Emotron FlowDrive Emotron FLD48, FlowDrive Emotron FLD69, FlowDrive Emotron FLD52 Installation & Getting Started Instruction

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Page 1

Emotron FlowDrive

Для заказов : +7(499)707-11-20 Email: i@sp-t.ru 8-800-511-65-88 (Бесплатно по РФ)

Dedicated drive

Emotron FLD48/52/69, frame sizes B - F and C2 - F2

0.75 - 200 kW

Installation & Getting started instruction

Page 2

Safety Instructions

Congratulations for choosing a product from CG Drives & Automation!

Before you begin with installation, commissioning or powering up the unit for the first time it is very important that you carefully study this Instruction manual. Following symbols can appear in this manual or on the product itself. Always read these first before continuing.

NOTE: Additional information as an aid to avoid problems.

CAUTION! Failure to follow these instructions can result in malfunction or damage to the AC drive.

Warning! Failure to follow these instructions can result in serious injury to the user in addition to serious damage to the AC drive.

HOT SURFACE! Failure to follow these instructions can result in injury to the user.

Earthing

The AC drive must always be earthed via the mains safety earth connection.

Earth leakage current

CAUTION! This AC drive has an earth leakage current

which does exceed 3.5 mA AC. Therefore the

minimum size of the protective earth conductor must comply with the local safety regulations for high leakage current equipment which means that according the standard IEC61800-5-1 the protective earth connection must be assured by one of following conditions: PE conductor cross-sectional area shall for cable size

16 mm2 (6 AWG) be equal to the used phase

< conductors, for cable size above

16 mm the PE conductor cross-sectional area shall be at least 16mm conductor cross-sectional area should be at least 50 % of the used phase conductor. When the PE conductor in the used cable type is not in accordance with the above mentioned cross-sectional area requirements, a separate PE conductor should be used to establish this.

(6 AWG) but smaller or equal to 35mm2(2 AWG)

(6 AWG). For cables >35 mm2 (2 AWG) the PE

Handling the AC drive

Installation, commissioning, demounting, taking measurements, etc, of or on the AC drive may only be carried out by personnel technically qualified for the task. A number of national, regional and local regulations govern handling, storage and installation of the equipment. Always observe current rules and legislation.

Opening the AC drive

WARNING! Always switch off the mains voltage before opening the AC drive and wait at least 7 minutes to allow the capacitors to discharge.

Always take adequate precautions before opening the AC drive. Although the connections for the control signals and the switches are isolated from the main voltage, do not touch the control board when the AC drive is switched on.

Precautions to be taken with a connected motor

If work must be carried out on a connected motor or on the driven machine, the mains voltage must always be disconnected from the AC drive first. Wait at least minutes before starting work.

Residual current device (RCD) compatibility

This product cause a DC current in the protective conductor. for protection in case of direct or indirect contact, only a Type B RCD is allowed on the supply side of this product. Use RCD of 300 mA minimum.

Where a residual current device (RCD) is used

EMC Regulations

In order to comply with the EMC Directive, it is absolutely necessary to follow the installation instructions. All installation descriptions in this manual follow the EMC Directive.

Mains voltage selection

The AC drive may be ordered for use with the mains voltage range listed below.

FLD48: 230-480 V FLD52: 440-525 V FLD69: 500-690 V

CG Drives & Automation, 01-6142-01r0 1

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Voltage tests (Megger)

Do not carry out voltage tests (Megger) on the motor, before all the motor cables have been disconnected from the AC drive.

Condensation

If the AC drive is moved from a cold (storage) room to a room where it will be installed, condensation can occur. This can result in sensitive components becoming damp. Do not connect the mains voltage until all visible dampness has evaporated.

Incorrect connection

The AC drive is not protected against incorrect connection of the mains voltage, and in particular against connection of the mains voltage to the motor outlets U, V and W. The AC drive can be damaged in this way.

Power factor capacitors for improving

cos

Remove all capacitors from the motor and the motor outlet.

Heat warning

HOT SURFACE! Be aware of specific parts on the AC drive having high temperature.

DC-link residual voltage

WARNING! After switching off the mains supply, dangerous voltage can still be present in the AC drive. When opening the AC drive for

installing and/or commissioning activities wait at least 7 minutes. In case of malfunction a qualified technician should check the DC-link or wait for one hour before dismantling the AC drive for repair.

Precautions during Autoreset

When the automatic reset is active, the motor will restart automatically provided that the cause of the trip has been removed. If necessary take the appropriate precautions.

Transpor t

To avoid damage, keep the AC drive in its original packaging during transport. This packaging is specially designed to absorb shocks during transport.

IT Mains supply

The AC drives can be modified for an IT mains supply, (non-earthed neutral), please contact your supplier for details.

Alarms

Never disregard an alarm. Always check and remedy the cause of an alarm.

2 CG Drives & Automation, 01-6142-01r0

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Safety Instructions ......................................... 1

Contents.......................................................... 3

1. Introduction..................................................... 5

1.1 Delivery and unpacking ............................................ 5

1.2 Using of the instruction manual ............................... 5

1.3 Warranty .................................................................... 6

1.4 Type code number..................................................... 7

1.5 Standards .................................................................. 8

1.6 Dismantling and scrapping..................................... 10

1.7 Glossary ................................................................... 10

2. Mounting ...................................................... 11

2.1 Lifting instructions................................................... 11

2.2 Stand-alone units .................................................... 11

3. Installation ................................................... 17

3.1 Before installation................................................... 17

3.2 Cable connections................................................... 18

3.3 Connection of motor and mains cables for larger

frame sizes .............................................................. 23

3.4 Cable specifications ................................................ 24

3.5 Thermal protection on the motor ........................... 28

3.6 Motors in parallel .................................................... 28

7.10 Safe Stop option...................................................... 49

7.11 EMC filter class C1/C2 ........................................... 52

7.12 Output chokes ......................................................... 52

7.13 Liquid cooling .......................................................... 52

7.14 Top cover for IP20/21 version ............................... 52

7.15 Other options........................................................... 52

8. Technical Data ............................................. 53

8.1 Electrical specifications related to model ............. 53

8.2 General electrical specifications............................ 55

8.3 Operation at higher temperatures ......................... 56

8.4 Operation at higher switching frequency............... 56

8.5 Dimensions and Weights........................................ 57

8.6 Environmental conditions....................................... 58

8.7 Fuses and glands .................................................... 59

8.8 Control signals......................................................... 62

Index ............................................................. 63

4. Control Connections.................................... 29

4.1 Control board........................................................... 29

4.2 Terminal connections ............................................. 30

4.3 Inputs configuration

4.4 Connect control cables ........................................... 31

4.5 Connecting options ................................................. 37

with the switches..................................................... 31

5. Getting Started ............................................ 39

5.1 Function keys .......................................................... 39

5.2 Generic configuration (all drives) ........................... 40

5.3 Additional configuration for Standalone / Master

5.4 Test run.................................................................... 42

5.5 Engage “auto tune” program to optimize energy

5.6 Configuration of additional features ...................... 44

drives........................................................................ 41

consumption............................................................ 43

6. EMC and standards ..................................... 45

6.1 EMC standards ........................................................ 45

6.2 Stop categories and emergency stop .................... 45

7. Options ......................................................... 47

7.1 Options for the control panel.................................. 47

7.2 Handheld Control Panel 2.0 ................................... 47

7.3 Gland kits................................................................. 48

7.4 EmoSoftCom............................................................ 48

7.5 I/O Board ................................................................. 48

7.6 PTC/PT100 .............................................................. 48

7.7 RTC- Real time clock board .................................... 48

7.8 Serial communication and fieldbus ....................... 48

7.9 Standby supply board option.................................. 49

CG Drives & Automation, 01-6142-01r0 3

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1. Introduction

Emotron FlowDrive is an AC drive dedicated for controlling wastewater pumps with focus on continuous pumping with best economy (lowest cost). FlowDrive can operate as a Standalone unit (1 drive) or in a Master-Follower configuration (2 drives).

1.1 Delivery and unpacking

Check for any visible signs of damage. Inform your supplier immediately of any damage found. Do not install the AC drive if damage is found. Check that all items are present and that the type number is correct.

1.2 Using of the instruction

Prerequisites

In order to utilize the FlowDrive, following is required:

• Analog level sensor for automatic level control,

preferably 4-20mA

• Master-Follower control cable (only required in a

Master-Follower configuration)

• One switch per drive for manual control; Auto, forced

run or off (optional but highly recommended)

• Digital switch for redundant overflow detection

(optional, can be disabled)

• 1 pump per drive (if dual pumps are used, equal pump

performance is required)

Several options are available, listed in chapter 7. page 47, that enable you to customize the AC drive for your specific needs.

NOTE: Read this instruction manual carefully before starting installation, connection or working with the AC drive.

manual

This installation and getting started instruction is intended for persons who dimension, install, commission Emotron FlowDrive units. More detailed information about using the FlowDrive is found in the “Emotron FlowDrive Software manual” to be found in the file archive on www.emoton.com.

Within this instruction manual the abbreviation “AC drive” is used to indicate the complete variable speed drive as a single unit.

With help of the index and the table of contents it is easy to track individual functions and to find out how to use and set them.

This instruction can be put in a cabinet door, so that it is always easy to access in case of an emergency.

Motors

The AC drive is suitable for use with standard 3-phase asynchronous motors. Under certain conditions it is possible to use other types of motors. Contact your supplier for details.

CG Drives & Automation, 01-6142-01r0 Introduction 5

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1.2.1 Instruction manuals for optional equipment

In the following table we have listed available options and the name of the Instruction manual or data sheet/ Instruction plus document number. Further in this main manual we are often referring to these instructions.

Table 1 Available options and documents

1.3 Warranty

The warranty applies when the equipment is installed, operated and maintained according to instructions in this instruction manual. Duration of warranty as per contract. Faults that arise due to faulty installation or operation are not covered by the warranty.

Option

I/O board

PTC/PT100 board

Fieldbus - Profibus

Fieldbus - DeviceNet

Ethernet - Modbus TCP

Ethernet - EtherCAT

Ethernet - Profinet IO 1-port

Ethernet - Profinet IO 2-port

Ethernet - EtherNet/IP 2-port

RS232/RS485 isolated

Control panel kit, Incl blank panel

Control panel kit, Incl control panel

Handheld Control Panel HCP2.0

Safe stop

Overshoot clamp

Liquid cooling

Output choke

Valid instruction manual/

document number

I/O board 2.0, instruction manual / 01-5916-01

PTC/PT100 board 2.0, instruction manual / 01-5920-01

Fieldbus Option, Instruction manual / 01-3698-01

Emotron isolated RS232 / 485 2.0 option Instruction manual / 01-5919-01

Emotron FDU/VFX 2.0 External Control Panel, instruction manual / 015928-01

Emotron HCP 2.0, instrucion manual / 015925-01

Option Safe Stop (STO – Safe Torque Off), Technical description / 01-5921-01

Overshoot clamp Datasheet/Instruction / 01-5933-11

Emotron FDU/VFX 2.0 Liquid Cooling, instruction manual / 01-4636-01

Output coils Datasheet/Instruction / 01-3132-11

6Introduction CG Drives & Automation, 01-6142-01r0

Page 7

1.4 Type code number

Fig. 1 gives an example of the type code numbering used on all AC drives drive can be determined. This identification will be required for type specific information when mounting and installing. The code number is located on the product label, on the unit.

. With this code number the exact type of the

Typ e code

Position No

FLD48-017-20CE–––AVNNNNAN––

1 2 3 4 5 6 7 8 9 10111213141516171819

Fig. 1 Type code number

Position

for 003-074

11AC drive type FLD

2 2 Supply voltage

3 3 Rated current (A) continuous

44Protection class

5 5 Control panel

6 6 EMC option

7 7 Brake chopper option

8 8 Stand-by power supply option

Position

for 090-293

Configuration

48=480 V mains 52=525 V mains 69=690 V mains

-003=2.5 A

-293=293 A

20=IP20 21=IP21 54=IP54

–=Blank panel C=Standard panel

E=Standard EMC (Category C3) F=Extended EMC (Category C2) I=IT-Net

–=No chopper B=Chopper built in D=DC+/- interface

–=No SBS S=SBS included

-9

910Brand label A=Standard

10 - Painted AC drive A=Standard paint

11 11 Coated boards V=Coated boards, standard

12 12 Option position 1 N=No option

13 13 Option position 2

14 14 Option position 3

CG Drives & Automation, 01-6142-01r0 Introduction 7

Safe stop option (Only valid for 090-

293)

–=No safe stop T=Safe stop incl.

P=PTC/PT100 (max. 1) I=Extended I/O (max. 3) S=Safe Stop (only 003-074/IP54) (max. 1) U= RTC- Real time clock (max. 1)

Page 8

Position

for 003-074

15 15 Option position, communication

16 16 Sof tware type A=Standard

17 -

18 -

19 17 Approval/certification

Position

for 090-293

Configuration

Motor PTC. (Only valid for 003-074/IP54)

Gland kit. (Only valid for003-074/IP54)

N=No option D=DeviceNet P=Profibus S=RS232/485 M=Modbus/TCP F=Modbus/TCP 2-port, M12 E=EtherCAT A=Profinet IO 1-port B=Profinet IO 2-port G=EtherNet/IP 2-port

N=No option P=PTC

–=Glands not included G=Gland kit included

–=CE approved D=Marine DNV Product certificate (above 100 kW) + CE approved M=Marine version + CE approved U=UL/cUL approved

1.5 Standards

The AC drives described in this instruction manual comply with the standards listed in Table 2. For the declarations of conformity and manufacturer’s certificate, contact your supplier for more information or visit www.emotron.com/ www.cgglobal.com.

1.5.1 Product standard for EMC

Product standard EN(IEC)61800-3, second edition of 2004 defines the:

First Environment (Extended EMC) as environment that includes domestic premises. It also includes establishments directly connected without intermediate transformers to a low voltage power supply network that supplies buildings used for domestic purposes.

Category C: Power Drive System (PDS) of rated voltage<1.000 V, which is neither a plug in device nor a movable device and, when used in the first environment, is intended to be installed and commissioned only by a professional.

Second environment (Standard EMC) includes all other establishments.

Category C3: PDS of rated voltage <1.000 V, intended for use in the second environment and not intended for use in the first environment.

may be used). The standard AC drive is designed to meet the requirements according to category C3.

By using the optional “Extended EMC” filter the AC drive fulfils requirements according to category C,

WARNING! In a domestic environment this product may cause radio interference, in which case it may be necessary to take adequate additional measures.

WARNING! The standard AC drive, complying with category C3, is not intended to be used on a low-voltage public network which supplies domestic premises; radio interference is expected if used in such a network. Contact your supplier if you need additional measures.

Category C4: PDS or rated voltage equal or above 1.000 V, or rated current equal to or above 400 A, or intended for use in complex systems in the second environment.

The AC drive complies with the product standard EN(IEC) 61800-3:2004 (Any kind of metal screened cable

8Introduction CG Drives & Automation, 01-6142-01r0

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Ta b le 2 St an d a rd s

Market Standard Description

European

EMC Directive 2004/108/EC

Low Voltage Directive 2006/95/EC

WEEE Directive 2002/96/EC

EN 60204-1

EN(IEC)61800-3:2004

All

North & South America

Russian GOST R For all sizes.

EN(IEC)61800-5-1 Ed. 2.0

IEC 60721-3-3

UL508C UL Safety standard for Power Conversion Equipment

USL

UL 840

CNL

Safety of machinery - Electrical equipment of machines

Part 1: General requirements.

Adjustable speed electrical power drive systems

Part 3: EMC requirements and specific test methods. EMC Directive: Declaration of Conformity and

Adjustable speed electrical power drive systems Part 5-1. Safety requirements - Electrical, thermal and energy.

Low Voltage Directive: Declaration of Conformity and

Classification of environmental conditions. Air quality chemical vapours, unit in operation. Chemical gases 3C2, Solid particles 3S2. Optional with coated boards Unit in operation. Chemical gases Class 3C3, Solid particles 3S2.

USL (United States Standards - Listed) complying with the requirements of UL508C Power Conversion Equipment

UL Safety standard for Power Conversion Equipment. Insulation coordination including clearances and creepage distances for electrical equipment.

CNL (Canadian National Standards - Listed) complying with the requirements of CAN/CSA C22.2 No. 14-10 Industrial Control Equipment.

CE marking

CG Drives & Automation, 01-6142-01r0 Introduction 9

Page 10

1.6 Dismantling and scrapping

The enclosures of the drives are made from recyclable material as aluminium, iron and plastic. Each drive contains a number of components demanding special treatment, for example electrolytic capacitors. The circuit boards contain small amounts of tin and lead. Any local or national regulations in force for the disposal and recycling of these materials must be complied with.

1.6.1 Disposal of old electrical and electronic equipment

This symbol on the product or on its packaging indicates that this product shall be taken to the applicable collection point for the recycling of electrical and electronic equipment. By ensuring this product is disposed of correctly, you will help prevent potentially negative consequences for the environment and human health, which could otherwise be caused by inappropriate waste handling of this product. The recycling of materials will help to conserve natural resources. For more detailed information about recycling this product, please contact the local distributor of the product.

1.7 Glossary

1.7.1 Abbreviations and symbols

In this manual the following abbreviations are used:

Table 3 Abbreviations

Abbreviation/

symbol

DSP Digital signals processor

AC drive Frequency converter

IGBT Insulated Gate Bipolar Transistor

HCP Handheld control panel (option)

EInt Communication format

UInt Communication format (Unsigned integer)

Int Communication format (Integer)

Long Communication format

SELV Safety Extra Low Voltage

Control panel, the programming and presentation unit on the AC drive

The function cannot be changed in run mode

1.7.2 Definitions

In this manual the following definitions for current, torque and frequency are used:

Description

Table 4 Definitions

Name Description Quantity

NOM

MOT

NOM

MOT

NOM

MOT

OUT

MOT

Speed Actual motor speed rpm

Torque Actual motor torque Nm

Sync speed

Nominal input current of AC drive A

Nominal output current of AC drive A

Nominal motor current A

Nominal power of AC drive kW

Motor power kW

Nominal torque of motor Nm

Motor torque Nm

Output frequency of AC drive Hz

Nominal frequency of motor Hz

Nominal speed of motor rpm

Maximum output current A

Synchronous speed of the motor rpm

RMS

10 Introduction CG Drives & Automation, 01-6142-01r0

Page 11

2. Mounting

Load: 56 to 74 kg (123 - 165 lbs)

This chapter describes how to mount the AC drive.

Before mounting it is recommended that the installation is planned out first.

• Be sure that the AC drive suits the mounting location.

• The mounting site must support the weight of the AC

drive.

• Will the AC drive continuously withstand vibrations

and/or shocks?

• Consider using a vibration damper.

• Check ambient conditions, ratings, required cooling air

flow, compatibility of the motor, etc.

• Know how the AC drive will be lifted and transported.

2.1 Lifting instructions

Note: To prevent personal risks and any damage to the unit during lifting, it is advised that the lifting methods described below are used.

Recommended for AC drive models

-090 to -250

2.2 Stand-alone units

The AC drive must be mounted in a vertical position against a flat surface. Use the template (in the File archive on our homepage) to mark out the position of the fixing holes.

Fig. 3 AC drive mounting model 003 to 293

2.2.1 Cooling

Fig. 3 shows the minimum free space required around the AC drive for the models 003 to 293 in order to guarantee adequate cooling. Because the fans blow the air from the bottom to the top it is advisable not to position an air inlet immediately above an air outlet.

The following minimum separation between two AC drives, or a AC drive and a non-dissipating wall must be maintained. Valid if free space on opposite side.

Table 5 Mounting and cooling

Frame size

C2, D2, E2, F2 with

IP21

top cover option

[mm(in)]

FLD - FLD, side-by-side mm (in)

FLD - wall, one side mm (in)

wall-

Frame size

B - F2

[mm(in)]

a 200(7.9) 200(7.9) b 200(7.9) 200(7.9) c 0 50(1.97) d 0 50(1.97) a 100(3.9) 100(3.9) b 100(3.9) 100(3.9) c 0 50(1.97) d 0 50(1.97)

Fig. 2 Lifting AC drive model -090 to -250

CG Drives & Automation, 01-6142-01r0 Mounting 11

Page 12

2.2.2 Mounting schemes

12.5 kg (26.5 lb)

ø13 mm(x2)

(0.51 in)

ø7 mm(x4)

(0.27 in)

Glands M20

Glands M32

Gland M16

Gland M25

Fig. 4 Emotron FLD Model 48/52-003 to 018

(Frame size B)

Table 6 Dimensions connected to Fig. 4.

Frame

size

B 003 - 018

Emotron FLD

model

A B C D E F G

416

(16.4)

396

(15.6)

Fig. 5 Cable interface for mains, motor and communication,

Emotron FLD Model 48/52-003 to 018 (Frame size B)

Fig. 6 Emotron FLDModel 48/52-003 to 018 (Frame size

B) example with optional CRIO interface and D-sub connectors.

Dimensions in mm (in)

128.5 (5.04)

(1.46)

(0.39)

202.6 (7.98)

200 (7.9)

12 Mounting CG Drives & Automation, 01-6142-01r0

Page 13

Fig. 7 Emotron FLD Model 48/52-026 to 046 (Frame size

24 kg (53 lb)

ø13 mm(x2)

ø7 mm(x4)

(0.27 in)

(0.51 in)

Gland M25 (026-031)

Glands M20

Glands M32 (026-031)

M32 (037-046)

M40 (037-046)

IP21 top cover (optional)

ø7mm (x4)

(0.27 in)

ø13 mm(x2)

(0.51 in)

17 k g (38 lb)

Fig. 9 Emotron FLD Model 48-025 to 48-058

(Frame size C2), backside view.

L1 L2 L3 DC- DC+ R U V W

Fig. 8 Cable interface for mains, motor and communication,

Emotron FLD Model 48/52-026 to 046 (Frame size C)

Table 7 Dimensions connected to Fig. 7 and Fig. 9.

Frame

size

C2 025 - 058

Emotron FLD

C 026 - 046

CG Drives & Automation, 01-6142-01r0 Mounting 13

model

Fig. 10 Bottom view Emotron FLD Model 48-025 to 48-058

(Frame size C2), with cable interface for mains, motor, DC+/DC-, brake resistor and control

Dimensions in mm (in)

A B C D E F G H I J K

512

(20.2)

585.5 (23)

(19.4)

(18.5)

492

471

128.5 (5.04)

24.8

(0.95)

(0.39)

23.8

(0.91)13(0.51)

178

(7)

167

(7)

292

(11.5)

267 (10.5)

IP21 282 (11.1)

----

196 (7.7)

(0.39)

23.5 (0.9)

496

(19.5)

Page 14

Fig. 11 Emotron FLD Model 48/52-061 and 074 (Frame

32 kg (71 lb)

ø7 mm(x4)

(0.27 in)

ø13 mm(x2)

(0.51 in)

Glands M20

Glands M50

Glands M40

IP21 top cover (optional)

30 kg (66 lb)

ø7 mm (x4)

(0.27 in)

ø13 mm(x2)

(0.51 in)

size D)

Fig. 12 Cable interface for mains, motor and communication,

Emotron FLD Model 48/52-061 and 074 (Frame size D).

NOTE: Glands for size B, C and D are available as option kit.

Table 8 Dimensions connected to Fig. 11 and Fig. 13.

Fig. 13 Emotron FLDModel 48-072 to

48-088 (Frame size D2), backside view.

Fig. 14 Bottom view Emotron FLD Model 48-072 to 48-088

(Size D2), with cable interface for mains, motor, DC+/DC-, brake resistor and control.

Frame

Emotron FLD

size

D 061 - 074

D2 072 - 088

model

A B C D E F G H I J K

570

(22.4)

570

(22.4)

590

(23.2)

669.5 (26.3)

160

(6.3)

160

(6.3)

(0.9)

(0.9)13(0.51)

Dimensions in mm (in)

(0.39)

220

(8.7)

220

291 (11.5)

(8.7)

295

(11.6)

IP21 - 307

(12.1)

----

240

(9.5)

(0.39)

12.5

(0.47)

14 Mounting CG Drives & Automation, 01-6142-01r0

590

(23.2)

Page 15

Fig. 15 Emotron FLD Model 48-090 to 175 (Frame size E).

56/60 kg

(124/132 lb)

ø16 mm(x3)

(0.63 in)

ø9 mm(x6)

(0.35 in)

Cable glands M20

Cable flexible leadthrough

Ø17-42 /M50

Ø11-32 /M40

(0.67 - 1.65in)

(0.43 - 1.2 in)

Cable flexible leadthrough

74 k g

(163 lb)

ø9 mm(x6)

(0.35 in)

ø16 mm(x3)

(0.63 in)

Cable glands M20

Cable flexible leadthrough

Ø23-55 /M63

Ø17-42 /M50

(0.91 - 2.1 in)

(0.67 - 1.65in)

Cable flexible leadthrough

Fig. 16 Cable interface for mains, motor, DC+/DC-, brake

resistor and communication, Emotron FLD Model 48-090 to 175 (Frame size E).

Table 9 Dimensions connected to Fig. 15 and Fig. 17.

Frame

size

E 090 - 175

Emotron FLD

model

A B C D E F G H

925

(36.4)

952.5 (37.5)

240

(9.5)

Fig. 17 Emotron FLD Model 48-210 to 250 (Frame size F)

Emotron FLD Model 69-090 to 200 (Frame size F69).

Fig. 18 Cable interface for mains, motor, DC+/DC-, brake

resistor and communication, Emotron FLD Model 48-210 to 250 Emotron FLD Model 69-090 to 200.

Dimension in mm (in)

22.5

(0.88)

(0.39)

284.5 (11.2)

314

(12.4)

120

F210 - 250

F69 090 - 200

CG Drives & Automation, 01-6142-01r0 Mounting 15

925

(36.4)

1065

(41.9)

950

(37.4)

1090

(42.9)

300

(11.8)

22.5

(0.88)

(0.39)

344.5 (13.6)

314

(12.4)

150

Page 16

Fig. 19 Emotron FLD Model 48-106 to

53 kg

ø16 mm(x3)

(0.63 in)

ø9 mm(x6)

(0.35 in)

(117 lb)

68 kg

(150 lb)

ø16 mm(x3)

(0.63 in)

ø9 mm(x6)

(0.35 in)

48-171 (Frame size E2).

Fig. 20 Bottom view Emotron FLD Model 48-106 to 48-293

(Frame size E2 and F2), with cable interface for mains, motor, DC+/DC-, brake resistor and control. (principle drawing)

Table 10 Dimensions connected to Fig. 19 and Fig. 21.

Frame

size

Emotron FLD

model

A B C D E F G H

Fig. 21 Emotron FLD Model 48-205 to

48-293 (Frame size F2).

Dimension in mm (in)

E2 106 - 171

F2 205 - 293

16 Mounting CG Drives & Automation, 01-6142-01r0

925

(36.4)

950

(37.4)

240

(9.5)

300

(11.8)

22.5

(0.88)

(0.39)

275

(10.8)

335

(13.2)

294 (11.6)

IP21 - 323 (12.7)

314 (12.4)

IP21 - 323 (12.7)

120

(4.7)

150

(5.9)

Page 17

3. Installation

The description of installation in this chapter complies with the EMC standards and the Machine Directive.

Select cable type and screening according to the EMC requirements valid for the environment where the AC drive is installed.

3.1 Before installation

Read the following checklist and prepare for your application before installation.

• Local or remote control.

• Long motor cables (>100m (> 330 ft)), refer to section Long motor cables page 22.

• Functions used.

• Suitable AC drive size in proportion to the motor/application.

If the AC drive is temporarily stored before being connected, please check the technical data for environmental conditions. If the AC drive is moved from a cold storage room to the room where it is to be installed, condensation can form on it. Allow the AC drive to become fully acclimatised and wait until any visible condensation has evaporated before connecting the mains voltage.

3.1.1 Remove/open front cover

Frame sizes B - F (IP54)

Remove/open the front cover to access the cable connections and terminals. On Frame size B and C loosen the 4 screws and remove the cover. On Frame size D and up unlock the hinged cover with the key and open it.

Frame size C2 - F2 (IP20/21)

Fig. 22 Remove the front cover on frame size C2 - F2 (princi-

ple drawing).

To be able to access all cable connections and terminals, first open and remove the front cover in following order.

• Loosen the two screws A (see Fig. 22) at the bottom of the cover a couple of turns (you do not have to remove the screws).

• Swing out the lower part of the cover a bit and remove the cover downwards. Be careful, don't swing out the cover too much as this could damage the “lips” at the upper hinges. Now it is easy to access all terminals.

CG Drives & Automation, 01-6142-01r0 Installation 17

Page 18

3.1.2 Remove/open the lower front

cover on Frame size E2 and F2 (IP20/21)

Fig. 23 Loosen the two screws and remove the lower cover

(principle drawing)

In order to access the mains, motor, DC+/DC- and brake terminals, remove the lower cover in following order

• Loosen the two screws B (see Fig. 23).

• Pull down the cover a bit and lift it away.

3.2 Cable connections

IP54-FLD48/52-003 to 074 (Frame sizes B, C and D) IP20/21 - FLD48 025 to 293 (Frame sizes C2,D2,E2 and F2).

3.2.1 Mains cables

Dimension the mains and motor cables according to local regulations. The cable must be able to carry the AC drive load current.

Recommendations for selecting mains cables

• To fulfil EMC purposes it is not necessary to use screened mains cables.

• Use heat-resistant cables, +60 °C (140 °F) or higher.

• Dimension the cables and fuses in accordance with local regulations and the nominal current of the motor. See table 37, page 61.

• PE conductor cross-sectional area shall for cable size <

16mm2 (6 AWG) be equal to the used phase conductors, for cable size above 16mm smaller or equal to 35mm cross-sectional area shall be at least 16mm For cables >35mm sectional area should be at least 50% of the used phase conductor. When the PE conductor in the used cable type is not in accordance with the above mentioned cross-sectional area requirements, a separate PE conductor should be used to establish this.

• The litz ground connection see fig. 33, is only necessary if the mounting plate is painted. All the AC drives have an unpainted back side and are therefore suitable for mounting on an unpainted mounting plate.

(2 AWG) the PE conductor

(>2 AWG) the PE conductor cross-

(6 AWG) but

(6 AWG).

Connect the mains cables according to fig. 24 to 30. The AC drive has as standard a built-in RFI mains filter that complies with category C3 which suits the Second Environment standard.

18 Installation CG Drives & Automation, 01-6142-01r0

Page 19

DC-

DC+

EMC gland,

Screen connection

of motor cables

EMC gland Screen connection of motor cables

L1 L2 L3 DC- DC+ R U V W

Strainrelief and EMC clamp

for brake resistor cables (option)

for screen connection of cables

DC-

DC+

EMC gland - screen connection of motor cables

Fig. 24 Mains and motor connections, model 003-018, frame

size B

Fig. 25 Mains and motor connections, model 026-046, frame

size C

Fig. 26 Mains and motor connections model 48-025 to 48-

058, frame size C2.

CG Drives & Automation, 01-6142-01r0 Installation 19

Fig. 27 Mains and motor connection, model 061 - 074, frame

size D.

Page 20

Fig. 28 Mains and motor connections model 48-072 to

L1 L2 L3 DC- DC+ R U V W

for brake resistor cables (option)

Strainrelief and EMC clamp

also for screen connection of cables

Strainrelief and EMC clamp

Strainrelief and EMC clamp also for screen connection of cables

DC+

DC-

Strainrelief and EMC clamp also for screen connection of cables

48-105, frame size D2.

Fig. 30 Mains and motor connections model 48-142 to 48-

293 (Size E2 and F2) with the optional terminals for DC-,DC+ and Brake (principle drawing)

Table 11 Mains and motor connections

Fig. 29 Mains and motor connections model 48-142 to 48-

20 Installation CG Drives & Automation, 01-6142-01r0

293 (Size E2 and F2) (principle drawing).

L1,L2,L3 PE

U, V, W

DC-,DC+,R

Mains supply, 3 -phase Safety earth (protected earth)

Motor earth Motor output, 3-phase

Brake resistor, DC-link connections (optional)

Fig. 31 Wiring example showing Protective earth, Motor earth

and Brake Resistor connection

NOTE: The Brake and DC-link Terminals are only fitted if the DC+/DC- option or Brake Chopper Option is built-in.

Page 21

WARNING!

Screen connection of signal cables

Motor cable shield connection

The Brake Resistor must be connected between terminals DC+ and R.

WARNING! In order to work safely, the mains earth must be connected to PE and the motor earth to

• The litz ground connection, see fig. 33, is only necessary if the mounting plate is painted. All the AC drives have an unpainted back side and are therefore suitable for mounting on an unpainted mounting plate.

Connect the motor cables according to U - U, V - V and W - W, see Fig. 24, to Fig. 30 .

NOTE: The terminals DC-, DC+ and R are options.

3.2.2 Motor cables

To comply with the EMC emission standards the AC drive is provided with a RFI mains filter. The motor cables must also be screened and connected on both sides. In this way a so-called “Faraday cage” is created around the AC drive, motor cables and motor. The RFI currents are now fed back to their source (the IGBTs) so the system stays within the emission levels.

Recommendations for selecting motor cables

• Use screened cables according to specification in table

12. Use symmetrical shielded cable; three phase conductors and a concentric or otherwise symmetrically constructed PE conductor, and a shield.

• PE conductor cross-sectional area shall for cable size <

16mm2 (6 AWG) be equal to the used phase conductors, for cable size above 16mm smaller or equal to 35mm

(2 AWG) the PE conductor cross-sectional area shall be at least 16mm For cables >35mm

(2 AWG) the PE conductor crosssectional area should be at least 50% of the used phase conductor. When the PE conductor in the used cable type is not in accordance with the above mentioned cross-sectional area requirements, a separate PE conductor should be used to establish this.

(6 AWG) but

(6 AWG).

Switches between the motor and the AC drive

If the motor cables are to be interrupted by maintenance switches, output coils, etc., it is necessary that the screening is continued by using metal housing, metal mounting plates, etc. as shown in the Fig. 33.

• Use heat-resistant cables, +60 °C (140 °F) or higher.

• Dimension the cables and fuses in accordance with the

Fig. 32 Screen connection of cables.

nominal output current of the motor. See table 37, page

61.

• Keep the motor cable between AC drive and motor as short as possible.

• The screening must be connected with a large contact surface of preferable 360

° and always at both ends, to

the motor housing and the AC drive housing. When painted mounting plates are used, do not be afraid to scrape away the paint to obtain as large contact surface as possible at all mounting points for items such as saddles and the bare cable screening. Relying just on the connection made by the screw thread is not sufficient.

NOTE: It is important that the motor housing has the same earth potential as the other parts of the machine.

CG Drives & Automation, 01-6142-01r0 Installation 21

Page 22

Pay special attention to the following points:

AC drive built into cabinet

AC drive

RFI-Filter Mains

Metal EMC cable glands

Output coil (option)

Screened cables

Unpainted mounting plate

Metal connector housing

Motor

Metal EMC coupling nut

Brake resistor (option)

Mains (L1,L2,L3,PE)

Litz

Motor

AC drive

RFI-Filter Mains

Metal EMC cable glands

Screened cables

Metal housing

Brake resistor (option)

Output coils (option)

Metal connector housing

Motor

Metal cable gland

Mains

• If paint must be removed, steps must be taken to prevent subsequent corrosion. Repaint after making connections!

• The fastening of the whole AC drive housing must be electrically connected with the mounting plate over an area which is as large as possible. For this purpose the removal of paint is necessary. An alternative method is to connect the AC drive housing to the mounting plate with as short a length of litz wire as possible.

• Try to avoid interruptions in the screening wherever possible.

• If the AC drive is mounted in a standard cabinet, the internal wiring must comply with the EMC standard. Fig. 33 shows an example of a AC drive built into a cabinet.

Fig. 34 AC drive as stand alone

Fig. 33 AC drive in a cabinet on a mounting plate

Fig. 34 shows an example when there is no metal mounting plate used (e.g. if IP54 AC drives are used). It is important to keep the “circuit” closed, by using metal housing and cable glands.

Connect motor cables

1. Remove the cable interface plate from the AC drive housing.

2. Put the cables through the glands.

3. Strip the cable according to Table 13.

4. Connect the stripped cables to the respective motor terminal.

5. Put the cable interface plate in place and secure with the fixing screws.

6. Tighten the EMC gland with good electrical contact to the motor and brake chopper cable screens.

Placing of motor cables

Keep the motor cables as far away from other cables as possible, especially from control signals. The minimum distance between motor cables and control cables is 300 mm (12 in).

Avoid placing the motor cables in parallel with other cables.

The power cables should cross other cables at an angle of 90°.

Long motor cables

If the connection to the motor is longer than 100 m (330 ft)(for powers below 7.5 kW (10.2 hp) please contact CG Drives & Automation), it is possible that capacitive current peaks will cause tripping at overcurrent. Using output coils can prevent this. Contact the supplier for appropriate coils.

22 Installation CG Drives & Automation, 01-6142-01r0

Switching in motor cables

Switching in the motor connections is not advisable. In the event that it cannot be avoided (e.g. emergency or maintenance switches) only switch if the current is zero. If this is not done, the AC drive can trip as a result of current peaks.

Page 23

3.3 Connection of motor and

Cable interface

Clamps for screening

Mains cable

DC+, DC-, R (optional)

Motor cable

mains cables for larger frame sizes

IP54 - FLD 48-090 to 250 (Frame sizes E - F) and

FLD 69-090 to 200 (Frame size F69)

Emotron FLD48-090 and up, Emotron FLD69090 and up

To simplify the connection of thick motor and mains cables to the AC drive, the cable interface plate can be removed.

6. Put the cable interface plate in place and secure with the fixing screws.

Fig. 35 Connecting motor and mains cables.

1. Remove the cable interface plate from the AC drive housing.

2. Put the cables through the glands.

3. Strip the cable according to Table 13.

4. Connect the stripped cables to the respective mains/ motor terminal.

5. Fix the clamps on appropriate place and tighten the cable in the clamp with good electrical contact to the cable screen.

CG Drives & Automation, 01-6142-01r0 Installation 23

Page 24

3.4 Cable specifications

(06-F45-cables only)

Motor/Brake

Mains

Table 12 Cable specifications

Cable Cable specification

3.4.1 Stripping lengths

Fig. 3.4.2 indicates the recommended stripping lengths for motor and mains cables.

Mains

Motor

Control

Power cable suitable for fixed installation for the voltage used.

Symmetrical three conductor cable with concentric protection (PE) wire or a four conductor cable with compact low-impedance concentric shield for the voltage used.

Control cable with low-impedance shield, screened.

Table 13 Stripping lengths for mains, motor, brake and earth cables

Mains cable Motor cable Brake cable Earth cable

Model

FLD##003 - 018 B

FLD##026 – 046 C

FLD48-025 – 058 C2

Frame

size

(in)

(3.5)

150

(5.9)

(2.7)

(in)

(0.4)

(0.2)

(0.7)

(in)

(3.5)

150

(5.9)

(2.7)

(in)

(0.4)

(0.2)

(0.7)

Fig. 36 Stripping lengths for cables

(in)

(0.8)

(1.4)

(in)

(3.5)

150

(5.9)

(2.7)

(in)

(0.4)

(0.2)

(0.7)

(in)

(0.8)

(1.4)

(in)

(3.5)

150

(5.9)

(2.7)

mm (in)

10 (0.4)

14 (0.2)

M6 screw*

FLD##061 – 074 D

FLD48-072 – 105 D2

FLD##090 - 175 E

FLD48-142 – 171 E2

FLD48-205 – 293 F2

FLD48-210 – 250 FLD69-090 – 200

110

(4.3)

(3.6)

173

(6.8)

178 (7)

(0.7)

25 (1)

(1.3)

* With cable shoe for M6 screw

**Valid when brake chopper electronics are built in

110

(4.3)

(3.6)

173

(6.8)

178 (7)

(0.7)

25 (1)

(1.3)

(1.4)

(1.6)

(1.8)

110

(4.3)

(3.6)

173

(6.8)

178 (7)

(0.7)

25 (1)

(1.4)

(1.6)

(1.8)

110

(4.3)

(3.6)

173

(6.8)

178 (7)

17 (0.7)

M6 screw*

25 (1)

40 (1.6)**

32 (1.3)

40 (1.6)**

24 Installation CG Drives & Automation, 01-6142-01r0

Page 25

3.4.2 Fuse data

Please refer to the chapter Technical data, section 8.7, page

61.

3.4.3 Cable connection data for mains, motor and PE cables according to IEC

ratings

NOTE: The dimensions of the power terminals used in the cabinet drive models 300 to 3K0 can differ depending on customer specification.

Table 14 Cable connector range and tightening torque for Emotron FLD48 and FLD52, according to IEC ratings.

Cable cross section connector range

Model

Frame

size

Mains and motor Brake PE

Cable area

Tightening

torque

Cable area

Tightening

torque

FLD##-003

FLD##-004

FLD##-006

FLD##-008

B 0.5 - 10 1.2-1.4 0.5 - 10 1.2-1.4 1.5 - 16 2.6

FLD##-010

FLD##-013

FLD##-018

FLD48-025

FLD48-030

FLD48-036

C2 4 - 25 2 4 - 25 2 4 - 25 * 4.3

FLD48-045

FLD48-058

FLD##-026

FLD##-031

FLD##-037

2.5-16

stranded

2.5-25 solid

1.2-1.4

2.5-16

stranded

2.5-25 solid

1.2-1.4

FLD##-046

FLD48-072 D2 0.75 - 50 3.3 0.75 - 50 3.3

FLD48-105

FLD##-061

FLD##-074

FLD48-142

FLD48-171

FLD48-090

FLD48-109

FLD48-146

FLD48-175

D2 16 - 50 7. 9 16 - 50 7. 9

10-35

stranded

10-50 solid

16- 150

2.8-3

31 (for

16-34 mm2)

42 (for

35-150 mm

)

10-35

stranded

10-50 solid

16 - 120

2.8-3

31 (for

16-34 mm2)

42 (for

35-120

)

Cable area

6-16 stranded

6-25 solid

10 - 70* 4.3FLD48-088

16-35

stranded

16-50 solid

16- 150

16 - 185 **

Tightening

torque

1.2-1.4

2.8-3

31 (for

16-34 mm

42 (for

35-150 mm

10 **

Copper (Cu) 75°C

)

Cable type

CG Drives & Automation, 01-6142-01r0 Installation 25

Page 26

Table 14 Cable connector range and tightening torque for Emotron FLD48 and FLD52, according to IEC ratings.

Cable cross section connector range

Model

FLD48-205

FLD48-244

FLD48-210

FLD48-228

FLD48-250

Frame

size

Mains and motor Brake PE

Cable area

25 - 240

Tightening

torque

31 (for

25-34 mm

42 (for

35-152 mm

56 (for

153-240

)

Cable area

)

16 - 150

Tightening

torque

31 (for

16-34 mm

42 (for

35-150

)

25 - 240

16 - 185 **

Cable area

* = With cable shoe for M6 screw.

**= Valid when brake chopper electronics are built in.

Table 15 Cable connector range and tightening torque for Emotron FLD69, according to IEC ratings.

Cable cross section connector range

Model

FLD69-090

FLD69-109

FLD69-146

FLD69-175

FLD69-200

Frame

size

F69 16 - 150

Mains and motor Brake PE

Cable area

Tightening torque

31 (for

16 - 34 mm

)

Cable area

Tightening torque

31 (for

16 - 34 mm

)

Cable area

16 - 150

16 - 120

42 (for

35-150 mm

)

42 (for

35-120 mm

)

16 - 185 **

Tightening

25-34 mm

35-152 mm

153-240 mm

torque

31 (for

)

42 (for

56 (for

)

10 **

Tightening torque

31 (for

16 - 34 mm2)

42 (for

35-150 mm

10 **

Cable type

Copper (Cu)

75°C

Cable

type

Copper

)

(Cu) 75°C

26 Installation CG Drives & Automation, 01-6142-01r0

Page 27

3.4.4 Cable connection data for mains, motor and PE cables according to NEMA

ratings

List of cable cross section connector range with minimum required AWG cable cross section which fits to the terminals according to UL-requirements.

Table 16 Cable connector range and tightening torque for Emotron FLD48 and FLD52, according to NEMA ratings

Cable cross section connector range

Model

Frame

size

Mains and motor Brake PE

Cable range

AWG

Tightening

torque

Lb-In

Cable range

AWG

Tightening

torque

Lb-In

FLD##-003

FLD##-004

FLD##-006

FLD##-008

B 20 - 6 11.5 20 - 6 11.5 20 - 6 23

FLD##-010

FLD##-013

FLD##-018

FLD48-025

FLD48-030

FLD48-036

C2 12 - 4 18 12 - 4 18 12 - 4* 38

FLD48-045

FLD48-058

FLD##-026

FLD##-031

FLD##-037

C 18 - 4 10.6-12.3 18 - 4 10.6-12.3 18 - 4 10.6-12.3

FLD##-046

FLD48-072 D2 10 - 0 30 - 50 10 - 0 30 - 50

FLD48-105

FLD##-061

FLD##-074

FLD48-142

FLD48-171

FLD48-090

FLD48-109

FLD48-146

FLD48-175

D2 3 - 2/0 70 3 - 2/0 70

D 10 - 0 24.3-26.1 10 - 0 24.3-26.1 10 - 0 24.3-26.1

6 - 300 kcmil

275 (for

AWG 6 - 2)

375 (for

AWG 1 -

300Kcmil)

275 (for

AWG 6 - 2)

6 - 250 kcmil

375 (for AWG

1 -250Kcmil)

FLD48-205

FLD48-244

FLD48-293

FLD48-210

FLD48-228

4 - 500 kcmil

275 (for

AWG 4 - 2)

375 (for AWG 1 -300 kcmil)

275 (for

AWG 6 - 2)

6 - 300 kcmil

375 (for AWG

FLD48-250

500 (for AWG

350 -500

1 -300Kcmil)

kcmil)

Cable range

AWG

8 - 2/0* 38FLD48-088

6 - 300 kcmil

6 - 2/0**

4 - 500 kcmil

6 - 2/0**

Tightening

torque

Lb-In

275 (for

AWG 6-2)

375 (for

AWG 1-

300Kcmil)

88**

275 (for

AWG 4 - 2)

375 (for AWG 1 -

300 kcmil)

500 (for AWG 350 500 kcmil)

88**

Cable

type

Copper (Cu) 75°C

* = With cable shoe for M6 screw.

**= Valid when brake chopper electronics are built in.

CG Drives & Automation, 01-6142-01r0 Installation 27

Page 28

3.5 Thermal protection on the motor

Standard motors are normally fitted with an internal fan. The cooling capacity of this built-in fan is dependent on the frequency of the motor. At low frequency, the cooling capacity will be insufficient for nominal loads. Please contact the motor supplier for the cooling characteristics of the motor at lower frequency.

WARNING! Depending on the cooling characteristics of the motor, the application, the speed and the load, it may be necessary to use forced cooling on the motor.

Motor thermistors offer better thermal protection for the motor. Depending on the type of motor thermistor fitted, the optional PTC input may be used. The motor thermistor gives a thermal protection independent of the speed of the motor, thus of the speed of the motor fan. See the functions, Motor I

t type [231] and Motor I2t current [232].

3.6 Motors in parallel

t is possible to have motors in parallel as long as the total current does not exceed the nominal value of the AC drive. The following has to be taken into account when setting the motor data:

Menu [221] Motor Voltage:

Menu [222] Motor Frequency:

Menu [223] Motor Power:

Menu [224] Motor Current:

Menu [225] Motor Speed:

Menu [227] Motor Cos PHI:

The motors in parallel must have the same motor voltage.

The motors in parallel must have the same motor frequency.

Add the motor power values for the motors in parallel.

Add the current for the motors in parallel.

Set the average speed for the motors in parallel.

Set the average Cos PHI value for the motors in parallel.

28 Installation CG Drives & Automation, 01-6142-01r0

Page 29

4. Control Connections

Relay outputs

Control signals

Switches

Option

Control Panel

Communication

4.1 Control board

Fig. 37 shows the layout of the control board which is where the parts most important to the user are located. Although the control board is galvanically isolated from the mains, for safety reasons do not make changes while the mains supply is on!

WARNING! Always switch off the mains voltage and wait at least 7 minutes to allow the DC capacitors

to discharge before connecting the control signals or changing position of any switches. If the option External supply is used, switch of the mains to the option. This is done to prevent damage on the control board.

Fig. 37 Control board layout

CG Drives & Automation, 01-6142-01r0 Control Connections 29

Page 30

4.2 Terminal connections

The terminal strip for connecting the control signals is accessible after opening the front panel.

The table describes the default functions for the signals. The inputs and outputs are programmable for other functions as described in chapter 10. page 65. For signal specifications refer to chapter 8. page 53.

NOTE: The maximum total combined current for outputs 11, 20 and 21 is 100mA.

NOTE: It is possible to use external 24V DC if connection to Common (15).

Table 17 Control signals

Termina l Name Function (Default)

Outputs

1 +10 V +10 VDC supply voltage

6-10 V

7 Common Signal ground

11 +24 V +24 VDC supply voltage

12 Common

15 Common

Digital inputs

8DigIn 1Auto run

9DigIn 2Forced run

10 DigIn 3 FlowLinkIn

16 DigIn 4 Of f

17 DigIn 5 Off

18 DigIn 6 Overflow level switch (optional)

19 DigIn 7 Off

22 DigIn 8 Reset

Digital outputs

20 DigOut 1

21 DigOut 2 FlowLinkOut

Analogue inputs

2 AnIn 1 Level sensor

3AnIn 2Off

4AnIn 3Off

5AnIn 4Off

Analogue outputs

13 AnOut 1

14 AnOut 2

Table 17 Control signals

Ter min al Name Function (Default)

Relay outputs

31 N/C 1

32 COM 1

33 N/O 1

41 N/C 2 Relay 2 ou t put

42 COM 2

43 N/O 2

51 CO M 3

52 N/O 3

NOTE: N/C is opened when the relay is active and N/O is closed when the relay is active.

NOTE! Using potentiometer for reference signal to Analogue input: Possible potentiometer value in range of 1 kΩ to 10 kΩ (¼ Watt) linear, where we advice to use a linear 1 kΩ / ¼ W type potentiometer for best control linearity.

WARNING!

The relay terminals 31-52 are single isolated.

Do NOT mix SELV voltage with e.g. 230 VAC

on these terminals. A solution when dealing

with mixed SELV/system voltage signals is to

install an additional I/O board option ( see

chapter 7.5 page 48) and connect all SELV

voltage signals to the relay terminals of this

option board while connecting all 230VAC

signals to the power board relay terminals 31

- 52.

Relay 1 output Trip, active when the AC drive is in a TRIP condition.

Run, active when the AC drive is started, also active during sleep mode.

Relay 3 output Off

30 Control Connections CG Drives & Automation, 01-6142-01r0

Page 31

4.3 Inputs configuration

with the switches

The switches S1 to S4 are used to set the input configuration for the 4 analogue inputs AnIn1, AnIn2, AnIn3 and AnIn4 as described in table 18. See Fig. 37 for the location of the switches.

4.4 Connect control cables

Here you will make up the minimum wiring for starting. To comply with the EMC standard, use screened control cables with plaited flexible wire up to 1.5 mm2 (AWG15) or solid wire up to 2.5 mm2(AWG13). We recommend using twisted pair cables between Master and follower for communication signals.

Table 18 Switch settings

Input Signal type Switch

Voltage

AnIn1

Current (default)

Voltage

AnIn2

Current (default)

Voltage

AnIn3

Current (default)

Voltage

AnIn4

Current (default)

NOTE: Scaling and offset of AnIn1 - AnIn4 can be configured using the software. See menus [512], [515], [518] and [51B] in section 10.5, page 138.

NOTE: the 2 analogue outputs AnOut 1 and AnOut 2 can be configured using the software. See menu [530] section 10.5.3, page 148

1. Connect a level sensor between terminals 1 (+10 VDC) and 2 (AnIn 1) as in Fig. 38 The default setting for the AnIn1 is 4-20 mA. If the level sensor has a 0-10 V interface, change the position of switch (S1) on control board (chapter 4.3 page 35).

2. Connect an external Auto run switch between terminal 11 (+24 VDC) and 8 (DigIn1, Flow Auto) as in Fig. 38. Set the switch in the open position (digital input set to low state). (Do not activate the signal at this point.)

3. Connect an external Full speed switch between terminal 11 (+24 VDC) and 9 (DigIn2, Flow Run) as in Fig. 38. Set the switch in the open position (digital input set to low state). (Do not activate the signal at this point.)

4. Connect a communication cable between Master terminal 10 (DigIn3) and Follower terminal 21 (DigOut2) as in Fig. 38. (Only if Master/Follower).

5. Connect a communication cable between Master terminal 21 (DigOut2) and Follower terminal 10 (DigIn3) as in Fig. 38. (Only if Master/Follower).

6. Connect an overflow level switch (optional) between terminal 11 (+24 VDC) and 18 (DigIn6, Lvl Overflow) as in Fig. 38 Connect the signal to the Follower drive instead in a Master-Follower configuration for redundancy.

CG Drives & Automation, 01-6142-01r0 Control Connections 31

Page 32

Man

+10 V

Master

Follower

Overflow level switch (optional)

Level sensor

Stand alone

Overflow

level switch

Level sensor

(optional)

+10 V

Man

Auto

Off

Auto

Off

Fig. 38 General control I/O wiring.

Table 19 Terminals and description of functions.

Stand alone / Master Follower

Terminal Name Function Termi nal Name Function

Analogue inputs

2 AnIn 1 Level sensor

Outputs

1 +10V +10V DC supply voltage

11 +24V +24V DC supply voltage 11 +24V +24V DC supply voltage

Digital inputs

8 DigIn 1 Auto run 8 DigIn 1 Auto run

9 DigIn 2 Forced run 9 DigIn 2 Forced run 10 DigIn 3 FlowLinkIn (Follower feedback) 10 DigIn 3 FlowLinkIn (Follower control) 22 DigIn 6 Overflow level switch (optional) 22 DigIn 6 Overflow level switch (optional)

Digital outputs

21 DigOut 2 FlowLinkOut (Follower control) 21 DigOut 2 FlowLinkOut (Follower feedback)

32 Control Connections CG Drives & Automation, 01-6142-01r0

Page 33

4.4.1 Connection example

EMCfilter

+10 VDC

AnIn 1: Level sensor*

AnIn 2

AnIn 3

AnIn 4

-10 VDC

Common

DigIn1:Auto run*

DigIn2:Forced run*

DigIn3

+24 VDC

Common

DigIn 4

DigIn 5

DigIn 6:Overflow**

DigIn 7

DigIn 8

Common

AnOut 1

AnOut 2

DigOut 2

DigOut 1

Motor

Fieldbus option

or PC

Option board

Other options

0 - 10 V 4 - 20 mA

Optional

** = Optional overflow level switch.

Relay 1

Relay 2

Relay 3

Comm. options

*** = Optional terminals X1: 78 - 79 for connection of Motor-PTC on frame sizes B, C and D.

Optional *** Motor PTC

FlowLinkIn*

FlowLinkOut*

:Reset*

* = Default setting

Fig. 39 gives an overall view of a AC drive connection example.

CE"FTKXG

TGUGV

NQE1 TGO

RTGX PGZV GUE

GPVGT

Fig. 39 Connection example

CG Drives & Automation, 01-6142-01r0 Control Connections 33

Page 34

4.4.2 Connecting the Control Signal

Control signals

Ter m in a l 7 8 & 7 9 see Table 20

Screen clamps for signal cables

Control signals

Terminal 78 & 79 see Table 20

Screen clamps for signal cables

motor PTC option

78 79

Feed-through of signal cables

Screen clamps for signal cables

See Tabl e 2 0

cables

The standard control signal connections are suitable for stranded flexible wire up to 1.5 mm wire up to 2.5 mm

NOTE: The screening of control signal cables must comply with the immunity levels given in the EMC Directive (reduction of noise level).

NOTE: The control cables must be separated from motor and mains cables.

(AWG14) .

Ta b le 20 De s c r i p t io n o f optional terminals in fig. 40 to fig.

44.

Terminals 78, 79 For connection of Motor PTC

(AWG16) and for solid

Ter m inal s A -, B+

For connection of 24V Stand-by Supply (only valid for sizes D & D2)

Fig. 41 Connecting the control signals, FLD model 026 to

046, frame size C.

Fig. 40 Connecting the control signals, FLD model 003 to

34 Control Connections CG Drives & Automation, 01-6142-01r0

018, frame size B.

Fig. 42 Connecting the control signals, FLD model 48-025 to

48-058 frame size C2.

Page 35

Fig. 43 Connecting the control signals, FLD model 061 to

DC-

DC+

Control signals

Screen clamps for signal cables

Ter m in a l 7 8 & 7 9 see Table 20

Ter m in a l A - & B+ see Table 20

L1 L2 L3 DC- DC+ R U V W

78 79, A- B+

Feed-through of signal cables

Screen clamps for signal cables

See Tab le 20

Control signals

Screen clamps

for signal cables

Screen clamps for signal cables

Feed-through of signal cables

Fig. 44 Connecting the control signals, FLD model 48-072 to

074, frame size D.

48-105 frame size D2.

Fig. 45 Connecting the control signals, FLD model 48-090 to

250 and FLD model 69-90 to 200, frame size E, F and F69 (principle drawing).

CG Drives & Automation, 01-6142-01r0 Control Connections 35

Fig. 46 Connecting the control signals, FLD model 48-142 to

48-293 frame size E2 and F2 (principle drawing)

Page 36

NOTE: The screening of control signal cables is necessary to comply with the immunity levels given in the EMC Directive (it reduces the noise level).

NOTE: Control cables must be separated from motor and mains cables.

4.4.3 Types of control signals

Always make a distinction between the different types of signals. Because the different types of signals can adversely affect each other, use a separate cable for each type. This is often more practical because, for example, the cable from a pressure sensor may be connected directly to the AC drive.

We can distinguish between the following types of control signals:

Analogue inputs

Voltage or current signals, (0-10 V, 0/4-20 mA) normally used as control signals for speed, torque and PID feedback signals.

Analogue outputs

Voltage or current signals, (0-10 V, 0/4-20 mA) which change slowly or only occasionally in value. In general, these are control or measurement signals.

Digital

Voltage or current signals (0-10 V, 0-24 V, 0/4-20 mA) which can have only two values (high or low) and only occasionally change in value.

Example:

The relay output from a AC drive which controls an auxiliary relay can, at the moment of switching, form a source of interference (emission) for a measurement signal from, for example, a pressure sensor. Therefore it is advised to separate wiring and screening to reduce disturbances.

4.4.4 Screening

For all signal cables the best results are obtained if the screening is connected to both ends: the AC drive side and at the source (e.g. PLC, or computer). See Fig. 47.

It is strongly recommended that the signal cables be allowed to cross mains and motor cables at a 90° angle. Do not let the signal cable go in parallel with the mains and motor cable.

4.4.5 Single-ended or double-ended connection?

In principle, the same measures applied to motor cables must be applied to all control signal cables, in accordance with the EMC-Directives.

For all signal cables as mentioned in section 4.4.3 the best results are obtained if the screening is connected to both ends. See Fig. 47.

NOTE: Each installation must be examined carefully before applying the proper EMC measurements.

Data

Usually voltage signals (0-5 V, 0-10 V) which change rapidly and at a high frequency, generally data signals such as RS232, RS485, Profibus, etc.

Relay

Relay contacts (0-250 VAC) can switch highly inductive loads (auxiliary relay, lamp, valve, brake, etc.).

Signal

type

Analogue Rigid cable:

Digital Screened

Data Screened

Relay Not screened

Maximum wire size

0.14-2.5 mm (AWG 26 - 14) Flexible cable:

0.14-1.5 mm (AWG 26 - 16) Cable with ferrule:

0.25-1.5 mm (AWG 24 - 16)

Tightening

torque

0.5 Nm (4.4 LB-in)

Cable type

Screened

36 Control Connections CG Drives & Automation, 01-6142-01r0

Page 37

4.4.6 Current signals ((0)4-20 mA)

Control board

Pressure sensor

(example)

External control (e.g. in metal housing)

Control consol

A current signal like (0)4-20 mA is less sensitive to disturbances than a 0-10 V signal, because it is connected to an input which has a lower impedance (250 Ω) than a voltage signal (20 kΩ). It is therefore strongly advised to use current control signals if the cables are longer than a few metres.

4.4.7 Twisted cables

Analogue and digital signals are less sensitive to interference if the cables carrying them are “twisted”. This is certainly to be recommended if screening cannot be used. By twisting the wires the exposed areas are minimised. This means that in the current circuit for any possible High Frequency (HF) interference fields, no voltage can be induced. For a PLC it is therefore important that the return wire remains in proximity to the signal wire. It is important that the pair of wires is fully twisted over 360°.

4.5 Connecting options

The option cards are connected by the optional connectors X4 or X5 on the control board see Fig. 37, page 29 and mounted above the control board. The inputs and outputs of the option cards are connected in the same way as other control signals.

Fig. 47 Electro Magnetic (EM) screening of control signal

cables.

CG Drives & Automation, 01-6142-01r0 Control Connections 37

Page 38

5. Getting Started

ESC

100

200

300

220

221

210

This chapter is a step by step guide that will show you the quickest way to get the pumps running.

We assume that:

• the AC drive is mounted on a wall or in a cabinet as in the chapter 2. page 11.

• mains and motor cable are connected according to chapter 3.3 page 23.

• control cables are connected according to chapter 4.4 page 31.

FlowDrive can operate as a Standalone unit (1 drive) or in a Master-Follower configuration (2 drives).

Sections

Chapter 5.1 - Describes how to use the function keys on the

control panel.

Chapter 5.2 - Covers generic configuration like language

and motor parameters.

Chapter 5.3 - Describes configuration of level control

parameters related to the pump sump.

5.1 Function keys

The function keys operate the menus and are also used for programming and read-outs of all the menu settings.

step to lower menu level or confirm changed setting

step to higher menu level or ignore changed setting

step to next menu on the same level

step to previous menu on the same level

increase value or change selection

decrease value or change selection

- Toggle between menus in the toggle loop

- Switching between local and remote control

- Change the sign of a value

Chapter 5.4 - Describes how to start up the system and

make sure everything is correctly configured.

Chapter 5.5 - Run the Auto tune program.

Chapter 5.6 - Configuration of additional features.

5.1.1 Using the function keys

ESC

Fig. 48 Example of menu navigation when entering motor

voltage

Example:

Setting Motor data.

Menu [100], “Preferred View” is displayed when started.

1. Press to display menu [200], “Main Setup”.

2. Press and then two times to display menu [220], “Motor Data”.

3. Press to display menu [221] and set motor voltage.

4. Change the value using the and keys. Confirm with .

CG Drives & Automation, 01-6142-01r0 Getting Started 39

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5.1.2 Toggle loop

211

221

3A11

341

3C13

3A21

3A31

3A42

3B31

3A41

Fig. 49 Default toggle loop

5.2 Generic configuration (all

drives)

This section is valid for all drive configurations, stand alone, master or follower.

5.2.1 Switch on the mains

Once the mains is switched on, the internal fan in the AC drive will run for 5 seconds (In frame size A3 the fan runs continuously). The control panel is lighted up and the drive can be configured. To change settings use the keys on the control panel as outlined above or remote access program such as EmoSoftCom. For further information about the control panel, EmoSoftCom and menu structure, see the software instruction

To ease commissioning there is a pre-programmed default toggle loop that can be used to jump between the parameters described in this guide. Often other settings adjacent to these entry points should be configured.

• [211] Language - Select language

• [221] Motor Volts - Motor configuration

• [3A11] Drive Conf .- Generic drive configuration

• [341] Min speed - Speed configuration

• [3C13] Sensor min – Level sensor configuration

• [3A21] Overflow low– Configurations of levels (where to start, stop pumping)

• [3A31] Level 1 – Reservoir configuration

• [3A42]LoadMonTune – Option to tune load monitor during auto tune program

• [3B31]Act.PumpCln - Option to clean pumps during auto tune program

• [3A41] Start AutoT – Start the Auto tune program

5.2.2 Language

Menu [100], “Preferred View” is displayed when started. Navigate to menu [211] or press toggle button once and you will jump directly to menu [211]. “[211] Language” – Set preferred language.

5.2.3 Set the Motor Data

Navigate to menu [221] or press toggle button once and you will jump directly to menu [221]. Enter correct motor data for the connected motor. Change settings using the keys on the control panel. For further information about the control panel and menu structure, see the software instruction.

1. Set motor voltage [221].

2. Set motor frequency [222].

3. Set motor power [223].

4. Set motor current [224].

5. Set motor speed [225].

6. Set power factor (cos ϕ) [227].

7. Press toggle button to continue.

40 Getting Started CG Drives & Automation, 01-6142-01r0

Page 40

5.2.4 Set FlowDrive configuration

The FlowDrive can work in two drive modes; FlowDrive mode and generic drive mode. In FlowDrive mode the drive is configured for reservoir level control and in generic drive mode it behaves just like a normal Emotron FDU drive.

By default the drive is configured in FlowDrive mode and the remaining quick start guide describes configuring this mode. In case you are interested in running the FlowDrive as a normal drive change parameter “[21C] Drive appl.” to “Generic” and consult the software instruction manual.

In FlowDrive mode the drive can operate as a Standalone unit (1 drive) or in a Master-Follower configuration (2 drives). The following configurations should be done on all drives independent of drive mode (Standalone, Master, or Follower).

1. Press toggle button once more or navigate to menu “[3A11] FLD Config“ Select whether the FlowDrive should be controlled as a

- ‘Standalone’, Configuration for a single drive/pump in

pump sump.

- ‘Master’ Configuration for the main drive in a dual

drive/pump setup

- ‘Follower’ Configuration for the secondary drive in a

dual drive/pump setup.

2. Press toggle button again or navigate to menu “ [341] Min frequency” Minimum frequency is by default set to 70% of nominal motor frequency. I.e. 35Hz in case nominal motor frequency is 50Hz. In most cases this is low enough to be able to find the best efficiency point and high enough to ensure that the pump generates a sufficient flow. Adjust upwards if the default value is considered to be too low for keeping up with normal inflow.

For units configured as “Follower” in menu [3A11] this concludes the configuration. For other units continue with the next section.

5.3 Additional configuration for Standalone / Master drives

5.3.1 Level sensor configuration

The level sensor connected to the standalone or master unit needs to be configured based on its type and placement. Navigate to menu [3C13] or press the toggle button.

1. “[3C13] Sensor min”

This is configuration of which level, in meters, the min analogue signal from the sensor should represent. Generally this is 0 for a pressure sensor placed in the bottom of

the sump. Press to continue.

2. “[3C14] Sensor max”

This is configuration of which level, in meters, the max analogue signal from the sensor represents. This data is dependent on the sensor but often sensors with a range of 5 or 10 meters is used.

5.3.2 Set sump levels

Set the desired levels for actions to be taken (starting and stopping of the pumps), see Fig. 50, page 42. Navigate to menu [3A21] or press the toggle button again and set following.

1. “[3A21]Overflow “ Level where the overflow alarm is

triggered. Press to continue.

2. “[3A23] Start level” Level where the pump is started,

Press to continue.

3. “[3A25] Stop level” Level where the pump is stopped

Press to continue.

Note: Overflow level has to be higher than Start level which has to be higher than Stop level.

CG Drives & Automation, 01-6142-01r0 Getting Started 41

Page 41

5.3.3 Set reservoir geometry

[3A31]Level 1 / [3A32]Area 1

[3A33]Level 2 / [3A34]Area 2

[3A35]Level 3 / [3A36]Area 3

[3A23]Start Level

[3A24]Stop Level

[3A21]Overflow Level

Area calculation:

[3A37]Level 4 / [3A38]Area 4

r = diameter/2

The reservoir geometry settings are crucial for the auto tune program and flow estimations. Please enter values as precisely as possible, failing to do so will result in inaccurate measurements. Navigate to menu “[3A31] Level 1” or press toggle button.

Start from the bottom level (level 1) and set a corresponding area for each change of shape in the reservoir. It is possible to use 5 levels and areas. Use as many as required, unused levels/areas should be set to 0/Off.

Level 1 [3A31] Area 1 [3A32] Level 2 [3A33] Area 2 [3A34] Level 3 [3A35] Area 3 [3A36] Level 4 [3A37] Area 4 [3A38] Level 5 [3A39] Area 5 [3A3A]

Fig. 50 Sump areas and levels, examples.

Example with round reservoir:

Level= X m,

Area = π

Level 1 = 0 m Area 1 = Radius is 0.6 m, area 1 is calculated:

π 0.6

Level 2 = 0.6 m,

Area 2 = Radius is 0.6 m, area 2 is calculated: π 0.6

Level 3 = 0.5 m Area 3 = Radius 0.9 m, area 3 is calculated: π 0.9

Level 4 = 1.5 m Area 4 = Radius 0.9 m, area 4 is calculated: π 0.9

42 Getting Started CG Drives & Automation, 01-6142-01r0

= 1.13m

= 2.54 m

Example with rectangular reservoir:

Level= X m,

Area = A x B m

Level 1: 0 m Area 1 : A= 1.2 m, B= 0.5m, area 1 is calculated:

1.2 x 0.5 = 0.6 m

Level 2 = 0.6 m,

Area 2 : A= 1.2 m, B= 0.5m, area 2 is calculated:

1.2 x 0.5 = 0.6 m

Level 3 = 0.5 m Area 3 : A= 1.8 m, B= 0.5m, area 3 is calculated:

1.8 x 0.5 = 0.9 m

Level 4 = 1.5 m Area 4 : A= 1.8 m, B= 0.5m, area 4 is calculated:

1.8 x 0.5 = 0.9 m

Page 42

5.4 Test run

Now the configuration is finished; time to test that everything works as expected

Sump Level

By default the sump level should be shown as first row in [100] menu. Make sure current sump level displayed corresponds to actual level in the sump.

Run switches

Make sure the external Auto/Off/Manual switch is configured correctly

1. Go to menu “[746] Pump mode”. In this menu the mode for the pumps are shown.

2. Make sure “Off” is shown for both pumps. If not make sure the switch is working, in right position and correctly connected. Also inspect the configuration in menu “[52X] DigIn X” where X is the digitial input pin number.

3. Turn the full speed switch“On” for one of the pumps. The corresponding pump should start and “[746] Pump mode” should change to “Manual” for the corresponding pump (the other pump should stay in “Off ” state). Test both pumps. Switch both back to “Off”.

4. Change both switches to Auto mode.

5. “[746] Pump mode” should change to “Auto”.

5.5 Engage “auto tune” program to optimize energy consumption

When concluded that the FlowDrive appears to be running correctly as described above the “Auto tune” program can be started. It is designed to measure reference outflows and find the best efficiency point. In addition the auto tune program can configure the load monitor enabling detection of obstructed pumps.

Load monitor

Decide if load monitor should be configured during the auto tune program. The load monitor needs to be configured to detect over/under load of the pumps during normal operation; e.g. to detect that a rug has got stuck in the pump.

• Go to menu [3A42] or press the toggle button.

“[3A42]LoadMonTune” – Set to “Yes” if you want the load monitor to be configured during auto tune program.

Clean pumps

It is not mandatory to run pump cleaning but it will help getting accurate measurements in the auto tune program. Decide if a pump cleaning should be done prior to the auto tune program.

Verify “Auto mode” operation

In “Auto” pump mode the pump should start when “[3A23] Start level” is reached. Monitor how the level decreases and that the pump stops when “[3A25] Stop level” is reached.

NOTE: Pump cleaning will reverse the pumps. Check with the pump manufacturer that the connected pump can operate in the reverse direction. Activating of pump cleaning is necessary for “Load monitor” to be able to clean the pump(s).

• Navigate to menu [3B31] or press the toggle button.

“[3B31]Allowed” – Set to “Yes” to allow pump cleaning. If allowed the auto tune program will start with cleaning the pump(s).

Start Auto tune

The auto tune program will do a lot of measurements and will take several hours, up to days, to complete. After completion the drive will automatically jump into normal running mode.

• Navigate to menu [3A41] or press toggle button.

“[3A41] Start AutoT” – Set to “Start” to initiate the Auto Tune program

The progress can be seen in menu “[7492] BEP progres” as a percentage. When finished the result can be seen in the following parameters: “[349] BEP Speed” – The frequency where it is most efficient to pump at “[94X] Flow log 1P” – Log of outflow and energy data for one pump at different frequencies “[95X] Flow log 2P” – Log of flows and energy data for two pumps at different frequencies “[41CX] Load Curve” – If load monitor was configured load data at different frequencies can be found here

CG Drives & Automation, 01-6142-01r0 Getting Started 43

Page 43

5.6 Configuration of additional features

Here is a very short description of some of the additional features built into the FlowDrive. Please consult the software manual for more options and a more throughout description.

Flush start

Function to always ramp up to full speed to get sludge and sediment moving. Flushing time and frequency can be configured in [3B1X] menus. By default this feature is turned on.

Random start level

To avoid building up residues at start level on the sump wall, it is possible to randomize where the pumps are started. By default randomized start level is turned off.

Activate this function by setting start level in “[3B2]Start lvl “, by default this is set to off.

“[3B2] Start lvl “– Set the desired variation in meters.

Example

Start level is set to: 1.5 meters Start lvl is set to: 0.4m Actual start level will then be randomized between 1.1m-

1.5m.

Sump cleaning

Pump sump cleaning empties the pump sump by running the selected pump(s) below the normal stop level until free running. This will help to get rid of accumulated residues in the bottom of the pump sump.

NOTE 1: Running pumps below their normal stop level might cause the pump to overheat. NOTE 2: Problems might emerge from sucking air into the pump/pipes in some installations.

“[3B41] Act.SumpCln” – Activates a “one-off” run of sump cleaning if set to ‘Yes’ in accordance with “Run mode” “[3B42] ForceSumpCl” – Configures how to run sump cleaning.

Pipe cleaning

Pipe cleaning function produce as much flow as possible for as long time as possible to clean the pipes from loose residues.

“[3B51] ForcePipeC” – Activate a “one-off ” run of pipe cleaning if set to ‘Yes’.

Pump cleaning

Pump cleaning runs the pump in a specific pattern in both forward and reverse direction to clean the pump from rugs and dirt buildup. By default this feature is turned off.

NOTE: Pump cleaning will reverse the pumps. Check with the pump manufacturer that the connected pump can operate in the reverse direction.

“[3B31] Act.PumpCln” – Set to ‘Yes’ to allow pump cleaning “[3B32] ForcePumpCl” – Set to ‘Master’, ‘Follower’, or ‘Both’ to request a “one-off” pump cleaning right away

44 Getting Started CG Drives & Automation, 01-6142-01r0

Page 44

6. EMC and standards

6.1 EMC standards

The AC drive complies with the following standards:

EN(IEC)61800-3:2004 Adjustable speed electronic power drive systems, part 3, EMC product standards:

Standard: category C3, for systems of rated supply voltage< 1000 VAC, intended for use in the second environment.

Optional: Category C2 and even Category C1 for frame size C drives, for systems of rated supply voltage <1.000 V, which is neither a plug in device nor a movable device and, when used in the first environment, is intended to be installed and commissioned only by experienced person with the necessary skills in installing and/or commissioning AC drives including their EMC aspects.

6.2 Stop categories and emergency stop

The following information is important if emergency stop circuits are used or needed in the installation where a AC drive is used. EN 60204-1 defines 3 stop categories:

Category 0: Uncontrolled STOP:

Stopping by switching off the supply voltage. A mechanical stop must be activated. This STOP may not be implemented with the help of a AC drive or its input/output signals.

Category 1: Controlled STOP:

Stopping until the motor has come to rest, after which the mains supply is switched off. This STOP may not be implemented with the help of a AC drive or its input/output signals.

Category 2: Controlled STOP:

Stopping while the supply voltage is still present. This STOP can be implemented with each of the AC drives STOP command.

WARNING! EN 60204-1 specifies that every machine must be provided with a category 0 stop. If the application prevents this from being

implemented, this must be explicitly stated. Furthermore, every machine must be provided with an Emergency Stop function. This emergency stop must ensure that the voltage at the machine contacts, which could be dangerous, is removed as quickly as possible, without resulting in any other danger. In such an Emergency Stop situation, a category 0 or 1 stop may be used. The choice will be decided on the basis of the possible risks to the machine.

NOTE: With option Safe Stop, a “Safe Torque Off (STO)” stop according EN-IEC 62061:2005 SIL 3 & EN-ISO 13849-1:2006, can be achieved. See chapter, Safe Stop option

CG Drives & Automation,01-6142-01r0 EMC and standards 45

Page 45

7. Options

The standard options available are described here briefly. Some of the options have their own instruction or installation manual. For more information please contact your supplier. See also in “Technical catalogue AC drives” for more info.

7.1 Options for the control panel

Part number Description

01-3957-00 Panel kit complete including panel

01-3957-01 Panel kit complete including blank panel

Mounting cassette, blank panel and straight RS232-cable are available as options for the control panel. These options may be useful, for example for mounting a control panel in a cabinet door.

7.2 Handheld Control Panel

2.0

Part number Description

01-5039-00

Handheld Control Panel 2.0 complete for FDU/VFX2.0 or CDU/CDX 2.0

Fig. 51 Control panel in mounting cassette

The Handheld Control Panel - HCP 2.0 is a complete control panel, easy to connect to the AC drive, for temporary use when e.g. commissioning, servicing and so on.

The HCP has full functionality including memory. It is possible to set parameters, view signals, actual values, fault logger information and so on. It is also possible to use the memory to copy all data (such as parameter set data and motor data) from one AC drive to the HCP and then load this data to other AC drives

CG Drives & Automation, 01-6142-01r0 Options 47

Page 46

7.3 Gland kits

Gland kits are available for frame sizes B, C and D.

Metal EMC glands are used for motor and brake resistor cables.

7.7 RTC- Real time clock board

Part number Description

Part Number Current (dimension)

01-4601-21 3 - 6 A (M16 - M20)

01-4601-23 13 - 18 A (M16 - M32)

01-4399-01 26 - 31 A (M12 - M32)

01-4399-00 37 - 46 A (M12 - M40)

01-4833-00 61 - 74 A (M20 - M50) D

Frame

size

B01-4601-22 8 - 10 A (M16 - M25)

7.4 EmoSof tCom

EmoSoftCom is an optional software that runs on a personal computer. It can also be used to load parameter settings from the AC drive to the PC for backup and printing. Recording can be made in oscilloscope mode. Please contact CG Drives & Automation sales for further information.

7.5 I/O Board

Part number Description

01-3876-01 I/O option board 2.0

Each I/O option board 2.0 provides three extra relay outputs and three extra isolated digital inputs (24V). The I/O Board works in combination with the Pump/Fan Control, but can also be used as a separate option. Maximum 3 I/O boards possible. This option is described in a separate manual.

7.6 PTC/PT100

01-3876-15 RTC option board

With this option board connected, it is possible to see and set actual time, date and weekday. This can be used to

start or stop certain functions such as pump cleaning, pipe cleaning or sump cleaning at certain time, date or weekdays.

7.8 Serial communication and fieldbus

Part number Description

01-3876-04 RS232/485

01-3876-05 Profibus DP

01-3876-06 DeviceNet

01-3876-09 Modbus/TCP, Industrial Ethernet

01-3876-14

01-3876-10 EtherCAT, Industrial Ethernet

01-3876-11 Profinet IO, one port Industrial Ethernet

01-3876-12 Profinet IO, two port Industrial Ethernet

01-3876-13 EtherNet/IP, two port industrial EtherNet

For communication with the AC drive there are several option boards for communication. There are different options for Fieldbus communication and one serial communication option with RS232 or RS485 interface which has galvanic isolation.

Modbus/TCP, two port M12 Industrial Ethernet

Part number Description

01-3876-08 PTC/PT100 2.0 option board

The PTC/PT100 2.0 option board for connecting motor thermistors and max 3 PT100 elements to the AC drive is described in a separate manual.

48 Options CG Drives & Automation, 01-6142-01r0

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7.9 Standby supply board

X1:1 Left terminal X1:2 Right terminal

Connect the power supply

board to the

two blue terminals marked A- and B+

0V to A24V to B+

option

Part number Description

Standby power supply kit for after

01-3954-00

The standby supply board option provides the possibility of keeping the communication system up and running without having the 3-phase mains connected. One advantage is that the system can be set up without mains power. The option will also give backup for communication failure if main power is lost.

The standby supply board option is supplied with external ±10% 24 V double isolated transformer. The terminals X1:1, X1:2 (on size B, C and E to F) are voltage polarity independent. The terminals A- and B+ (on size D) are voltage polarity dependent.

mounting. Not for frame sizes D & D2

protected by a 2 A slow acting fuse, from a

Fig. 53 Connection of standby supply option on frame size D

and D2

Fig. 52 Connection of standby supply option n frame sizes B,

C, C2, E, E2, F and F2.

terminal

1 Ext. supply 1

2 Ext. supply 2

Name Function Specification

External, AC drive main power independent, supply voltage for control and communication circuits

or V

24 V

±10% Double isolated

Termin al Name Function Specification

A - 0V

B + +24V

External, AC drive main power independent, supply voltage for control and communication circuits

±10%

24 V

Double isolated

7.10 Safe Stop option

To realize a Safe Stop configuration in accordance with Safe Torque Off (STO) EN-IEC 62061:2005 SIL 3 & EN-ISO 13849-1:2006, the following three parts need to be attended to:

1. Inhibit trigger signals with safety relay K1 (via Safe Stop

option board).

2. Enable input and control of AC drive (via normal I/O

control signals of AC drive).

3. Power conductor stage (checking status and feedback of

driver circuits and IGBT’s).

To enable the AC drive to operate and run the motor, the following signals should be active:

• "Inhibit" input, terminals 1 (DC+) and 2 (DC-) on the

Safe Stop option board should be made active by connecting 24 V driver circuits of the power conductors via safety relay K1. See also Fig. 107.

• High signal on the digital input, e.g. terminal 10 in Fig.

107, which is set to "Enable". For setting the digital input please refer to section 10.5.2, page 132.

to secure the supply voltage for the

CG Drives & Automation, 01-6142-01r0 Options 49

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These two signals need to be combined and used to enable

the output of the AC drive and make it possible to activate a Safe Stop condition.

NOTE: The "Safe Stop" condition according to EN-IEC 62061:2005 SIL 3 & EN-ISO 13849-1:2006, can only be realized by de-activating both the "Inhibit" and "Enable" inputs.

When the "Safe Stop" condition is achieved by using these two different methods, which are independently controlled, this safety circuit ensures that the motor will not start running because:

• The 24VDC signal is disconnected from the "Inhibit" input, terminals 1 and 2, the safety relay K1 is switched off.

The supply voltage to the driver circuits of the power conductors is switched off. This will inhibit the trigger pulses to the power conductors.

• The trigger pulses from the control board are shut down.

The Enable signal is monitored by the controller circuit which will forward the information to the PWM part on the Control board.

To make sure that the safety relay K1 has been switched off, this should be guarded externally to ensure that this relay did not refuse to act. The Safe Stop option board offers a feedback signal for this via a second forced switched safety relay K2 which is switched on when a detection circuit has confirmed that the supply voltage to the driver circuits is shut down. See Table 34 for the contacts connections.

To monitor the "Enable" function, the selection "RUN" on a digital output can be used. For setting a digital output, e.g. terminal 20 in the example Fig. 107, please refer to section

10.5.4, page 138 [540].

WARNING! The safe stop function can never be used for electrical maintenance. For electrical maintenance the AC drive should always be disconnected from the supply voltage.

Fig. 54 Connection of safe stop option in size B .

When the "Inhibit" input is de-activated, the AC drive display will show a flashing "SST" indication in section D (bottom left corner) and the red Trip LED on the Control panel will be flashing.

To resume normal operation, the following steps have to be taken:

• Release "Inhibit" input; 24V

(High) to terminal 1

and 2.

• Give a STOP signal to the AC drive, according to the set Run/Stop Control in menu [215].

• Give a new Run command, according to the set Run/ Stop Control in menu [215].

NOTE: The method of generating a STOP command is dependent on the selections made in Start Signal Level/ Edge [21A] and the use of a separate Stop input via digital input.

Fig. 55 Connection of safe stop option in size E and up.

50 Options CG Drives & Automation, 01-6142-01r0

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Table 21 Specification of Safe Stop option board

Safe Stop

+5V

+24 V

Power board

PWMController

DigIn

DigOut

Enable

Stop

1 Inhibit +

2 Inhibit -

Name Function Specification

Inhibit driver circuits of power conductors

NO contact relay K2

P contact

Feedback; confirmation of activated inhibit

relay K2

5 GND Supply ground

Supply Voltage for

6+24 VDC

operating Inhibit input only.

DC 24 V (20–30 V)

48 V

/2 A

30 V

+24 V

50 mA

Fig. 56 Safe Stop connection

CG Drives & Automation, 01-6142-01r0 Options 51

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7.11 EMC filter class C1/C2

EMC filter according to EN61800-3:2004 class C1 (for frame size C types) and C2 - 1st environment restricted distribution. For sizes BC, C2, D and D2, the filter is mounted inside the drive module. For sizes E , external EMC filters are available. For more information refer to “Technical catalogue for AC drives”. Note: EMC filter according to class C3 - 2nd environment included as standard in all drive units.

7.12 Output chokes

Output chokes, which are supplied separately, are recommended for lengths of screened motor cable longer than 100 m. Because of the fast switching of the motor voltage and the capacitance of the motor cable (both line to line and line to earth screen), large switching currents can be generated with long lengths of motor cable. Output chokes prevent the AC drive from tripping and should be installed as closely as possible to the AC drive. See also in “Technical catalogue AC drives” for filter selection guide.

Fig. 57 Optional top cover mounted on frame size D2

7.15 Other options

Following options are also available, for more information regarding these options, see in “Technical catalogue AC drives”.

7.13 Liquid cooling

AC drive modules in frame sizes E - O and F69 - T69 are available in a liquid cooled version. These units are designed for connection to a liquid cooling system, normally a heat exchanger of liquid-liquid or liquid-air type. Heat exchanger is not part of the liquid cooling option. Drive units with parallel power modules (frame size G - T69) are delivered with a dividing unit for connection of the cooling liquid. The drive units are equipped with rubber hoses with leak-proof quick couplings. The Liquid cooling option is described in a separate manual.

7.14 Top cover for IP20/21

version

Part number Description

01-5356-00 Top cover for frame size

01-5355-00 Top cover for frame sizes D2, E2 and F2

This Top cover can be mounted on IP20 versions of frame sizes C2, D2, E2 and F2. By mounting the top cover, the protection class will change to IP21 in accordance with EN 60529 standard.

Overshoot clamp

Sine wave filter

Common mode filter

Brake resistors

52 Options CG Drives & Automation, 01-6142-01r0

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8. Technical Data

8.1 Electrical specifications related to model

Emotron FLD - IP20/21 version

Table 22 Typical motor power at mains voltage 230, 400 and 460V. AC drive main voltage range 230 - 480 V.

Max.

Model

FLD48-025-20 30 25 5.5 7. 5 11 15 FLD48-030-20 36 30 7. 5 1 0 1 5 2 0 FLD48-036-20 43 36 7. 5 10 18.5 25 FLD48-045-20 54 45 11 15 22 30 FLD48-058-20 68 58 15 20 30 40 FLD48-072-20 86 72 18.5 25 37 50 FLD48-088-20 106 88 22 30 45 60 FLD48-105-20 126 105 30 40 55 75 FLD48-142-20 170 142 37 50 75 100 FLD48-171-20 205 171 45 60 90 125 FLD48-205-20 246 205 55 75 110 150

FLD48-293-20 352 293 90 125 160 250

output

current

[A]*

Rated

current

[A]

Power

@230V

[kW]

Normal duty

(120%, 1 min every 10 min)

Power

@230V

[HP]

@400V

Power

[kW]

Power

@460V

[HP]

* Available during limited time and as long as allowed by drive temperature.

Emotron FLD - IP54 version

Table 23 Typical motor power at mains voltage 230, 400 and 460 V. AC drive main voltage range 230 - 480 V.

Frame size

F2FLD48-244-20 293 244 75 100 132 200

Max.

Model

FLD48-003-54 3.0 2.5 0.37 0.5 0.75 1 FLD48-004-54 4.8 4.0 0.75 1 1.5 2 FLD48-006-54 7. 2 6.0 1.1 1.5 2.2 3 FLD48-008-54 9.0 7. 5 1.5 2 3 3 FLD48-010-54 11.4 9.5 2.2 3 4 5 FLD48-013-54 15.6 13.0 2.235.57.5 FLD48-018-54 21.6 18.0 4 5 7. 5 10 FLD48-026-54 31 26 5.5 7.5 11 15 FLD48-031-54 37 31 7. 5 10 15 20 FLD48-037-54 44 37 7.5 10 18.5 25 FLD48-046-54 55 46 11 15 22 30 FLD48-061-54 73 61 15 20 30 40 FLD48-074-54 89 74 18.5 25 37 50 FLD48-090-54 108 90 22 30 45 60 FLD48-109-54 131 109 30 40 55 75 FLD48-146-54 175 146 37 50 75 100 FLD48-175-54 210 17 5 45 60 90 125 FLD48-210-54 252 210 55 75 110 150 FLD48-228-54 300 228 55 75 110 200 FLD48-250-54 300 250 75 100 132 200

output

current

[A]*

Rated

current

[A]

Power

@230V

[kW]

Normal duty

(120%, 1 min every 10 min)

Power

@230V

[HP]

Power

@400V

[kW]

Power

Frame

@460V

[HP]

size

klass

IP 54

wall

mounted

* Available during limited time and as long as allowed by drive temperature.

CG Drives & Automation 01-6142-01r0 Technical Data 53

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Emotron FLD 2.0 - IP54 version (Model 69-250 and up also available as IP20)

Table 24 Typical motor power at mains voltage 525, 575 and 690 V.

AC drive main voltage range, for 52: 440 - 525 V and for 69: 500 - 690 V.

Max.

Model

FLD52-003-54 3.0 2.5 1.1 - FLD52-004-54 4.8 4.0 2.2 - FLD52-006-54 7. 2 6.0 3 - FLD52-008-54 9.0 7. 5 4-FLD52-010-54 11.4 9.5 5.5 - FLD52-013-54 15.6 13.0 7. 5 - FLD52-018-54 21.6 18.0 11 - FLD52-026-54 31 26 15 - FLD52-031-54 37 31 18.5 - FLD52-037-54 44 37 22 - FLD52-046-54 55 46 30 - FLD52-061-54 73 61 37 - FLD52-074-54 89 74 45 - FLD69-090-54 108 90 55 75 90 FLD69-109-54 131 109 75 100 110 FLD69-146-54 175 146 90 125 132 FLD69-175-54 210 175 110 150 160 FLD69-200-54 240 200 132 200 200

output

current

[A]*

Rated

current

[A]

Normal duty

(120%, 1 min every 10 min)

Power

@525V

[kW]

Power

@575V

[HP]

Power

@690V

[kW]

Frame size

F69

class

IP 54

wall

mounted

* Available during limited time and as long as allowed by drive temperature.

54 Technical Data CG Drives & Automation 01-6142-01r0

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8.2 General electrical specifications

Table 25 General electrical specifications

General

Mains voltage: 48

69 Mains frequency: Mains voltage imbalance: Input power factor: Output voltage: Output frequency: Output switching frequency: Efficiency at nominal load:

Control signal inputs: Analogue (differential)

Analogue Voltage/current: Max. input voltage: Input impedance:

Resolution: Hardware accuracy: Non-linearity

Digital:

Input voltage: Max. input voltage: Input impedance:

Signal delay:

230-480V +10%/-15% (-10% at 230 V) 440-525 V +10 %/-15 % 500-690V +10%/-15% 45 to 65 Hz

3.0% of nominal phase to phase input voltage.

max. +

0.95 0–Mains supply voltage: 0–400 Hz 3 kHz (adjustable 1,5-6 kHz) 97% for models 003 to 018 98% for models 025 to 3K0

0-±10 V/0-20 mA via switch +30 V/30 mA 20 kohm (voltage) 250 kohm (current) 11 bits + sign 1% type + 1 ½ LSB fsd 1½ LSB

High: >9 VDC, Low: <4 VDC +30 VDC <3.3 VDC: 4.7 kohm

≥3.3 VDC: 3.6 kohm

≤8 ms

Control signal outputs Analogue

Output voltage/current: Max. output voltage: Short-circuit current ( Output impedance: Resolution: Maximum load impedance for current Hardware accuracy: Offset: Non-linearity:

Digital

Output voltage:

Shortcircuit current(∞):

Relays

Contacts

References

+10VDC

-10VDC +24VDC

∞):

0-10 V/0-20 mA via software setting +15 V @5 mA cont. +15 mA (voltage), +140 mA (current) 10 ohm (voltage) 10 bit 500 ohm

1.9% type fsd (voltage), 2.4% type fsd (current) 3 LSB 2 LSB

High: >20 VDC @50 mA, >23 VDC open Low: <1 VDC @50 mA 100 mA max (together with +24 VDC)

0.1 – 2 A/Umax 250 VAC or 42 VDC (30 VDC acc. to UL requirement) for general Purpose or Resistive use only .

+10 VDC @10 mA Short-circuit current +30 mA max

- 10 VDC @10 mA +24 V

Short-circuit current +100 mA max (together with Digital Outputs)

CG Drives & Automation 01-6142-01r0 Technical Data 55

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8.3 Operation at higher

8.4 Operation at higher

temperatures

Most Emotron AC drives are made for operation at maximum of 40°C (104 °F) ambient temperature. However, it is possible to use the AC drive at higher temperatures with reduced output rating.

Possible derating

Derating of output current is possible with

-1% / degree Celsius to max +15 °C (= max temp 55 °C) or

-0.55%/ degree Fahrenheit to max +27 °F (= max temp. 131 °F).

Example

In this example we have a motor with the following data that we want to run at the ambient temperature of 45 °C (113 °F):

Voltage 400 V Current 72 A Power 37 kW (50 hp)

Select AC drive

The ambient temperature is 5 °C (9 °F) higher than the maximum ambient temperature. The following calculation is made to select the correct AC drive model.

Derating is possible with loss in performance of 1%/°C (0.55%/ degree F).

Derating will be: 5 x 1% = 5%

switching frequency

Table 26 shows the switching frequency for the different AC drive models. With the possibility of running at higher switching frequency you can reduce the noise level from the motor. The switching frequency is set in menu [22A], Motor sound, see software instruction. At switching frequencies >3 kHz derating might be needed.

Table 26 Switching frequency

Standard

Models

FLD##-003 to FLD##-250 3 kHz 1.5–6 kHz

Switching frequency

Range

Calculation for model 48-074 74 A - (5% x 74) = 70.3 A; this is not enough.

Calculation for model 48-090 90 A - (5% x 90) = 85.5 A

In this example we select the 48-090.

56 Technical Data CG Drives & Automation 01-6142-01r0

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8.5 Dimensions and Weights

The table below gives an overview of the dimensions and weights. The models 003 to 250 are available in IP54 as wall mounted modules. Protection class IP54 is according to the EN 60529 standard.

Table 27 Mechanical specifications, 48, 52

IP54

Models Frame size

003 to 018 B 350/416 x 203 x 200 (13.8/16.4 x 8 x 7.9) 12.5 (27.6) 026 to 046 C 440/512 x178x292 (17.3/20.2 x 7 x 11.5) 24 (52.9)

061 to 074 D 545/590 x 220 x 295 (21.5/23.2 x 8.7 x 11.5) 32 (70.6)

90 to 109 E 950 x 285 x 314 (37.4 x 11.2 x 12.4) 56 (123.5)

146 to 175 E 950 x 285 x 314 (37.4 x 11.2 x 12.4) 60 (132.3)

210 to 250 F 950 x 345 x 314 (37.4 x 13.6 x 12.4) 74 (163.1)

Dim. H x W x D

mm (in)

Table 28 Mechanical specifications, 69

IP54

Models Frame size

90 to 200 F69 1090 x 345 x 314 (42.9 x 13.6 x 12.4) 77 (169.8)

Dim. H x W x D

mm (in)

Weight IP54

Dimensions and weights for models Emotron 48 - IP20/21 version

The table below gives an overview of the dimensions and weights of the Emotron IP20/21 version.

These AC drives are available as wall mounted modules; The IP20 version is optimised for cabinet mounting. With the optional top cover, protection class is in compliance with IP21, making it suitable for mounting directly on the electrical room wall.

IP54

Weight

kg (lb)

The protection classes IP20 and IP21 are defined according to the EN 60529 standard.

Table 29 Mechanical specifications, 48 - IP20 and IP21 version

Models

025 to 058 C2

072 to 105 D2

142 to 171 E2

205 to 293 F2

H1 = Enclosure height. H2 = Total height including cable interface. * with optional top cover

Frame

size

Dim. H1/H2 x W x D

438 / 536 x 176 x 267

(17.2/21.1 x 6.9 x 10.5)

545 / 658 x 220 x 291

(21.5/25.9 x 8.7 x 11.5)

956 / 956 x 275 x 294

(37.6/37.6 x 10.8 x 11.6)

956 / 956 x 335 x 294

(37.6/37.6 x 13.2 x 11.6)

IP20

mm (in)

IP21*

Dim. H1/H2 x W x D

mm (in)

438 / 559 x 196 x 282

(17.2/22 x 7.7 x 11.1)

545 / 670 x 240 x 307

(21.5/26.4 x 9.5 x 12.1)

956 / 956 x 275 x 323

(37.6/37.6 x 10.8 x 12.7)

956 / 956 x 335 x 323

(37.6/37.6 x 13.2 x 12.7)

IP20/21

Weight

kg (lb)

17 ( 37.5)

30 (66)

53 (117)

68 (150)

CG Drives & Automation 01-6142-01r0 Technical Data 57

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8.6 Environmental conditions

Table 30 Operation

Parameter Normal operation

Nominal ambient temperature 0

Atmospheric pressure 86–106 kPa (12.5 - 15.4 PSI)

Relative humidity

according to IEC 60721-3-3

Contamination,

according to IEC 60721-3-3

Vibrations

Altitude

°C–40 °C (32 °F - 104 °F) See table, see chapter 8.3 page 56 for different conditions

Class 3K4, 5...95% and non condensing

No electrically conductive dust allowed. Cooling air must be clean and free from corrosive materials. Chemical gases, class 3C2. Solid particles, class 3S2.

According to IEC 600068-2-6, Sinusodial vibrations: 10<f<57 Hz, 0.075 mm (0.00295 ft) 57<f<150 Hz, 1g (0,035 oz)

0–1000 m (0 - 3280 ft) 480V AC drives, with derating 1%/100 m (328 ft) of rated current up to 4000 m (13123 ft) 690V AC drives, with derating 1%/100 m (328 ft) of rated current up to 2000 m (6562) ft Coated boards required for 2000 - 4000 m(6562 - 13123 ft)

Table 31 Storage

Parameter Storage condition

Temperature -20 to +60 °C (-4 to + 140 °F)

Atmospheric pressure 86–106 kPa (12.5 - 15.4 PSI)

Relative humidity

according to IEC 60721-3-1

Class 1K4, max. 95% and non condensing and no formation of ice.

58 Technical Data CG Drives & Automation 01-6142-01r0

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8.7 Fuses and glands

8.7.1 According to IEC ratings

Use mains fuses of the type gL/gG conforming to IEC 269 or breakers with similar characteristics. Check the

NOTE: The dimensions of fuse and cable cross-section are dependent on the application and must be determined in accordance with local regulations.

equipment first before installing the glands.

Max. Fuse = maximum fuse value that still protects the AC drive and upholds warranty.

NOTE: The dimensions of the power terminals used in the cabinet drive models 300 to 3K0 can differ depending on customer specification.

Table 32 Fuses, cable cross-sections and glands

Nominal input

Model

##-003 2.2 4 ##-004 3.5 4 ##-006 5.2 6 ##-008 6.9 10

##-010 8.7 10

##-013 11.3 16 ##-018 15.6 20 ##-025 22 25 - (12 - 16 mm(0.55 - 0.63 in))

##-026 22 25

##-030 26 35 - (16 - 20 mm (0.63 - 0.79 in))

##-031 26 35

##-036 31 35 - (20 - 24 mm(0.79 - 0.94))

##-037 31 35

##-045 38 50 - (24 - 28 mm(0.94 - 1.1 in))

##-046 38 50

##-058 50 63 - (24 - 28 mm(0.94 - 1.1 in))

##-061 52 63

##-072 64 80 - (28 - 32 mm(1.1 - 1.26 in))

##-074 65 80

##-088 78 100 - (32 - 36 mm(1.26 - 1.42 in))

##-090 78 100

##-105 91 100 - (32 - 36 mm(1.26 - 1.42 in))

##-109 94 100

##-142 126 160 - (40 - 44 mm (1.57 - 1.73 in)) - (36 - 40 mm(1.42 - 1.57 in))

current

[A]

Maximum value

fuse

[A]

Cable glands (clamping range ) *

mains / motor Brake

M32 opening

M20 + reducer

(6–12 mm(0.24 - 0.47 in))

M32 (12–20)/M32 opening

M25+reducer

(10-14 mm(0.39 - 0.55 in))

M32 (16–25)/M32 (13–18)

M32

(15–21 mm(0.59 - 0.83 in))

M32

(15–21 mm(0.59 - 0.83 in))

M40

(19–28 mm (0.75 - 1.1 in))

M40

(19–28 mm (0.75 - 1.1 in))

M50

(27 - 35 mm(1.06 - 1.38 in))

M50

(27 - 35 mm(1.06 - 1.38 in))

48: (Ø17-42 mm (0.67 - 1.65 in))

cable flexible leadthrough or M50

opening.

69: (Ø23-55 mm (0.9 - 2.16 in))

Cable flexible leadthrough or M63

opening.

48: (Ø17-42 mm (0.67 - 1.65 in))

cable flexible leadthrough or M50

opening.

69: (Ø23-55 mm (0.9 - 2.16 in))

Cable flexible leadthrough or M63

opening.

M25 opening

M20 + reducer

(6–12 mm(0.24 - 0.47 in))

M25

(10-14 mm(0.39 - 0.55 in))

M25

M32

M40

(19–28 mm (0.75 - 1.1 in))

M40

(19–28 mm(0.75 - 1.1 in))

48: (Ø11-32 mm(0.43 - 1.26 in))

Cable flexible leadthrough or M40

opening.

69: (Ø17-42 mm (0.67 - 1.65 in))

Cable flexible leadthrough or M50

opening.

48: (Ø11-32 mm(0.43 - 1.26 in))

Cable flexible leadthrough or M40

opening.

69: (Ø17-42 mm (0.67 - 1.65 in))

Cable flexible leadthrough or M50

opening.

CG Drives & Automation 01-6142-01r0 Technical Data 59

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Table 32 Fuses, cable cross-sections and glands

Nominal input

Model

##-146 126 160

##-171 152 160 - (40 - 44 mm (1.57 - 1.73 in)) - (36 - 40 mm(1.42 - 1.57 in))

##-175 152 160

##-205 17 8 200

##-210 182 200

##-228 197 250

##-244 211 250

##-250 216 250

##-293 254 300

current

[A]

Maximum value

fuse

[A]

Cable glands (clamping range ) *

mains / motor Brake

48: (Ø17-42 mm (0.67 - 1.65 in))

cable flexible leadthrough or M50

opening.

69: (Ø23-55 mm (0.9 - 2.16 in))

Cable flexible leadthrough or M63

opening.

48: (Ø17-42 mm (0.67 - 1.65 in))

cable flexible leadthrough or M50

opening.

69: (Ø23-55 mm (0.9 - 2.16 in))

Cable flexible leadthrough or M63

opening.

- (48 - 52 mm(1.89 - 2.05 in)/ 52 56 mm (2.05 - 2.2 in))

(Ø23 - 55 mm (0.9 - 2.16 in))

cable flexible leadthrough or M63

opening.

- (48 - 52 mm(1.89 - 2.05 in)/ 52 56 mm (2.05 - 2.2 in))

Ø(23 - 55 mm (0.9 - 2.16 in))

cable flexible leadthrough or M63

opening.

- (48 - 52 mm(1.89 - 2.05 in)/ 52 56 mm (2.05 - 2.2 in))

48: (Ø11-32 mm(0.43 - 1.26 in))

Cable flexible leadthrough or M40

opening.

69: (Ø17-42 mm (0.67 - 1.65 in))

Cable flexible leadthrough or M50

opening.

48: (Ø11-32 mm(0.43 - 1.26 in))

Cable flexible leadthrough or M40

opening.

69: (Ø17-42 mm (0.67 - 1.65 in))

Cable flexible leadthrough or M50

opening.

- (44 - 48 mm (1.73 - 1.89 in))

(Ø17- 42 mm (0.67 - 1.65 in))

cable flexible leadthrough or M50

opening.

- (44 - 48 mm (1.73 - 1.89 in))

Ø(23 - 55 mm (0.9 - 2.16 in))

cable flexible leadthrough or M63

opening.

- (44 - 48 mm (1.73 - 1.89 in))

Note: For IP54 models 003 to 074 cable glands are optional.

* IP20/21 models are equipped with cable clamps instead of glands.

For data on cable connection ranges, see section 3.4.3, page 25

60 Technical Data CG Drives & Automation 01-6142-01r0

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8.7.2 Fuses according to NEMA ratings

Table 33 Types and fuses

Input

Model

48-003 2.2 6 AJT6 48-004 3.5 6 AJT6 48-006 5.2 6 AJT6 48-008 6.9 10 AJT10 48-010 8.7 10 AJT10 48-013 11.3 15 AJT15 48-018 15.6 20 AJT20 48-025 21.7 25 AJT25 48-026 22 25 AJT25 48-030 26 30 AJT30 48-031 26 30 AJT30 48-036 31 35 AJT35 48-037 31 35 AJT35 48-045 39 45 AJT45 48-046 40 45 AJT45 48-058 50 60 AJT60 48-061 52 60 AJT60 48-072 64 80 AJT80 48-074 65 80 AJT80 48-088 78 100 AJT100 48-090 78 100 AJT100 48-105 91 110 AJT110 48-109 94 110 AJT110 48-142 126 125 AJT150 48-146 126 150 AJT150 48-171 152 175 AJT175 48-175 152 175 AJT175 48-205 178 200 AJT200 48-210 182 200 AJT200 48-228 197 250 AJT250 48-244 211 250 AJT250 48-250 216 250 AJT250

current

[Arms]

Mains input fuses

Class J TD

(A)

Ferraz-

Shawmut

type

CG Drives & Automation 01-6142-01r0 Technical Data 61

Page 60

8.8 Control signals

Ta b le 34

Ter min al X 1 Name: Function (Default): Signal: Type:

1 +10 V +10 VDC Supply voltage +10 VDC, max 10 mA output

2 AnIn1 Level sensor

3 AnIn2 Off

4 AnIn3 Off

5 AnIn4 Off

6 -10 V -10VDC Supply voltage -10 VDC, max 10 mA output

7 Common Signal ground 0V output

8 DigIn 1 Auto run 0-8/24 VDC digital input

9 DigIn 2 Forced run 0-8/24 VDC digital input

10 DigIn 3 FlowLinkIn 0-8/24 VDC digital input

11 +24 V +24VDC Supply voltage +24 VDC, 100 mA output

12 Common Signal ground 0 V output

13 AnOut 1 Min speed to max speed 0 ±10 VDC or 0/4– +20 mA analogue output

14 AnOut 2 0 to max torque 0 ±10 VDC or 0/4– +20 mA analogue output

15 Common Signal ground 0 V output

16 DigIn 4 Off 0-8/24 VDC digital input

17 DigIn 5 Off 0-8/24 VDC digital input

18 DigIn 6 Overflow level switch (optional) 0-8/24 VDC digital input

19 DigIn 7 Off 0-8/24 VDC digital input

20 DigOut 1 Ready 24 VDC, 100 mA digital output

21 DigOut 2 FlowLinkOut 24 VDC, 100 mA digital output

22 DigIn 8 Reset 0-8/24 VDC digital input

Ter m inal X 2

31 N/C 1 Relay 1 output

32 COM 1

33 N/O 1

41 N/C 2 Relay 2 O utput

42 COM 2

43 N/O 2

Ter m inal X 3

51 C OM 3

52 N/O 3

Trip, active when the AC drive is in a TRIP condition N/C is opened when the relay is active (valid for all relays) N/O is closed when the relay is active (valid for all relays)

Run, active when the AC drive is started, also active during sleep mode.

Relay 3 Output Off

0 -10 VDC or 0/4–20 mA bipolar: -10 - +10 VDC or -20 - +20 mA

potential free change over

0.1 – 2 A U

= 250 VAC or 42 VDC

max

potential free change over

0.1 – 2 A = 250 VAC or 42 VDC

max

potential free change over

0.1 – 2 A

= 250 VAC or 42 VDC

max

analogue input

relay output

NOTE: Possible potentiometer value in range of 1 kΩ to 10 kΩ (¼ Watt) linear, where we advice to use a linear 1 kΩ / ¼ W type potentiometer for best control linearity.

62 Technical Data CG Drives & Automation 01-6142-01r0

Page 61

Index

Для заказов : +7(499)707-11-20 Email: i@sp-t.ru 8-800-511-65-88 (Бесплатно по РФ)

Symbols

+10VDC Supply voltage ..................62

+24VDC Supply voltage ..................62

Numerics

-10VDC Supply voltage ...................62

Abbreviations ...................................10

Analogue Output .............................62

Auto mode .......................................43

Auto tune ........................................43

Autoreset ...........................................2

Cable connector ...............................25

Cable specifications ..........................24

CE-marking .......................................9

Connecting control signals ...............34

Connections

Brake chopper connections .......20

Control signal connections .......34

Mains supply ............................20

Motor earth ..............................20

Motor output ...........................20

Safety earth ...............................20

control panel ....................................47

Control signal connections ..............34

Control signals ...........................30, 36

Current ............................................31

Current control (0-20mA) ...............37

DC-link residual voltage ....................2

Declaration of Conformity ................9

Definitions ......................................10

Dismantling and scrapping .............. 10

Double-ended connection ................36

ECP .................................................47

Electrical specification ......................55

EMC ...............................................21

Current control (0-20mA) ........37

Double-ended connection ........36

RFI mains filter ........................21

Single-ended connection ...........36

Twisted cables ..........................37

Emergency stop ...............................45

EmoSoftCom ..................................48

EN60204-1 .......................................9

EN61800-3 .......................................9

EN61800-5-1 ....................................9

EtherCAT ........................................48

External Control Panel ....................47

Fieldbus ...........................................48

FlowDrive mode ..............................41

Flush start ........................................44

Function keys ...................................39

Fuses and glands ..............................59

General electrical specifications ........55

generic drive mode ...........................41

Gland kits ........................................48

Handheld Control Panel 2.0 ............47

I/O Board ........................................48

IEC269 ............................................59

Industrial Ethernet ...........................48

IT Mains supply .................................2

Language ..........................................40

Level sensor ......................................41

Liquid cooling ..................................52

Load monitor ...................................43

Long motor cables ............................22

Low Voltage Directive ........................9

Machine Directive ..............................9

Mains supply ..............................20, 29

Manis cables .....................................18

Modbus/TCP ..................................48

Motor cables ....................................21

Motor Data ......................................40

Motor PTC ................................33, 34

Motors ...............................................5

Motors in parallel .............................28

Options ......................................37, 47

External Control Panel (ECP) ...47

I/O Board .................................48

Output chokes .................................52

Pipe cleaning ....................................44

Product standard, EMC .....................8

PTC/PT100 board ...........................48

Pump cleaning .................................44

reservoir ...........................................42

RFI mains filter ................................21

RTC- Real time clock ......................48

Safe Stop option .............................. 49

Serial communication ...................... 48

Signal ground .................................. 62

Single-ended connection ................. 36

Standards .......................................... 8

Standby supply board ...................... 49

Stop categories ................................. 45

Stripping lengths ............................. 24

Sump cleaning ................................. 44

Sump Level ..................................... 43

sump levels ...................................... 41

Switches .......................................... 31

Switching in motor cables ............... 22

Technical Data ................................ 53

Terminal connections ...................... 30

Test run .......................................... 42

Toggle loop ..................................... 40

Top cover ........................................ 52

Twisted cables ................................. 37

Type code number ............................ 7

Voltage ............................................ 31

CG Drives & Automation, 01-6142-01r0 63

Emotron FlowDrive Emotron FLD48, FlowDrive Emotron FLD69, FlowDrive Emotron FLD52 Installation & Getting Started Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Instructions

Contents

1. Introduction

1.1 Delivery and unpacking

1.2.1 Instruction manuals for optional equipment

1.3 Warranty

1.4 Type code number

1.5 Standards

1.5.1 Product standard for EMC

1.6 Dismantling and scrapping

1.6.1 Disposal of old electrical and electronic equipment

1.7 Glossary

1.7.1 Abbreviations and symbols

1.7.2 Definitions

2. Mounting

2.1 Lifting instructions

2.2 Stand-alone units

2.2.1 Cooling

2.2.2 Mounting schemes

3. Installation

3.1 Before installation

3.1.1 Remove/open front cover

3.2 Cable connections

3.2.1 Mains cables

3.2.2 Motor cables

3.4 Cable specifications

3.4.1 Stripping lengths

3.4.2 Fuse data

3.5 Thermal protection on the motor

3.6 Motors in parallel

4. Control Connections

4.1 Control board

4.2 Terminal connections

4.4 Connect control cables

4.4.1 Connection example

4.4.3 Types of control signals

4.4.4 Screening

4.4.5 Single-ended or double-ended connection?

4.4.6 Current signals ((0)4-20 mA)

4.4.7 Twisted cables

4.5 Connecting options

5. Getting Started

5.1 Function keys

5.1.1 Using the function keys

5.1.2 Toggle loop

5.2.1 Switch on the mains

5.2.2 Language

5.2.3 Set the Motor Data

5.2.4 Set FlowDrive configuration

5.3 Additional configuration for Standalone / Master drives

5.3.1 Level sensor configuration

5.3.2 Set sump levels

5.3.3 Set reservoir geometry

5.4 Test run

5.5 Engage “auto tune” program to optimize energy consumption

5.6 Configuration of additional features

6. EMC and standards

6.1 EMC standards

6.2 Stop categories and emergency stop

7. Options

7.1 Options for the control panel

7.3 Gland kits

7.7 RTC- Real time clock board

7.4 EmoSof tCom

7.5 I/O Board

7.6 PTC/PT100

7.8 Serial communication and fieldbus

7.10 Safe Stop option

7.11 EMC filter class C1/C2

7.12 Output chokes

7.15 Other options

7.13 Liquid cooling

8. Technical Data

8.1 Electrical specifications related to model

8.2 General electrical specifications

8.5 Dimensions and Weights