Elmo Rletschle 2FC4, 1CB User Manual

Edition 05.2014 · 610.00260.40.000 Original operating instructions · English

Operating Instructions

2FC4...-1ST | 2FC4...-1PB | 2FC4...-1PN | 2FC4...-1SC | 2FC4...-1CB

Contents

1 Overview of sizes ......................................................................... 4

2 Further information ...................................................................... 5

2.1 Storing the documentation ............................................................. 5

2.2 Explanation of the terms and symbols ........................................... 5

2.3 Changes in comparison to the previous version ............................ 6

2.4 Other valid documents ................................................................... 6

3 Safety and responsibility ............................................................. 7

3.1 Explanation of warning signs ......................................................... 7

3.2 Safety instructions .......................................................................... 7

3.2.1 General information ........................................................................ 7

3.2.2 Transport and Storage ................................................................... 8

3.2.3 Commissioning ............................................................................... 9

3.2.4 Operation ........................................................................................ 10

3.2.5 Maintenance and inspection .......................................................... 10

3.2.6 Repairs ........................................................................................... 11

3.2.7 Disassembly and Disposal ............................................................. 12

3.3 Correct use of the equipment ........................................................ 12

3.4 Staff qualifications and training ...................................................... 12

3.5 Requirements of the operator ........................................................ 13

4 Product identification ................................................................... 14

4.1 Model description ........................................................................... 14

4.2 Description of the drive control ...................................................... 14

4.3 CE marking ..................................................................................... 14

5 Installation ..................................................................................... 15

5.1 Safety instructions for installation .................................................. 15

5.2 Installation requirements ................................................................ 15

5.2.1 Suitable ambient conditions ........................................................... 15

5.2.2 Suitable installation location for the motor-integrated drive control

......................................................................................................... 16

5.2.3 Basic connection variations ........................................................... 16

5.2.4 Short-circuit and earth-fault protection .......................................... 17

5.2.5 Wiring instructions .......................................................................... 17

5.2.6 Preventing electromagnetic interference ....................................... 18

5.3 Installation of the drive controller integrated in the motor ............. 18

5.3.1 Mechanical installation of sizes A - C ............................................ 18

5.3.2 Mechanical installation of size D .................................................... 20

5.3.3 Power connection of sizes A - C .................................................... 22

5.3.4 Power connection of size D ............................................................ 23

5.3.5 Connections for braking resistor .................................................... 24

5.3.6 Control terminals ............................................................................ 24

5.3.7 Wiring diagram ............................................................................... 25

5.4 Installing the wall-mounted drive controller ................................... 26

5.4.1 Installation location that is suitable for wall mounting ................... 26

5.4.2 Mechanical installation ................................................................... 27

5.4.3 Power connection .......................................................................... 30

5.4.4 Braking chopper ............................................................................. 30

5.4.5 Control terminals ............................................................................ 30

6 Commissioning ............................................................................. 31

6.1 Safety information for commissioning ............................................ 31

6.2 Communication .............................................................................. 32

6.3 Block diagram ................................................................................ 33

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Contents

6.4 Commissioning steps ..................................................................... 34

6.4.1 Start up the integrated drive control .............................................. 34

6.4.2 Commission the drive control wall assembly and replacement ..... 34

7 Parameters .................................................................................... 36

7.1 Safety instructions for handling the parameters ............................ 36

7.2 General information on parameters ................................................ 36

7.2.1 Explanation of operating modes .................................................... 36

7.2.2 Structure of parameter tables ........................................................ 39

7.3

pplication parameter .................................................................... 40

7.3.1 Basic parameters ........................................................................... 40

7.3.2 Fixed frequency .............................................................................. 44

7.3.3 Motor potentiometer ...................................................................... 45

7.3.4 PID process controller .................................................................... 46

7.3.5

nalogue inputs .............................................................................. 47

7.3.6 Digital inputs ................................................................................... 49

7.3.7

nalogue output ............................................................................. 50

7.3.8 Digital outputs ................................................................................ 51

7.3.9 Relay ............................................................................................... 52

7.3.10 External error .................................................................................. 53

7.3.11 Motor current limit .......................................................................... 53

7.3.12 Blocking detection ......................................................................... 54

7.4 Power parameters .......................................................................... 55

7.4.1 Motor data ...................................................................................... 55

7.4.2 I

T ................................................................................................... 57

7.4.3 Switching frequency ....................................................................... 57

7.4.4 Controller data ................................................................................ 57

7.4.5 Square-law characteristic ............................................................... 59

7.4.6 Controller data for synchronous motor .......................................... 59

8 Error detection and elimination .................................................. 61

8.1 Display of the LED flash codes for error detection ........................ 61

8.2 List of errors and system errors ..................................................... 62

9 Technical data .............................................................................. 64

9.1 General data ................................................................................... 64

9.2 Derating of output power ............................................................... 65

9.2.1 Derating through increased ambient temperature ......................... 66

9.2.2 Derating due to installation altitude ................................................ 67

9.2.3 Derating due to the clock frequency .............................................. 68

10 Optional accessories ................................................................... 69

10.1

dapter plates ................................................................................ 69

10.2 Hand-held unit MMI, including 3 m connection cable RJ11 to

connector M12 ............................................................................... 71

10.3 PC communication cable USB to connector M12 (RS485/RS232

converter integrated) ...................................................................... 71

11 Guidelines, norms and standards ............................................... 72

11.1 EMC limit classes ........................................................................... 72

11.2 Classification acc. to IEC/EN 61800-3 ........................................... 72

11.3 Standards and guidelines ............................................................... 72

11.4

pproval according to UL .............................................................. 73

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Overview of sizes

Dimensional drawings

The drive controls are available in the following performance classes with the specified size names.

Sizes

Sizes drive controls motor

MA MB MC MD

integrated

Recommended motor power [kW]

Dimensions L x B x H [mm] 233 x 153 x 120 270 x 189 x 140 307 x 223 x 181 414 x 294 x 232

1.5 2.2 / 3.0 / 4.0 5.5 / 7.5 11.0 / 15.0 /

18.5 / 22.0

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Further information

Storing the documentation

2.1

Store this manual and all other applicable documents safely so they are available as and when required.

Provide the operator of the system with this manual so it is available as and when required.

Explanation of the terms and symbols

2.2

In these instructions symbols and terms will be used to mean the following.

Symbol Explanation

Requirement, pre-requisite

One-step handling instructions

1 2 3 Multi-step handling instructions

Result

Cross reference with page reference

dditional information, tips

Direction of rotation arrow

Direction of conveyance arrow

General warning sign (warns of risk of injury)

Electrical voltage warning

Hot surface warning

Disconnect prior to maintenance or repai

Further information

Observe the instructions

Use foot protection

Use hand protection

Use eye protection

Use head protection

Use ear protection

Earth prior to use

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Further information

Term Explanation

Plant Part provided by the user in which the vacuum pump/compressor is installed. Vacuum

pump/compressor

Ready to connect machine for the generation of a vacuum and/or overpressure. The vacuum pump/compressor consists of a compressor part and motor, as well

as other accessories where applicable. Motor Asynchronous motor for driving the vacuum pump/compressor. Compressor Mechanical part of the vacuum pump/compressor without motor. Assembly environment Space in which the vacuum pump/compressor is set up and operated (this may

differ from the suction environment). Drive control Device for rotation speed control of the vacuum pump/compressor. The drive

control can be mounted close to the motor (wall assembly) or integrated into the

vacuum pump/compressor

Changes in comparison to the previous version

2.3

Amendments in comparison to version 02.2014 ▪ 2.2 Explanation of the terms and symbols ▪ 5.3.6 Control terminals

Table: Terminal assignment X5 of the standard application card, terminal no. 6 ▪ 6.4.1 Start up the integrated drive control ▪ 6.4.2 Commission the drive control wall assembly and replacement ▪ 7.2.1 Explanation of the operating modes

Table: Logic table of fixed frequencies parameter 1,020 deleted ▪ 7.3.1 Basic parameters

Parameter 1,131

Other valid documents

2.4

All instructions that describe the use of the drive control and if applicable, further instructions of all accessory parts used, e.g.

Document number Purpose — Vacuum pump/compressor operating ma

610.00260.01.010 *

610.00260.01.020 *

610.00260.01.030 *

Operating manual 2FC4...-1PB OR Operating manual 2FC4...-1PN OR Operating manual 2FC4...-1SC OR

610.00260.01.040 * Operating manual 2FC4...-1CB

610.00260.01.600 * MMI hand-held unit operating manual

*according to the model option or accessories

Download of 3D files (.stp) for drive control and adapter plates under www.gdelmorietschle.com.

To parameterise the drive control, the parameter description is ready to be downloaded (www.gd-elmorietschle.com). The download contains all necessary information for correct parameterisation.

nual

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Safety and responsibility

The manufacturer is not liable for damage caused by the failure to observe these instructions and the related documents [➙ 6].

Explanation of warning signs

3.1

Warning sign Explanation

Danger that failure to observe the measures could lead to death or serious physical injuries.

Danger that failure to observe the measures could lead to minor physical injuries.

Danger that failure to observe the measures could lead to

3.2

Safety instructions

material damage.

The following warnings, precautionary measures and comments are provided for your safety and serve to prevent damage to the drive control and the components connected to it. This chapter contains warnings and information that are generally applicable when handling drive controls. They are split into general information, transport and storage, start-up, operation, repairs and dismantling & disposal.

Specific warnings and comments that apply to specific activities can be found at the start of the appropriate chapters and are repeated and added to at various critical points in these chapters.

Please read this information carefully as it is provided for your personal safety and will also prolong the life of the drive control and connected devices.

3.2.1

General information

WARNING

This drive controller carries dangerous voltages and controls rotating mechanical parts which may be dangerous! Disregarding the warnings or failure to follow the instructions contained in this manual may lead to death, serious bodily injury or substantial property damage.

 Only qualified personnel should work on this drive controller. These personnel

must be thoroughly familiar with all safety instructions, installation, operation and maintenance procedures contained in this manual. The smooth and safe operation of the drive controller depends on proper handling, installation, operation and maintenance.

WARNING

Risk of fire or electric shock! Improper use, modifications and the use of spare parts and accessories that are not sold or recommended by the manufacturer of the drive controller can cause fire, electric shock and bodily injury.

 The cooling element of the drive controller and motor can reach temperatures

of above 70°C [158 °F]. During installation, sufficient spacing between adjacent components should be maintained. Before working on the drive controller or motor, required cooling time must be ensured. If necessary, a protection against accidental contact should be installed.

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Safety and responsibility

NOTICE

The drive controller may be operated safely only if the required ambient conditions are met, see Suitable ambient conditions [➙ 15].

NOTICE

This operating manual must be kept in the vicinity of the equipment, so as to be readily accessible to all users.

NOTICE

Please read these safety instructions and warnings carefully and all the warning labels attached to the equipment before installing and commissioning. Make sure that the warning labels are kept in a legible condition and replace missing or damaged labels.

3.2.2

Transport and Storage

NOTICE

Risk of damage to the drive controller! The drive controller can be damaged in the case of non-compliance with the instructions and destroyed during subsequent handling.

 The smooth and safe operation of this drive controller requires proper mount-

ing, installation and assembly as well as careful operation and maintenance. The drive controller must be protected during transport and storage against mechanical shocks and vibration. The protection against excessive temperatures (see Technical data [➙ 64]) must be guaranteed.

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3.2.3

Commissioning

Safety and responsibility

DANGER

Risk of injury due to electric shock! The non-observance of warnings can result in severe bodily injury or substantial property damage.

1. Only hard-wired grid connections are permitted. The device must be earthed (DIN EN 61140; VDE 0140-1).

2. The drive controls may have contact currents > 3.5mA. According to DIN EN 61800-5-1 chapter 4.3.5.5.2, an additional protective earth conductor with the same cross section as the original earth conductor must be attached. The possibility of connecting a second protective earth conductor is located underneath the power supply (with marked ground symbol) on the outside of the device. For the connection, a suitable M6x15 screw (torque: 4.0 Nm [2.95 ft lbs]) is included in the scope of delivery of the adapter plates.

3. When using alternating current drive controls, conventional FI circuit breakers of type A, also known as RCDs (residual current-operated protective devices) are not permitted for the protection of direct or indirect contact! As per DIN VDE 0160, section 5.5.2 and EN 50178, section 5.2.11.1, the FI circuit breaker (RCD type B) must be suitable for all types of current.

4. The following terminals can also lead to dangerous voltages when the engine is at a standstill:

 the mains connection terminals X1: L1, L2, L3  the motor connection terminals X2: U, V, W  the connection terminals X6, X7: Relay contacts relays 1 and 2  the PTC connection terminals T1/T2

5. When using different voltage levels (e.g. +24V/230V), always ensure that lines do not cross! Furthermore, the operator must ensure that the applicable regulations are adhered to (e.g. doubled or reinforced insulation according to DIN EN 61800-5-1).

6. The drive control contains electrostatically sensitive assemblies. These assemblies can be destroyed due to improper handling, therefore safety measures against electrostatic loading must be adhered to when work must be done on these assemblies.

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Safety and responsibility

3.2.4

Operation

DANGER

Risk of injury from electric shock or restarting motors! The non-observance of warnings can result in severe bodily injury or substantial property damage.

 Observe the following instructions during operation:

 The drive controller operates at high voltages.  When operating electrical equipment, certain parts of the equipment carry

dangerous voltage.

 Emergency stop devices according to EN 60204-1:2006 must remain op-

erative in all operating modes of the control unit. Resetting the emergency stop device must not lead to uncontrolled or undefined restart.

 Safe disconnection from the mains requires synchronous and all-pole dis-

connection of the mains supply line to the drive controller.

 For devices with single-phase supply and for the BG D (11 to 22 kW), at

least 1 to 2 min break should be kept between successive connections to the mains.

 Certain parameter settings may cause the drive controller to restart auto-

matically after a power failure.

NOTICE

Risk of damage to the drive controller! The drive controller can be damaged in the case of non-compliance with the instructions and destroyed during subsequent handling.

1. Observe the following instructions during operation:

2. For a functioning motor overload protection, the motor parameters must be configured correctly.

3. Ensure the motor overload protection via a PTC. In addition, the drive control provides an internal motor protection. See also parameter 33.100 and 33.101. According to the presetting, the I eration without PTC.

4. The drive controller must not be used as an 'emergency stop device' (see EN 60204-1:2006).

T is OFF and must be activated during op-

3.2.5

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Maintenance and inspection

Maintenance and inspection of the drive controllers must be performed only by electrically certified, qualified person. Changes in hardware and software, unless explicitly described in this manual, may only be performed by the manufacturer.

Cleaning the drive controllers

The drive controllers are maintenance-free when operated properly. In a dusty environment, the cooling ribs on the motor and the drive controller must be cleaned regularly. For equipment that are equipped with integrated fans, option for BG C, series in BG D, cleaning with compressed air is recommended.

Measurement of insulation resistance on the control unit

Insulation test at the input terminals of the control card is not permitted.

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Safety and responsibility

Measurement of insulation resistance on the power unit

In the course of the series testing, the power unit of the drive controller is tested by applying 1.9 kV.

Should the measurement of insulation resistance be necessary in a system check, then this can be carried out under the following conditions:

▪ an insulation test can be performed only for the power unit, ▪ to avoid impermissible high voltages, all connecting cables of the drive con-

troller must be disconnected prior to the test,

▪ a 500 V DC insulation tester is used.

Insulation test on the power unit

Pressure test on a DRIVE CONTROLLER

3.2.6

A pressure test of the drive controller is not allowed.

Repairs

DANGER

Danger of injury through electric shock! Non-observance of warnings may result in serious injury or damage.

 When the drive control is disconnected from the mains voltage, live device

parts and connections may not be touched immediately in case the condensers are still live.

NOTICE

Risk of damage to the drive control! If the information is not observed, the drive control could be damaged and destroyed during subsequent start-up.

 Repairs to the drive control may only be performed by the manufacturer.

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Safety and responsibility

3.2.7

Disassembly and Disposal

Screw and snap-on connections are easy to release and allow the drive control to be dismantled into its individual parts. These parts can be sorted for recycling. Please comply with local regulations during disposal.

Components with electronic parts may not be disposed of along with normal household waste. They have to be collected separately with used electrical and electronic equipment in accordance with applicable legislation.

Correct use of the equipment

3.3

During installation in machinery, commissioning of the drive controller (i.e. starting of intended operation) is prohibited until it is proven that the machine complies with the regulations of the EC Directive 2006/42/EC (Machinery Directive); EN 60204-1:2006 is to be observed.

Commissioning (i.e. starting of intended operation) is only permitted if the EC Directive 2004/108/EC (EMC Directive) allows it.

The harmonised standards of the series EN 50178:1997 in conjunction with EN 60439-1/A1:2004 shall be applied to this drive controller.

This drive controller is not approved for operation in potentially explosive areas!

Repairs may only be carried out by authorised repair workshops. Unauthorised interventions can lead to death, bodily injury and property damage. The warranty provided by the manufacturer expires in this case.

External mechanical loads, such as stepping on the casing are not allowed!

The use of the drive units in non-stationary equipment is considered as unusual environmental conditions, and is permitted only in accordance with the locally applicable standards and guidelines.

Staff qualifications and training

3.4

All those who will work on the must have read and understood these instructions and the related documents [➙ 6].

Personnel in training may only work on the under supervision of personnel who have the required knowledge.

Only allow work on the to be carried out by personnel with the following knowledge:

In the context of this operating manual and the information relating to the product itself, qualified staff refers to electronic specialists who are familiar with the installation, assembly, start-up and operation of the drive control and the dangers involved, and whose specialist training and knowledge of relevant standards and regulations provide them with the necessary abilities.

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Requirements of the operator

3.5

Safety and responsibility

As a basic principle, electronic devices are not fail-proof. The operator and/or the contractor setting up the machine or system is responsible for ensuring that the drive switches to a safe state if the device fails.

The “Electrical equipment of machines” section in EN 60204-1, “Safety of machinery” describes the safety requirements for electrical control units. These are provided for the safety of people and machines and must be observed in order to retain the functional capability of the machine or system.

An emergency stop feature does not have to result in the power supply to the drive being switched off. To avoid dangerous situations, it may be useful for individual drives to remain operational or for specific safety procedures to be initiated. The effectiveness of emergency stop measures is evaluated by means of a risk assessment for the machine or system and its electrical equipment, and is determined by selecting a circuit category according to EN 13849 “Safety of machinery – Safety-related parts of control systems”.

The operator ensures that: ▪ All work on the is carried out by:

– personnel that have the necessary Staff qualifications and training [➙ 12] – personnel that have been sufficiently informed of these instructions and all

related documents [➙ 6] ▪ Assignment, responsibility and supervision of personnel is regulated. ▪ The content of these and locally applicable instructions are always available to

personnel.

▪ All local and plant-specific safety measures are adhered to, such as:

– Prevention of accidents – safety and operating regulations – Utility company regulations – Standards and laws

▪ Dangers due to electrical energy are not possible.

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Product identification

Model description

4.1

Item designation

2FC = drive control

4 Type of assembly:

1 = integrated drive control

2 Connection voltage:

4 = 400 V -15% — 480 V +10%

ersion:

ST = Standard PB = Profibus PB = Profinet SC = Sercos III CB = CANopen

3 Performance:

152 = 1.5 kW

6 reserved:

0 = Standard 222 = 2.2 kW 302 = 3.0 kW 402 = 4.0 kW 552 = 5.5 kW

4.2

752 = 7.5 kW

Description of the drive control

The drive control is a device for speed control in three-phase AC motors.

The drive control can be integrated in the motor (with the standard adapter plate) or fitted close to the motor (with the wall installation adapter plate).

The permitted ambient temperatures specified in the technical data refer to operation at nominal load. In many cases, higher temperatures may be permitted after a detailed technical analysis. These have to be approved by manufacturer on a case-by-case basis.

4.3

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CE marking

With the CE marking, we, as the manufacturer of the device, confirm that the drive control meets the basic requirements of the following guidelines:

▪ Directive on Electromagnetic Compatibility (Directive 2004/108/EC) ▪ Low Voltage Directive (Directive 2006/95/EC)

You can download the declaration of conformity from www.gd-elmorietschle.com.

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Installation

Safety instructions for installation

5.1

WARNING

1. Installation may only be performed by appropriately qualified employees who are trained in the set-up, installation, start-up and operation of the product. Work performed on the drive control by unqualified staff and non-observance of warnings may result in serious injury or damage.

2. The device must be grounded in accordance with EN 61140, NEC and other

5.2

5.2.1

relevant standards. Mains connections must be hardwired.

Installation requirements

Suitable ambient conditions

Ambient conditions

ltitude of the installation

site:

Up to 1000 m above sea level [3280 ft above sea level] / over 1000 m [3280 ft] with reduced performance (1% per 100 m [328 ft]) max. 2000 m [6560 ft], see

mbient temperature:

-25°C [-13°F] to +50°C [122°F]

(different ambient temperatures may be possible in individual cases) , see Relative humidity: ≤ 96%, condensation not permitted Resistance to vibration and

shock: Electromagnetic compatibil-

acc. to FN 942 017 part 4; 5.3.3.3 Combined test 2;

5...200 Hz for sinusoidal oscillation

Immune to interference acc. to EN 61800-3 ity:

Cooling: Surface cooling:

sizes A to C: free convection;

size D: with integrated fans

! Ensure that the housing type (protection type) is suitable for the operating en-

vironment:

1. Ensure that the seal between the motor and the adapter plate is inserted correctly.

2. All unused cable screw connections must be sealed.

3. Check that the cover of the drive control is closed and bolted down tightly.

Although the drive control can, in principle, be painted later on, the user must nevertheless check the material compatibility of the intended paint. Failure to comply with this requirement may eventually result in the loss of the protection class (particularly in respect to seals and fibre-optic elements). The standard colour is black (RAL 9005).

Disassembling the circuit boards (even for the purpose of painting the housing sections) renders the warranty void!

Mounting points and sealing surfaces must be kept free of paint for purposes of EMC and grounding!

Installation

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Installation

5.2.2

Suitable installation location for the motor-integrated drive control

 Ensure that the motor with a motor-integrated drive control is only installed

and operated if aligned as shown in the following diagram.

5.2.3

Motor installation location/permitted alignments

Basic connection variations

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Star or delta connection with the drive controller integrated in the motor

NOTICE

Risk of damage to the drive controller! When connecting the drive controller, the correct phase sequence must be adhered to; otherwise, the motor can be overloaded.

 Thus, the correct phase sequence should be ensured when connecting the

motor.

With the supplied installation material, wire-end sleeves and cable lugs can be connected. The connection options are shown in Figure 4.

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Unused open cable ends in the motor connection box must be insulated.

If a PTC or Klixxon is used, the jumper, seated in the terminal for the PTC in

Installation

the delivery condition, must be removed.

The cross section of the mains supply line should be designed according to the type of wiring and the max. current allowed. The mains supply protection must be

5.2.4

5.2.5

ensured by the system start-up engineer.

Short-circuit and earth-fault protection

The drive controller has an internal short-circuit and earth-fault protection.

Wiring instructions

The control terminals of the application card are located inside the drive controller.

Depending on the version, the pins may be allocated differently.

Terminals: Plug-in terminal connector with actuating pusher

(slot-head screwdriver, max. width 2.5 mm [0.098 in])

Connection crosssection:

0.5 to 1.5 mm

single wire, AWG 20 to AWG 14

0.75 to 1.5 mm

fine-wired, AWG 18 to AWG 14

0.5 to 1.0 mm

fine-wired

(0.02 to 0.06 inch2),

(0.03 to 0.06 inch2),

(0.02 to 0.04 inch2),

(wire-end sleeves with and without plastic collar)

Wire stripping length:

9 to 10 mm (0.35 – 0.40 inch)

The terminals for the mains supply line are within the drive controller. The drive controller is fitted with terminals for connecting a braking resistor.

Depending on the version, the pins may be allocated differently.

Wire-end sleeves with plastic collar and lugs are recommended.

Terminals: Spring-loaded contact (slot-head screwdriver, max.

width 2.5 mm [0.098 in])

Connection crosssection:

rigid 0.2 to 10 mm flexible wire 0.2 to 6 mm

0.25 to 6 mm

(wire-end sleeves without plastic collar)

0.25 to 4 mm

(wire-end sleeves with plastic collar)

0.25 to 1.5 mm

same cross section

, (0.008 – 0.4 inch2)

(0.008 – 0.24 inch2)

(0.01 to 0.24 inch2)

(0.01 to 0.16 inch2)

( – 0.06 inch2) for 2 conductors with the

(twin wire-end sleeves with plastic collar) Wire cross-section: Wire stripping length: Installation tempe

ture:

WG 24 to AWG 8

15 mm [0.6 inch]

+5°C to +100°C [41 – 212°F]

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Installation

5.2.6

Preventing electromagnetic interference

For control circuits shielded cables must be used, where possible. At the cable end, the shield should be applied with due care without leaving the wires unshielded over longer distances.

The shielding of analogue setpoints should only be applied on one side of the drive controller.

Basically, the control wires should always be routed as far away as possible from power cables; separate cable ducts may have to be used, if required. If lines cross, an angle of 90° should be adhered to, where possible.

Upstream circuit elements, such as contactors and brake coils or circuit elements which are connected across the outputs of the drive controllers must be suppressed in terms of interference. In AC contactors, RC (resistor-capacitor) circuits can be used; suppressor diodes or varistors can be normally used for DC contactors. This interference suppressor is attached directly to the contactor coil. Basically, the power supply to a mechanical brake should not be routed in the same cable!

Power connections between the drive controller and motor should always be used in shielded or reinforced design and the shield must be earthed at both ends over a large area! The use of EMC cable glands is recommended. These are not in-

5.3.1

cluded in the delivery.

Installation of the drive controller integrated in the motor

5.3

Mechanical installation of sizes A - C

For mechanical installation of the drive controller, proceed as follows:

1. Open the standard motor connection box.

2. Disconnect the wires to the terminals. Remember or write down the connection sequence.

3. If necessary, remove the motor terminal block.

4. Remove the fastening screws securing the housing and remove the housing. Be careful not to damage the gasket.

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Assembly sequence: Junction box - adapter plate (BG A - C)

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The standard adapter plate is an adapter plate whose lower part has not

Installation

been refinished. No holes are drilled.

 For the motors supplied, you can order adapter plates from the manufacturer.

5. Adjust them to the adapter plate (1) by drilling appropriate holes (2) in them for attachment to the motor.

The system start-up engineer is responsible for maintaining the protection class for the gasket of the adapter plate on the motor.

 For questions, please contact your sales representative.

6. Insert the gasket (3).

7. Lead the motor connection cable through the adapter plate while bypassing the terminal and screw the adapter plate onto the motor using four fastening screws and four spring elements (4) (torque: 2.0 Nm [1.48 ft lbs]).

when mounting the adapter plates, ensure that all four screws, including the spring elements are tightened by applying the correct torque! All contact areas must be dirt/ paint-free, as correct protective earth connection cannot be ensured otherwise.

8. Connect the motor wires to the required interconnection, see also Figure 5 (Torque: 3.0 Nm [2.21 ft lbs]). We recommend using insulated M5 ring termi-

nals, with a connection cross-section of 4-6 mm

When installing the motor wires make sure that all bolts on the adapter

[0.16 to 0.24 inch2]

board are fitted with the enclosed nuts, even if the neutral point is not connected.

Jumper

9. Wire any available connection cable of the Motor PTC/ Klixxon to terminals T1

when installing, make sure that the connection cables are not pinched.

If the motor is equipped with a temperature sensor, it is connected to terminals T1 and T2 (1) and the jumper (2) included in the delivery must be removed. If the jumper is used, there is no temperature monitoring of the motor!

10. Plug the drive controller to the adapter plate and secure it evenly using the

and T2 (1) (torque: 0.6 Nm [0.44 ft lbs]).

four screws at the side (torque: 4.0 Nm [0.3 ft lbs]).

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Installation

5.3.2

Mechanical installation of size D

For mechanical installation of the drive controller, proceed as follows:

1. Open the standard motor connection box.

2. Remove the fastening screws securing the housing and remove the housing. Be careful not to damage the gasket.

Assembly sequence: Junction box - adapter plate (BG D)

1 Adapter plate option (variant) 6

Support the drive controller / adapter plate

2 Motor-dependent holes 7 Terminal board expansion option

3 Seal 8

Fastening screws with spring

elements

5 O-ring- gasket 10

The standard adapter plate is an adapter plate whose lower part has not

Original terminal board (not included in the delivery)

9 Elongated screw option (for 7)

Fastening screws with spring elements option

been refinished. No holes are drilled.

 For the motors supplied, you can order adapter plates from the manufacturer.

3. Adjust them to the adapter plate (1) by drilling appropriate holes (2) in them for attachment to the motor.

The system start-up engineer is responsible for maintaining the protection class for the gasket of the adapter plate on the motor.

 For questions, please contact your sales representative.

4. Insert the gasket (3).

5. Screw the adapter plate onto the motor using the four fastening screws and the four spring elements (10) (torque: M4 with 2.4 Nm [1.77 ft lbs], M5 with

5.0 Nm [3.70 ft lbs], M6 with 8.5 Nm [6.27 ft lbs]).

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when mounting the adapter plates, ensure that all four screws, including the

Installation

spring elements are tightened by applying the correct torque! All contact areas must be dirt/ paint-free, as correct protective earth connection cannot be ensured otherwise.

6. Reattach the original terminal board (8) to the motor, possibly with the aid of the terminal board expansion option (7) and the elongated screw option (9).

7. Connect four wires (PE, U, V, W) with the appropriate cross section (depending on the output of the drive controller used) to the original terminal board.

The connecting wires required for wiring the motor terminal board/ drive controller are not include in the delivery in the case of spare parts.

8. Screw the support (6) onto the adapter plate using the four fastening screws with spring elements (4). Please pay attention to the proper seating of the gasket (5). Insert the four wires (PE, U, V, W) into the support of the drive controller.

9. Plug the drive controller onto the support (6) and secure it evenly using the two M8 screws (torque: max. 21.0 Nm [15.5 ft lbs]).

Jumper

10. Wire any available connection cable of the Motor PTC/ Klixxon to terminals T1 and T2 (1) (torque: 0.6 Nm [0.44 ft lbs]).

when installing, make sure that the connection cables are not pinched.

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Installation

5.3.3

Power connection of sizes A - C

Power connection BG A - C

1. Unscrew the four screws from the housing cover of the drive controller and remove the cover.

2. Run the mains cable through the threaded cable gland and connect the phases with the contacts L1, L2, L3 for 400 V and the buried cable with the PE contact on the terminal. The threaded cable gland provides cable relief, the PE connection line must be connected as a leading contact (significantly longer)!

When connecting a braking resistor to an optional brake module, shielded and double-insulated cables must be used.

3 ~ 400 V terminal assignment X1

Terminal no. Designation (Terminal) assignment

1 L1 Mains phase 1 2 L2 Mains phase 2 3 L3 Mains phase 3 4 PE Buried cable

DC supply 250 to 750 V terminal assignment X1

Terminal no. Designation (Terminal) assignment

1 L1 DC network (+) (565V) 2 L2 Not assigned. 3 L3 DC network (-) 4 PE Buried cable

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5.3.4

Power connection of size D

Installation

Power connection BG D

1. Unscrew the four screws from the housing cover of the drive controller and remove the cover.

When connecting a braking resistor to an optional brake module, shielded and double-insulated cables must be used.

3 ~ 400 V terminal assignment X1

Terminal no. Designation (Terminal) assignment

1 L1 Mains phase 1 2 L2 Mains phase 2 3 L3 Mains phase 3 4 PE Buried cable

DC supply 250 to 750 V terminal assignment X1

Terminal no. Designation (Terminal) assignment

1 L1 DC network (+) (565V) 2 L2 Not assigned. 3 L3 DC network (-) 4 PE Buried cable

Motor terminal assignment X4

Terminal no. Designation (Terminal) assignment

1 PE Buried cable 2UMotor phase 1 3 4WMotor phase 3

Motor phase 2

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