Emerson E300 Series, 05200250, 04200185, 06200330, 06200440 Design Manual

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Design Guide

E300 Advanced Elevator Drive

Model sizes 3 to 7

Dedicated Elevator Variable Speed AC drive for induction and permanent magnet motors

Part Number: 0479-0024-01 Issue: 1

www.controltechniques.com

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 Control Techniques 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 Firmware Version (J04).

Environmental statement

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

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

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

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

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

REACH legislation

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

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

http://www.controltechniques.com/REACH

For patent and intellectual property related information please go to: www.ctpatents.info

How to use this guide

NOTE

Quick start /

bench testing

Quick start /

bench

testing

Familiarization

System designSystem design

Programming

and

commissioning

Programming

and

commissioning

Troubleshooting

1 Safety information

2 Product information

3 Mechanical installation

4 Electrical installation

5 Getting started

6 User Menu A

7 Commissioning

10 Optimization

11 Technical data

8 Advanced parameters

9 Diagnostics

This Design 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 on page 8 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 Design Guide helps to find the right sections for the task you wish to complete, but for specific information, refer to the table of contents.

Conventions used in this guide

The configuration of the drive and any option modules is done using menus and parameters. A menu is a logical collection of parameters that have similar functionality.

In the case of an option module, the option module set-up parameters in menu 0 will appear in drive menu P, Q and R depending on which slot the module is installed in.

The method used to determine the menu or parameter is as follows:

•Pr S.mm.ppp - Where S signifies the option module slot number and mm.ppp signifies the menu and parameter number respectively. If the option module slot number is not specified then the parameter reference will be a drive parameter.

•Pr mmpp - Where mm signifies the menu and pp signifies the parameter number within the menu.

•Pr mm00 - Signifies parameter number 00 in any drive menu.

•Pr S.mm.000 - Signifies parameter number 000 in any option module menu.

Contents

Declaration of Conformity .......................6

Declaration of Conformity (including 2006

Machinery Directive) ................................7

1 Safety information .................................8

1.1 Warnings, Cautions and Notes .............................8

1.2 Electrical safety - general warning ........................8

1.3 System design and safety of personnel ................8

1.4 Environmental limits ..............................................8

1.5 Access ...................................................................8

1.6 Fire protection .......................................................8

1.7 Compliance with regulations .................................8

1.8 Motor .....................................................................9

1.9 Mechanical brake control ......................................9

1.10 Adjusting parameters ............................................9

1.11 Electrical installation ..............................................9

2 Product information ............................10

2.1 E300 Advanced Elevator drive ............................10

2.2 Model number .....................................................11

2.3 Nameplate description ........................................11

2.4 Ratings ................................................................12

2.5 Operating modes .................................................16

2.6 Compatible position feedback devices ................17

2.7 Drive features ......................................................18

2.8 Options ................................................................19

2.9 Items supplied with the drive ...............................21

2.10 EMC filters ...........................................................22

2.11 AC input line reactors ..........................................23

2.12 EMC compliance (general standards) .................24

2.13 EMC compliance (elevator standards) ................26

3 Mechanical installation .......................29

3.1 Safety information ...............................................29

3.2 Installation ...........................................................29

3.3 Terminal cover removal .......................................30

3.4 Installing / removing option modules, keypad .....32

3.5 Dimensions and mounting methods ....................35

3.6 Enclosure for Elevator drive ................................42

3.7 Heatsink fan operation ........................................43

3.8 Enclosing standard drive for high environmental

protection ............................................................43

3.9 Electrical terminals ..............................................48

3.10 EMC filters ...........................................................49

3.11 Routine maintenance ..........................................56

4 Electrical installation .......................... 58

4.1 AC supply requirements ..................................... 59

4.2 Fuse types .......................................................... 59

4.3 Power connections ............................................. 60

4.4 Communications connections ............................ 66

4.5 Control connections ........................................... 67

4.6 Position feedback interface ................................ 73

4.7 Shield, Ground connections ............................... 79

4.8 Minimum connections ........................................ 80

4.9 24 Vdc supply ..................................................... 84

4.10 Low voltage operation ........................................ 85

4.11 Supplies requiring Input line reactors ................. 90

4.12 Cable selection ................................................... 90

4.13 Output circuit and motor protection .................... 93

4.14 Braking ............................................................... 94

4.15 Ground leakage .................................................. 96

4.16 EMC (Electromagnetic compatibility) ................. 97

4.17 General requirements for EMC .......................... 98

4.18 Safe Torque Off (STO) ..................................... 104

5 Getting started .................................. 106

5.1 Keypad set-up menu ........................................ 106

5.2 Keypad display ................................................. 107

5.3 Display messages ............................................ 108

5.4 Security and parameter access ........................ 109

5.5 Changing security and parameter access ........ 109

5.6 Keypad menu and parameter navigation ......... 110

5.7 Keypad menu and parameter shortcuts ........... 110

5.8 Saving parameters ........................................... 111

5.9 Restoring parameter defaults ........................... 111

5.10 Displaying destination parameters only ........... 111

5.11 Displaying non default parameters ................... 111

5.12 Menus, Parameters .......................................... 113

5.13 Powering up the drive ...................................... 115

5.14 Programming the drive ..................................... 115

5.15 Keypad operation ............................................. 115

5.16 NV Media Card operation ................................. 115

5.17 NV Media Card transferring data ..................... 117

5.18 Elevator Connect PC tool ................................. 118

5.19 Changing the operating mode .......................... 119

5.20 Communications .............................................. 119

6 User Menu A ...................................... 122

6.1 Basic parameter descriptions Creep to floor

operation .......................................................... 122

6.2 Parameter descriptions .................................... 128

6.3 Full parameter descriptions .............................. 129

4 E300 Design Guide

Issue Number: 1

7 Commissioning .................................150

7.1 Operating mode ................................................150

7.2 Motor and Encoder data ...................................150

7.3 Autotune ............................................................151

7.4 Elevator mechanical data ..................................158

7.5 Creep to floor profile .........................................159

7.6 Direct to floor profile ..........................................160

7.7 Creep to floor / Direct to floor - Start .................162

7.8 Travel ................................................................166

7.9 Stop ...................................................................167

7.10 Additional control functions ...............................169

7.11 Motor contactor control .....................................169

7.12 Load cell compensation ....................................170

7.13 Fast stop ...........................................................172

7.14 Rapid stop during acceleration .........................172

7.15 Load measurement ...........................................173

7.16 Inertia compensation .........................................174

7.17 Simulated encoder output .................................174

7.18 Advanced door opening ....................................175

7.19 Emergency backup power supply control .........175

7.20 Peak curve operation ........................................177

7.21 Floor sensor correction .....................................179

7.22 Short floor landing .............................................182

7.23 Fast start ...........................................................182

7.24 Backing up the drive parameter set ..................183

7.25 NV Media Card .................................................184

7.26 Elevator Connect PC tool ..................................185

9 Diagnostics ........................................436

9.1 Keypad ..............................................................436

9.2 Status LED ........................................................436

9.3 Communications protocols ................................436

9.4 Trip indications ..................................................437

9.5 Identifying a trip, trip source ..............................437

9.6 Displaying trip history ........................................438

9.7 Behavior of drive when tripped .........................439

9.8 Trip reset ...........................................................439

9.9 Status, Alarm, Trip indications ..........................442

9.10 Programming error indications ..........................443

9.11 Trip indications ..................................................443

9.12 Internal hardware trips ......................................443

9.13 Trips and sub-trip numbers ...............................444

9.14 Travel interrupt code .........................................444

9.15 Control state ......................................................445

9.16 Troubleshooting and identifying faults ..............450

9.17 Trip codes .........................................................454

10 Optimization .......................................474

10.1 Optimization ......................................................474

10.2 Control loop gain adjustment ............................474

10.3 Motor acoustic noise .........................................475

10.4 Creep to floor - Start optimization .....................476

10.5 Creep to floor - Travel optimization ...................476

10.6 Creep to floor - Stop optimization .....................477

10.7 Brake control optimization .................................478

8 Advanced Parameters ......................186

8.1 Menu B: Motor ..................................................191

8.2 Menu C: Encoder ..............................................219

8.3 Menu D: Brake ..................................................243

8.4 Menu E: Mechanical .........................................253

8.5 Menu F: - I/O Hardware ....................................262

8.6 Menu G: Profile .................................................287

8.7 Menu H: Configuration ......................................304

8.8 Menu I: Tuning ..................................................324

8.9 Menu J: Monitoring ...........................................333

8.10 Menu K: Logic ...................................................368

8.11 Menu L: Diagnostics .........................................385

8.12 Menu M: Comms ...............................................407

8.13 Menu N: Storage ...............................................410

8.14 Menu O: Back-up power ...................................414

8.15 Menus P, Q and R: Option module set-up ........425

8.16 Menu S: Application menu 1 .............................426

8.17 Menu T: Application menu 2 .............................426

8.18 Menu U: Application menu 3 .............................426

8.19 Menu Y: Data Logger ........................................427

8.20 Menu Z: Menu A Setup .....................................434

11 CT MODBUS RTU ..............................479

11.1 MODBUS RTU ..................................................479

11.2 Slave address ...................................................479

11.3 MODBUS registers ...........................................479

11.4 Data encoding ...................................................480

11.5 Function codes ..................................................480

11.6 Exceptions ........................................................483

11.7 CRC ..................................................................483

12 Technical Data ...................................484

12.1 Motor requirements ...........................................484

12.2 Temperature, humidity and cooling method ......484

12.3 Storage .............................................................484

12.4 Altitude ..............................................................484

12.5 IP / UL Rating ....................................................484

12.6 Corrosive gasses ..............................................485

12.7 RoHS compliance .............................................485

12.8 Vibration ............................................................485

12.9 Starts per hour ..................................................485

12.10 Start up time ......................................................485

12.11 Output frequency / speed range .......................485

12.12 Accuracy and resolution ....................................486

12.13 Acoustic noise ...................................................486

12.14 Overall dimensions ...........................................486

12.15 Weights .............................................................487

Index .................................................. 488

E300 Design Guide 5 Issue Number: 1

Declaration of Conformity

Control Techniques Ltd

The Gro

Newtown

Powys

SY16 3BE

This declaration applies to Elevator E200 and E300 variable speed drive products, comprising models numbers as shown below:

Eaaa-bbbbbbbbb Valid characters:

aaa 200, 300

03200050A, 03200066A, 03200080A, 03200106A, 03400025A, 03400031A, 03400045A, 03400062A, 03400078A, 03400100A

04200137A, 04200185A, 04400150, 04400172A

05200250A, 05400270A, 05400300A, 05500030A, 05500040A, 05500069A

bbbbbbbbb

The AC variable speed drive products listed above have been designed and manufactured in accordance with the following European

harmonized standards:

06200330A, 06200440A, 06400350A, 06400420A, 06400470A, 06500100A, 06500150A, 06500190A, 06500230A, 06500290A, 06500350A

07200610A, 07200750A, 07200830A, 07400660A, 07400770A, 07401000A, 07500440A, 07500550A, 07600190A, 07600240A, 07600290A, 07600380A, 07600440A, 07600540A

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: 20th January 2015

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

EN 61800-5-1:2007

EN 61800-3:2004

EN 61000-6-2:2005

EN 61000-6-4:2007

EN 61000-3-2:2006

EN 61000-3-3:2008

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

Adjustable speed electrical power drive systems - safety requirements - electrical, thermal and energy

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

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

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

Electromagnetic compatibility (EMC), Limits, Limits for harmonic current emissions (equipment input current <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 E300 Design Guide

Issue Number: 1

Declaration of Conformity (including 2006 Machinery Directive)

T. Alexander

VP Technology

Date: 19th January 2015

Place: Newtown, Powys. UK

Control Techniques Ltd The Gro Newtown Powys UK SY16 3BE

This declaration applies to Elevator E200 and E300 variable speed drive products, comprising models numbers as shown below

Eaaa-bbbbbbbbb Valid characters:

aaa 200, 300

03200050A, 03200066A, 03200080A, 03200106A, 03400025A, 03400031A, 03400045A, 03400062A, 03400078A, 03400100A

04200137A, 04200185A, 04400150, 04400172A

05200250A, 05400270A, 05400300A, 05500030A, 05500040A, 05500069A

bbbbbbbbb

This declaration relates to these products when used as a safety component of a machine. Only the SAFE TORQUE OFF function may be used for a safety function of a machine. None of the other functions of the drive may be used to carry out a safety function.

These products fulfil all the relevant provisions of Directives 2006/42/EC (The Machinery Directive) and 2004/108/EC (The EMC Directive).

EC type-examination has been carried out by the following notified body: TÜV Rheinland Industrie Service GmbH Am Grauen Stein D-51105 K

Notified Body identification number: 0035 EC type-examination certificate number: 01/205/5270/12

Öln

06200330A, 06200440A, 06400350A, 06400420A, 06400470A, 06500100A, 06500150A, 06500190A, 06500230A, 06500290A, 06500350A

07200610A, 07200750A, 07200830A, 07400660A, 07400770A, 07401000A, 07500440A, 07500550A, 07600190A, 07600240A, 07600290A, 07600380A, 07600440A, 07600540A

Moteurs Leroy-Somer Usine des Agriers Boulevard Marcellin Leroy CS10015 16915 Angoulême Cedex 9 France

The harmonized standards used are shown below:

Adjustable speed electrical power drive

EN 61800-5-1:2007

EN 61800-3:2004

EN 61000-6-2:2005

EN 61000-6-4:2007

EN 61000-3-2:2006

EN 61000-3-3:2008

Person authorised to compile the technical file: C Hargis Chief Engineer Newtown, Powys. UK

IMPORTANT NOTICE

These drive products are intended to be used with appropriate motors, sensors, electrical protection components and other equipment to form complete systems. It is the responsibility of the installer to ensure that the design of the complete machine, including its safety-related control system, is carried out in accordance with the requirements of the Machinery Directive and any other relevant legislation. The use of a safety-related drive in itself does not ensure the safety of the machine.

Compliance with safety and EMC regulations depends upon installing and configuring inverters correctly.

systems - safety requirements - electrical, thermal and energy

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

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

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

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

E300 Design Guide 7 Issue Number: 1

Safety

WARNING

CAUTION

NOTE

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

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.

User Menu A Commissioning

Advanced

Parameters

Diagnostics Optimization CT MODBUS RTU Technical Data

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 Design Guide.

1.3 System design and safety of personnel

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 Design Guide carefully.

The STOP and Safe Torque Off (STO) 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 (STO) 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 - for example, an over-speed protection device in case of failure of the speed control, or a fail-safe mechanical brake in case of loss of motor braking.

The Safe Torque Off (STO) 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.

1.4 Environmental limits

Instructions in this Design 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.

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 Fire protection

The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided. For further information, refer to section 3.2.5 Fire protection on page 29.

1.7 Compliance with regulations

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

This guide contains instructions for achieving compliance with specific EMC standards. Within the European Union, all machinery in which this product is used must comply with the following directives:

2006/42/EC: Safety of machinery. 2004/108/EC: Electromagnetic Compatibility.

8 E300 Design Guide

Issue Number: 1

Safety

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

User Menu A Commissioning

Advanced

Parameters

Diagnostics Optimization CT MODBUS RTU Technical Data

1.8 Motor

Ensure the motor is installed in accordance with the manufacturer’s recommendations. Ensure the motor shaft is not exposed. Standard squirrel cage induction motors are designed for single speed operation. If it is intended to use the capability of the drive to run a motor at

speeds above its designed maximum, it is strongly recommended that the manufacturer is consulted first. Low speeds may cause the motor to overheat because the cooling fan becomes less effective. The motor should be installed with a protection

thermistor. If necessary, an electric forced vent fan should be used. The values of the motor parameters set in the drive affect the protection of the motor. The default values in the drive should not be relied upon. It is essential that the correct value is entered into the Motor Rated Current (B02). This affects the thermal protection of the motor.

1.9 Mechanical brake control

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

1.10 Adjusting parameters

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

1.11 Electrical installation

1.11.1 Electric shock risk

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

• AC supply cables and connections

• Output cables and connections

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

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

1.11.2 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.

E300 Design Guide 9 Issue Number: 1

Safety

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

User Menu A Commissioning

Advanced

Parameters

Diagnostics Optimization CT MODBUS RTU Technical Data

2 Product information

2.1 E300 Advanced Elevator drive

E300 Advanced Elevator drive features

• Universal high performance drive for asynchronous induction motors and synchronous permanent magnet motors.

• Flexibility with speed and position measurement, supporting multiple devices and all common interfaces

• Analog and digital I/O with single channel Safe Torque Off (STO) input

• Local and Remote keypad options

• NV Media Card for parameter copying and data storage

Configuration

The E300 Advanced Elevator drive can operate in either Open loop or RFC-A mode with asynchronous induction motors for geared Elevator applications or in RFC-S mode with synchronous permanent magnet motors for gearless Elevator applications. The default operating mode for the E300 Advanced Elevator drive is RFC-S mode with this targeted at gearless Elevator applications using PM synchronous motors.

Full support is provided for a both a rotating and static autotune. There is support for a wide range of position feedback devices from the incremental encoder to high resolution SinCos encoders along with a simulated encoder output as standard onboard the drive.

The E300 Advanced Elevator drive also has TuV Nord approval to EN81 for a zero output motor contactor solution using the drives Safe Torque Off (STO), Drive enable input.

Profile

The default operating profile for the E300 Advanced Elevator drive is Creep to floor mode. Optimization of the profile is possible through the separate acceleration and deceleration rates along with multiple jerks. Variable speed and current control loop gains are available for the start, travel and stop.

The E300 Advanced Elevator drive additionally offers enhanced profile control:

• Direct to floor mode - decelerates the elevator car directly to the floor following a signal to stop, with no creep speed.

• Peak curve operation - profile peak speed and stopping distance controlled regardless of when the signal to stop is given, optimizing travel time.

• Floor sensor correction - using a floor sensor / limit switch to compensate for rope slip, rope stretch and other mechanical offsets.

• Position controlled short floor operation. An optional external load cell compensation input can be connected to the drive where required.

Parallel interface

The E300 Advanced Elevator drive and control software can support either digital only parallel interfaces (binary or priority speed selection) or digital parallel interfaces with an analog speed reference. The drive has brake control set-up configured as default with the option of selecting the additional output motor contactor control.

Programming, monitoring

The E300 Advanced Elevator drive has a standard Keypad which allows set-up and optimization of the drive along with monitoring of parameters. An NV Media Card can be used which allows drive parameters to be uploaded and downloaded. The NV Media Card can also be used to back up the

drive parameter set. The NV Media Card support is via a SMARTCARD or SD card Adaptor and SD card. The Elevator Connect PC tool allows programming, uploading and downloading of drive parameter sets along with monitoring the E300 Advanced

Elevator drive during operation and optimization. The Elevator Connect PC tool is free of charge and can be downloaded from www.controltechniques.com.

Communications

The E300 Advanced Elevator drive has RS485 serial communications by default. This supports communications to the Elevator controller, PC tools and Firmware programming. Additional communications protocols are supported via SI option modules.

10 E300 Design Guide

Issue Number: 1

Safety

E300

300-1xSTO, RS845 comms

Approvals

Input voltage

Output

voltage

Power rating

Customer and date code

Serial number

Input

frequency

No.of phases & Typical input current

Output current rating

0.75 kW

EN81-1/2

Refer to

Documentation

Model

Frame

size

Voltage

Current rating

Drive format

E300 - 032 00050 A

Key to approvals

CE approval Europe

C Tick approval Australia

UL / cUL approval USA & Canada

RoHS compliant Europe

Large label *

NOTE

information

Product

information

Mechanical

installation

Electrical

installation

Getting started

User Menu A Commissioning

Advanced

Parameters

Diagnostics Optimization CT MODBUS RTU Technical Data

2.2 Model number

The way in which the model numbers for the E300 Advanced Elevator drive range is formed is illustrated below:

Figure 2-1 Model number

2.3 Nameplate description

Figure 2-2 Typical drive rating labels

* This label is only applicable to size 7

Date code format

The date code is split into two sections: a letter followed by a number. The letter indicates the year, and the number indicates the week number within the year in which the option module was built.The letters go in alphabetical order, starting with A in 1990 (B in 1991, C in 1992 etc).

Example:

A date code of W28 would correspond to week 28 of year 2013.

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2.4 Ratings

The E300 Advanced Elevator drive is configured for Heavy Duty operation, For constant torque applications or applications which require a high overload capability, or full torque is required at low speeds (e.g. elevators, hoists). The thermal protection is set to protect force ventilated induction motors and permanent magnet servo motors by default.

t protection defaults to be compatible with:

Motor I

If the application uses a self ventilated (TENV/TEFC) induction motor and increased thermal protection is required for speeds below 50 % base speed, then this can be enabled by setting Low Speed Thermal Protection Mode (B44) = On (1).

The rating label details the available output current under the following conditions:

• 40 °C (104 °F) maximum ambient,

• 1000 m altitude,

• 8 kHz switching frequency,

• A typical elevator profile (50 % ED),

• IGBT lifetime optimization enabled (reduction of switching frequency based on drive inverter temperature). Derating is required for higher switching frequencies, ambient temperatures >40 °C (104 °F) and higher altitude. For derating information, refer to

section 2.4.2 Power and current ratings (derating for switching frequency and temperature) on page 14.

The input current is affected by the supply voltage and impedance. The input current given on the rating label is the typical input current and is stated for a balanced supply.

Fuses

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

Table 2-1 200 V drive and AC fuse ratings

Heavy Duty Fuse

Nom power

230 V

Motor power

230 V

IEC UL

Class

Nom

Model

Max. cont.

input current

3 ph Nom

Max. cont.

output current

AAkWhpA A

03200106 20 10.6 2.2 3 25 gG 25 CC, J or T* 04200137 20 13.7 3 3 25 04200185 28 18.5 4 5 32 30

05200250 31 25 5.5 7.5 40 gG 40 CC, J or T* 06200330 48 33 7.5 10 63 06200440 56 44 11 15 63 70

07200610 67 61 15 20 80

07200830 105 83 22 30 125 125

Table 2-2 400 V drive and AC fuse ratings

Heavy Duty Fuse

Nom power

400 V

Motor power

460 V

IEC UL

Class

Nom

Model

Max. cont.

input current

3ph Nom

Max. cont.

output current

AAkWhpA A

03400062 13 6.2 2.2 3.0 20

gG 03400100 16 10 4 5.0 20 20 04400150 19 15 5.5 10.0 25 04400172 24 17.2 7.5 10.0 32 30 05400270 29 27 11 05400300 30 30 15 40 35

06400350 36 35 15 25 63

gR 06400470 60 47 22 30 63 70 07400660 74 66 30 50 100

07401000 105 100 45 75 125 125

* These fuses are fast acting.

Class

CC, J or T*

CC, J or T*07200750 84 75 18.5 25 100 100

Class

CC, J or T*03400078 13 7.8 3 5.0 20 20

CC, J or T*

HSJ or DFJ06400420 46 42 18.5 30 63 50

CC, J or T*07400770 88 77 37 60 100 100

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Total Output Current (J22)

as 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 %

B44 B44=0=1

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2.4.1 Typical short term overload limits

The maximum overload limit changes depending on the selected motor. Variations in motor rated current, motor power factor and motor leakage inductance all result in changes in the maximum possible overload due to the thermal models estimation of the motor temperature as a percentage of its maximum allowed temperature. Typical values for overload are shown in the table below:

Table 2-3 Typical overload limits

Operating mode Closed loop from cold Closed loop from 100 % Open loop from cold Open loop from 100 %

Heavy Duty overload Motor rated current = drive rated current

Heavy duty operating mode

The thermal protection is set to protect force ventilated induction motors and permanent magnet servo motors by default. If the application uses a self ventilated (TENV/TEFC) induction motor and increased thermal protection is required for speeds below 50 % base speed, then this can be enabled by setting Low Speed Thermal Protection Mode (B44) = On (1).

Operation of motor I2t protection

t protection defaults to be compatible with:

Motor I

• Forced ventilation induction motors

• Permanent magnet servo motors

175 % for 40 s 175 % for 5 s 150 % for 60 s 155 % for 8 s

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2.4.2 Power and current ratings (derating for switching frequency and temperature)

Table 2-4 Maximum permissible continuous output current @ 40 °C (104 °F) ambient

Heavy Duty

Model

Nominal rating Maximum permissible continuous output current (A) for the following switching frequencies

kW hp

kHz

200 V

03200106 2.2 3.0 10.6 TBC TBC

04200137 3.0 3.0 13.7 TBC TBC

04200185 4.0 5.0 18.5 TBC TBC

05200250 5.5 7.5 25 TBC TBC

06200330 7.5 10 33.0 TBC TBC

06200440 11 15 44.0 TBC TBC

07200610 15 20 61 TBC TBC

07200750 18.5 25 75 TBC TBC

07200830 22 30 83 TBC TBC

400 V

03400062 2.2 3.0 6.2 5.8 TBC TBC

03400078 3.0 5.0 7.8 6.0 TBC TBC

03400100 4.0 5.0 10 6.0 TBC TBC

04400150 5.5 10 15.0

04400172 7.5 10 17.2 TBC TBC

12.8

TBC TBC

05400270 11 20 27 20.2 TBC TBC

05400300 15 20 30 26.5 TBC TBC

06400350 15 25 35

06400420 18.5 30 42 TBC TBC

27.1

TBC TBC

06400470 22 30 47 TBC TBC

07400660 30 50 66

07400770 37 60 77 TBC TBC

TBC TBC

07401000 45 75 100 TBC TBC

kHz

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Table 2-5 Maximum permissible continuous output current @40 C (104 F) ambient with high IP insert installed

Heavy Duty

Model

Maximum permissible continuous output current (A) for the following switching frequencies

kHz

200 V

03200106 TBC

04200137 TBC

04200185 TBC

05200250 TBC

400 V

03400062 TBC

03400078 TBC

03400100 TBC

04400150 TBC

04400172 TBC

05400270 TBC

05400300 TBC

Table 2-6 Maximum permissible continuous output current @ 50 C (122 F)

Model

kHz

Maximum permissible continuous output current (A)

for the following switching frequencies

kHz

200 V

03200106 TBC

04200137 TBC

04200185 TBC

05200250 TBC

06200330 TBC

06200440 TBC

07200610 TBC

07200750 TBC

07200830 TBC

400 V

03400062 TBC

03400078 TBC

03400100 TBC

04400150 TBC

04400172 TBC

05400270 TBC

05400300 TBC

06400350 TBC

06400420 TBC

06400470 TBC

07400660 TBC

07400770 TBC

07401000 TBC

kHz

Heavy Duty

kHz

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2.5 Operating modes

The E300 Advanced Elevator drive is designed to operate in any of the following modes, with the default operating mode being RFC-S.

Open loop mode

Open loop vector mode Fixed V/F mode (V/Hz)

RFC - A, Closed loop vector

With position feedback sensor Sensorless mode without position feedback for rescue operation

RFC - S, Closed loop Servo

With position feedback sensor Sensorless mode without position feedback for rescue operation

2.5.1 Open loop mode

The drive applies power to the motor at frequencies varied by the user. The motor speed is a result of the output frequency of the drive and slip due to the mechanical load. The drive can improve the speed control of the motor by applying slip compensation. The performance at low speed depends on whether Fixed V/F mode or Open loop vector mode is selected.

Vector mode

The voltage applied to the motor is directly proportional to the frequency except at low speed where the drive uses motor parameters to apply the correct voltage to keep the flux constant under varying load conditions. Typically 100 % torque is available down to 1 Hz for a 50 Hz motor.

Fixed V/F mode

The voltage applied to the motor is directly proportional to the frequency except at low speed where a voltage boost is provided which is set by the user. This mode can be used for multi-motor applications. Typically 100 % torque is available down to 4 Hz for a 50 Hz motor.

2.5.2 RFC-A

Rotor Flux Control for Asynchronous induction motors RFC-A encompasses closed loop vector control with a position feedback device

With position feedback

For use with induction motors with a feedback device installed. The drive directly controls the speed of the motor using the feedback device to ensure the rotor speed exactly as demanded. Motor flux is accurately controlled at all times to provide full torque all the way down to zero speed.

Sensorless mode without position feedback for rescue operation

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.

2.5.3 RFC- S

Rotor Flux Control for Synchronous permanent magnet brushless motors RFC-S provides closed loop control with position feedback device.

With position feedback

For use with permanent magnet brushless motors with a feedback device installed. The drive directly controls the speed of the motor using the feedback device to ensure the rotor speed is exactly as demanded. Flux control is not required because the motor is self excited by the permanent magnets which form part of the rotor. Absolute position information is required from the feedback device to ensure the output voltage is accurately matched to the back EMF of the motor. Full torque is available all the way down to zero speed.

Sensorless mode without position feedback for rescue operation

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.

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2.6 Compatible position feedback devices

Table 2-7 Supported feedback devices

Encoder type Drive encoder type (C01)

Quadrature incremental encoders with or without marker pulse AB (0) Quadrature incremental encoders with UVW commutation signals for absolute position for permanent magnet motors

with or without marker pulse Forward / reverse incremental encoders with or without marker pulse FR (2) Forward / reverse incremental encoders with UVW commutation signals for absolute position for permanent magnet

motors with or without marker pulse Frequency and direction incremental encoders with or without marker pulse FD (1) Frequency and direction incremental encoders with UVW commutation signals for absolute position for permanent

magnet motors with or without marker pulse Sincos incremental encoders SC (6) Sincos incremental with commutation signals SC Servo (12) Heidenhain sincos encoders with EnDat comms for absolute position SC EnDat (9) Stegmann sincos encoders with Hiperface comms for absolute position SC Hiperface (7) Sincos encoders with SSI comms for absolute position SC SSI (11) Sincos incremental with absolute position from single sin and cosine signals SC SC (15) SSI encoders (Gray code or binary) SSI (10) EnDat communication only encoders EnDat (8) BiSS communication only encoders* (not currently supported) BiSS (13) UVW commutation only encoders** (not currently supported) Commutation only (16)

* Only BiSS type C encoders are supported. ** This feedback device provides very low resolution feedback and should not be used for applications requiring a high level of performance.

AB Servo (3)

FR Servo (5)

FD Servo (4)

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2.7 Drive features

Figure 2-3 Features of the drive (size 3 to 7)

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Key

1. Keypad connection 6. Option module slot 2 11. NV Media Cardslot 15. DC bus -

2. Rating label 7. Option module slot 3 12. Braking terminal 16. Motor connections

3. Identification label 8. Relay connections 13. Internal EMC filter 17. AC supply connections

4. Status LED 9. Position feedback connections 14. DC bus + 18. Ground connections

5. Option module slot 1 10. Control connections

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2.8 Options

Figure 2-4 Drive features and options

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Key

1. Keypad - Local 4. Option module slot 2 7. KI-485 Adaptor

2. Keypad - Remote 5. Option module slot 3

3. Option module slot 1 6. NV Media Card

Option modules come in two different formats, a standard option module and a large option module. All standard option modules are color-coded in order to make identification easy, whereas the larger option module is black. 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, whereas the large option modules can only be installed to option slot

3. The following tables shows the color-code key and gives further details on their function.

Table 2-8 Option module identification

Type Color Name Further Details

Drive encoder input converter

Provides screw terminal interface for encoder wiring and spade terminal for shield

Single ended encoder interface

Provides an interface for single ended ABZ encoder signals such as those from hall effect sensors. 15 V and 24 V versions are available

Additional combined encoder input and output interface supporting Incremental, SinCos, HIPERFACE, EnDAT and SSI encoders.

Feedback

N/A 15 way D type converter

N/A

Single ended encoder

interface (15 V or 24 V)

Dark Brown SI-Universal Encoder

External Ethernet module that supports EtherNet/IP, Modbus TCP/IP and

Fieldbus Beige SI-Ethernet

RTMoE. The module can be used to provide high speed drive access, global connectivity and integration with IT network technologies, such as wireless networking

Extended I/O

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

Automation

(I/O expansion)

Orange SI-I/O

• Digital I/O

• Digital Inputs

• Analog Inputs (differential or single ended)

• Analog Output

• Relays

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Type Color Name Further Details

Moss Green MCi 200

Machine Control Studio compatible applications processor

2nd processor for running pre-defined and/or customer created application software.

Machine Control Studio compatible applications processor (with Ethernet

Automation

(Applications)

Moss Green MCi 210

communications)

2nd processor for running pre-defined and/or customer created application software with Ethernet communications.

SyPTPro compatible applications processor (with CTNet)

Black SI-Applications Plus

2nd processor for running pre-defined and/or customer created application software with CTNet support (can only be used on Slot 3).

Table 2-9 Keypad identification

Type Name Further Details

KI-Elv Keypad RTC

Keypad

CI-Elv Remote Keypad

LCD RTC keypad option

Keypad with LCD display and real time clock

LCD Remote keypad option

Keypad with LCD display which can be mounted remotely (KI-485 Adaptor and CT USB comms cable required)

Table 2-10 Additional options

Type Name Further Details

SD Card Adaptor

Back-up

SMARTCARD

SD card adaptor

Allows the drive to use an SD card for drive back-up

SMARTCARD

Used for parameter back-up with the drive

485 Comms adaptor

KI-485 Adaptor

Communications

CT USB comms cable

485 Comms adaptor provides 485 communication interface and connection of the remote keypad. This adaptor supports 115 k Baud, node addresses between 1 to 16 and 8 1 NP M serial mode.

Comms cable

CT USB to RJ485 comms cable for use with KI-485 Adaptor to provide communications interface

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2.9 Items supplied with the drive

The drive is supplied with a copy of the safety information booklet, the Certificate of Quality and an accessory kit box including the items shown in Table 2-11 below.

Table 2-11 Parts supplied with the drive (size 3 to 7)

Description Size 3 Size 4 Size 5 Size 6 Size 7

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 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

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2.10 EMC filters

There are three EMC filter options available:

Table 2-12 EMC filter options

Filter option Requirements of EN 61800-3:2004 met

Internal EMC filter Second environment, with short motor cable Standard external EMC filter First and second environment with motor cable length up to 100 m Compact external EMC filter First and second environment with motor cable length up to 20 m

2.10.1 Internal EMC filter

It is recommended that the internal EMC filter be kept in place unless there is a specific reason for removing it, for example the drive is part of a Regen system or there is excessive ground leakage current in the system. 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. 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, or where the ground leakage current is unacceptable.

If the drive is used with ungrounded (IT) supplies, the internal EMC filter must be removed unless additional motor ground fault protection is installed.

The power supply must be removed prior to removing the internal EMC filter.

2.10.2 Standard external EMC filter

The external EMC filter for all drive size can be either footprint or bookcase mounted, the details for each EMC filter is provided in the following.

Table 2-13 External EMC filter data

Model CT part number

200 V

03200050 to 03200106 4200-3230 1.9 4.20 04200137 to 04200185 4200-0272 4.0 8.82

05200250 4200-0312 5.5 12.13 06200330 to 06200440 4200-2300 6.5 14.3 07200610 to 07200830 4200-1132 6.9 15.2

400 V

03400025 to 03400100 4200-3480 2.0 4.40 04400150 to 04400172 4200-0252 4.1 9.04 05400270 to 05400300 4200-0402 5.5 12.13 06400350 to 06400470 4200-4800 6.7 14.8 07400660 to 07401000 4200-1132 6.9 15.2

575 V

05500030 to 05500069 4200-0122 7.0 15.4 06500100 to 06500350 4200-3690 7.0 15.4 07500440 to 07500550 4200-0672

690 V

07600190 to 07600540 4200-0672

The external EMC filters for sizes 3 to 6 can be footprint mounted or bookcase mounted.

Weight

kg Ib

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2.10.3 Compact external EMC filters

The external Compact EMC filter for size 3, 4 and 5, drives can be bookcase mounted, the details for each of the Compact EMC filters is provided following.

Table 2-14 External Compact EMC filter data

Model CT part number

Weight

kg lb

400 V

03400025 to 03400100

4200-6126 0.4 0.88

4200-6219 0.6 1.32 04400150 to 04400172 4200-6220 0.7 1.54 05400270 to 05400300 4200-6221-01 1.7 3.75

When using the external Compact EMC filters an additional AC input line reactor is required which is selected to meet the requirements of EN 12015.

2.11 AC input line reactors

The AC power supply current harmonics for the complete Elevator system will be the vector sums of the harmonic currents for all of the individual electrical loads in the system. Usually the main drive will dominate the electrical load, and it will be sufficient to ensure that these meet the harmonic requirements detailed in IEC 61000-3-12 (EN 12015). Where drives are also used for ancillary functions such as door opening, ventilation etc., it may be necessary to ensure that their harmonic contributions are not excessive, although generally their power ratings will be too small to be significant.

AC input line reactors must be provided in order to maintain the harmonics below the required levels detailed in IEC 61000-3-12 (EN 12015), the following table provides details of suitable AC input line reactors to meet this standard whilst operating at rated power. Note the correct value reactor depends upon the maximum input power for the particular Elevator system, and not necessarily the drive model / rating. For a given application, it is important the actual maximum input power is measured / estimated and the correct reactor value calculated in inverse proportion to the power.

Table 2-15 AC input line reactors

AC Input Line reactor

Drive model

03200050 6 3.8 0.75 03200066 5 5.0 1.1 03200080 3 6.2 1.5 03200106 3 8.1 2.2 04200137 2.0 10.4 3.0 04200185 1.5 14 4.0 05200250 0.75 19.7 5.5 06200330 0.40 26.5 7.5 06200440 0.40 34.5 11.0 07200610 0.19 47.76 15.0 07200750 0.178 57.97 18.5 07200830 0.089 64.68 22.0 03400025 18 1.8 0.75 03400031 15 2.2 1.1 03400045 11 3.2 1.5 03400062 8 5.1 2.2 03400078 5 6.7 3.0 03400100 4 8.8 4.0 04400150 2.0 12.6 5.5 04400172 2.0 14.4 7.5 05400270 1.5 22 11.0 05400300 1.5 24.4 15.0 06400350 0.80 29.0 15.0 06400420 0.80 34.5 18.5 06400470 0.80 38.4 22.0 07400660 0.315 55.79 30.0 07400770 0.190 65.23 37.0 07401000 0.190 83.33 45.0

Inductance

Current rating

Input power

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AC Input Line reactor

Drive model

Inductance

Current rating

Input power

05500030 19 2.2 1.5 05500040 13 3.0 2.2 05500069 7 5.1 4.0 06500100 4.0 8.4 5.5 06500150 4.0 12.3 7.5 06500190 2.0 15.8 11.0 06500230 2.0 19.1 15.0 06500290 1.5 22.6 22.0 06500350 1.0 29.5 30.0 07500440 1.0 33.8 37.0 07500550 1.0 38.6 45.0

Where input line reactors are not required to meet IEC 61000-3-12 (EN 12015) line reactors may still be required due to power supply quality issues, poor phase balance, severe disturbances etc in this case refer to section 4.11 Supplies requiring Input line reactors on page 90.

2.12 EMC compliance (general standards)

This is a summary of the EMC performance of the drive. For full details, refer to the EMC Data Sheet which can be obtained from the supplier of the drive.

Table 2-16 Immunity compliance

Standard Type of immunity Test specification Application Level

IEC61000-4-2 EN61000-4-2 Electrostatic discharge

IEC61000-4-3 EN61000-4-3

IEC61000-4-4 EN61000-4-4

IEC61000-4-5 EN61000-4-5

IEC61000-4-6 EN61000-4-6

IEC61000-4-11 EN61000-4-11

IEC61000-6-1 EN61000-6-1:2007

IEC61000-6-2 EN61000-6-2:2005

IEC61800-3 EN61800-3:2004

See section 4.17.8 Surge immunity of control circuits on page 103 for control ports for possible requirements regarding grounding and external

Radio frequency radiated field

Fast transient burst

Surges

Conducted radio frequency

Voltage dips and interruptions

Generic immunity standard for the residential, commercial and light industrial environment

Generic immunity standard for the industrial environment

Product standard for adjustable speed power drive systems (immunity requirements)

6 kV contact discharge 8 kV air discharge

10 V/m prior to modulation 80 - 1000 MHz 80 % AM (1 kHz) modulation

5/50 ns 2 kV transient at 5 kHz repetition frequency via coupling clamp

5/50 ns 2 kV transient at 5 kHz repetition frequency by direct injection

Common mode 4 kV

1.2/50 μs waveshape Differential mode

2 kV

1.2/50 μs waveshape

Lines to ground

10V prior to modulation

0.15 - 80 MHz 80 % AM (1 kHz) modulation

-30 % 10 ms +60 % 100 ms

-60 % 1 s <-95 % 5 s

Module enclosure

Control lines

Power lines

AC supply lines: line to ground

AC supply lines: line to line

Signal ports to ground

Control and power lines

AC power ports

Meets immunity requirements for first and second environments

surge protection

Emission

The drive contains an in-built filter for basic emission control. An additional optional external filter provides further reduction of emission. The requirements of the following standards are met, depending on the motor cable length and switching frequency.

Level 3 (industrial)

Level 4 (industrial harsh)

Level 3 (industrial)

Level 4

Level 3

Level 2

Level 3 (industrial)

Complies

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Table 2-17 Size 3 emission compliance (200 V drives)

Motor cable

length (m)

234681216

Switching Frequency (kHz)

Using internal filter:

0 – 2 C3 C4

Using internal filter and ferrite ring (2 turns):

0 – 10 C3 C4

10-20 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Table 2-18 Size 3 emission compliance (400 V drives)

Motor cable

length (m)

234681216

Switching Frequency (kHz)

Using internal filter:

0 – 5 C3 C4

Using internal filter and ferrite ring (2 turns):

0 – 10 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Table 2-19 Size 4 emission compliance (200 V drives)

Motor cable

length (m)

234681216

Switching Frequency (kHz)

Using internal filter:

0 – 2 C3 C4

Using internal filter and ferrite ring (2 turns):

0 – 4 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Table 2-20 Size 4 emission compliance (400 V drives)

Motor cable

length (m)

234681216

Switching Frequency (kHz)

Using internal filter:

0 – 4 C3 C4

Using internal filter and ferrite ring (2 turns):

0 – 10 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Table 2-21 Size 5 emission compliance (200 V drives)

Motor cable

length (m)

234681216

Switching Frequency (kHz)

Using internal filter:

0 – 2 C3 C4

Using internal filter and ferrite ring (1 turn – no advantage to 2 turns):

0 – 2 C3 C4 0 – 5 C3 C4 0 – 7 C3 C4

0 – 10 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Table 2-22 Size 5 emission compliance (400 V drives)

Motor cable

length (m)

234681216

Switc0hing Frequency (kHz)

Using internal filter:

0 – 4 C3 C4

0 – 10 C3 C4 No advantage to using ferrite ring Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Table 2-23 Size 5 emission compliance (575 V drives)

Motor cable

length (m)

234681216

Switching Frequency (kHz)

Using internal filter:

-C4 Using internal filter and ferrite ring (2 turns):

0 – 4 C3 C4 0 – 2 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Table 2-24 Size 6 emission compliance (200 V drives)

Motor cable

length (m)

234681216

Switching Frequency (kHz)

Using internal filter: 0 – 2 C3 C4 Using internal filter and ferrite ring (1 turn – no advantage to 2 turns):

0 – 2 C3 C4 0 – 5 C3 C4 0 – 7 C3 C4

0 – 10 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Table 2-25 Size 6 emission compliance (400 V drives)

Motor cable

length (m)

234681216

Switching Frequency (kHz)

Using internal filter:

0 – 4 C3 C4

0 – 10 C3 C4 No advantage to using ferrite ring Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

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Table 2-26 Size 6 emission compliance (575 V drives)

Motor cable

length (m)

Using internal filter:

-C4 Using internal filter and ferrite ring (2 turns):

0 – 4 C3 C4 0 – 2 C3 C4

Using external filter:

0 – 20 R (C1) R (C1) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 100 I (C2) I (C2) C3 C3 C3 C3 C3

Table 2-27 Size 7 emission compliance (200 V drives)

Motor cable

length (m)

Using the internal filter

2~10

Using the external filter (CT No. 4200-1132)

0 – 20 R (C1) R (C1) R (C1) R (C1) R (C1) R (C1)

20 – 40 R (C1) R (C1) R (C1) R (C1) R (C1) R (C1)

40 – 100 R (C1) R (C1) R (C1) R (C1) I (C2) I (C2)

Table 2-28 Size 7 emission compliance (400 V drives)

Motor cable

length (m)

Using the internal filter

2~10 C4

Using the external filter (CT No. 4200-1132)

0 – 20 R (C1)

20 – 50 I (C2) I (C2) I (C2) I (C2) I (C2) I (C2) I (C2)

50 – 100 I (C2) I (C2) I (C2) - - - -

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234681216

2346812

234681216

(C1)

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Switching frequency (kHz)

I (C2) I (C2) I (C2) I (C2) I (C2)

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Table 2-29 Size 7 emission compliance (575 V and 690 V drives)

Motor cable

length (m)

Using the internal filter

2~10

Using the external filter (CT No. 4200-0672)

0 – 20 R (C1) I (C2) I (C2) I (C2) I (C2) I (C2) I (C2)

20 – 50 R (C1) I (C2) I (C2) I (C2) I (C2) I (C2) I (C2)

50 – 100 I (C2) I (C2) - - - -

234681216

Switching frequency (kHz)

Key (shown in decreasing order of permitted emission level):

E2R EN 61800-3:2004 second environment, restricted distribution

(Additional measures may be required to prevent interference)

E2U EN 61800-3:2004 second environment, unrestricted distribution I Industrial generic standard EN 61000-6-4:2007

EN 61800-3:2004 first environment restricted distribution (The

following caution is required by EN 61800-3:2004)

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.

R Residential generic standard EN 61000-6-3:2007

EN 61800-3:2004 first environment unrestricted distribution

EN 61800-3:2004 defines the following:

• The first environment is one that includes residential premises. It also includes establishments directly connected without intermediate transformers to a low-voltage power supply network which supplies buildings used for residential purposes.

• The second environment is one that includes all establishments other than those directly connected to a low-voltage power supply network which supplies buildings used for residential purposes.

• Restricted distribution is defined as a mode of sales distribution in which the manufacturer restricts the supply of equipment to suppliers, customers or users who separately or jointly have technical competence in the EMC requirements of the application of drives.

IEC 61800-3:2004 and EN 61800-3:2004

The 2004 revision of the standard uses different terminology to align the requirements of the standard better with the EC EMC Directive. Power drive systems are categorized C1 to C4:

Category Definition Corresponding code used above

C1 Intended for use in the first or second environments R

C3 Intended for use in the second environment, not the first environment E2U

Note that category 4 is more restrictive than E2R, since the rated current of the PDS must exceed 400 A or the supply voltage exceed 1000 V, for the complete PDS.

Not a plug-in or movable device, and intended for use in the first environment only when installed by a professional, or in the second environment

Rated at over 1000 V or over 400 A , intended for use in complex systems in the second environment

E2R

2.13 EMC compliance (elevator standards)

This section provides specific information for the E300 drives when used in lifts, elevators and escalators which are required to comply with the harmonized European EMC standards EN 12015 (emission) and EN 12016 (immunity). These standards were revised in 2004, although in some EU countries the revised versions did not become available until 2006. The revised versions became mandatory in June 2006. They contain some important changes from the previous (1998) versions. The information given here includes the requirements of the revised versions. For full details refer to the EMC data sheet, which can be obtained from the supplier of the drive.

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2.13.1 Emission - EN 12015

The standard sets limits in the following categories:

1. Radiated emission from the enclosure

This covers the frequency range 30 MHz to 1000 MHz. The limits are the same as for the generic standard EN 61000-6-4 and are unchanged from the 1998 version.

2. Conducted emission from the AC mains port(s)

This covers the frequency range 0.15 MHz to 30 MHz. The limits are the same as for the generic standard EN 61000-6-4 and are unchanged from the 1998 version.

3. Conducted emission from the power port(s) (motor port etc).

This covers the frequency range 0.15 MHz to 30 MHz. These are new limits, which apply unless the motor cable length does not exceed 2 m or it is screened.

4. Impulse noise

This is a special requirement for impulsive conducted emission. The limits are the same as for the 1998 version.

5. Voltage fluctuations

This covers fluctuations, which are variations in the supply voltage which result in lighting flicker. These are new limits. They are based on the standard EN 61000-3-11.

6. Mains current harmonics

This covers harmonics up to order 40. These are new limits. They are based on standard IEC 61000-3-4.

Conformity of the Control Techniques drive products with EN 12015

The drives conform to the standard for Power Drives Systems, EN 61800-3, and the generic standard for industrial environments EN 61000-6-4. In many respects this also covers the requirements of EN 12015.

Mains conducted emission

Generally the standard optional external filter must be used. The motor cable length is set by the filter capability, on the assumption that the highest available switching frequency is in use. If longer lengths are required this can usually be achieved by reducing the switching frequency, see the appropriate EMC data sheet for further information. Where the lift system has a rated input current exceeding 100 A, and a dedicated supply transformer, higher emission levels are permitted and then

only the built-in filter is required. Please note that the standard test method requires the use of a mains supply cable 1 m long, this being the cable which connects the system under

test to the LISN (line impedance stabilization network). This requirement might be inconvenient and appear to be unrealistic in some cases. However it is important to adhere to this recommendation to ensure a valid and comparable test result.

Output conducted emission

The cable must be screened and the screen must be correctly bonded in accordance with the EMC (Electromagnetic compatibility) section of this Design Guide or the EMC data sheet for the product, unless the motor cable length is less than or equal to 2 m in length.

Impulse noise

The drive does not generate impulse noise. Care is required to ensure that associated power contactors do not generate impulse noise.

Voltage fluctuations

The drive does not in itself cause significant voltage fluctuations or flicker. The control system must be designed so as not to cause rapid changes in motor power which could result in flicker. Generally the requirements for passenger comfort ensure that this is the case.

Mains current harmonics

The mains current harmonics for the complete lift system will be the vector sums of the harmonic currents for all of the individual electrical loads in the system. Usually the main lift drive(s) will dominate the electrical load, and it will be sufficient to ensure that these meet the harmonic requirements. Where electronic drives are also used for ancillary functions such as door opening, ventilation etc., it may be necessary to ensure that their harmonic contributions are not excessive, although generally their power ratings will be too small to be significant. It is important that test conditions should be realistic and/or calculations done correctly, in order for harmonic emission from small drives to be correctly assessed. Please see the note below on test conditions for harmonic testing.

The information in section 2.11 AC input line reactors on page 23, shows the measures required for drives rated at 2.2 kW upwards, in order to meet the harmonics requirements. For harmonic data related to the smaller drives which might be used for auxiliary functions, please refer to the relevant EMC data sheet.

Input chokes must be provided in order to maintain the harmonics below the required levels. Table 2-15 gives the choke data. Note that the correct value of choke depends upon the maximum input power for which the particular lift controller is designed, and not necessarily on the drive model number or rating. The figure for input power in Table 2-15 is based on the efficiency of a typical standard Eff2 induction motor. For a given application, it is important that the actual maximum input power should be measured or estimated and the necessary choke value calculated in inverse proportion to the power.

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Table 2-30 Emissions compliance

Item Limit (%) Typical (%)

Harmonic:

5 30 27.6

7187.9

11 1 3 6. 4

13 8 3.7

THD 35 29.9

PWHD 39 16.5

cosφ

Distortion factor

Power factor

0.9790

0.9580

0.9379

The limits in the table are based on the ratios of the specific harmonics to the rated fundamental current (In / I1 in clause 6.7.2 of EN 12015:2004).

2.13.2 Immunity - EN 12016

The standard gives immunity requirements over a range of standard immunity test methods. Generally these correspond to the tests required by the generic standards for the residential and industrial environments, EN 61000-6-1 and EN 61000-6-2. However there are more severe test levels

prescribed for safety circuits. In the tests for safety circuits, the drive is permitted to trip but the safety function must continue to operate. The following table shows the status of the whole range of drives covered by this data sheet.

Table 2-31 Immunity compliance

Test Status – drive functions Status – Safe Torque Off used in safety circuits

Electrostatic discharge Conform Electrostatic discharge Conform Radio frequency electromagnetic field Conform Conform (the drive might trip but no loss of safety function) Fast transients common mode – to

signal and power ports Surge:

Signal and control lines Power ports Conform Conform Radio frequency common mode – to

signal and power ports Voltage dips Conform Conform Voltage interruptions Conform Conform

* Suppression is not required to ensure safety, and is generally not required. Control Techniques recommends that the suppression be installed if the lines connected to the port exceed 30 m in length, based on the requirements of EN 61000-6-2. See section 4.17.8 Surge immunity of control circuits on page 103.

Conform Conform

Conform Conform (External suppression is required to prevent trip or damage)*

Conform Conform

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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:

• Installing the drive

• Option module installation

• 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.

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 Installation

The following considerations must be made for 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 3.8 Enclosing standard drive for high

environmental protection on page 43

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.

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.

3.2.4 Electrical safety

The installation must be safe under normal and fault conditions.

3.2.5 Fire protection

The drive enclosure is not classified as a fire enclosure. A separate fire enclosure must be provided which can be metal and/or polymeric. Polymer must meet requirements which can be summarized for larger enclosures as using materials meeting at least UL 94 class 5VB at the point of minimum thickness. Air filter assemblies to be at least class V-2.

3.2.6 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 (located very close to the drives input) may be required.

3.2.7 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.

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terminal cover

Control / AC /

Motor terminal cover

DC / Braking

terminal cover

AC / Motor

terminal cover

Control terminal

cover

Control / AC /

Motor terminal cover

DC / Braking

terminal cover

AC / DC

terminal cover

Motor / Braking

terminal cover

Control terminal

cover

DC / Braking

terminal cover

left

Control

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AC / Motor

terminal cover

DC / Braking

terminal cover

right

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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 for 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 (size 3 to 7)

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Frequently Asked Questions

User Manual

Declaration of Conformity

Declaration of Conformity (including 2006 Machinery Directive)

1 Safety information

1.1 Warnings, Cautions and Notes

1.2 Electrical safety - general warning

1.3 System design and safety of personnel

1.4 Environmental limits

1.5 Access

1.6 Fire protection

1.7 Compliance with regulations

1.8 Motor

1.9 Mechanical brake control

1.10 Adjusting parameters

1.11 Electrical installation

1.11.1 Electric shock risk

1.11.2 Stored charge

2 Product information

2.1 E300 Advanced Elevator drive

2.2 Model number

2.3 Nameplate description

2.4 Ratings

2.4.1 Typical short term overload limits

2.4.2 Power and current ratings (derating for switching frequency and temperature)

2.5 Operating modes

2.5.1 Open loop mode

2.5.2 RFC-A

2.5.3 RFC- S

2.6 Compatible position feedback devices

2.7 Drive features

2.8 Options

2.9 Items supplied with the drive

2.10 EMC filters

2.10.1 Internal EMC filter

2.10.2 Standard external EMC filter

2.10.3 Compact external EMC filters

2.11 AC input line reactors

2.12 EMC compliance (general standards)

2.13 EMC compliance (elevator standards)

2.13.1 Emission - EN 12015

2.13.2 Immunity - EN 12016

3 Mechanical installation

3.1 Safety information

3.2 Installation

3.2.1 Access

3.2.2 Environmental protection

3.2.3 Cooling

3.2.4 Electrical safety

3.2.5 Fire protection

3.2.6 Electromagnetic compatibility

3.2.7 Hazardous areas

3.3 Terminal cover removal

3.3.1 Removing the terminal covers