoders have galvanic isolation of the signal circuit from the motor frame, in which case no precautions are required. For data networks, follow the specific recommendations for the particular network.

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1 1

NOTE

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Slave

0V /TxRx

TxRx

37 2

0V /Rx Rx /Tx Tx

12345

Master

termination resistor

CSD100

NOTE

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4.7 Communications connections

The drive offers a 2 wire 485 interface. This enables the drive set-up, operation and monitoring to be carried out with a PC or controller if required.

Figure 4-26 Location of the comms connectors

The 485 option provides two parallel RJ45 connectors are provided allowing easy daisy chaining. The drive only supports MODBUS RTU protocol. See Table 4-13 for the connection details.

Standard Ethernet cables are not recommended for use when connecting drives on a 485 network as they do not have the correct twisted pairs for the pinout of the serial comms port.

Table 4-13 Serial communication port pin-outs

Minimum number of connections are 2, 3, 7 and shield.

4.7.1 Isolation of the 485 serial communications

The serial PC communications port is double insulated and meets the requirements for SELV in EN 50178:1998.

An isolated serial communications lead has been designed to connect the drive to IT equipment (such as laptop computers), and is available from the supplier of the drive. See below for details:

Table 4-14 Isolated serial comms lead details

The “isolated serial communications” lead has reinforced insulation as defined in IEC60950 for altitudes up to 3,000 m.

Pin Function

1 120 Ω Termination resistor 2 RX TX (Receive / transmit line - positive) 3 Isolated 0 V 4 +24 V (100 mA) 5 Isolated 0 V 6 TX enable 7 RX\ TX\ (Receive / transmit line - negative) 8 RX\ TX\ (if termination resistors are required, link to pin 1)

Shell Isolated 0 V

port

In order to meet the requirements for SELV in IEC60950 (IT equipment) it is necessary for the control computer to be grounded. Alternatively, when a lap-top or similar device is used which has no provision for grounding, an isolation device must be incorporated in the communications lead.

Part number Description

4500-0096 CT USB Comms cable

4.7.2 2 wire EIA-RS485 network

The diagram below shows the connections required for a 2 wire EIARS485 network, using a master controller with an EIA-RS485 port.

Figure 4-27 2 wire EIA-RS485 network connections

If more than one drive is connected to a host computer / PLC etc, each drive must have a unique serial address see Section 10.2 Slave address and Section 5.10 Communications

Any number in the permitted range 1 to 247 may be used.

4.7.3 Routing of the cable

A data communications cable should not run parallel to any power cables, especially ones that connect drives to motors. If parallel runs are unavoidable, ensure a minimum spacing of 300 mm (1 ft) between the communications cable and the power cable.

Cables crossing one another at right-angles are unlikely to give trouble. The maximum cable length for a EIA-RS485 jumper (link) is 1200 metres (4,000 ft). This is at low baud rates only. The higher the baud rate the lower the maximum cable length.

4.7.4 Termination

When a long-distance multi-drop EIA-RS485 system is used, the transmit and receive pairs should have a termination resistor of 120 W installed across them in order to reduce signal reflections. However, at the lower data rates this is not so critical.

4.8 Control connections

4.8.1 General

Table 4-15 The control connections consist of:

Function Qty

Control parameters

available

Differential analog input 1 Mode, offset, invert, scaling 5, 6 Single ended analog

input

Mode, offset, invert, scaling,

destination

Analog output 2 Source, mode, scaling, 9, 10

Digital input 3

Destination, invert, logic select

Input / output mode select,

Digital input / output 3

destination / source, invert,

logic select Relay 1 Source, invert 41, 42 Drive enable (SAFE

TORQUE OFF)

131

+10 V User output 1 4 +24 V User output 1 Source, invert 22

0V common 6

+24V External input 1 Destination, invert 2

Ter min al

number

7, 8

27, 28, 29

24, 25, 26

1, 3, 11, 21,

23, 30

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Key:

Destination parameter:

Source parameter:

Mode parameter:

Indicates the parameter which is being controlled by the terminal / function

Indicates the parameter being output by the terminal

Analog - indicates the mode of operation of the terminal, i.e. voltage 0-10 V, current 4-20 mA etc. Digital - indicates the mode of operation of the terminal, i.e. positive / negative logic (the Drive Enable terminal is fixed in positive logic), open collector.

All analog terminal functions can be programmed in menu 7. All digital terminal functions (including the relay) can be programmed in menu 8.

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 a personal computer), an additional isolating barrier must be included in order to maintain the SELV classification.

If any of the digital inputs (including the drive enable input) are connected in parallel with an inductive load (i.e. contactor or motor brake) then suitable suppression (i.e. diode or varistor) should be used on the coil of the load. If no suppression is used then over voltage spikes can cause damage to the digital inputs and outputs on the drive.

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4.9 CSD100 specific Input/Output and control

4.9.1 Analog signals

A discharge Line Temperature signal must be present and its range checked to prove that it is not short circuit.

• Analog input 2. [Optional] (Terminal 7 on drive). Analog speed

reference input (0 to 10 V).

• Analog input 3. [Optional] (Connected between terminals 8 and 11

on drive) DLT sensor input.

To use the analogue speed reference input:-

• Set parameter Pr 07.012 to equal 0.220 to provide a scaling of 10 V

gives 7200 rpm.

• Set parameter Pr 07.014 to equal 18.011 to route the scaled

reference to the "User speed reference in RPM"

• Save and press the reset (red) button to action this change.

4.9.2 Digital signals

Digital signals are used in controlling and resetting the drive:

• Drive hardware enable [Required] (Terminal 31 on drive)

• Reset (triggered on transition from low to high) [optional] Digital input

2 (Terminal 25 on drive)

• Start/Run [optional] Digital input 3 (Terminal 26 on drive)

• Stator heating during idle enable [optional] (Terminal 27 on drive)

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Ensure the logic sense is correct for the control circuit to be used. Incorrect logic sense could cause the motor to be started unexpectedly. Positive logic is the default state for the drive.

Any signal cables which are carried inside the motor cable (i.e. motor thermistor, motor brake) will pick up large pulse currents via the cable capacitance. The shield of these signal cables must be connected to ground close to the point of exit of the motor cable, to avoid this noise current spreading through the control system.

The SAFE TORQUE OFF drive enable terminal is a positive logic input only. It is not affected by the setting of Input Logic Polarity (08.029).

The common 0 V from analog signals should, wherever possible, not be connected to the same 0 V terminal as the common 0 V from digital signals. Terminals 3 and 11 should be used for connecting the 0 V common of analog signals and terminals 21, 23 and 30 for digital signals. This is to prevent small voltage drops in the terminal connections causing inaccuracies in the analog signals.

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Polarized

connectors

21 31

0V common

0 V common

1 2

41 42

Reset

Start / controlled stop *

Stator heater On

SAFE TORQUE OFF / Drive enable **

Relay (Over voltage category II)

Drive OK

** The SAFE TORQUE OFF / Drive enable terminal is a positive logic input only

*Start / controlled stop and Stator heater On inputs are only used if Pr {18.016} bit8=000.024

+ 10 V (not used)

Analog input 2 Speed Reference

(0-10 V) input (optional)

Analog input 1

(not used)

Analog input 3 Discharge Line

Temperature Sensor input (optional)

External 24 V supply (not used)

Analog outputs 1 and 2 (not used)

0 V common

+24 V

0 V common

0V common

Digital I/O 1 (not used)

Digital inputs 5 and 6 (not used)

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4.9.3 Control terminal configuration diagram

Figure 4-28 Default terminal functions

4.9.4 Control terminal specification

1 0V common

Function

2 +24V external input

Function

Programmability

Nominal voltage +24.0 Vdc Minimum continuous operating

voltage Maximum continuous operating

voltage Minimum start-up voltage 21.6 Vdc Recommended power supply 40 W 24 Vdc nominal Recommended fuse 3 A, 50 Vdc

3 0V common

Function

4 +10V user output

Function Supply for external analog devices

Voltage 10.2 V nominal Voltage tolerance ±1 % Nominal output current 10 mA Protection Current limit and trip @ 30 mA

Common connection for all external devices

To supply the control circuit without providing a supply to the power stage

Can be switched on or off to act as a digital input by setting the source Pr 08.063 and input invert Pr

+19.2 Vdc

+30.0 Vdc

08.053

Common connection for all external devices

*The SAFE TORQUE OFF / Drive enable terminal is a positive logic input only.

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Precision reference Analog input 1

5 Non-inverting input

6 Inverting input

Default function Not used

Type of input

Mode controlled by: Pr

Operating in Voltage mode

Full scale voltage range ±10 V ±2 % Maximum offset ±10 mV Absolute maximum

voltage range Working common mode voltage

range Input resistance ≥100 kΩ Monotonic Yes (including 0 V) Dead band None (including 0 V) Jumps None (including 0 V) Maximum offset 20 mV Maximum non linearity 0.3% of input Maximum gain asymmetry 0.5 % Input filter bandwidth single pole ~3 kHz Operating in current mode

Current ranges

Maximum offset 250 μA Absolute maximum voltage

(reverse biased) Equivalent input resistance ≤300 Ω Absolute maximum current ±30 mA Operating in thermistor input mode (in conjunction with analog input 3) Internal pull-up voltage 2.5 V Trip threshold resistance User defined in Pr Short-circuit detection resistance 50 Ω ± 40 % Common to all modes Resolution 12 bits (11 bits plus sign)

Sample / update period

Bipolar differential analog voltage or current, thermistor input

07.007

±36 V relative to 0 V

±13 V relative to 0 V

0 to 20 mA ±5 %, 20 to 0 mA ±5 %, 4 to 20 mA ±5 %, 20 to 4 mA ±5 %

±36 V relative to 0 V

07.048

250 µs with destinations Pr

01.037, Pr 03.022 or Pr 04.008 in RFC-A

Pr and RFC-S modes. 4 ms for open loop mode and all other destinations in RFC-A or RFC-S modes.

01.036,

Analog input 2

Default function Speed reference

Type of input

Mode controlled by... Pr

Bipolar single-ended analog voltage or unipolar current

07.011

Operating in voltage mode

Full scale voltage range ±10 V ±2 %

Maximum offset ±10 mV

Absolute maximum voltage range ±36 V relative to 0 V

Input resistance

≥100 k Ω

Operating in current mode

Current ranges

Maximum offset 250 μA

Absolute maximum voltage (reverse bias)

Absolute maximum current ±30 mA

Equivalent input resistance ≤ 300 Ω

0 to 20 mA ±5 %, 20 to 0 mA ±5 %, 4 to 20 mA ±5 %, 20 to 4 mA ±5 %

±36 V relative to 0V

Common to all modes

Resolution 12 bits (11 bits plus sign)

01.036,

Sample / update

Analog input 3

250 µs with destinations Pr

01.037 or Pr 03.022, Pr 04.008 in RFC-A

Pr or RFC-S. 4ms for open loop mode and all other destinations in RFC-A or RFC-S mode.

Default function Discharge line temperature sensor

input

Type of input

Mode controlled by... Pr

Bipolar single-ended analog voltage, or thermistor input

07.015

Operating in Voltage mode (default)

Voltage range ±10 V ±2 %

Maximum offset ±10 mV

Absolute maximum voltage range ±36 V relative to 0 V

Input resistance ≥100 k Ω

Operating in thermistor input mode

Supported thermistor types

Internal pull-up voltage 2.5 V

Trip threshold resistance User defined in Pr

Reset resistance User defined in Pr 07.048

Short-circuit detection resistance 50 Ω ± 40 %

Din 4408, KTY 84, PT100, PT 1000, PT 2000

07.048

Common to all modes

Resolution 12 bits (11 bits plus sign)

01.036,

Sample / update period

250 µs with destinations Pr

01.037, Pr 03.022 or Pr 04.008 in RFC-A

Pr and RFC-S modes. 4ms for open loop mode and all other destinations in RFC-A or RFC-S mode.

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Analog output 1

10 Analog output 2

Terminal 9 default function

Not used

Terminal 10 default function Not used

Type of output Bipolar single-ended analog voltage

Operating in Voltage mode (default)

Voltage range ±10 V ±5 %

Maximum offset ±120 mV

Maximum output current ±20 mA

Load resistance ≥1 k Ω

Protection 20 mA max. Short circuit protection

Common to all modes

Resolution 10-bit

Sample / update period

250 µs (output will only change at update the rate of the source parameter if slower)

11 0V common

Function

Common connection for all external devices

21 0V common

Function

Common connection for all external devices

22 +24 V user output (selectable)

Terminal 22 default function +24 V user output

Can be switched on or off to act as a fourth

Programmability

Nominal output current 100 mA combined with DIO3

Maximum output current

Protection Current limit and trip

Sample / update period

digital output (positive logic only) by setting the source Pr

08.018

100 mA 200 mA (total including all Digital I/O)

2 ms when configured as an output (output will only change at the update rate of the source parameter if slower)

08.028 and source invert

Digital I/O 1

25 Digital I/O 2

26 Digital I/O 3

Terminal 24 default function Not used

Terminal 25 default function DRIVE RESET input

Terminal 26 default function Start / Controlled stop

Type

Input / output mode controlled by... Pr

Positive or negative logic digital inputs, positive logic voltage source outputs

08.031, Pr 08.032 and Pr 08.033

Operating as an input

Logic mode controlled by... Pr 08.029

Absolute maximum applied voltage range

Impedance

Input thresholds 10 V ±0.8 V from IEC 61131-2, type 1

-3 V to +30 V

>2 mA @15 V from IEC 61131-2, type 1,

6.6 k Ω

Operating as an output

100 mA (DIO1 & 2 combined)

Nominal maximum output current

Maximum output current

100 mA (DIO3 & 24 V User Output Combined)

100 mA 200 mA (total including all Digital I/O)

Common to all modes

Voltage range 0 V to +24 V

Sample / Update period

250 µs when configured as an input with destinations Pr 2 ms when configured as an output (output will only change at the update rate of the source parameter

06.035 or Pr 06.036.

27 Digital Input 4

Digital Input 5

Terminal 27 default function Terminal 28 default function

Type Negative or positive logic digital inputs

Logic mode controlled by... Pr

Stator heater on

Not used

08.029

23 0V common

Function

Common connection for all external devices

Voltage range 0 V to +24 V

Absolute maximum applied voltage range

Impedance

Input thresholds 10 V ±0.8 V from IEC 61131-2, type 1

Sample / Update period

-3 V to +30 V

>2 mA @15 V from IEC 61131-2, type 1,

6.6 k Ω

250 µs when configured as an input with destinations Pr when configured as an input with destination

06.029. 2 ms in all other cases.

06.035 or Pr 06.036. 600 µs

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Digital Input 6

Terminal 29 default function Not used

Type Negative or positive logic digital inputs

Logic mode controlled by... Pr

Voltage range 0 V to +24 V

Absolute maximum applied voltage range

Impedance

Input thresholds 10 V ±0.8 V from IEC 61131-2, type 1

Sample / Update period

08.029

-3 V to +30 V

>2 mA @15 V from IEC 61131-2,

6.6 k Ω

250 µs when configured as an input with destinations Pr 2 ms in all other cases.

06.035 or Pr 06.036.

type 1,

30 0V common

Function

Common connection for all external devices

Refer to section 4.10 SAFE TORQUE OFF (STO) on page 56 for further information.

31 SAFE TORQUE OFF function (drive enable)

Type Positive logic only digital input Voltage range 0 V to +24 V

Absolute maximum applied voltage

Logic Threshold 10 V ± 5 V Low state maximum voltage for

disable to SIL3 and PL e

Impedance

Low state maximum current for disable to SIL3 and PL e

Response time

The SAFE TORQUE OFF function may be used in a safety-related application in preventing the drive from generating torque in the motor to a high level of integrity. The system designer is responsible for ensuring that the complete system is safe and designed correctly according to the relevant safety standards. If the SAFE TORQUE OFF function is not required, this terminal is used for enabling the drive.

Relay contacts

30 V

5 V

>4 mA @15 V from IEC 61131-2, type 1,

k Ω

3.3

0.5 mA

Nominal: 8 ms Maximum: 20 ms

Default function Drive OK indicator

Contact voltage rating

Contact maximum current rating

Contact minimum recommended rating

Contact type Normally open

Default contact condition Closed when power applied and drive OK

Update period 4 ms

240 Vac, Installation over-voltage category II

2 A AC 240 V 4 A DC 30 V resistive load

0.5 A DC 30 V inductive load (L/R = 40 ms)

12 V 100 mA

51 0 V

52 +24 Vdc

Nominal operating voltage 24.0 Vdc

Minimum continuous operating voltage 18.6 Vdc

Maximum continuous operating voltage 28.0 Vdc

Minimum startup voltage 18.4 Vdc

Maximum power supply requirement 40 W

Recommended fuse 4 A @ 50 Vdc

To prevent the risk of a fire hazard in the event of a fault, a fuse or other over-current protection must be installed in the relay circuit.

4.10 SAFE TORQUE OFF (STO)

The SAFE TORQUE OFF function provides a means for preventing the drive from generating torque in the motor, with a very high level of integrity. It is suitable for incorporation into a safety system for a machine. It is also suitable for use as a conventional drive enable input.

The safety function is active when the STO input is in the logic-low state as specified in the control terminal specification. The function is defined according to EN 61800-5-2 and IEC 61800-5-2 as follows. (In these standards a drive offering safety-related functions is referred to as a PDS(SR)):

‘Power, that can cause rotation (or motion in the case of a linear motor), is not applied to the motor. The PDS(SR) will not provide energy to the motor which can generate torque (or force in the case of a linear motor)’.

This safety function corresponds to an uncontrolled stop in accordance with stop category 0 of IEC 60204-1.

The SAFE TORQUE OFF function makes use of the special property of an inverter drive with an induction motor, which is that torque cannot be generated without the continuous correct active behavior of the inverter circuit. All credible faults in the inverter power circuit cause a loss of torque generation.

The SAFE TORQUE OFF function is fail-safe, so when the SAFE TORQUE OFF input is disconnected the drive will not operate the motor, even if a combination of components within the drive has failed. Most component failures are revealed by the drive failing to operate. SAFE TORQUE OFF is also independent of the drive firmware. This meets the requirements of the following standards, for the prevention of operation of the motor.

Data as verified by TÜV Rheinland: According to EN ISO 13849-1: PL = e Category = 4 MTTF

= High

Mission Time and Proof Test Interval = 20 years

The calculated MTTF

STO1 2574 yr

According to EN 61800-5-2: SIL = 3

PFH = 4.21 x 10

The SAFE TORQUE OFF input also meets the requirements of EN 81-1 (clause 12.7.3 b) as part of a system for preventing unwanted operation of the motor in a lift (elevator).

for the complete STO function is:

-11 h-1

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SAFE TORQUE OFF can be used to eliminate electro-mechanical contactors, including special safety contactors, which would otherwise be required for safety applications.

The function can be used in safety-related machines or systems which have been designed according to IEC 62061 or IEC 61508, or other standards which are compatible with IEC 61508, since the analysis and the integrity metrics used in EN 61800-5-2 are the same.

Note on response time of SAFE TORQUE OFF, and use with safety controllers with self-testing outputs.

SAFE TORQUE OFF has been designed to have a response time of greater than 1 ms, so that it is compatible with safety controllers whose outputs are subject to a dynamic test with a pulse width not exceeding 1 ms.

Note on the use of servo motors, other permanent-magnet motors, reluctance motors and salient-pole induction motors.

When the drive is disabled through SAFE TORQUE OFF, a possible (although highly unlikely) failure mode is for two power devices in the inverter circuit to conduct incorrectly.

This fault cannot produce a steady rotating torque in any AC motor. It produces no torque in a conventional induction motor with a cage rotor. If the rotor has permanent magnets and/or saliency, then a transient alignment torque may occur. The motor may briefly try to rotate by up to 180° electrical, for a permanent magnet motor, or 90° electrical, for a salient pole induction motor or reluctance motor. This possible failure mode must be allowed for in the machine design.

The design of safety-related control systems must only be done by personnel with the required training and experience. The SAFE TORQUE OFF function will only ensure the safety of a machine if it is correctly incorporated into a complete safety system. The system must be subject to a risk assessment to confirm that the residual risk of an unsafe event is at an acceptable level for the application.

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It is essential to observe the maximum permitted voltage of 5 V for a safe low (disabled) state of SAFE TORQUE OFF. The connections to the drive must be arranged so that voltage drops in the 0 V wiring cannot exceed this value under any loading condition. It is strongly recommended that the SAFE TORQUE OFF circuit be provided with a dedicated 0 V conductor which should be connected to terminal 30 at the drive.

SAFE TORQUE OFF over-ride

The drive does not provide any facility to over-ride the SAFE TORQUE OFF function, for example for maintenance purposes.

For more information regarding the SAFE TORQUE OFF input, please see the Control Techniques Safe Torque Off Engineering Guide available for download from www.controltechniques.com.

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SAFE TORQUE OFF inhibits the operation of the drive, this includes inhibiting braking. If the drive is required to provide both braking and SAFE TORQUE OFF in the same operation (e.g. for emergency stop) then a safety timer relay or similar device must be used to ensure that the drive is disabled a suitable time after braking. The braking function in the drive is provided by an electronic circuit which is not fail-safe. If braking is a safety requirement, it must be supplemented by an independent fail-safe braking mechanism.

SAFE TORQUE OFF does not provide electrical isolation. The supply to the drive must be disconnected by an approved isolation device before gaining access to power connections.

With SAFE TORQUE OFF there are no single faults in the drive which can permit the motor to be driven. Therefore it is not necessary to have a second channel to interrupt the power connection, nor a fault detection circuit.

It is important to note that a single short-circuit from the SAFE TORQUE OFF input to a DC supply of approximately +24 V would cause the drive to be enabled. This can be excluded under EN ISO 13849-2 by the use of protected wiring. The wiring can be protected by either of the following methods:

• By placing the wiring in a segregated cable duct or other enclosure.

• By providing the wiring with a grounded shield in a positive-logic grounded control circuit. The shield is provided to avoid a hazard from an electrical fault. It may be grounded by any convenient method; no special EMC precautions are required.

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5 Getting started

This chapter introduces the user interfaces, menu structure and security levels of the drive.

5.1 Understanding the display

The keypad can only be mounted on the drive.

5.1.1 HOA-Keypad

The HOA-Keypad display consists of two rows of text. The upper row shows the drive status or the menu and parameter number currently being viewed. The lower row of the display line shows the parameter value or the specific trip type. The last two characters on the first row may display special indications. If more than one of these indications is active then the indications are prioritized as shown in Table 5-2.

When the drive is powered up the lower row will show the power up parameter defined by Parameter Displayed At Power-Up (11.022).

Figure 5-1 HOA-Keypad

Table 5-2 Active action icon

Active action icon Description

Accessing non-volatile media card

Row

(1=top)

Priority

in row

Alarm active 1 2

Keypad real-time clock battery low

Drive security active and locked or unlocked

5.2 Keypad operation

5.2.1 Control buttons

The keypad consists of:

• Navigation Keys - Used to navigate the parameter structure and change parameter values.

• Enter / Mode button - Used to toggle between parameter edit and view mode.

• Escape / Exit button - Used to exit from parameter edit or view mode. In parameter edit mode, if parameter values are edited and the exit button pressed the parameter value will be restored to the value it had on entry to edit mode.

• Hand button - Not used.

• Auto button - Not used.

• Stop / Reset / OFF button - Used to reset the drive.

Low battery voltage is indicated by low battery symbol on the keypad display. Refer to section 3.12.1 Real time clock battery replacement on

page 35 for information on battery replacement.

Figure 5-2 overleaf shows an example on moving between menus and editing parameters.

1. Escape button

2. Auto (blue) button

3. Hand (green)

4. Navigation keys (x4)

5. Stop / Reset / OFF (red) button

6. Enter button

The red stop button is also used to reset the drive.

The parameter value is correctly displayed in the lower row of the keypad display, see table below.

Table 5-1 Keypad display formats

Display formats Value

IP Address 127.000.000.000

MAC Address 01ABCDEF2345

Time 12:34:56

Date 31-12-11 or 12-31-11

Version number 01.02.02.00

Character ABCD

32 bit number with decimal point 21474836.47

16 bit binary number 0100001011100101

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To enter Edit Mode, press key,

Status Mode

Parameter

Mode

Edit Mode

(Character to be edited in lower line of display flashing)

Change parameter values

using keys.

When returning to Parameter Mode use the

keys to select another parameter to change, if required

To enter Parameter Mode, press key or

Temporary Parameter Mode

Timeout

To return to Status Mode,

parameter

R/W parameter

To select parameter Press

is displayed)

To return to Parameter Mode, Press key to keep the new parameter value Press key to ignore the new parameter value and return the parameter to the pre-edited value

Press key

Timeout

Press key

(

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Figure 5-2 Display modes

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The navigation keys can only be used to move between menus if Pr 00.049 has been set to show 'All Menus'. Refer to section 5.7 Parameter access level and security on page 62.

5.2.2 Quick access mode

The quick access mode allows direct access to any parameter without scrolling through menus and parameters.

To enter the quick access mode, press and hold the Enter button on the keypad while in ‘parameter mode’.

Figure 5-3 Quick access mode

5.2.3 Keypad shortcuts

In ‘parameter mode’:

• If the up and down keypad buttons are pressed

together, then the keypad display will jump to the start of the parameter menu being viewed, i.e. Pr 05.005 being viewed, when the above buttons pressed together will jump to Pr 05.000.

• If the left and right keypad buttons are pressed together,

then the keypad display will jump to the last viewed parameter in Menu 0.

In ‘parameter edit mode’:

• If the up and down keypad buttons are pressed

together, then the parameter value of the parameter being edited will be set to 0.

• If the left and right keypad buttons are pressed together, the

least significant digit (furthest right) will be selected on the keypad display for editing.

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Menu 0

....MM.000....

00.050

00.049

00.048

00.047

00.046

00.001

00.002

00.003

00.004

00.005

Moves between parameters

Menu 41

Menu 1

Menu 2

Moves between Menus

41.029

41.028

41.027

41.026

41.025

41.001

41.002

41.003

41.004

41.005

01.001

01.002

01.003

01.004

01.005

01.050

01.049

01.048

01.047

01.046

Option module menus (S.mm.ppp)*

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Figure 5-4 Mode examples

1. Parameter view mode: Read write or Read only

2. Status mode: Drive OK status

If the drive is ok and the parameters are not being edited or viewed, the upper row of the display will show one of the following:

• ‘Inhibit’, ‘Ready’ or ‘Run’.

3. Status mode: Trip status

When the drive is in trip condition, the upper row of the display will indicate that the drive has tripped and the lower row of the display will show the trip code. For further information regarding trip codes. refer to Table 12-10 Trip indications on page 117.

4. Status mode: Alarm status

During an ‘alarm’ condition the upper row of the display flashes between the drive status (Inhibit, Ready or Run, depending on what is displayed) and the alarm.

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5.3 Menu structure

The drive parameter structure consists of menus and parameters. The drive initially powers up so that only Menu 0 can be viewed. The up

and down arrow buttons are used to navigate between parameters and once Pr 00.049 has been set to 'All Menus' the left and right buttons are used to navigate between menus. For further information, refer to section 5.7 Parameter access level and security on page 62

Figure 5-5 Parameter navigation

* Can only be used to move between menus if all menus have been enabled (Pr 00.049). Refer to section 5.7 Parameter access level and security on page 62.

The menus and parameters roll over in both directions. i.e. if the last parameter is displayed, a further press will cause the

display to rollover and show the first parameter. When changing between menus the drive remembers which parameter

was last viewed in a particular menu and thus displays that parameter.

Figure 5-6 Menu structure

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Do not change parameter values without careful consideration; incorrect values may cause damage or a safety hazard.

When changing the values of parameters, make a note of the new values in case they need to be entered again.

For new parameter-values to apply after the line power supply to the drive is interrupted, new values must be saved. Refer to section

5.6 Saving parameters on page 62.

* The option module menus (S.mm.ppp) are only displayed if option modules are installed. Where S signifies the option module slot number and the mm.ppp signifies the menu and the parameter number of the option module's internal menus and parameter.

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Menu 0

00.004

00.005

00.006

Menu 2

02.021

Menu 1

01.014

Menu 4

04.007

5 0

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5.4 Menu 0

Menu 0 is used to bring together various commonly used parameters for basic easy set up of the drive. The parameters displayed in Menu 0 can be configured in Menu 22.

Appropriate parameters are copied from the advanced menus into Menu 0 and thus exist in both locations.

For further information, refer to Chapter 6 Compressor specific functions on page 65.

Figure 5-7 Menu 0 copying

5.5 Advanced menus

The advanced menus consist of groups or parameters appropriate to a specific function or feature of the drive. Menus 0 to 41 can be viewed on the HOA-Keypad. The option module menus (S.mm.ppp) are only displayed if option modules are installed. Where S signifies the option module slot number and the mm.ppp signifies the menu and parameter number of the option module’s internal menus and parameter.

Table 5-3 Advanced menu descriptions

Menu Description

Commonly used basic set up parameters for quick / easy

programming 1 Frequency / Speed reference 2Ramps 3 Frequency slaving, speed feedback and speed control 4 Torque and current control 5 Motor control 6 Sequencer and clock 7 Analog I/O 8 Digital I/O

10 Status and trips 11 Drive set-up and identification, serial communications 15 Option module slot 1 set-up menu 16 Option module slot 2 set-up menu 17 Option module slot 3 set-up menu 18 General option module application menu 1 19 General option module application menu 2 20 General option module application menu 3 22 Menu 0 set-up 23 Not allocated 28 Reserved menu

29 Reserved menu Slot 1 Slot 1 option menus* Slot 2 Slot 2 option menus* Slot 3 Slot 3 option menus*

*Only displayed when the option modules are installed.

5.5.1 HOA-Keypad set-up menu

To enter the keypad set-up menu press and hold the escape button on the keypad from status mode. All the keypad parameters are saved to the keypad non-volatile memory when exiting from the keypad set-up menu.

To exit from the keypad set-up menu press the escape or or

button. Below are the keypad set-up parameters.

Table 5-4 HOA-Keypad set-up parameters

Parameters Range Type

Keypad.01 Language selection English (1) RW Keypad.02 Show parameter units OFF (0), On (1) RW Keypad.03 Backlight level 0 to 100 % RW

Keypad.04* Keypad real-time clock date

Keypad.05* Keypad real-time clock time

Keypad.06 Keypad software version

01.01.10 to

31.12.99 00:00:00 to

23:59:59

00.00.00.00 to

99.99.99.99

* These parameters are only displayed on the HOA-Keypad RTC.

It is not possible to access the keypad parameters via any communications channel.

5.5.2 Display messages

The following tables indicate the various possible mnemonics which can be displayed by the drive and their meaning.

Table 5-5 Status indications

Upper row

string

Description

The drive is inhibited and cannot be run. The SAFE TORQUE OFF signal is not applied to SAFE TORQUE OFF terminals

Inhibit

or Pr 06.015 is set to 0. The other conditions that can prevent the drive from enabling are shown as bits in Enable Conditions (06.010)

The drive is ready to run. The drive enable

Ready

is active, but the drive inverter is not active because the final drive run is not active

Stop The drive is stopped / holding zero speed Enabled Run The drive is active and running Enabled

Supply Loss Supply loss condition has been detected Enabled

The motor is being decelerated to zero

Deceleration

speed / frequency because the final drive run has been deactivated

The drive has tripped and no longer

Trip

controlling the motor. The trip code appears in the lower display

Active

Under

Vol tag e

The Regen unit is enabled and synchronized to the supply

The drive is in the under voltage state either in low voltage or high voltage mode

Heat The motor pre-heat function is active Enabled

Drive

output

stage

Disabled

Enabled

Disabled

Enabled

Disabled

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5.5.3 Alarm indications

An alarm is an indication given on the display by alternating the alarm string with the drive status string on the upper row and showing the alarm symbol in the last character in the upper row. Alarms strings are not displayed when a parameter is being edited, but the user will still see the alarm character on the upper row.

Table 5-6 Alarm indications

Alarm string Description

Motor Protection Accumulator (04.019) in the drive

Motor Overload

Ind Overload

Drive Overload

Auto Tune

Limit Switch

Table 5-7 Option module and NV media card and other status

First row

string

Booting Parameters Parameters are being loaded

Drive parameters are being loaded from a NV Media Card

Booting User Program User program being loaded

User program is being loaded from a NV Media Card to the drive

Booting

User program is being loaded from a NV Media Card to the option module in slot X

Writing To NV Card

Data is being written to a NV Media Card to ensure that its copy of the drive parameters is correct because the drive is in Auto or Boot mode

Waiting For Power System Waiting for power stage

The drive is waiting for the processor in the power stage to respond after power-up

Waiting For Options Waiting for an option module

has reached 75.0 % of the value at which the drive will trip and the load on the drive is >100 %.

Regen inductor overload. Inductor Protection Accumulator (04.019) in the drive has reached

75.0 % of the value at which the drive will trip and the load on the drive is >100 %.

Drive over temperature. Percentage Of Drive Thermal Trip Level (07.036) in the drive is greater than 90 %.

The autotune procedure has been initialized and an autotune in progress.

Limit switch active. Indicates that a limit switch is active and that is causing the motor to be stopped.

indications at power-up

Second row string Status

Option Program

User program being loaded

Data being written to NV Media Card

5.6 Saving parameters

When changing a parameter in Menu 0, the new value is saved when

pressing the Enter button to return to parameter view mode from parameter edit mode.

If parameters have been changed in the advanced menus, then the change will not be saved automatically. A save function must be carried out.

Procedure

See section 6.2.6 Housekeeping functions on page 70 .

5.7 Parameter access level and security

The parameter access level determines whether the user has access to Menu 0 only or to all the advanced menus (Menus 1 to 41) in addition to Menu 0.

The User Security determines whether the access to the user is read only or read write.

Both the User Security and Parameter Access Level can operate independently of each other as shown in table Table 5-8.

Table 5-8 Parameter access level and security

User

security

status

Access level

User

security

(11.044)

0 Menu 0

1 All Menus

Read-only

Menu 0

3 Read-only

4 Status only

5 No access

Open RW Not visible Closed RO Not visible Open RW RW Closed RO RO Open RO Not visible Closed RO Not visible Open RO RO Closed RO RO Open Not visible Not visible Closed Not visible Not visible Open Not visible Not visible Closed Not visible Not visible

The default settings of the drive are Parameter Access Level Menu 0 and user Security Open i.e. read / write access to Menu 0 with the advanced menus not visible.

Menu 0

status

Advanced

menu status

The drive is waiting for the options modules to respond after power-up

Uploading From

Options Loading parameter database

At power-up it may be necessary to update the parameter database held by the drive because an option module has changed or because an applications module has requested changes to the parameter structure. This may involve data transfer between the drive an option modules. During this period ‘Uploading From Options’ is displayed

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5.7.1 User Security Level / Access Level

The drive provides a number of different levels of security that can be set by the user via User Security Status (11.044); these are shown in the

table below.

User Security

Status

Description

(Pr 11.044)

Menu 0 (0)

All menus (1)

Read- only

Menu 0 (2)

Read-only (3)

Status only (4)

All writable parameters are available to be edited but only parameters in Menu 0 are visible

All parameters are visible and all writable parameters are available to be edited

Access is limited to Menu 0 parameters only. All parameters are read-only

All parameters are read-only however all menus and parameters are visible

The keypad remains in status mode and no parameters can be viewed or edited

The keypad remains in status mode and no

No access (5)

parameters can be viewed or edited. Drive parameters cannot be accessed via a comms/ fieldbus interface in the drive or any option module

5.7.2 Changing the User Security Level /Access Level

The security level is determined by the setting of Pr 00.059 or Pr 11.044. The Security Level can be changed through the keypad even if the User Security Code has been set.

5.7.3 User Security Code

The User Security Code, when set, prevents write access to any of the parameters in any menu.

Setting User Security Code

Enter a value between 1 and 2147483647 in Pr 11.030 and press the

button; the security code has now been set to this value. In order to activate the security, the Security level must be set to desired level in Pr 00.059. When the drive is reset, the security code will have been

activated and the drive returns to Menu 0 and the symbol is displayed in the right hand corner of the keypad display. The value of

Pr 11.030 will return to 0 in order to hide the security code.

Unlocking User Security Code

Select a parameter that need to be edited and press the button, the upper display will now show ‘Security Code’. Use the arrow buttons

to set the security code and press the button. With the correct security code entered, the display will revert to the parameter selected in edit mode.

If an incorrect security code is entered, the following message ‘Incorrect security code’ is displayed, then the display will revert to parameter view mode.

Disabling User Security

Unlock the previously set security code as detailed above. Set Pr 11.030

to 0 and press the button. The User Security has now been disabled, and will not have to be unlocked each time the drive is powered up to allow read / write access to the parameters.

5.8 Displaying parameters with nondefault values only

By selecting 'Show non-default' in Pr mm.000 (Alternatively, enter 12000 in Pr mm.000), the only parameters that will be visible to the user will be those containing a non-default value. This function does not require a drive reset to become active. In order to deactivate this function, return to Pr mm.000 and select 'No action' (alternatively enter a value of 0). Please note that this function can be affected by the access level enabled, refer to section 5.7 Parameter access level and security on page 62 for further information regarding access level.

5.9 Displaying destination parameters only

By selecting 'Destinations' in Pr mm.000 (Alternatively enter 12001 in Pr mm.000), the only parameters that will be visible to the user will be destination parameters. This function does not require a drive reset to become active. In order to deactivate this function, return to Pr mm.000 and select 'No action' (alternatively enter a value of 0).

Please note that this function can be affected by the access level enabled, refer to section 5.7 Parameter access level and security on page 62 for further information regarding access level.

5.10 Communications

The CSD100 drive offers a 2 wire EIA485 interface. This enables the drive set-up, operation and monitoring to be carried out with a PC or controller if required.

5.10.1 485 Serial communications

The EIA485 option provides two parallel RJ45 connectors allowing easy daisy chaining. The drive only supports MODBUS RTU protocol.

The serial communications port of the drive is a RJ45 socket, which is isolated from the power stage and the other control terminals (see section 4.7 Communications connections on page 51 for connection and isolation details).

The communications port applies a 2 unit load to the communications network.

USB/EIA232 to EIA485 Communications

An external USB/EIA232 hardware interface such as a PC cannot be used directly with the 2-wire EIA485 interface of the drive. Therefore a suitable converter is required.

Suitable USB to EIA485 and EIA232 to EIA485 isolated converters are available as follows:

• CT USB Comms cable (CT Part No. 4500-0096)

• CT EIA232 Comms cable (CT Part No. 4500-0087)

When using the CT EIA232 Comms cable the available baud rate is limited to 19.2 k baud.

When using one of the above converters or any other suitable converter with the drive, it is recommended that no terminating resistors be connected on the network. It may be necessary to 'link out' the terminating resistor within the converter depending on which type is used. The information on how to link out the terminating resistor will normally be contained in the user information supplied with the converter.

Serial communications set-up parameters

The following parameters need to be set according to the system requirements.

Serial Address (Pr 11.023)

This parameter defines the serial address and an addresses between 1 and 247 are permitted.

Changing the parameters does not immediately change the serial communications settings. See note below for more details.

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Serial Mode (Pr 11.024)

This parameter defines the data format used by the EIA485 comms port on the drive.

Value Text

0 (Default) 8 2 NP

18 1 NP 28 1 EP 38 1 OP 48 2 NP M 58 1 NP M 68 1 EP M 78 1 OP M 87 2 NP

97 1 NP 10 7 1 EP 11 7 1 OP 12 7 2 NP M 13 7 1 NP M 14 7 1 EP M 15 7 1 OP M

The bits in the value of Serial Mode (Pr 11.024) define the data format as follows.:

Bits 3 2 1 and 0

Stop bits and Parity

0 = 2 stop bits, no parity

1 = 1 stop bit, no parity

2 = 1 stop bit, even parity

3 = 1 stop bit, odd parity

Format

Number of

data bits 0 = 8 bits 1 = 7 bits

0 = Standard

1 = Modified

Bit 3 is always 0 in the core product as 8 data bits are required for MODBUS RTU.

Bit 2 selects either standard or modified register mode. The menu and parameter numbers are derived for each mode as given in the table below. Standard mode is the default setting and allows up to 99 parameters to be accessed within a menu. Modified mode is provided to

allow register numbers up to 255 to be addressed.

Standard (mm x 100) + ppp - 1 where mm ≤ 162 and ppp ≤ 99

Modified (mm x 256) + ppp - 1 where mm ≤ 63 and ppp ≤ 255

This parameter can be changed via the drive keypad, or via the comms interface itself. Changing the parameters does not immediately change the serial communications settings. See note below for more details.

Serial Baud Rate (Pr 11.025)

This parameter defines the baud rate used by the serial comms interface.

Value Text

0300 1600 21200 32400 44800 59600

6 (Default) 19200

7 38400 8 57600 9 76800

10 115200

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Changing the parameters does not immediately change the serial communications settings. See note below for more details.

Minimum Comms Transmit Delay (Pr 11.026)

There will always be a finite delay between the end of a message from the host (master) and the time at which the host is ready to receive the response from the drive (slave). The drive does not respond until at least 1ms after the message has been received from the host allowing 1ms for the host to change from transmit to receive mode. This initial delay can be extended using Minimum Comms Transmit Delay (Pr 11.026) if required.

Value Action

The transmitters are turned on and data transmission begins immediately after the initial delay (≥1 ms)

The transmitters are turned on after the initial delay (≥1ms) and data transmission begins 1ms later

The transmitters are turned on after a delay of at least

2 or more

the time specified by Minimum Comms Transmit Delay (Pr 11.026) and data transmission begins 1ms later

The drive holds its own transmitters active for up to 1 ms after it has transmitted data before switching to the receive mode; the host should not send any data during this time.

Changing the parameters does not immediately change the serial communications settings See note below for more details.

Silent Period (Pr 11.027)

The silent period defines the idle time required to detect the end of a received data message. If Silent Period (Pr 11.027) = 0 then the silent period is at least 3.5 characters at the selected baud rate. This is the standard silent period for MODBUS RTU. If Silent Period (Pr 11.027) is non-zero it defines the minimum silent period in milliseconds.

Changing the parameters does not immediately change the serial communications settings. See note below for more details.

When Serial Address (Pr 11.023), Serial Mode (Pr 11.024), Serial Baud

Rate (Pr 11.02 5), Minimum Comms Transmit Delay (Pr 11.026) or Silent Period (Pr 11.027 ) are modified the changes do not have an immediate

effect on the serial communications system. The new values are used after the next power-up or if Reset Serial Communications (Pr 11.0 20) is set to one. Reset Serial Communications (Pr 11.020) is automatically cleared to zero after the communications system is updated.

This does not save any changes made and a separate parameter save is required.

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6 Compressor specific functions

6.1 Menu 0 - compressor specific parameters

Menu 0 is used to bring together all the compressor specific parameters for easy basic setup of the CSD100. All of the parameters in menu 0 appear in other menus in the CSD (denoted by {…}). Where control is via 485 serial communications, a MODBUS address is given for each parameter (assumes 32-bit access).

Table 6-1 Menu 0: Compressor specific parameters

Data

Parameter

Range(

Ú) Default(Ö)

(bits)

00.001 User soft-start dwell speed {01.021} 1500.0 to 7200.0 rpm 3600.0 rpm 32 4000 6.4.1

00.002 Normal running final reference {01.022} 0.0 to 7200.0 rpm 0.0 rpm 32 4001 6.4.2

00.003 Controlled shutdown final reference {01.023} 0.0 to 7200.0 rpm 3600.0 or envelope minimum 32 4002 6.4.3

00.004 Stop reference {01.024} 0.0 rpm 0.0 rpm 32 4003 6.4.3

00.005 Defrost final reference {01.025} 1500.0 to 7200.0 rpm 1500.0 or envelope minimum 32 4004 6.4.4

00.006 Oil boost reference {01.026} 3600.0 to 7200.0 rpm 3600.0 rpm 32 4005 6.3.5

00.007 Skip Reference 1 {01.029} 0 to 7200 rpm 0 rpm [no filter] 16 4006 6.4.5

00.008 Skip Reference Band 1 {01.030} 0 to 250 rpm 0 rpm 8 4007 6.4.5

00.009 Soft-start acceleration rate {02.011} 1.000 to 2.500 s/1000 rpm 1.000 s/1000 rpm 32 4008 6.4.1

00.010 Normal running acceleration rate {02.012} 5.000 to 1000.000 s/1000 rpm 5.000 s/1000 rpm 32 4009 6.4.2

00.011 Defrost acceleration rate {02.015} 2.000 to 20.000 s/1000 rpm 2.000 s/1000 rpm 32 400A 6.4.4

00.012 Oil boost acceleration rate {02.016} 2.000 to 20.000 s/1000 rpm 5.000 s/1000 rpm 32 400B 6.3.5

00.013 Normal running deceleration rate {02.022} 5.000 to 1000.000 s/1000 rpm 5.000 s/1000 rpm 32 400C 6.4.2

Controlled shutdown deceleration

00.014

rate

00.015 Stop deceleration rate {02.024} 2.000 to 20.000 s/1000 rpm 2.000 s/1000 rpm 32 400E 6.4.3

00.016 Defrost deceleration rate {02.025} 2.000 to 20.000 s/1000 rpm 2.000 s/1000 rpm 32 400F 6.4.4

00.017 Oil boost deceleration rate {02.026} 2.000 to 20.000 s/1000 rpm 5.000 s/1000 rpm 32 4010 6.3.5

00.018 Total number of trips {18.001} 0 to 10000 0 16 4011 12

00.019 User speed reference in RPM {18.011} 0 to 7200 rpm 0 rpm 16 4012 6.4.2

00.020 System control word {18.012} 0 to 32767 0 16 4013 6.2.2

00.021 Trip/Lockout number {18.013} 0 to 255 0 16 4014 12

00.022 Condition alerts {18.014} 0 to 255 0 16 4015 12

00.023 Condition warnings {18.015} 0 to 255 0 16 4016 12

00.024 Configuration control parameter {18.016} 0 to 32767 0 16 4017 6.2.1

00.025 Condenser pressure {18.017} 0 to 650 psig 250 psig 16 4018 6.3.3

00.026 Evaporator pressure {18.018} 0 to 650 psig 80 psig 16 4019 6.3.3

00.027 Soft-start dwell time {18.019} 120 to 300 s 120 s 16 401A 6.4.1

00.028 Locked Rotor Failure start count {18.020} 0 to 10 0 16 401B 6.2.12

00.029 Locked rotor idle time {18.021} 30 to 300 s 35 s 16 401C 6.2.12

Number of reverse rotation detection

00.030

events

00.031 DLT (Discharge line temperature) {18.024} -40 to 330 degrees F 0 16 401E 6.3.2

00.032 DLT over temperature fault count {18.025} 0 to 4 0 16 401F 6.3.2

00.033 Time between reverse wiring checks {18.029} 30 to 300 s 30 s 16 4020 6.2.11

00.034 Trigger a save of the parameters {18.031} 0 to 1 0 1 4021 6.2.6

00.035 Short cycle count {19.011} 0 to 4 0 16 4022 6.3.1

00.036 Short cycle limit {19.012} 1 to 144 cycles 48 cycles 16 4023 6.3.1

00.037 Short cycle time {19.013} 60 to 600 s 60 s 16 4024 6.3.1

00.038 Running log of alerts entry number {19.014} 0 to 20 0 16 4025 12

Running log alert ID number and

00.039

days and hours

{02.023} 2.000 to 20.000 s/1000 rpm 5.000 s/1000 rpm 32 400D 6.4.3

{18.023} 0 to 2 0 16 401D 6.2.11

{19.015} 0 to 32767 0 16 4026 12

size

MODBUS

Address

(hex)

See

section

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00.040 Return to application defaults {19.016} 0 to 1 0 16 4027 6.2.6

00.041 Stator heating wattage {19.017} 10 W to 150 W 100 W 16 4028 6.3.4

Compressor missing a phase

00.042

counter

{19.018} 0 to 10 0 16 4029 6.2.10

00.043 Oil boost threshold speed {19.019} 1800 to 3600 rpm 3600 rpm 16 402A 6.3.5

00.044 Oil boost threshold time

{19.020}

1 to 120 minutes 120 minutes 16 402B 6.3.5

00.045 Oil boost solution time {19.021} 5 to 30 minutes 5 minutes 16 402C 6.3.5

00.046 Reverse rotation indicator threshold {19.022} 1 to 100 % 35 % 16 402D 6.2.11

Lost rotor ride-through dynamic

00.047

threshold Lost rotor ride-through constant

00.048

threshold

{19.023} 30 to 400 rpm 200 rpm 16 402E 6.2.13

{19.024} 30 to 400 rpm 100 rpm 16 402F 6.2.13

00.049 Controlled shutdown dwell time {19.027} 0 to 300 s 120 s 16 4030 6.4.3

00.050 Number of soft-start attempts {19.028} 0 to 3 0 16 4031 6.4.1

00.051 User defrost speed reference {19.029} 1500 to 7200 rpm 1500 rpm 16 4032 6.4.4

00.052 Defrost cycle end dwell time {19.030} 30 to 300 60 s 16 4033 6.4.4

00.053 Stator heating control mode {19.032} 0 to 1 0 1 4034 6.3.4

00.054 Fieldbus comms monitor {20.001} 0 to 300s 0 s 16 4035 6.4.6

00.055 Active CSD100 trip number {20.002} 0 to 255 0 16 4036 12

00.056 CSD100 software version {20.003} 0 to 255 Current software version 16 4037 6.2.6

00.057 Software system state {20.004} 0 to 20 0 16 4038 6.2.4

Speed reference after envelope

00.058

control

{20.005} 0 to 7200 rpm 0 16 4039 6.3.3

00.059 User security level {11.044} 0 to 5 1 (all menus visible) 8 403A 5.7

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6.2 Detailed compressor function descriptions

6.2.1 Configuration parameter

To allow simple configuration via communications, all functions are enabled / disabled with a single bitwise parameter: Pr 00.024 {Pr 18.016}. For example: If Pr 00.024 {Pr 18.016} contained a decimal value of 197, this is 0000000011000101 in binary meaning that bits 0, 2, 6 and 7 are set (at a value of 1)

Table 6-2 Key to the configuration parameter (first bit is on the right):

Pr 00.024

{Pr 18.016} Bit

0 (1st)

)

1 (2

)

2 (3

)

3 (4

)

4 (5

5 (6

)

6 (7

)

7 (8

)

8 (9

9 (10

)

10 (11

)

11 ( 1 2

)

12 (13

)

13 (14

Enable the CSD100 motor thermal model 1: Enable 0: Disable 0 (Disabled)

Reserved N/A N/A

Disable short cycle protection 1: Disable 0: Enable 0 (Enabled)

Disable CSD100 envelope control 1: Disable 0: Enable 0 (Enabled)

Temperature unit 0 = Fahrenheit, 1 = Celsius

Pressure unit 0 = Psig, 1 = Bar 0 (Psig)

Enable oil control 1: Disable 0: Enable 0 (Enabled)

Enable defrost cycle control 1: Enable 0: Disable 0 (Disabled)

Select control source for Start/run and stator heater

Disable DLT protection 1: Disable 0: Enable 0 (Enabled)

Disable locked rotor on start indicator 1: Disable 0: Enable 0 (Enabled)

Disable reversed rotation indicator 1: Disable 0: Enable 0 (Enabled)

Disable lost rotor ride-through 1: Disable 0: Enable 0 (Enabled)

OEM updates the DLT temperature 1: Disable 0: Enable 0 (Enabled)

Name Function Default

0 (°F)

1: Start and stator heater are by system control word parameter (Pr 18.012).

0 (Digital)

0: Start and stator heater enable are from digital input.*

Bits 14 to 15 Reserved N/A N/A

Note when digital inputs are used as the control source (Pr 00.024 bit 8=0), if the logic level returns to zero, the CSD100 will move to the controlled shut down state if currently in the normal running state. When the system control word is selected (Pr 00.024 bit 8=1), the start bit starts the CSD100 but the drive will not stop the motor if the bit is reset. To stop using a controlled shut down, a separate control word bit is used.

6.2.2 System control word parameter

To allow simple control via communications, all functions are controlled with a single bitwise parameter: Pr 00.020 {Pr 18.012}. For example: If Pr 00.020 {Pr 18.012} contained a decimal value of 9, this is 0000000000001001 in binary, meaning that bits 0 and 3 are set (at a value of 1). Key to the System Control Word Parameter (first bit is on the right):

Pr 00.020 {Pr 18.012} Bit Name Function Default

0 (1st)

1 (2

2 (3

3 (4

4 (5

5 (6

Start

)

Controlled shutdown

Stator heating control

Defrost cycle trigger

Reset trips if possible

Trip on communication loss

1: Start 0: No action

1: Shut down the compressor 0: No action

1: Turn on the stator heater 0: No action

1: Trigger the defrost cycle on transition 0: No action

1: Reset trips on transition 0: No action

1: Enable the communication watchdog 0: No action

Bits 6 to 15 Reserved N/A N/A

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6.2.3 Preset speeds

The preset speed parameters and acceleration/deceleration rates are defaulted to basic values but can be modified and saved by the user.

CSD100

deceleration

parameter

Function

CSD100 Preset speed

parameter

Default speed value

(rpm)

CSD100 acceleration

parameter

Soft-start Pr 00.001 {01.021} 3600.0 Pr 00.009 {02.011} N/A 1.000

Normal running

Pr 00.019 {18.011} User

speed reference

Pr 00.002 {01.022}

Final reference

controlled by the

1500 Pr 00.010 {02.012} Pr 00.013 {2.022} 5.000 / 5.000

0Pr 00.010 {02.012} Pr 00.013 {2.022} 5.000 / 5.000

software

Controlled

shutdown

Pr 00.003 {01.023}

3600 (or envelope

minimum)

N/A Pr 00.014 {02.023} 5.000

Stop Pr 00.004 {01.024} 0N/APr 00.015 {02.024} 2.000

Pr 00.051 {19.029} User defrost speed

1500 Pr 00.011 {02.015} Pr 00.016 {02.025} 2.000 / 2.000

reference

Defrost speed

Pr 00.005 {01.025} Final defrost speed

reference controlled by

1500 (or envelope

minimum) Pr 00.011 {02.015} Pr 00.016 {02.025} 2.000 / 2.000

the software

Pr 00.006 {01.026}

Oil boost solution

speed

Final oil boost speed

reference controlled by

1500.0 Pr 00.012 {02.016} Pr 00.017 {02.026} 5.000 / 5.000

the software

Default accel/decel

value (s/1000rpm)

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6.2.4 State machine

The CSD100 software operates as a state machine in which each state provides a specific set of functions. This approach permits the sequencing of functions to be presented in a simple manner.

Table 6-3 Key to the software system state

Function active

Numerical state

shown in

Pr 00.057 {20.004}

0IDLEXXXXX

2 SOFT-START XXXXX XXX X X 3 NORMAL RUNNING X X X X X X X 4 DEFROST CYCLE X X X X X X X 5 OIL BOOST X X X X X X X

20 TRIPPED

Name

IDLE WITH STATOR

HEATING

CONTROLLED SHUT

DOWN

Skip frequencies

Oil boost

Controlled shut down

Fieldbus monitoring

Missing phase

Motor over current

Miswire detection

Locked rotor detection

Short cycle detection

Discharge line temperature

Lost rotor

Envelope control & protection

Stator heating

Defrost control

Max load and low voltage fold back

XX XXX X

XX XX X XX

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State machine

React to VSD

firmware trips

Interface with VSD

speed loop

100ms cycle

IDLE WITH S TATOR

HEATING

IDLE

Is CSD100

run/enabled?

MISSING PHASE

TEST ON START

TRIP

NO TRIP

TRIPPED

REVERSED WIRE

DETECT

TRIP

NO TRIP

TRIPPED

LOCKED ROTOR

DETECTION

TRIP

NO TRIP

TRIPPED

SOFT START

NORMAL RUNNING

CONTROLLED SHUT

DOWN

DEFROST CYCLE

COMPLETE

TRIP

TRIPPED

Missing phase

Miswired motor

Locked rotor

Dischargelinetemperatur

ΞSomefunctionswillbebypassedifdisable

TRIPPED

Too many short cycles

TRIPPED

Outofenvelope

Running

TRIP

ENVELOPECONTROL

DLTPROTECTION

Start-up

Idle

TRIPPED

CSD100firmwareassertedtri

TRI

CSD100INTERFACE

Is heating

required?

YES

OIL BOOST

Is oil boost

required?

TRIPPED

Lostrotor

TRI

LOSTROTOR

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The software structural diagram below presents the top level groups of functions and how they are sequenced from the time of power up of the CSD100. Details of the individual groups of tasks and functions are given later in this section.

Figure 6-1 Software structure:

The state machine is a top level block within the software structural diagram and numerically represents the CSD100 specific functions. Figure 6-2 shows the process flow through the state machine and thus how the individual CSD100 specific software functions are sequenced.

Figure 6-2 CSD100 software state machine (main states shown in boxes and additional functions in ovals)

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User speed reference

Pr {18.011}00.019

Lost rotor prevention

Normal running final

reference Pr 00.002 {01.022}

Discharge line

temperature protection

Envelope override function

(Modified reference is visible

in Pr {20.005})00.058

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The states are arranged in three groups:

•Idle This group includes stator heating and occurs when the compressor is not active.

•Start-up This state includes the motor/compressor wiring and direction checks.

• Running This group contains the running, defrost, oil boost and the controlled shut down functions. The envelope and lost rotor protection is run in all of the

states contained in this group. The CSD100 interface function and the discharge line protection functions are running all of the time irrespective of the current state or group of

states.

6.2.5 Speed reference

The main reference signal flow diagram below defines how the speed reference is modified/limited/controlled within the CSD100 software - from receipt from the OEM controller to the speed demand passed to the standard drive speed loop and motor control.

Figure 6-3 Main reference signal flow

In the case of the CSD100, the envelope override function can limit the speed reference before it enters the state machine functions and that the final modification is under the control of the discharge line temperature protection function.

6.2.6 Housekeeping functions

Parameter Parameter name Description Units Range Default

00.034

{18.031}

00.056

{20.003}

00.057

{20.004}

00.040

{19.016}

The user can trigger a save of the parameters and have the ability of returning the CSD100 specific parameters to their default values. The CSD100 software version and the system state can be viewed. To return the CSD100 specific parameters to their default values, set Return to application defaults Pr 00.040 {19.016} to zero and save the

parameters using Trigger a save of the parameters Pr 00.034 {18.031}. Power cycle the CSD100, the defaults are loaded during the initialization.

Trigger a save of the parameters

CSD100 software version

Software system state

Return to application defaults

Only operates during idle with no heating active. Resets to off (0) when complete.

none 0 to 1 0

Displays the CSD100 software version where V01.12 = 112 none 0 to 9999 0

Current software state none 0 to 20 0 [Idle]

If saved to zero, the CSD100 will load the application defaults on the next power-up. The application will set to 1 whenever application defaults have been

none 0 to 1 0

loaded.

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6.2.7 Compressor motor protection

The motor protection heading brings together all of the CSD100 software motor protection functions.

6.2.8 Motor over current

Motor over current protection is provided by the CSD100 protection and motor overload protection model. The over current trip is provided to prevent motor demagnetization. This trip cannot be reset during the first 10 s after the trip occurred.

• A power cycle or reset command, via MODBUS keypad or digital input is required to clear the lockout.

The motor over current protection is similar to CoreSense 1379 Alert/Lockout Code 9 - Over-Current Protection

6.2.9 Missing phase connection

Function runs in the following state(s): Description

Soft-start Missing phase on start

Parameter Parameter Name Function area Description Units Range Default

00.042 {19.018}

Compressor missing a phase counter

Compressor missing a phase

Increments with every missing phase

event detected up to 10 in 24 hrs

None 0 to 10 0

This feature is set up by the CSD100 software and implemented in the standard drive firmware.

• The standard drive firmware will trip Out Phase Loss.1. The CSD100 software will trip "Compressor Missing Phase" and move to the TRIPPED state.

• After 5 minutes the trip is automatically reset.

• The system will lockout after 10 trips within 24 hours [the count of trips is reset on lock-out].

• A power cycle or reset command, via MODBUS keypad or digital input is required to clear the lockout.

The missing phase detection is similar to CoreSense 1384 Alert/Lockout Code 6 - Missing Phase

Figure 6-4 Missing phase detection function block

Sub-trip Reason

1 U phase detected as disconnected when drive enabled to run 2 V phase detected as disconnected when drive enabled to run 3 W phase detected as disconnected when drive enabled to run

CSD100 User Guide 71 Issue Number: 3

Page 72

Safety

Normal torque required

Speed profile

Initial ramp

Dwell

Trip

Time

Reverse drag brake torque

Reverse wiring condition

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6.2.10 Miswire/Reverse phase run prevention

Function runs in the following state(s): Description

Soft-start Miswire detection

Parameter Parameter Name Function area Description Units Range Default

UL listing

information

This shows the number of reverse rotation events that have been detected. A trip is generated as the 2nd event is detected

Threshold at which reverse rotation is detected.

none 0 to 2 0

% of

Pr 4.020

1 to 100 % 35 %

00.030 {18.023}

00.033 {18.029}

00.046 {19.022}

Number of reverse rotation detection events

Time between reverse wiring checks

Reverse rotation indicator threshold

Reversed rotation indicator

Reversed rotation indicator Defines the time between start attempts. s 30 to 300 s 30 s

Reversed rotation indicator

• Detection is only required on first compressor start after module power-up. If the input to the compressor is miswired (phase rotation) then the compressor may run in reverse. When the compressor runs in reverse operation,

a Fluid Brake is applied.

Miswire/Reverse phase detection

Reverse rotation is detected using a torque profile method as shown in Figure 6-5 below:

Figure 6-5 Miswire/Reverse phase detection

A normal and flooded start condition start, requires a high current during the initial ramp and then a reduced current during the dwell time. The reversed condition requires a torque demand that is approximately proportional to the speed.

The torque profile detection system filters the current load demand (Pr 04.020) to reduce the effect of measurement noise but with a time constant shorter than the shortest normal start high torque period. The maximum current load demand is stored during the initial ramp soft-start. If this is below a default 35 % [user configurable] threshold, a reversed motor condition is detected.

The reverse wiring (reversed mechanical direction) test is only performed on the first run after power-up to reduce the possibility of refrigerant or oil swirl effects.

The detection is started from when the estimated speed becomes positive to prevent initial magnetic synchronisation affecting the detection.

72 CSD100 User Guide

Issue Number: 3

Page 73

Safety

Begin speed demand

ramp as part of soft-

start

Start detection when estimate

speed is positive. Reset if

estimate speed goes negative.

Produce a filtered calculation of

the “torque per speed” ratio, and

store the maximum value

After 5 seconds or until the start

of the soft-start dwell time

Check if

the maximum

“torque per speed” ratio is

above the reversing

threshold

YES =

>continuethesoft-start.

setthealarmifset.Resetthecount.

Check if count

is above 1

Remove the motor supply

YES => Lockou

ttrip

Reset the ala

rm.

Reset the co

unt

Wait 30 seconds

NO =>Set the alarm

Reset the count to zero.

NO => Increment the count

NOTE

Reversed rotation

detection

Speed demand

Alarm

Lockout

Torque required

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Figure 6-6 FLOW reverse wiring

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The miswire detection function is similar to CoreSense 1384 Alert/Lockout Code 7 - Reverse Phase

Table 6-4 Miswire detection function block

CSD100 User Guide 73 Issue Number: 3

Page 74

Safety

Normal torque required

Speed profile

Flood start torque

Speed error

Subsequent liquid plugs due to system pipework

Initial ramp

Dwell

Trip

Time

Locked rotor torque

Locked rotor condition

NOTE

Begin speed demand

ramp as part of soft-

start

After 12 seconds or until the start

of the soft-start dwell time

Check if the

speed is less than 20 %

of the target

NO => continue the soft-start.

Reset the alarm if set.

Reset the count.

Check if count

is above 9

Remove the motor supply

YES => Lockout trip.

Reset the alarm. Reset the count.

Wait for a default time

of 35 seconds

YES =>Set the alarm

Reset the count to zero.

NO => Increment the count

NOTE

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6.2.11 Locked rotor condition

Function runs in the following state(s): Description

Soft-start Locked rotor detection

Table 6-5 Parameters associated with the locked rotor detection function:

Parameter Parameter Name Function area Description Units Range Default

UL listing

information

00.028 {18.020}

Locked Rotor Failure start count

Locked Rotor Indicator

00.029 {18.021} Locked rotor idle time Locked Rotor Indicator

Records number of failed starts due to Locked Rotor protection

After a failed start, the drive has to wait for a period of idle time before attempting to start the motor again

none 0 to 10 0

30 to

300

• The locked rotor condition is detected if the speed is less than 20% of the target speed at the end of the initial soft-start ramp. During the detection phase the "locked rotor" condition warning flag is set.

After a failed start, the drive will wait for a default idle time of 35 s before restarting the compressor. After 10 consecutive Locked Rotor Starts have occurred, the drive will disable itself and produce a "locked rotor" condition trip and the software state is set to TRIPPED.

A power cycle is required before the next batch of restarts is attempted (This is to satisfy the UL requirement for a manual reset device).

The locked rotor detection function is similar to CoreSense 1379 Alert/Lockout Code 4 - Locked Rotor Trips

74 CSD100 User Guide

Issue Number: 3

Page 75

Safety

Lock rotor detection

Speed demand

Alarm

Lockout

Torque required

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Figure 6-7 Locked rotor detection function block diagram

Standard drive trips ‘Phasing Error and Overspeed.1’ will be latched, requiring the user to power-cycle the drive. These trips can be caused by the drive being unable to synchronize to the motor due to the locked rotor condition. UL requires a power-cycle reset to permit the UL test to be the ‘50 test’ method rather than the ‘15 day test’ method.

6.2.12 Lost Rotor Trip Prevention, Detection, Retry and Ride-Through Control

Function runs in the following state(s): Description

Normal running Lost rotor condition management

Parameter Parameter Name Function area Description Units Range Default

00.047 {19.023} Lost rotor ride-through dynamic threshold Lost rotor ride-through Speed error rpm 30 to 400 rpm 100 rpm

00.048 {19.024} Lost rotor ride-through constant threshold Lost rotor ride-through Speed error rpm 30 to 400 rpm 50 rpm

• The aim is to avoid nuisance trips by either riding through, or by dealing with the issue and then automatically restarting.

• Operates in the RUNNING state not during soft-start or controlled stop.

The lost rotor detection system detects conditions where the speed error is greater than expected which could be due to a locked or stalling rotor while running. The detection method must not trip during normal operation when speed error would be expected. During dynamic drive output frequency demand change the expected speed error is higher than during constant drive output frequency demand so two sets of limits are used.

The limits during dynamic drive output frequency demand change must permit the completion of flood starting (after the soft-start is complete) where there is liquid in the scroll rather than vapor. The limits during constant drive output frequency demand, must allow for small slugs of liquid produced by isolated cooling in the system pipe work, to pass through the compressor.

• Constant drive output frequency demand is defined as less than a 2 % rated frequency change in the last 10 s.

Limits during dynamic drive output frequency demand change:

The "lost rotor" condition is detected if the modulus of the speed error (Pr 03.003) is greater than 100 rpm [user configurable] for longer than 4 s. The aim is to keep the compressor running.

Limits during constant drive output frequency demand: The "lost rotor" condition is detected if the modulus of the speed error (Pr 03.003) is greater than 50 rpm [user configurable] for longer than 4 s.

Action if lost rotor detected

If a lost rotor condition is detected the speed demand is lowered by 200 rpm (at the normal running deceleration rate where it remains for a 10 s dwell while the lost rotor condition is again checked. The "lost rotor" alert is set.

This is repeated until the speed demand is at the minimum envelope speed or 1000 rpm if the envelope protection is not enabled. The supply is removed and the drive waits for 60 s before the "lost rotor" alert is reset and the soft-start begins again.

If the lost rotor condition is not detector during one of the 10 s dwell periods, the speed demand is increased by 200 rpm or to the OEM speed demand level (which every is lowest) at 200 rpm per s. The "lost rotor" alert is reset.

CSD100 User Guide 75 Issue Number: 3

Page 76

Safety

Check every 100ms

In the running state

Check if the

output frequency has

Changed by more than 2% in

the last 10

seconds

Check if

speed error is

greater than

20%

Reduce the speed by 200rpm

Remove motor supply

NO => use “constant

demand” thresholds

Reset both timers to zero

and reset the alarm

YES => use

“dynamic demand”

thresholds

NO => Reset detector

timer

Check if

speed error is

greater than

30%

NO => Reset

detector timer

Is detector

timer greater

than 4

seconds

YES

YES => Set the alarm

Is speed

less than the

minimum

Wait 60 seconds

YES

Is dwell

timer greater

than 10

seconds

Increase the speed by 200rpm

YES

Is speed Equal to

OEM demand

YES => reset

the alarm.

Reset all timers

Lost rotor ride

through

Speed demand

Alarm

Speed reductionSpeed error

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Figure 6-8 Lost rotor alert

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Figure 6-9 Lost rotor function block

6.2.13 Max-load and Low-Voltage fold back management

The aim of this is to avoid nuisance trips and keep the motor running.

• No values for user configuration.

• Uses the drives standard motor current/load and dc bus voltage foldback/limit method. Fold back the current/torque and speed under the following circumstances:

• Reaching the motor current limit

• If the drive thermal protection is active

• Reaching the motor voltage limit

• Operating with a low voltage supply

76 CSD100 User Guide

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6.3 Compressor protection

The system protection heading brings together all of the compressor system protection functions.

6.3.1 Anti short cycling (Short cycle prevention)

Function runs in the following state(s): Description

Soft-start Short cycle detection

Parameter Parameter Name Function area Description Units Range Default

00.035 {19.011} Short cycle count Anti-short cycle Number of short cycles that have occurred none 0 to Pr 19.012 0

00.036 {19.012} Short cycle limit Anti-short cycle Maximum allowed short cycles in a day none 1 to 144 48

00.037 {19.013} Short cycle time Anti-short cycle Short cycle duration s 60-600 60 s

Excessive short duration cycles can cause damage to the compressor. The short-cycle prevention scheme detects if there have been too many shortcycles. It will then alert the user and impose a restart lockout time to prevent further short-cycles.

Short cycling can occur if control limits are set too tight. This can cause damage to the compressor as correct oil lubrication may not be achieved. This can also occur as a result of problems with the system control: for example, fluctuating loads and sensor faults.

• A short cycle is defined by a start to stop time of less than the setting of Pr 00.037 {19.013}.

• The start time begins when the system starts the soft-start.

The short-cycle prevention scheme uses an accumulator to detect if there have been too many short-cycles and an alert and restart lockout time to manage and thus prevent further short-cycles.

Detection of the short-cycle event

A timer is started at the beginning of the soft-start and is checked when the compressor next shuts down.

• If the time between the beginning of the start-up and completion of the shut-down is less than the short cycle duration Pr 00.037 {19.013} an event has been detected.

Accumulator

• The accumulator is incremented whenever a short-cycle event has been detected.

• The accumulator is decremented every "minimum time between short-cycles" which is the 24 hours divided by the user parameter "maximum allowed short cycles in a day".

• The accumulator is never permitted to go negative.

Minimum time between short-cycles" = 24hours / "maximum allowed short cycles in a day".

If the time between short-cycles is greater than or equal to the "minimum time between short-cycles", the accumulator value will reduce to zero. If however, the time between short-cycles is less than the "minimum time between short-cycles", the accumulator will increase.

CSD100 User Guide 77 Issue Number: 3

Page 78

Safety

Soft start requested

Is time

difference less

than “short cycle

duration?

Increment

the accumulator

Start the

short-cycle timer

Motor supply removed

Stop the

short cycle timer

Soft start dwell completes

accumulator

>= 4?

YES

Check every 1

second

Has min

time between

short-cycles

elapsed?

YES => decrement the

accumulator and reset the

“time between” timer

Is alert active?

accumulator

>= 4?

Set the alert

accumulator

<= 2?

YES

Reset the alert

YES

Short cycle

prevention

Run command Alarm

Restart lock-out time

Speed demand

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Management of the short cycle event

• If the accumulator is equal to or greater than 4 the prevention management is activated.

• The value of 4 has been chosen to permit a number of short-cycles to take place in the short term while providing protection long term.

• While the prevention management is active, the next start is delayed until the accumulator value has reduced from 4. The accumulator is reduced every "minimum time between short-cycles", and thus the starts are restricted to the "minimum time between short-cycles".

• The short-cycle prevention alert is set when the accumulator value is equal to 4 and reset when the accumulator value is equal to 2.

Figure 6-10 Short cycle prevention block

6.3.2 Discharge Line Temperature (DLT)

Parameter Parameter Name Function area Description Units Range Default

00.031 {18.024}

00.032 {18.025}

If configuration parameter bit 13 (14th) is set to zero, the DLT signal is measured directly by the drive with a range check to detect if the signal is short circuit.

If configuration parameter bit 13 (14th) is set to one, the DLT temperature (in

This function is designed to prevent the compressor from running in an over-temperature situation. This situation can occur anywhere, but the key area is at the top left of the operating envelope. An over-temperature event can also be indicative of system transients / faults: locked rotor, blocked suction, blocked discharge, condensing fan failure, system loss of refrigerant charge, improper field charging of the system.

Function runs in the following state(s): Description

Idle and all running states Over temperature protection

DLT (Discharge line temperature)

DLT over temperature fault count

Discharge line temperature Temperature protection/control

Discharge line temperature Number of over temperature faults none 0 to 4 0

° F) is written to the drive by the OEM controller.

° F

° to 330° F

- 40

78 CSD100 User Guide

Issue Number: 3

Page 79

Safety

Check every 1s

In the running state

Is the DLT temp

greater than

275degF

Is the count greater than

YES => Set the alarm

Reset the count and the alarm

NO => Reset the

count and the alarm

YES => set Trip

Increment the count

Wait 60 seconds

DLT protection

Run command

Alarm

Trip

DLT measurement

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Over temperature protection

• The temperature is checked every 1 second.

• If the temperature is above the fault level, an alert is set.

• If the DLT temperature is below the trip level, the alert is reset.

• If the temperature is above the trip level for more than 3 samples each taken at 60 second intervals, the drive is disabled, the "DLT" trip set

(Pr 00.021 = 42) and the software state set to TRIPPED.

• The trips will automatically be cleared if the DLT temperature is below the trip level for 10 minutes. The trip log will still log that the trip has

occurred.

• The DLT over temperature feature can be disabled using the disable function flag for field charging, system setup and commissioning.

Figure 6-11 Over temperature protection

Figure 6-12 DLT protection function block

6.3.3 Envelope control

Parameter Parameter Name Function area Description Units Range Default

00.025 {18.017} Condenser pressure Envelope control Condenser pressure Pressure

00.026 {18.018} Evaporator pressure Envelope control Evaporator pressure Pressure

00.058 {20.005}

• If the envelope is not enabled, the frequency minimum is 1000 rpm. This functionality will prevent the compressor from being used outside of its design limits (Envelope). The benefit to the customer of this functionality

is a control simplification for the OEM (design time).

Function runs in the following state(s): Description

Running states Envelope control

Speed reference after envelope control

Envelope control Speed reference after envelope control rpm

0 to 650

psig

0 to 650

psig

0 to 7200

rpm

250 psig

80 psig

0 rpm

CSD100 User Guide 79 Issue Number: 3

Page 80

Safety

ZPV063

Envelope protection

Tevap/Pevap Warning

Max/Min output speed

Tcond/Pcond

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Figure 6-13 Preliminary operating envelope

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• Pressure out to the Condenser Pc (Pr 18.017)

• Pressure in from the Evaporator Pe (Pr 18.018)

The shape of the envelope and regions are shown in Figure 6-13 Preliminary operating envelope above.

The control system has two stages:-

• Out of outer envelope detection

• Speed limits within an envelope sub-region

Out of outer envelope detection

The outer envelope is defined based on a set of points which are used within a straight line formula to detect whether a pressure point is in or out of the outer envelope. The quantisation is to 1psig. When rounding is required, this is performed "into" the envelope (so round down if the value is just above, and round up if the value is just below) to avoid rogue trips.

• The CSD100 will trip "out of envelope" if the pressure point is out of the outer envelope for more than 10 minutes. If the pressures are within the envelope for 10 minutes, the trip is cleared automatically.

• If Condensing / Evaporation pressures are out of envelope for 15 s, an alert is set.

Speed limits within an envelope sub-region

The sub-region is determined if the pressure points are within the outer envelope Given the two pressure inputs, this function will provide a maximum range for the speed which is applied to the reference. The software will set the "Envelope Override Active" alert flag when the speed reference is being limited by this function. The CSD100 will act as an override on the speed reference signal, preventing over/under speed at the operating envelope point. The envelope

override limits both the minimum and maximum speed. Envelope override is only active during the running group of states and affects the input speed reference before the other functions modify the reference.

Figure 6-14 Envelope protection function block

80 CSD100 User Guide

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6.3.4 Stator heating

Function runs in the following state(s): Description

IDLE WITH STATOR HEATING

TI M ED STATOR HEAT I NG

Parameter Parameter Name Function area Description Units Range Default

Controlled stator heating if there is a sump/outdoor sensor

Timed stator heating if no sump/outdoor sensor

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00.053 {19.032} Stator heating control mode Stator heating

0 => Off [default] 1 => OEM (digital or comms) control

00.041 {19.017} Stator heating wattage Stator heating Controls the heating current [Default to 100 W] Watts

none 0 to 1 0 [off]

10 to

150 W

100 W

A user parameter is provided to alter the stator heating power with a default setting of 100 Watts.

OEM (digital or comms) control mode:

• The field-bus/comms control is through the System control word Pr 00.020 {18.012}.

• The digital control is through digital input 4 (CSD100 control terminal 27).

• The stator heater is activated if the software is in the idle state and the command bit or the digital signal is active by the OEM controller.

• The stator heater is deactivated if the command bit or the digital signal is not active.

6.3.5 Oil boost

Function runs in the following state(s): Description

Oil boost

Parameter Parameter Name

00.006 {01.026} Oil boost speed

Function

area

Boost speed used if oil boost required 0.1 rpm

00.012 {02.016} Oil boost acceleration rate Oil boost acceleration rate

00.017 {02.026} Oil boost deceleration rate Oil boost deceleration rate

Oil boost

00.043 {19.019} Oil boost threshold speed Oil boost threshold speed rpm 0 to 7200 1000 rpm

Description Units Range Default

0.000 s per 1000 rpm

1500.0 to

7200.0

0.500 to

20.000

0.500 to

20.000

1500.0 rpm

5.000 s

00.044 {19.020} Oil boost threshold time Period of time for oil boost mode to be entered minutes 1 to 120 120

00.045 {19.021} Oil boost solution time

Period of time that the motor will be run at the oil boost speed if oil boost mode is entered

minutes 5 to 30 s 5

If the compressor is running at a speed that is insufficient to guarantee lubrication (for a defined time), oil boost mode is entered. During oil boost, the motor speed is increased for a period of time to ensure the compressor is correctly lubricated.

The function is active in all run conditions except for soft-start. The function's logic is as follows:

• If the motor speed is higher than the user configured threshold for 5 minutes, reset the timing.

• Otherwise start timing.

• If the compressor is turned off, stop the counter and store the value ready for when the compressor turns on again.

• If the threshold time (user configurable) has elapsed, ramp to the oil boost speed (user defined in Pr 00.006 {01.026} but can only be higher than the default) at 200 rpm per second default. Set the oil boost warning.

• Hold for the solution time (user defined in Pr 00.045 {19.021} but cannot be less than the default 60 s).

• Once the time has elapsed, return to the previous state ramping if necessary at 200 rpm per s. Reset the oil boost warning.

The purpose of the oil boost is to ensure adequate lubrication of the compressor components, and to return oil from the system to the compressor.

CSD100 User Guide 81 Issue Number: 3

Page 82

Safety

Check every 1

second

Output speed

greater than

threshold?

YES => reset

timer

Is compressor

active?

NO => reset

timer

YES

Has time elapsed?

YES

Ramp to solution

speed

Hold for solution time

Reset the timer

Control

the output

speed

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Figure 6-15 Reset oil boost warning

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6.4 System control

This section heading brings together all of the control functions provided by the CSD100 software.

6.4.1 Start and Shut down procedures

Soft-start

• The soft-start and controlled stop modes override the OEM speed reference.

Function runs in the following state(s): Description

SOFT-START Start-up

Parameter Parameter Name

00.001 {01.021} User soft-start dwell speed

00.009 {02.011} Soft-start acceleration rate Soft-start acceleration rate 0.000 s per 1000 rpm 0.500 to 2.500 1.000 s

00.027 {18.019} Soft-start dwell time Soft-start dwell time s 120 to 300 120 s

00.050 {19.028} Number of soft-start attempts

The drive controls the starting routine of the variable speed scroll compressor. The routine allows soft-starting, an advantage over traditional on-off control of non variable speed compressors.

• On a call for operation from the system controller, the drive will start the compressor and ramp its speed up to the soft start dwell speed (default 3600 rpm). The default acceleration rate is 1000 rpm per second. This acceleration rate can be set using the soft start acceleration parameterPr 00.009 {02.022} but it should be noted that the initial acceleration rate up to a speed of 300 rpm is fixed at 1000 rpm per second.

• The final motor speed may be affected by the loading conditions and fold back. The speed estimation is checked 1 second after the soft-start demand should have reached 3600 rpm. If the torque loading (Pr 04.020) is greater than 90 %, the soft-start demand is reduced to zero at

Function

area

Soft-start

1000rpm per second and an alert is set. When the demand has reached 0 rpm the system waits for 1 s (for the rotor speed to meet the demand) before the motor supply is removed. The system waits 10 s before re-starting the soft-start.

• If there are three consecutive soft-start failures, the drive will trip and lockout the compressor. A power cycle, MODBUS reset command, reset

• The drive will maintain the 3600 rpm command for a user defined time (range 2.0 to 5.0 minutes with a default of 2.0 minutes [120 seconds]) and

82 CSD100 User Guide

signal to T25 or keypad reset is required to clear the lockout.

then ramp the speed up or down to the speed requested by the system controller at a rate of 200 rpm per second. This applies to all start up conditions.

Description Units Range Default

User soft-start dwell speed 0.1 rpm 1500.0 to 7200.0 3600.0 rpm

Number of soft-start attempts

none 0 to 3 0

Issue Number: 3

Page 83

Safety

Tim

Speed

profile

Initial ramp

Dwell

NormalTorque

required

Soft start

Run command

Alarm

Lockout

Speed demand

Speed error

Entering the running

states

Reset the count and the alert

YES => set Alert and

increment the count

NO => remove alert

Ramp to 3600rpm at 1000rpm per second

Wait for 1 second for

speed to stabilise

Is torque demand

> 90%

Hold 3600rpm for the

user defined time

Change at 200rpm

per second to

demand speed

Normal runnin

Ramp to 0rpm at

1000rpm per second

Have there

been three

consecutive

frails?

Wait for 1 second for

speed to stabilise

YES

LOCK OUT

Wait for 10 seconds

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Figure 6-16 Soft start sequence

Figure 6-17 Soft start function block

Figure 6-18 Soft start function flow chart

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6.4.2 Normal running

During normal running, the change in the OEM speed reference is internally limited to +/-200 rpm.

Reference after limits and protection

Set by the software 0.1 rpm 0 to 7200.0 0 rpm

Normal running Normal running acceleration rate 0.000 s per 1000 rpm 5.000 to 1000.000 5.000 s

Normal running Normal running deceleration rate 0.000 s per 1000 rpm 5.000 to 1000.000 5.000 s

Reference From OEM controller rpm 0 to 7200 1500 rpm

Parameter Parameter Name Function area Description Units Range Default

00.002

{01.022}

00.010

{02.012}

00.013

{02.022}

00.019

{18.011}

CSD100 User Guide 83 Issue Number: 3

Normal running reference

Normal running acceleration rate

Normal running deceleration rate

User speed reference in RPM

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6.4.3 Controlled shut down

Function runs in the following state(s): Description

CONTROLLED SHUTDOWN Shut down

Parameter Parameter Name Function area Description Units Range Default

00.003 {01.023}

Controlled shut down final reference

Controlled shut down

Controlled shut down final reference

0.1 rpm 0 to 7200.0

00.004 {01.024} Stop reference Controlled shut down Held at zero 0.1 rpm 0 0

00.014 {02.023}

00.015 {02.024}

Controlled shutdown deceleration rate

Stop deceleration rate

Controlled shut down Controlled stop deceleration rate

Controlled shut down Stop reference deceleration rate

0.000 s per 1000 rpm

0.500 to

20.000

0.500 to

20.000

Controlled

00.049 {19.027}

shutdown dwell

Controlled shut down Controlled shutdown dwell time s 0 to 300 120 s

time

This function requires the compressor to complete a shutdown and stop before starting up again. When the system controller signals for the compressor to stop, by sending controlled shut down command, the controlled shut down is triggered.

If the envelope protection is active:

• If 70 % of the final speed reference, Pr 03.001 (which is the OEM reference subjected to the acceleration and deceleration limits) is still higher than the minimum operating speed envelope condition, reduce the speed by 30 % to 70 % of the final speed reference.

• Else, stay at the current speed.

• Hold for 3 minutes and then check the reference.

• If the command is no longer there, go back to normal running state.

• Else, ramp to minimum envelope speed at 200 rpm per second.

• Shutdown (remove the supply) for 10 s then go to the idle state.

If the envelope control is not active:

• If the estimated speed is above 3600 rpm, ramp down to 3600 rpm at 200 rpm per second.

• Else if the estimated speed is below 3600 rpm, remain at the current speed.

• Hold for 3 minutes and then check the reference.

• If the command is no longer there, go back to normal running state.

• Else, shutdown (remove the supply) for 10 s then go to the idle state.

If a minor fault condition occurs during operation the drive will perform a controlled shutdown triggered by the OEM controller.

3600 or envelope

minimum

5.000 s

2.000 s

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Entering the

controlled shut-down

Is envelope

enabled?

Is 70%

OEM demand

speed within

envelope?

Ramp to 70%

demand

YES

Hold for 3 minutes

Is command

still received?

Normal

running state

Ramp to minimum

envelope speed

Remove motor

supply

Wait 10 seconds

Idle state

YES

output speed

above

3600rpm?

Ramp to 3600rpm

YES

Hold for 3 minutes

Is command

still received?

Normalrunningstat

Controlled shut-

down

Command

Speed demand

Minimum envelope speed

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Figure 6-19 Entering controlled shut-down

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Figure 6-20 Controlled shut-down function block

6.4.4 Defrost control/procedure

Parameter Parameter Name Function area Description Units Range Default

00.005 {01.025}

00.011 {02.015}

00.016 {02.025}

00.051 {19.029}

00.052 {19.030}

Function runs in the following state(s): Description

DEFROSTCYCLE Defrosting

Final defrost speed reference

Defrost acceleration rate

Defrost deceleration rate

User defrost speed reference

Defrost cycle end dwell time

Defrost cycle Speed during defrost dwell 0.1 rpm 1500.0 to 7200.0

Defrost cycle Defrost acceleration rate

Defrost cycle Defrost deceleration rate

Defrost cycle

User defrost speed reference

Defrost cycle end dwell time

0.000 s per 1000 rpm

rpm 1500 to 7200 1500 rpm

s 30 to 300 60 s

0.500 to 20.000 2.000 s

1500.0 or envelope minimum

Once triggered, through the System control word Pr 00.020 {18.012}, the defrost cycle will operate until complete. During operation the defrost active flag is set high in the condition warnings parameter Pr 00.023 {18.015} bit 4.

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Defrost command

received

Is envelope

enabled?

YES

Ramp down to

minimum envelope

speed

Ramp down to

User defrost speed

Is user

defrost speed

lower than minimum

envelope speed?

YES

Note: The user defrost

speed is limited to a

minimum of 1500rpm

Hold for the

Hold time

Set the Defrost warning

Reset the Defrost warning

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• If the envelope protection is active, the minimum speed is used. If envelope protection is not active 1500 rpm (default - user defined by Pr 00.051 {19.029}) is used as the minimum speed.

• The drive will slow the compressor to 1500 rpm (user defined by Pr 00.051 {19.029}) (or the minimum speed from the envelope condition) at a default rate of 2 s per 1000 rpm - user defined by Pr 00.016 {02.025}.

• The compressor will remain at this speed for 60 s (default- user defined in Pr 00.052 {19.030}) to let the suction and discharge pressures stabilize.

• After the hold time, the system will return to the normal running state, changing the speed at a default rate of 2 s per 1000 rpm (user defined by Pr 00.011 {02.015}).

Figure 6-21 Defrost command

6.4.5 Resonance avoidance

Function runs in the following state(s): Description

Running states

Parameter Parameter Name Function area Description Units Range Default

00.007 {01.029} Skip Reference 1 Resonance avoidance Skip Reference rpm 0 to 7200 0 rpm [no filter]

00.008 {01.030} Skip Reference Band 1 Resonance avoidance

Defines the range either side of Pr 01.029

01.031 Skip Reference 2 Resonance avoidance Skip Refeence rpm 0 to 7200 0 rpm [no filter]

01.032 Skip Reference Band 2 Resonance avoidance

01.033 Skip Reference 3 Resonance avoidance Skip Refeence rpm 0 to 720 0 rpm [no filter]

This function is provided to avoid running at motor speeds which cause mechanical resonance effects. In the default state no filter is applied, however it can be configured if required.

Skip Reference Band 1 (01.030) defines the range either side of Skip Reference 1 over which references are rejected in either direction. The actual rejection band is therefore twice that defined by Skip Reference Band 1 (01.030) with Skip Reference 1 (01.029) as the centre of the band. When the selected reference is within the rejection band the lower limit of the band is passed through the filter so that reference is always less than demanded.

01.034 Skip Reference Band 3 Resonance avoidance

Defines the range either side of Pr 01.031

Defines the range either side of Pr 01.033

Use the standard skip frequencies function

available in the CSD100 firmware

rpm 0 to 250 0 rpm

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6.4.6 Fieldbus (MODBUS) over RS485

The OEM controller can read all of the available standard drive parameters. Certain trips and lock out conditions are resettable through the Fieldbus link using the System control word Pr 00.020 {18.012}.

Parameter Parameter Name Function area Description Units Range Default

00.054 {20.001} Fieldbus comms monitor Fieldbus comms monitor

If zero [default] the comms monitoring is disabled.

none 0 to 300 0

If this parameter is set to 0 (default) Fieldbus comms monitoring is disabled. If a value greater than 1 is written by the OEM to this parameter, the software will begin to increment the parameter every 1 second. If the parameter

reaches a value larger than 300 (5 minutes), the system will move to the trip state (Pr 00.021 = 45) and stop the compressor using a controlled stop. This parameter is therefore designed to be periodically reset to a non zero value (in a watchdog type fashion) by the OEM controller. If a Fieldbus

communication problem occurs, this reset will not occur and the system will trip within 300 s. It should be noted that the OEM can select the timeout: for example writing 1 to the parameter provides the full five minutes, writing 240 would give 1 minute.

This function is similar to CoreSense 1384 Warning Code 1 - Loss of Communication].

6.5 Parameter descriptions

6.5.1 Pr mm.000

Pr mm.000 is available in all menus, commonly used functions are provided as text strings in Pr mm.000 shown in Table 6-6.

Table 6-6 Commonly used functions in xx.000

Value Equivalent value String Action

[No Action]

1000 1 [Save parameters] Save parameters when under voltage is not active and low voltage threshold is not active

6001 2

4001 3

6002 4

4002 5

6003 6

4003 7

12000 8

12001 9

[Load file 1] Load the drive parameters or user program file from NV media card file 001

[Save to file 1] Transfer the drive parameters to parameter file 001

[Load file 2] Load the drive parameters or user program file from NV media card file 002

[Save to file 2] Transfer the drive parameters to parameter file 002

[Load file 3] Load the drive parameters or user program file from NV media card file 003

[Save to file 3] Transfer the drive parameters to parameter file 003

[Show non-default] Displays parameters that are different from defaults

[Destinations] Displays parameters that are set

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7 Running the motor

This chapter takes the new user through all the essential steps to running a motor for the first time.

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Motor parameters are pre-configured to suit an individual compressor, hence no setting of these parameters or motor autotuning is required.

Ensure that no damage or safety hazard could arise from the motor starting unexpectedly.

If the intended maximum speed affects the safety of the machinery, additional independent over-speed protection must be used.

7.1 Quick start connections

7.1.1 Basic requirements

This section shows the basic connections which must be made for the drive to run. When the basic connections shown in Figure 7-2 Minimum connections to get the motor running (size 5) on page 90 have been made, the CSD100 is started as described below:

• Turn on the power supply.

•Set Pr 00.024 {18.016} Configuration Control Parameter appropriately (see section 6.2.1 Configuration parameter on page 67).

• Provide a user speed reference in Pr 00.019 {18.011}.

• Apply an enable signal to control terminal T31

• Apply a start signal to T26 (if configured Pr 00.024 {18.016} bit 8 = 0), or apply the control word start/run bit (if configured 00.024 {18.016} bit 8 =

0).

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Permanent

magnet motor

Start / Controlled stop

Stator heater on

24V

Communications

port

L1 L2 L3

Fuses

SAFE TORQUE OFF

(drive enable)

L1 L2 L3UVW

UVW

RFC-S

Sensorless

OEM

Controller

Discharge line temperature

Reset

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Figure 7-1 Minimum connections to get the motor running in any operating mode (size 4)

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* Not required if using Control word mode.

CSD100 User Guide 89 Issue Number: 3

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Permanent

magnet motor

Discharge line temperature

Start/controlled stop

Reset

Stator heater on

24V

Communications

port

RS485

OEM

Controller

L1 L2 L3

Fuses

SAFE TORQUE OFF

(drive enable)

L1 L2 L3

UVW

RFC-S

Sensorless

* *

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Figure 7-2 Minimum connections to get the motor running (size 5)

Running the

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* Not required if using Control word mode.

90 CSD100 User Guide

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Start/controlled stop

Reset

Stator heater on

24V

Discharge line temperature

L1 L2 L3

Fuses

SAFE TORQUE OFF

(drive enable)

Permanent

magnet motor

UVW

Communications

port

OEM Controller

L1 L2 L3

RFC-S

Sensorless

* *

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Figure 7-3 Minimum connections to get the motor running in any operating mode (size 6)

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* Not required if using Control word mode.

CSD100 User Guide 91 Issue Number: 3

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0.00

0.70

1.00

Pr = 004.025

1.00

1.01

Base speed/ frequency

50 % of base speed/ frequency

15 % of

base speed/

frequency

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8 Optimization

This chapter takes the user through methods of optimizing the drive setup and maximize the performance.

8.1 Motor thermal protection

A dual time constant thermal model is provided to estimate the motor temperature as a percentage of its maximum allowed temperature.

The motor thermal protection is modelled using losses in the motor. The losses in the motor are calculated as a percentage value, so that under these conditions the Motor Protection Accumulator (04.019) would eventually reach 100 %.

Percentage losses = 100 % x [Load related losses + Iron losses] Where:

Load related losses = (1 - K Iron losses = Kfe x (w / w

) x (I / (K1 x I

1.6

)

Rated

Where: I = Current Magnitude (04.001)

= Rated Current (05.007)

Rated

= Rated Iron Losses As Percentage Of Losses (04.039) / 100 %

The Motor Protection Accumulator (04.019) is given by:

Pr 04.019 = Percentage Losses x [(1 - K

Where: T = Motor Protection Accumulator (04.019)

= Motor Thermal Time Constant 2 Scaling (04.038) / 100 %

τ1

= Motor Thermal Time Constant 1 (04.015)

τ2

= Motor Thermal Time Constant 2 (04.037)

= Varies, see below

Figure 8-1 Motor thermal protection

Rated

) (1 - e-

)

t/τ1

) + K2 (1 - e-

t/τ2

)]

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The characteristic is intended for motors where the cooling effect reduces with motor speed below 15 % of base speed/frequency. The maximum value for K1 is 1.01, so that above the knee of the characteristics the motor can operate continuously up to 101 % current.

When the estimated temperature in Pr 04.019 reaches 100 % the drive trips.

The thermal model temperature accumulator is reset to zero at power-up and accumulates the temperature of the motor while them drive remains powered-up.

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Pr = Read +00.030

Drive reads all parameters from the NV Media Card

Pr = Program +00.030

Programs all drive parameters to the NV Media Card

NOTE

Overwrites any data already in data block 1

Pr = Auto +00.030

Auto Save

Drive automatically writes to the NV Media Card when a parameter save is performed

Pr = Boot +00.030

Boot

Auto Save

Drive boots from the

on power up and automatically writes to the NV Media Card when a parameter save is performed

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9 NV Media Card Operation

9.1 Introduction

The Non-Volatile Media Card feature enables simple configuration of parameters, parameter back-up, storing / reading PLC programs and drive copying using a SMARTCARD or SD card storing / reading PLC programs. The drive offers backward compatibility for a Unidrive SP SMARTCARD.

The NV Media Card can be used for:

• Parameter copying between drives

• Saving drive parameter sets

• Saving an onboard user program

The NV Media Card is located at the top of the module under the drive display (if installed) on the left-hand side.

Ensure the NV Media Card is inserted with the contacts facing the lefthand side of the drive.

The drive only communicates with the NV Media Card when commanded to read or write, meaning the card may be "hot swapped".

Beware of possible live terminals when installing the NV Media Card.

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Optimization

Figure 9-2 Basic NV Media Card operation

NV Media Card

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Figure 9-1 Installation of the NV Media Card

1. Installing the NV Media Card

2. NV Media Card installed

SD Card Adaptor (memory card not included) 3130-1212-03

9.2 NV Media Card support

The NV Media Card can be used to store drive parameter sets from the CSD100 in data blocks 001 to 499 on the card.

CSD100 User Guide 93 Issue Number: 3

NV Media Card Part number

8 kB SMARTCARD 2214-4246-03

64 kB SMARTCARD 2214-1006-03

The whole card may be protected from writing or erasing by setting the read-only flag as detailed in section 9.3.9 9888 / 9777 - Setting and clearing the NV Media Card read only flag on page 95.

The card should not be removed during data transfer, as the drive will produce a trip. If this occurs then either the transfer should be reattempted or in the case of a card to drive transfer, default parameters should be loaded.

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9.3 Transferring data

Data transfer, erasing and protecting the information is performed by entering a code in Pr

Table 9-1 SMARTCARD and SD card codes

Code Operation SMARTCARD SD card

2001

4yyy

Transfer the drive parameters to parameter file 001 and sets the block as bootable. This will include the parameters from attached option modules.

Transfer the drive parameters to parameter file yyy. This will include the parameters from attached option

modules. 6yyy Load the drive parameters from parameter file yyy. 7yyy Erase file yyy.

Compare the data in the drive with file yyy. If the files are the same then Pr mm.000 (mm.000) is simply 8yyy

reset to 0 when the compare is complete. If the files are different a ‘Card Compare’ trip is initiated. All

other NV media card trips also apply.

9555 Clear the warning suppression flag 9666 Set the warning suppression flag 9777 Clear the read-only flag 9888 Set the read-only flag 9999 Erase and format the NV media card

Where yyy indicates the block number 001 to 999.

Pr 05.007 Rated Current Pr 05.009 Rated Voltage

If the read only flag is set then only codes 6yyy or 9777 are effective.

9.3.1 Writing to the NV Media Card

4yyy - Writes defaults differences to the NV Media Card

The data block only contains the parameter differences from the last time default settings were loaded.

All parameters except those with the NC (Not copied) coding bit set are transferred to the NV Media Card. In addition to these parameters all menu 20 parameters (except Pr 20.000), can be transferred to the NV Media Card.

Writing a parameter set to the NV Media Card (Pr 11.042 = Program (2))

Setting Pr 11.04 2 to Program (2) and resetting the drive will save the parameters to the NV Media Card, i.e. this is equivalent to writing 4001 to Pr mm.000. All NV Media Card trips apply except 'Card Change'. If the data block already exists it is automatically overwritten. When the action is complete this parameter is automatically reset to None (0).

9.3.2 Reading from the NV Media Card

6yyy - Reading from NV Media Card

When the data is transferred back to the drive, using 6yyy in Pr mm.000, it is transferred to the drive RAM and the EEPROM. A parameter save is not required to retain the data after-power down. Set up data for any option modules installed stored on the card are transferred to the drive. If the option modules installed are different between source and destination drives, the menus for the option module slots where the option module categories are different are not updated from the card and will contain their default values after the copying action. The drive will produce a 'Card Option' trip if the option module installed to the source and the destination drives are different or are in different slots. If the data is being transferred to the drive with different voltage or current rating a 'Card Rating' trip will occur.

The following drive rating dependant parameters (RA coding bit set) will not be transferred to the destination drive by a NV Media Card when the voltage rating of the destination drive is different from the source drive and the file is a parameter file.

However, drive rating dependent parameters will be transferred if only the current rating is different. If drive rating dependant parameters are not transferred to the destination drive they will contain their default values.

Pr 05.017 Stator Resistance Pr 05.018 Maximum Switching Frequency Pr 05.024 Ld Pr 06.048 Supply Loss Detection Level Pr 06.065 Standard Under Voltage Threshold Pr 06.066 Low Under Voltage Threshold

Reading a parameter set from the NV Media Card (Pr 11.042 = Read (1))

Setting Pr 11.042 to Read (1) and resetting the drive will transfer the parameters from the card into the drive parameter set and the drive EEPROM, i.e. this is equivalent to writing 6001 to Pr mm.000.

All NV Media Card trips apply. Once the parameters are successfully copied this parameter is automatically reset to None (0). Parameters are saved to the drive EEPROM after this action is complete.

9.3.3 Auto saving parameter changes (Pr 11.042 =

This setting causes the drive to automatically save any changes made to menu 0 parameters on the drive to the NV Media Card. The latest menu 0 parameter set in the drive is therefore always backed up on the NV Media Card. Changing Pr 11.042 to Auto (3) and resetting the drive will immediately save the complete parameter set from the drive to the card, i.e. all parameters except parameters with the NC coding bit set. Once the whole parameter set is stored only the individual modified menu 0 parameter setting is updated.

Advanced parameter changes are only saved to the NV Media Card when Pr mm.000 is set to 'Save Parameters' or a 1000 and the drive reset.

All NV Media Card trips apply, except 'Card Change'. If the data block already contains information it is automatically overwritten.

If the card is removed when Pr 11.042 is set to 3 Pr 11.042 is then automatically set to None (0).

When a new NV Media Card is installed Pr 11.042 must be set back to Auto (3) by the user and the drive reset so the complete parameter set is rewritten to the new NV Media Card if auto mode is still required.

When Pr 11.042 is set to Auto (3) and the parameters in the drive are saved, the NV Media Card is also updated, and therefore the NV Media Card becomes a copy of the drives stored configuration.

Pr 02.008 Standard Ramp Voltage Pr

04.005

to Pr

04.007

Motoring Current Limits

Pr 04.024, User Current Maximum Scaling

mm.000

Auto (3))

and then resetting the drive as shown in Table 9-1.

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99 99 99 99 9

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At power up, if Pr 11.042 is set to Auto (3), the drive will save the complete parameter set to the NV Media Card. The drive will display 'Card Write' during this operation. This is done to ensure that if a user puts a new NV Media Card in during power down the new NV Media Card will have the correct data.

When Pr 11.042 is set to Auto (3) the setting of Pr 11.042 itself is saved to the drive EEPROM but not the NV Media Card.

9.3.4 Booting up from the NV Media Card on every power up (Pr 11.042 = Boot (4))

When Pr 11.042 is set to Boot (4) the drive operates the same as Auto mode except when the drive is powered-up. The parameters on the NV Media Card will be automatically transferred to the drive at power up if the following are true:

• A card is inserted in the drive

• Parameter data block 1 exists on the card

• The data in block 1 is type 1 to 4 (as defined in Pr 11.038)

•Pr 11.042 on the card set to Boot (4)

The drive will display 'Booting Parameters during this operation. If the drive mode is different from that on the card, the drive gives a 'Card Drive Mode' trip and the data is not transferred.

If 'Boot' mode is stored on the copying NV Media Card this makes the copying NV Media Card the master device. This provides a very fast and efficient way of re-programming a number of drives.

'Boot' mode is saved to the card, but when the card is read, the value of Pr 11.042 is not transferred to the drive.

9.3.5 Booting up from the NV Media Card on every power up (Pr mm.000 = 2001)

It is possible to create a bootable parameter data block by setting Pr mm.000 to 2001 and initiating a drive reset. This data block is created in one operation and is not updated when further parameter changes are made.

Setting Pr mm.000 to 2001 will overwrite the data block 1 on the card if it already exists.

9.3.6 8yyy - Comparing the drive full parameter set with the NV Media Card values

Setting 8yyy in Pr mm.000, will compare the NV Media Card file with the data in the drive. If the compare is successful Pr mm.000 is simply set to

0. If the compare fails a 'Card Compare' trip is initiated.

9.3.7 7yyy / 9999 - Erasing data from the NV Media Card values

Data can be erased from the NV Media Card either one block at a time or all blocks in one go.

• Setting 7yyy in Pr mm.000 will erase NV Media Card data block yyy

• Setting 9999 in Pr mm.000 will erase all the data blocks on a

SMARTCARD, but not on an SD Card.

9.3.8 9666 / 9555 - Setting and clearing the NV Media Card warning suppression flag

If the option modules installed to the source and destination drive are different or are in different slots the drive will produce a 'Card Option' trip. If the data is being transferred to a drive of a different voltage or current rating a 'Card Rating' trip will occur. It is possible to suppress these trips by setting the warning suppression flag. If this flag is set the drive will not trip if the option module(s) or drive ratings are different between the source and destination drives. The options module or rating dependent parameters will not be transferred.

• Setting 9666 in Pr mm.000 will set the warning suppression flag

• Setting 9555 in Pr mm.000 will clear the warning suppression flag

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9.3.9 9888 / 9777 - Setting and clearing the NV Media Card read only flag

The NV Media Card may be protected from writing or erasing by setting the read only flag. If an attempt is made to write or erase a data block when the read only flag is set, a 'Card Read Only' trip is initiated. When the read only flag is set only codes 6yyy or 9777 are effective.

• Setting 9888 in Pr mm.000 will set the read only flag

• Setting 9777 in Pr mm.000 will clear the read only flag

9.4 Data block header information

Each data block stored on a NV Media Card has header information detailing the following:

• NV Media Card File Number (11.037)

• NV Media Card File Type (11.038)

• NV Media Card File Version (11.039)

• NV Media Card File Checksum (11.040)

The header information for each data block which has been used can be viewed in Pr 11.038 to Pr 11.040 by increasing or decreasing the data block number set in Pr 11. 037. If there is no data on the card Pr 11.037 can only have a value of 0.

9.5 NV Media Card parameters

Table 9-2 Key to parameter table coding

RW Read / Write ND No default value

RO Read only NC Not copied

Num Number parameter PT Protected parameter

Bit Bit parameter RA Rating dependant Txt Text string US User save Bin Binary parameter PS Power-down save

FI Filtered DE Destination

11.036 {00.029} NV Media Card File Previously Loaded

RO Num NC PT

0 to 999

RFC-S

This parameter shows the number of the data block last transferred from a NV Media Card to the drive. If defaults are subsequently reloaded this parameter is set to 0.

11. 037 NV Media Card File Number

RW Num

0 to 999

RFC-S

This parameter should have the data block number which the user would like the information displayed in Pr 11.038, Pr 11.039 and Pr 11.040.

11. 038 NV Media Card File Type

RO Txt ND NC PT

RFC-A

RFC-S (3)

RFC-S

Displays the type/mode of the data block selected with Pr 11.037.

0RFC-A

UL listing

information

Pr 11.038 String Type / mode

3 RFC-S RFC-S mode parameter file

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11.039 NV Media Card File Version

RO Num ND NC PT

RFC-A

0 to 9999

RFC-S

Displays the version number of the file selected in Pr 11.037.

11.040 NV Media Card File Checksum

RO Num ND NC PT

RFC-A

--2147483648 to 2147483647

RFC-S

Displays the checksum of the data block selected in Pr 11.037.

11.042 Parameter Cloning

RW Txt NC US*

RFC-S

None (0), Read (1),

Program (2), Auto (3),

Boot (4)

None (0)RFC-A

* Only a value of 3 or 4 in this parameter is saved.

If Pr 11.042 is equal to 1 or 2, this value is not transferred to the drive or saved to the EEPROM. If Pr 11.042 is set to 3 or 4 the value is saved to the EEPROM

None (0) = Inactive Read (1) = Read parameter set from the NV Media Card Program (2) = Program a parameter set to the NV Media Card Auto (3) = Auto save Boot (4) = Boot mode

11.076 NV Media Card Warning Suppression Flag

RO Bit ND NC PT

RFC-A

Off (0) or On (1)

RFC-S

NV Media Card Warning Suppression Flag (11.076) shows the state of the warning flag for the currently installed card.

11.077 NV Media Card File Required Version

RW Num ND NC PT

RFC-A

0 to 9999

RFC-S

The value of NV Media Card File Required Version (11.077) is used as the version number for a file when it is created on an NV Media Card. NV Media Card File Required Version (11.077) is reset to 0 when the file is created or the transfer fails.

9.6 NV Media Card trips

After an attempt to read, write or erase data from a NV Media Card a trip is initiated if there has been a problem with the command.

See Chapter 13 Diagnostics on page 258 for more information on NV Media Card trips.

11.073 NV Media Card Type

RO Txt ND NC PT

RFC-A

RFC-S

None (0),

SMART Card (1),

SD Card (2)

This will display the type of media card inserted; it will contain one of the following values:

"None" (0) - No NV Media Card has been inserted. "SMART Card" (1) - A SMARTCARD has been inserted. "SD Card" (2) - A FAT formatted SD card has been inserted.

11.075 NV Media Card Read-only Flag

RO Bit ND NC PT

RFC-A

Off (0) or On (1)

RFC-S

NV Media Card Read-only Flag (11.075) shows the state of the readonly flag for the currently installed card.

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10 CT MODBUS RTU

This section describes the adaptation of the MODBUS RTU protocol offered on Control Techniques' products. The portable software class which implements this protocol is also defined.

MODBUS RTU is a master slave system with half-duplex message exchange. The Control Techniques (CT) implementation supports the core function codes to read and write registers. A scheme to map between MODBUS registers and CT parameters is defined. The CT implementation also defines a 32-bit extension to the standard 16-bit register data format.

Figure 10-1 Architecture of MODBUS RTU

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The frame is terminated with a minimum silent period of 3.5 character times (for example, at 19200 baud the minimum silent period is 2 ms). Nodes use the terminating silence period to detect the end of frame and begin frame processing. All frames must therefore be transmitted as a continuous stream without any gaps greater or equal to the silence period. If an erroneous gap is inserted then receiving nodes may start frame processing early in which case the CRC will fail and the frame will be discarded. See description of Silent Period (Pr 11.027) in section

5.10.1 485 Serial communications on page 63. MODBUS RTU is a master slave system. All master requests, except

broadcast requests, will lead to a response from an individual slave. The slave will respond (i.e. start transmitting the response) within the quoted maximum slave response time (this time is quoted in the data sheet for all drive products). The minimum slave response time is also quoted but will never be less than the minimum silent period defined by 3.5 character times.

If the master request was a broadcast request then the master may transmit a new request once the maximum slave response time has expired.

The master must implement a message time out to handle transmission errors. This time out period must be set to the maximum slave response time + transmission time for the response.

Figure 10-3 MODBUS RTU timing

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10.1 MODBUS RTU

Physical layer

Attribute Description

Normal physical layer for multi-drop operation

Bit stream

Symbol

Baudrates

RTU framing

The frame has the following basic format:

Figure 10-2 MODBUS RTU format

RS285 2-wire

Standard UART asynchronous symbols with Non Return to Zero (NRZ)

Each symbol consists of:1 start bit 8 data bits (transmitted least significant bit first) 2 stop bits

300, 600, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 76800, 115200

10.2 Slave address

The first byte of the frame is the slave node address. Valid slave node addresses are 1 through 247 decimal. In the master request this byte indicates the target slave node; in the slave response this byte indicates the address of the slave sending the response.

Global addressing

Address zero addresses all slave nodes on the network. Slave nodes suppress the response messages for broadcast requests.

10.3 MODBUS registers

The MODBUS register address range is 16-bit (65536 registers) which at the protocol level is represented by indexes 0 through 65535.

PLC registers

Modicon PLCs typically define 4 register 'files' each containing 65536 registers. Traditionally, the registers are referenced 1 through 65536 rather than 0 through 65535. The register address is therefore decremented on the master device before passing to the protocol.

File type Description

1 Read only bits 2 Read / write bits 3 Read only 16-bit register 4 Read / write 16-bit register

The register file type code is NOT transmitted by MODBUS and all register files can be considered to map onto a single register address space. All parameters in the drive are holding registers.

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0 1

16-bit 32-bit

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CT parameter mapping

The drive is parameterized using the mm.ppp notation. Indexes 'mm' and 'ppp' are in the range 0 through 99. Parameters are mapped into the MODBUS register space in standard addressing mode as:

Protocol register = (mm x 100) + ppp - 1

To correctly map the parameters at the application layer, the slave device increments the received register address. The consequence of this behavior is that Pr 00.000 cannot be accessed.

Data types

The MODBUS protocol specification defines registers as 16-bit signed integers. Each drive parameter is internally mapped to a single 16-bit MODBUS register, all MODBUS function codes access 16-bit registers only so to access a 32-bit parameter, two contiguous MODBUS registers must be specified in the request and the 32-bit data access scheme must be used.

32-bit data access

Standard MODBUS registers are 16 bits in size and reference a single drive parameter. To access a 32-bit data value the multiple read/write services must be used to transfer a contiguous array of 16-bit registers. Selection between either 16-bit or 32-bit access is specified using bit 14 of the register address. Note: Bit 15 of the register address is reserved for future use.

Reads when actual parameter type is different from selected

The slave will send the least significant word of a 32-bit parameter if that parameter is read as part of a 16-bit access.

The slave will sign extend the least significant word if a 16-bit parameter is accessed as a 32-bit parameter. The number of 16-bit registers must be even during a 32-bit access.

Writes when actual parameter type is different from selected

The slave will allow writing a 32-bit value to a 16-bit parameter as long as the 32-bit value is within the normal range of the 16-bit parameter.

The slave will allow a 16-bit write to a 32-bit parameter. The slave will sign extend the written value, therefore, the effective range of this type of write will be ±32767.

10.4 Data encoding

MODBUS RTU uses a 'big-endian' representation for addresses and data items (except the CRC, which is 'little-endian'). This means that when a numerical quantity larger than a single byte is transmitted, the MOST significant byte is sent first. So for example:

16-bits 0x1234 would be 0 x12 0 x34 32-bits 0x12345678 would be 0 x12 0 x34 0 x56 0 x78

There is no facility to encode a decimal point, therefore values must be written and read raw (e.g. a value of 2.000 is written or read as 2000).

10.5 Function codes

The function code determines the context and format of the message data. Bit 7 of the function code is used in the slave response to indicate an exception.

The following function codes are supported:

If 32-bit data type is selected then this effectively adds 16384 (0x4000) to the start register address.

e.g. For drive parameter Pr 01.021 in standard addressing mode, the start register value is 16384 + 120 = 16504 (0x4078)

If a 32-bit data type is selected then the drive uses two consecutive 16bit MODBUS registers (in 'big endian'). The master must also set the correct 'number of 16-bit registers' in the request.

Example: read Pr 00.001 (Pr 01.021) as a 32-bit parameter, using FC03 from node 1:

Master request

Byte Value Description

0 0x01 Slave destination node address 1 0x03 Function code 0x03 20x40 30x00 40x00 50x02

Start register Pr 00.001 (16384 + (100 x 0) + 1 – 1) = 16384 = 0x4000

Number of 16-bit registers to read

Pr 00.001 is 1 x 32-bit register = 2 x 16-bit registers 6 0xD1 CRC LSB 7 0xCB CRC MSB

Slave response

Byte Value Description

0 0x01 Slave destination node address 1 0x03 Function code 0x03

20x04

Length of data (bytes) = 1 x 32-bit register =

4 bytes

Code Description

03 Read multiple 16-bit registers 06 Write single register 16 Write multiple 16-bit registers 23 Read and write multiple 16-bit registers

FC03 Read multiple registers

Read a contiguous array of registers. The drive imposes an upper limit on the number of registers (16 in the case of CSD100), which can be read. If this is exceeded the drive will issue an exception code 2.

The normal response includes the function code, number of data bytes in the read block followed by the register data (unless an exception occurs).

If 32-bit parameter addressing is used, then for each parameter read:

• Two 16-bit registers must be used in the request

• The register data in the response will contain 4 bytes of data

Master request

Byte Description

0 Slave destination node address (1 – 247, 0 is global) 1 Function code 0x03 2 Start register address MSB 3 Start register address LSB 4 Number of 16-bit registers to read MSB 5 Number of 16-bit registers to read LSB 6 CRC LSB 7 CRC MSB

3Pr 00.001 data 4 5 6 7CRC LSB 8CRC MSB

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Slave response

Byte Description

0 Slave destination node address 1 Function code 0x03 2 Length of data in read block (bytes) 3 Register data 0 MSB

4 Register data 0 LSB 3+byte count CRC LSB 4+byte count CRC MSB

Example Read Pr 00.011 to Pr 00.014 with 32-bit data access

Master request

Byte Value Description

0 0x01 Slave destination node address 1 0x03 Function code 0x03 20x40 30x0A 40x00 50x08

Start register Pr 00.011 (16384 + (100 x 0) + 11 – 1) = 16394 = 0x400A

Number of 16-bit registers to read 4 x 32-bit register = 8 x 16-bit registers

60x71CRC LSB 70xCECRC MSB

Slave response

Byte Value Description

0 0x01 Slave destination node address 1 0x03 Function code 0x03

20x10

Length of data (bytes) = 4 x 32-bit registers = 16 bytes

3-6 Pr 00.011 data

7-10 Pr 00.012 data 11- 14 Pr 00.013 data 15-18 Pr 00.014 data

19 CRC LSB 20 CRC MSB

FC06 Write single register

Writes a single 16-bit value to a register. The normal response is an echo of the request (unless an exception occurs) returned after the parameter has been written.

The register address can correspond to a 32-bit parameter, but only the lower 16-bits of the value will be written.

Master request

Byte Description

0 Slave destination node address (1 – 247, 0 is global) 1 Function code 0x06 2 Start register address MSB 3 Start register address LSB 4 Register data MSB 5 Register data LSB 6CRC LSB 7CRC MSB

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Slave response

Byte Description

0 Slave destination node address 1 Function code 0x06 2 Start register address MSB 3 Start register address LSB 4 Register data MSB 5 Register data LSB 6 CRC LSB 7 CRC MSB

Example Write the value 0x0000 to Pr 00.020 (Pr 18.012)

Master request

Byte Value Description

0 0x01 Slave destination node address 1 0x06 Function code 0x06 20x00 30x13

Start register Pr 00.020 (100 x 0) + 20 – 1) = 19 = 0x0013

4 0x00 Register data MSB 5 0x00 Register data LSB 6 0x78 CRC LSB 7 0x0F CRC MSB

Slave response

Byte Value Description

0 0x01 Slave destination node address 1 0x06 Function code 0x06 2 0x00 Start register MSB 3 0x13 Start register LSB 4 0x00 Register data MSB 5 0x00 Register data LSB 60x78CRC LSB 70x0FCRC MSB

FC16 - Write multiple registers

This function code allows a contiguous series of registers to be written. The drive imposes an upper limit on the number of registers to be written (16 in the case of CSD100), and if this is exceeded the drive will issue an exception response code 2.

The normal response includes the function code, start register address and number of 16-bit registers written (unless an exception occurs), returned after the parameters have been written.

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If 32-bit parameter addressing is used, then for each parameter written:

• Two 16-bit registers must be used in the request

• Four bytes must be specified in the request

• The number of registers written in the response will be twice the number of parameters written

Master request

Byte Description

0 Slave destination node address (1 – 247, 0 is global) 1 Function code 0x10 2 Start register address MSB 3 Start register address LSB 4 Number of 16-bit registers to write MSB 5 Number of 16-bit registers to write LSB 6 Length of register data to write (bytes) 7 Register data 0 MSB

8 Register data 0 LSB 7+byte count CRC LSB 8+byte count CRC MSB

Slave response

Byte Description

0 Slave destination node address 1 Function code 0x10 2 Start register address MSB 3 Start register address LSB 4 Number of 16-bit registers written MSB 5 Number of 16-bit registers written LSB

6CRC LSB 7CRC MSB

Example

Write the value 2000 to Pr 00.011 and 3000 to Pr 00.012 with 32-bit data access

Master request

Byte Value Description

0 0x01 Slave destination node address 1 0x10 Function code 0x10 20x40 30x0A

Start register Pr 00.011

16384 + (100 x 0) + 11 – 1) = 16394 = 0x400A 4 0x00 Number of 16-bit registers MSB 5 0x04 Number of 16-bit registers LSB 6 0x08 Length of register data to write (bytes)

7-10

11- 14

0x00 0x00

0x07 0xD0

0x00 0x00

0x0B 0xB8

15 0x97 CRC LSB 16 0x85 CRC MSB

Slave response

Byte Value Description

0 0x01 Slave destination node address 1 0x10 Function code 0x10 2 0x40 Start register address MSB 3 0x0A Start register address LSB 4 0x00 Number of 16-bit registers written MSB 5 0x04 Number of 16-bit registers written LSB 6 CRC LSB 7 CRC MSB

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FC23 - Read/Write multiple registers

This function code allows a contiguous series of registers to be written and another contiguous series of registers to be read. The drive imposes an upper limit on the number of registers to be written (16 in the case of CSD100), and if this is exceeded the drive will issue an exception response code 2.

The normal response includes the function code, number of data bytes in the read block followed by the register data (unless an exception occurs).

If 32-bit parameter addressing is used:

• For each parameter read or written, two 16-bit registers must be used in the request

• For each parameter written, four bytes must be specified in the request

• For each parameter read, four bytes of data will be used in the response

It should be noted that the FC23 request is effectively an FC03 (read multiple) request followed by an FC16 (write multiple) request. The write is performed first and continues until any of the errors given for FC16 occur. Some parameters may have been written when an error is detected, but no indication is given about how many parameters have been written successfully. The read is always performed even if an error is detected during writing. Any of the errors given for FC03 can occur and the exception response is the same as for FC03.

Master request

Byte Description

0 Slave destination node address (1 – 247, 0 is global) 1 Function code 0x17 2 Start register address to read MSB 3 Start register address to read LSB 4 Number of 16-bit registers to read MSB 5 Number of 16-bit registers to read LSB 6 Start register address to write MSB 7 Start register address o write LSB 8 Number of 16-bit registers to write MSB

9 Number of 16-bit registers to write LSB 10 Length of register data to write (bytes) 11 Register data 0 MSB 12 Register data 0 LSB

11+byte count CRC LSB 12+byte count CRC MSB

Slave response

Byte Description

0 Slave destination node address 1 Function code 0x10 2 Length of register data in read block (bytes) 3 Register data 0 MSB

4 Register data 0 LSB 3+byte count CRC LSB 4+byte count CRC MSB

Example

Write the value 200 to Pr 00.054 and read Pr 00.057 with 32-bit data access

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