Lenze 4800, 4900 User Manual

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EDS4900U-REG

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00408862

Table of contents Preface and general

information Safety information

Technical data Installation

Commissioning During operation

Manual

Configuration Code table

Troubleshooting and fault elimination

Maintenance

DC bus connection

Application of brake units

Automation

Accessories and motors

Selection aid Application examples

Signal-flow charts

Glossary Table of keywords

DC speed controller 4800/4900

Manual 4800 / 4900

ATableofcontent

Prefaceandgeneralinformatio

BTechnicaldat

CCommissionin

DConfiguratio

ETroubleshootingandfaultelimination

FDC

KSelectionaid

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Part Content Notes A

B Technical data

C Commissioning

D Configuration

E Troubleshooting and fault elimination

G Application of brak e units H Automation I Accessories and motors K Selection aid

L Signal-flow charts M Glossary

able of contents Preface and general information Safety information

Installation

During operation

Code table

Maintenance

us connec

Application examples

Ta bl e of k e yw o r ds

Explanation: - in the Manual.

All documentation indicated have a material number a nd the type code in the left upper corner of the cover page. In part M there is a list with these data.

The controller’s features and data indicated in this Manual are at the state-of-art at the time of print. (The print data is indicated on the inner cover page of each of part.) Lenze endeavours to regularly update all documentation to the current technical state. If you should find any deviations, please refer to the Operating Instructions, which are part of the delivery package, or to your nearest Lenze representative.

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Part A

1 Preface and general information 1-1..........................

1.1 About these Operating Instructions ... 1-1...........................

1.1.1 Terminology used 1-1....................................

1.2 Scope of delivery 1-1.............................................

1.3 48XX/49XX controller 1-2.........................................

1.3.1 Labelling 1-2...........................................

1.3.2 Application as directed 1-2...............................

1.3.3 Legal regulations 1-3....................................

1.4 EC Directives/Declaration of Conformity 1-4..........................

1.4.1 What is the purpose of EC directives? 1-4..................

1.4.2 What does the CE mark imply? 1-4........................

1.4.3 EC Low-Voltage Directive 1-4.............................

1.4.4 EC Directive Electromagnetic Compatibility 1-6..............

1.4.5 EC Machinery Directive 1-9...............................

2 Safety information 2-1.......................................

2.1 Persons responsible for the safety 2-2..............................

2.2 General safety information 2-3.....................................

2.3 Residual hazards 2-3.............................................

2.4 Layout of the safety information 2-4................................

Part B

3 Technical data 3-1...........................................

3.1 Features 3-1....................................................

3.2 General data / application conditions 3-3............................

3.3 Rated data 3-4..................................................

3.3.1 Mains voltage 400V 3-4..................................

3.3.2 Mains voltage 500V (Variant V014) 3-6.....................

3.4 Dimensions 3-8..................................................

3.4.1 Controller 4902 to 4X09 3-8..............................

3.4.2 Controllers 4811 to 4813, 4911 to 4913 3-9................

4 Installation 4-1..............................................

4.1 Mechanical installation 4-1........................................

4.1.1 Important notes 4-1.....................................

4.2 Electrical installation 4-2..........................................

4.2.1 Protection of persons 4-2................................

4.2.2 Protection of the controller 4-3............................

4.2.3 Screening of the control cables 4-3........................

4.2.4 Earthing of the control electronics 4-4......................

4.2.5 Mains types and conditions 4-4...........................

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4.3 Connection 4-5..................................................

4.3.1 Power connection of standard controller 4-6................

4.3.2 Separate supply of the field-current bridge at

a high motor field voltage 4-9.............................

4.3.3 Separate supply for the control electronics 4-11..............

4.3.4 Control connections 4-13.................................

4.3.4.1 Connection of analog signals 4-14...............

4.3.4.2 Connection of digital signals 4-17................

4.3.5 Feedback systems 4-21...................................

4.3.6 Change of the direction of rotation in 2Q operation 4-23.......

4.3.7 Digital frequency selection and encoder emulation 4-24........

4.3.8 Serial interface RS232/485 4-26............................

4.3.9 Fieldbus connection 4-27..................................

4.4 Installation of a CE-typical drive system 4-29..........................

4.4.1 General notes 4-29.......................................

4.4.2 Components of the CE-typical drive system 4-30..............

4.4.3 Measures required 4-30...................................

Part C

5 Commissioning 5-1..........................................

5.1 Initial switch-on 5-1..............................................

5.2 Commissioning of speed-controlled drives 5-2.......................

5.2.1 Wiring recommendation for speed control with tacho 5-3.....

5.2.2 Wiring recommendation for speed control with resolver 5-4....

5.2.3 Speed control with armature voltage feedback 5-5...........

5.3 Commissioning of torque-controlled drives 5-6.......................

5.3.1 Wiring recommendation for torque control with speed limitation 5-7

5.4 Input of the motor data 5-8........................................

5.5 Controller enable 5-9.............................................

5.6 Selection of direction of rotation and quick stop 5-10...................

5.7 Changing the internal control structure 5-12..........................

5.8 Changing the terminal assignment 5-12..............................

6 During operation

48XX/49XXSHB00399

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Part D

7 Configuration 7-1...........................................

7.1 Speed-controlled operation 7-1....................................

7.1.1 Setpoint selection 7-1...................................

7.1.1.1 Main setpoint 7-2.............................

7.1.1.2 Additional setpoint 7-2........................

7.1.1.3 JOG setpoints 7-2............................

7.1.1.4 Master current 7-4............................

7.1.1.5 External torque reduction 7-4..................

7.1.1.6 Acceleration and deceleration times Tir ,Tif 7-6...

7.1.1.7 Limiation of the speed setpoint 7-9..............

7.1.2 Actual value feedback 7-10................................

7.1.2.1 Armature voltage feedback 7-10.................

7.1.2.2 DC tacho feedback 7-11.......................

7.1.2.3 Resolver feedback 7-13........................

7.1.2.4 Incremental encoder feedback 7-13..............

7.1.3 Freely assignable inputs and outputs 7-14...................

7.1.3.1 Freely assignable digital inputs (FDI) 7-14.........

7.1.3.2 Freely assignable digital outputs (FDO) 7-16.......

7.1.3.3 Frei belegbare “analoge” Eingänge (FAE) 7-21.....

7.1.3.4 Freely assignable monitor outputs 7-25...........

7.2 Torque control with speed limitation 7-29.............................

7.3 Digital frequencycoupling 7-31......................................

7.3.1 Master 7-32.............................................

7.3.2 Slave for digital frequency bar 7-34.........................

7.3.3 Slave for digital frequency cascade 7-38.....................

7.3.4 Digital frequency output 7-43..............................

7.3.5 Speed synchronism 7-44..................................

7.3.5.1 Speed-synchrnous running 7-44.................

7.3.5.2 Speed ratio synchronism 7-44...................

7.3.6 Phase synchronisation 7-45................................

7.3.6.1 Phase controller 7-46..........................

7.3.6.2 Phase trimming 7-47...........................

7.3.6.3 Following error limit 7-47.......................

7.4 Additional control functions 7-48....................................

7.4.1 Redundant actual value feedback 7-48......................

7.4.2 Changeable parameter sets 7-50...........................

7.4.3 4Q / 2Q changeover 7-53.................................

7.4.4 Standstill excitation (field heating) 7-54......................

7.4.5 Control of a holding brake 7-55.............................

7.4.5.1 Engage brake 7-57............................

7.4.5.2 Open brake (release) 7-58......................

7.5 Additional function blocks 7-60.....................................

7.5.1 Process controller 7-60...................................

7.5.2 Arithmetic blocks 7-63....................................

7.5.3 Motor potentiometer 7-66.................................

7.5.3.1 Control of the motor potentiometer 7-67..........

7.5.3.2 Memory function of the

motor potentiometer (S&H) 7-68.................

7.5.4 Fixed set-value 7-70......................................

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7.5.5 Absolute value generator 7-71.............................

7.5.6 Limitation elements 7-72..................................

7.5.7 PT1 element 7-73........................................

7.5.8 Addition 7-74............................................

7.5.9 Square-wave generator 7-76...............................

7.5.10 Dead-band element 7-77..................................

7.5.11 DT1 element 7-78........................................

7.5.12 Freely assignable comparator 7-79..........................

7.6 Additional control functions 7-82....................................

7.6.1 Additional torque values 7-82..............................

7.6.2 Speed dependent armature current limitation 7-83............

7.6.3 n controller adaptation 7-86................................

7.6.4 S-shaped ramp function generator characteristic 7-87.........

7.6.5 Actual speed filter 7-87....................................

7.6.6 Excitation characteristic 7-88..............................

7.7 Monitoring 7-90...................................................

7.7.1 Change of the monitoring functions 7-90....................

7.7.2 Overload monitoring for the controller (IVt monitoring) 7-94.....

7.7.3 Overload monitoring for the motor (I2Vtmonitoring) 7-95........

7.7.4 Blocking protection for the motor 7-97......................

7.7.5 Mains monitoring 7-99....................................

7.7.6 Monitoring of the serial interface 7-101.......................

7.8 Parameter setting 7-102............................................

7.8.1 Ways of parameter setting 7-102............................

7.8.2 Functions of the operation unit 7-103.........................

7.8.3 Operating modes 7-104....................................

7.8.4 Display functions 7-105....................................

7.9 Code table 7-107..................................................

7.10 Table of attributes 7-133............................................

48XX/49XXSHB00399

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Part E

8 Troubleshooting and fault elimination 8-1.....................

8.1 Troubleshooting 8-1..............................................

8.1.1 Display on the operating unit of the controller 8-1............

8.1.2 Display via LECOM 8-2...................................

8.2 Fault analysis with the history buffer 8-3............................

8.2.1 Structure of the history buffer 8-3..........................

8.3 Fault messages 8-4..............................................

8.4 Reset of fault indications 8-6......................................

8.5 Checking the drive system 8-7.....................................

8.5.1 Checking the motor 8-7..................................

8.5.2 Checking the controller 8-8...............................

9 Maintenance 9-1............................................

9.1 Maintenance 9-1.................................................

9.2 Service addresses 9-1............................................

Part F

10 DC-bus operation

Part G

11 Application of brake units

48XX/49XXSHB00399

Contents

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Part H

12 Automation 12-1.............................................

12.1 LECOM1 interface 12-1............................................

12.2 LECOM2 interface (option) 12-1.....................................

12.3 LECOM code number 12-1.........................................

12.4 Enable LECOM interface 12-3.......................................

12.4.1 Process data and parameter channel 12-3...................

12.4.2 High precision set and actual values 12-5....................

Part I

13 Accessories 13-1.............................................

13.1 Fuses 13-2.......................................................

13.1.1 Mains fuses 13-3.........................................

13.1.2 Armature fuses 13-4......................................

13.1.3 Internal fuses 13-5........................................

13.1.4 Fuse holder 13-5........................................

13.2 Mains chokes 13-7................................................

13.2.1 Mains chokes for powr connection 13-7.....................

13.2.2 Mains choke for separate supply of the field bridge 13-8.......

13.3 Pre-assembled Lenze system cable 13-10.............................

13.3.1 Resolver connection cable 13-10............................

13.3.2 Incremental encoder connection cable 13-11..................

13.3.3 System cable for digital frequency coupling 13-11..............

13.4 RFI filter 13-12.....................................................

13.4.1 RFI filter for power connection 13-12.........................

13.4.2 RFI filter for fan supply 13-14................................

13.5 Networking accessories 13-15.......................................

13.5.1 Connection elements for optical fibres 13-15..................

13.5.2 Level converter 13-15......................................

48XX/49XXSHB00399

Contents

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Part K

14 Selection aid 14-1............................................

14.1 Assignment of controller and motor 14-1.............................

14.1.1 Selection criteria 14-1.....................................

14.1.2 Armature choke 14-3.....................................

15 Application examples 15- 1...................................

15.1 Speed control with armature-voltage feedback 15-2....................

15.2 Speed control with resolver 15-4....................................

15.3 Torque control with speed limitation 15-6.............................

15.4 Current-ratio control 15-8..........................................

15.5 Dancer-position control at an unwinder 15-10..........................

15.6 Hoists 15-13......................................................

15.7 Speed-ratio synchronism 15-15......................................

15.8 Modular box 2215 15-18............................................

15.8.1 Winding drive 15-18.......................................

15.8.2 Positioning drive 15-20.....................................

15.9 Mains isolation 15-23...............................................

15.9.1 Tipping with mains isolation 15-23...........................

15.9.2 Mains switch-off logic 15-25................................

Part L

16 Signal-flow charts 16-1.......................................

Part M

17 Glossary 17-1................................................

18 Index 18-1...................................................

This chapter is part of the Lenze documentation structure. It remains free for the 48XX/49XX DC speed controller.

48XX/49XXSHB00399

vii

Contents

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viii

48XX/49XXSHB00399

EDS4900U--A

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00408849

Manual Part A

Contents

Preface and general information

Safety information

DC speed controller 4800/4900

The features, data and versions indicated in this Manual met the state of the art at

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thetimeofprinting.

(Printing date: inner cover pages of the parts).

In the event of deviations, please see the Operating Instructions or contact Lenze.

Edition of: 01/03/1999

revised

Preface and general information

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1 Preface and general information

1.1 About these Operating Instructions ...

- These Operating Instructions are intended for safety- relevant operations on and with the 48XX/49XX DC controllers. They contain safety information which must be observed.

- All persons who work on and with 48XX/49XX DC controllers must have the Operating Instructions available and observe all relevant notes and instructions.

- The Operating Instructions must always be in a complete and perfectly readable state.

1.1.1 Terminology used

Controller

In the following, the term ”controller” is used for ” 48XX/49XX DC controllers”.

Drive system

In the following text, the term ”drive system” is used for drive systems with 48XX/49XX DC controllers and other Lenze drive components.

1.2 Scope of delivery

- The scope of delivery includes:

- 1 48XX/49XX DC controller

- 1 Operating Instructions

- 1 Accessory kit with plug-in terminals

- After receipt of the delivery, check immediately whether the scope of delivery matches the accompanying papers. Lenze does not accept any liability for deficiencies claimed subsequently. Make a claim for

- visible transport damage immediately to the forwarder.

- visible deficiencies/incompleteness immediately to your Lenze

representative.

48XX/49XXSHB0399

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Preface and general information

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1.3 48XX/49XX controller

1.3.1 Labelling

- Lenze 48XX/49XX controllers are unambiguously designated by the contents of the nameplate.

- CE mark:

- Conformity with the Low-Voltage Directive

- Conformity with the EMC Directive

- Manufacturer

-LenzeGmbH&CoKG

Postfach 101352 D-31763 Hameln

1.3.2 Application as directed

48XX/49XX controllers

- must only be operated under the conditions prescribed in these Instruc t ions.

- are components

- for open-loop and closed-loop control of variable speed drives with

separately excited DC motors.

- to be installed into a machine.

- used for assemblies together with other components to form a machine.

- should not be driven together with other DC motors, such as shunt motors or separately excited motors with a stabilizing series winding, before you have contacted Lenze.

- are electric units for the installation into control cabinets or similar enclosed operating housings.

- are not to be used as domestic appliances, but only for industrial purposes.

Drive systems with 48XX/49XX controllers

- comply with the EMC Directive, if they are installed according to the guidelines for CE-typical drive systems.

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48XX/49XXSHB0399

- can be used

- on public and non-public mains.

- in industrial premises.

The user is responsible for the compliance of his application with the EC directives.

Any other use shall be deemed inappropriate!

1.3.3 Legal regulations

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Liability

- The information, data and notes in these Operating Instructions met the state-of-the-art at the time of printing. Claims referring to drive systems which have already been supplied cannot be derived from the information, illustrations, and descriptions.

- The specifications, processes, and circuitry described in these Operating Instructions are for guidance only and must be adapted to your own specific application. Lenze does not take responsibility for the suitability of the process and circuit proposals.

- The indications given in these Operating Instructions describe the features of the product without warranting them.

- Lenze does not accept any liability for damage and operating interference caused by:

- disregarding these Operating Instructions

- unauthorized modifications to the controller

- operating errors

- improper working on and with the controller

Preface and general information

Warranty

- Terms of warranty: see terms of sale and delivery of Lenze GmbH & Co KG.

- Warranty claims must be made immediately after detecting defects or faults.

- The warranty is void in all cases where liability claims cannot be made.

Disposal

The controller consists of different materials.

The following table lists which materials can be recycled and which must be disposed of.

Material recycle dispose

Me tal - Plastic - Printed-board assemblies - -

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Preface and general information

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1.4 EC Directives/Declaration of Conformity

1.4.1 What is the purpose of EC directives?

EC directives are issued by the European Council and are intended for the determination of common technical requirements (harmonization) and certification procedures within the European Community. At the moment, there are 21 EC directives for product ranges. The directives are or will be converted to national laws of the member states. A certification issued by one member state is automatically valid without any further approval in all other member states.

The texts of the directive are restricted to the essential requirements. Technical details are or will be determined by European harmonized standards.

1.4.2 What does the CE mark imply?

After a verification, the conformity according to the EC directives is certified by affixing a CE mark. Within the EC there are no commercial barriers for a product with the CE mark.

Controllers on their own with the CE mark correspond exclusively to the Low Voltage Directive. For the compliance with the EMC Directive, only general recommendations have been issued so far. The CE conformity of the installed machine remains the responsibility of the user. For the installation of CE-typical drive systems with the basic version of 48XX/49XX controllers and the variants V011, V013 and V014, Lenze has already proved the conformity with the EMC Directive (see chapter 4.4).

1.4.3 EC Low-Voltage Directive

(73/23/EEC)

amended by: CE Mark Directive (93/68/EEC)

General

- The Low-Voltage Directive is effective for all electrical equipment for use with a rated voltage between 50 V and 1000 V AC and between 75 V and 1500 V DC, and under normal ambient conditions. The use, for instance, of electrical equipment in explosive atmospheres and electrical parts in passenger and goods lifts are excepted.

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48XX/49XXSHB0399

- The objective of the Low-Voltage Directive is to ensure that only electrical equipment which does not endanger the safety of persons or animals is placed on the market. It should also be designed to conserve material assets.

Preface and general information

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EC Declaration of Conformity ’99

for the purpose of the EC Low Voltage Directive (73/23/EEC)

amended by: CE Mark Directive (93/68/EEC)

48XX/49XX controllers were developed, designed, and manufactured in compliance with the EC Directive under the sole responsibility of

Lenze GmbH & Co KG, Postfach 10 13 52, D-31763 Hameln

Considered standards:

Standard

DIN EN 50178 Classification VDE 0160 / 04.98

DIN VDE 0100 Standards for the erection of power installations EN 60529 IP degrees of protection IEC 249 / 1 10/86, IEC 249 / 2-15 / 12/89 Base material for printed circuits IEC 326 / 1 10/90, EN 60097 / 9.93 Printed circuits, printed boards DIN VDE 0110 /1-2 /1/89 /20/ 8/90 Creepage distances and clearances

Electronic equipment for use in electrical power installations

Hameln, 01/03/1999

(i.V.Schäfer) (i.A.Tolksdorf)

Product Manager Commissioned for CE

48XX/49XXSHB0399

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1.4.4 EC Directive Electromagnetic Compatibility

(89/336/EEC)

amended by: First Amendment Directive (92/ 31/EEC)

CE Mark Directive (93/68/EEC)

General

- The EC Electromagnetic Compatibility Directive is effective for ”devices” which may cause electromagnetic interference, or the operation of which may be impaired by such interference.

- The aim is to limit the generation of electromagnetic interference so that an operation is possible without interference to radio and telecommunication systems and other equipment. The devices must also show an appropriate resistance to electromagnetic interference, to ensure the application as directed.

- Controllers cannot be evaluated on their own in terms of EMC. Only after the integration of the controllers into a drive system, can this system be tested concerning the objectives of the EC EMC Directive and the compliance with the ”Law about the Electromagnetic Compatibility of Devices”.

- Lenze has verified the conformity of 48XX/49XX controllers integrated into certain defined drive systems . In the following, these systems are called ”CE-typical drive systems” (see chapter 4.4).

- The following configurations can now be selected by the user:

- The user himself can determine the system components and their

integration into the drive system, and is then held responsible for the conformity of the drive.

- The user can select the CE-typical drive systems for which the

manufacturer has already proved the conformity.

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Preface and general information

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EC Declaration of Conformity ’97 for the purpose of the EC Directive

on Electromagnetic compatibility (89/336/ EEC)

amended by: First Amendment Directive (92/ 31/EEC)

CE Mark Directive (93/68/EEC)

48XX/49XXcontrollerscannot be driven in stand-aloneoperation for thepurposes of the Regulation on Electromagnetic Compatibility (EMVG of 09 November, 1992 and the first Amendment of 08 August, 1995). The EMC can only be verified when the controller is integrated into a drive system.

Lenze GmbH & Co KG, Postfach 10 13 52, D-31763 Hameln

declares that the described ”CE-typical drive systems” with the basic version of 48XX/49XX controller and the variants V011, V013 and V014 comply with the above EC Directive.

The conformity evaluation is based on the product standard for drive systems EN 61800-3.

EN 61800-3 EMC product standard including special test methods for electric drives

Generic standards considered:

Generic standard

EN 50081-2 /93 Generic standard for noise emission; part 2: Industrial premises

The noise emission in industrial premises is not limited in EN 61800-3. These generic standards are used in addition to the requirements of the standard DIN IEC 22G.

EN 50082-2 3/94 Generic standard for noise immunity

part 2: Industrial premises (The requirements of noise immunity for residential areas were not considered, since these are less strict.)

Generic standards considered for the test of noise emission:

Generic standard Tes t Limit value

EN 55011 7/92 Radio interferences, housing and mains

Frequency range 0.15 - 1000MHz The noise emission in industrial premises is not limited in EN61800-3. These generic standards are used in addition to the requirements of EN61800-3.

Class A for use in industrial premises

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Generic standards considered for the test of noise emission:

Basic standard Tes t Limit value

EN 61000-4-2 3/95 Electrostatic discharge on housing and heatsink Seve rity 3

IEC 1000-4-3 2/95 Electromagnetic fields

Frequency range 26-1000MHz

ENV 50140 8/93 High-fre quency field

Frequency range 80-1000MHz, 80% amplitude modulated

Fixed frequency 900MHz with 200Hz, 100 %modulated

EN 61000-4-4 3/95 Fast transients,

burst on power terminals Burst on bus and control cables Se verity 4

EN 61000-4-5 10/94 Surge t est

Mains cable

6kV for contact, 8kV clearance

Seve rity 3 10V/m

10V/m

Seve rity 3 2kV/5kHz

2kV/5kHz Installation class 3

Hameln, 01/03/1999

(i.V.Schäfer) (i.A.Tolksdorf)

Product Manager Commissioned for CE

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48XX/49XXSHB0399

Preface and general information

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1.4.5 EC Machinery Directive

(89/392/EEC)

amended by: First Amendment Directive (91/368/EEC)

Second Amendment Directive (93/ 44/EEC)

CE Mark Directive (93/68/EEC)

For the purpose of the Machinery Directive, ”machinery” means an assembly of linked parts or components, at least one of which can move, with the appropriate actuators, control and power circuits, etc., joined together for a specific application, in particular for the processing, treatment, moving or packaging of a material.

EC M anufacturer’s Declaration

for the purpose of the EC Machinery Directive (89/392/EEC)

amended by: First Amendment Directive (91/368/EEC)

Second Amendment Directive (93/ 44/EEC)

CE Mark Directive (93/68/EEC)

48XX/49XX controllers were developed, designed, and manufactured under the sole responsibility of

Lenze GmbH & Co KG, Postfach 10 13 52, D-31763 Hameln

Commissioning of the controllers is prohibited until it is proven that the machine in which they are to be installed corresponds to the EC Machinery Directive.

Hameln, 01/03/1999

(i.V.Schäfer)

Product Manager

48XX/49XXSHB0399

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2 Safety information

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Safety and application notes for controllers

Safety information

(to: Low-Voltage Directive 73/23/EEC)

1. General

During op eration, drive controllers may have, acc ording to their type of protection, live, bare, in some c ases also movable or rotatingpartsaswellashotsurfaces.

Non- authorized removal of the req uired cover, inappropriate use, inc orrect installation or operat ion, creat es the risk of severe injury to persons or damage t o material assets.

Further information can be obtained from the documentation.

All operations concerning transport, installation, and commissioning as well as maintenance must b e carried out by qualified, skilled personnel (IEC 364 and CENELEC HD 384 or DIN VDE 0100 and IEC report 664 or DIN VDE 0110 and national regulations for the prevention of accidents must be observed).

Acc ord ing to this basic safety information qualified sk illed personnel are persons w ho are familiar with t he erection, assembly, commissioning, and operation of the product and who have the q ualifications necessary for t heir o cc upation.

2. Application as directed

Drive controllers are components which are designed for installation in electrical systems or machinery.

When installing in mac hines, commissioning of the drive controllers (i.e. the starting of operation as d irected) is prohibit ed until it is proven that the machine corresponds to the regulations of the EC Directive 89/392/ EEC (Machinery Directive); EN 60204 must be observed.

Commissioning (i.e. start ing of operat ion as d irected) is only allowed when there is complianc e wit h the EMC Directive (89/336/EEC).

Thedrive controllersmeet therequirements of the Low Voltage Directive 73/23/EEC. The harmonized standards of the prEN 50178/ DIN VDE 0160 series together with EN 60439-1/DIN VDE 0660 part 500 and EN 60146/DIN VDE 0558 are applicab le t o d rive c ont rollers.

The technical data and information on the connection condit ions must be ob tained from the namep late and the doc ument ation and must be observed in all c ases.

3. Transport, storage

Notes on transport, storage and appropriate handling must be observed.

Climat ic condit ions must b e observed according to prEN

50178.

4. Erection

The devices must be erected and cooled according to the regulations of the corresponding documentation.

The drive controllers must be protected from inappropriate loads. Particularlyduring transport and handling, components must not be bent and/or isolating distances must not be changed. Touching of electronic components and contact s must be avoided.

Drive co ntrollers contain electrostat ically sensitive components which c an easily be damaged by inapp ropriate handling. Electric al components must not be damaged or destroyed mechanically (health risks are possible!).

5. Electrical connection

When wo rking on live drive controllers, t he valid nat ional regulations for the prevention of accidents (e.g. VBG 4) must be observed.

The electrical installation must be carried out according to the appropriate regulations (e.g. cab le cross- sect ions, fuses, PE connection). M ore d etailed informat ion is included in the documentation.

Not es concerning the installation in compliance w ith EMC such as screening, grounding, arrangement of filters and laying of cables - are included in the documentation of the drive controllers. These notes must also be observed in all cases for drive c ont rollers with t he CE mark.The compliance w ith the required limit values demand ed by the EMC legislation is the responsib ility of t he manufacturer of t he system or mac hine.

6. Operation

Systems w here drive controllers are inst alled must b e equipped, if necessary, with additional monitoring and protec tive d evices acc ord ing to t he valid safet y regulations, e.g. law on technical tools, regulations for the prevention of accidents, etc. Modifications of the drive controllers by the operating software are allowed.

After d isconnec ting the d rive controllers from t he sup ply voltage, live part s of the controller and pow er connections must not be touched immediately, because of possibly charged capacitors. For this, observethe corresponding labels on the drive controllers.

During operation, all c overs and doors must be closed.

7. M aintenance and servicing

The manufacturer’s documentation must be observed.

The safety information must be preserved!

The product- specific safet y and application notes in these Operat ing Instructions must also be observed!

48XX/49XXSHB0399

2-1

Safety information

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2.1 Persons responsible for the safety

Operator

( An operator is any natural or legal person who uses the drive system or on

behalf of whom the drive system is used.

( The operator or his safety officer are obliged to ensure that

- all relevant regulations, notes and laws are observed

- only qualified personnel work on and with the drive system.

- the personnel have the Operating Instructions available for all

corresponding operations and

- unqualified personnel are prohibited from working with and on the

controller.

Qualified personnel

Qualified personnel are persons who - because of their education, experience, instruction, and knowledge about corresponding standards and regulations, rules for the prevention of accidents, and operating conditions - are authorized by the person responsible for the safety of the plant to perform the required actions and who are able to recognize and avoid potential hazards. (see IEC 364, definition of qualified personnel)

2-2

48XX/49XXSHB0399

2.2 General safety information

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( These safety notes do not claim to be complete. In case of questions and

problems please contact your Lenze representative.

( At the time of supply the drive system is state-of-the-art and ensures

basically safe operation.

( The indications given in these Operating Instructions refer to the stated

hardware and software versions of the controller.

( The controller is hazardous to persons, the controller itself and other

property of the operator, if

- unqualified personnel work on and with the drive system.

- the controller is used inappropriately.

( The specifications, processes, and circuitry described in these Operating

Instructions are for guidance only and must be adapted to your own specific application.

Safety information

( Controllers must be designed so that they comply with their function and do

not cause any hazards to persons, when correctly installed and in fault- free operation as directed. This also applies to the whole system.

( Take additional measures to limit consequences of malfunctions which may

cause hazards to personnel or damage to properties:

- further independent equipment which can take over the function of the controller

- electrical or non-electrical protection (latching or mechanical blocking)

- measures covering the complete system

( The drive system must only be operated in perfect condition.

( Retrofittings, modifications, or changes are generally prohibited. For some

applications, Lenze authorizes the operation of retrofitted, modified or changed controllers. Please contact Lenze.

2.3 Residual hazards

Excessive speed

Drive systems may reach dangerously high speeds (e.g. caused by active loads like hoists):

( 48XX/49XX controllers do not offer any protection against these operating

conditions. Use additional components for this.

48XX/49XXSHB0399

2-3

Safety information

hazardouselectrical

ons

sifdisr

ded

generaldanger

Possiblecons

sifdisr

ded

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2.4 Layout of the safety information

( All safety information given in these Operating Instructions has the same

layout:

Signal word

Note

- The icon characterizes the type of danger.

- The signal word characterizes the severity of danger.

- The note describes the danger and suggests how to avoid the danger.

Warning of danger for persons

Icons used Signal words

Wa rn i ng o f

volta ge

Wa rn i ng o f a

eneral dange

Danger! Wa rn s o f impending dangeU.

equence

Death or very severe injuries.

Warning! Wa r ns o f potential, very hazardous situations.

Possible consequences if disregarded: Death or very severe injuries.

Caution! Wa r ns o f potential, hazardous situations.

equence

Light or minor injuries.

ega

Warning of damage to material

Icons used Signal words

Stop! Wa r n s of potential damage to material .

Other notes

Icons used Signal words

Note! Designates a general, useful tip.

Possible consequences if disregarded: Damage to the controller/drive system or its environment .

If you observe it, handling of the controller/drive system is made easier.

2-4

48XX/49XXSHB0399

EDS4900U--B

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00408850

Manual Part B

Technical Data

Installation

DC speed controller 4800/4900

The features, data and versions indicated in this Manual met the state of the art at

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thetimeofprinting.

(Printing date: inner cover pages of the parts).

In the event of deviations, please see the Operating Instructions or contact Lenze.

Edition of: 01/03/1999

revised

3 Technical data

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3.1 Features

Controller and system features

( Control electronics and system software are the same for 48XX/49XX

( Digital speed feedback with resolver or incremental encoder

( Torque control with superimposed speed monitoring for winding drives

( Phase control for drift-free positioning

( Digital frequency coupling as setpoint bar or setpoint cascade for

- phase synchronisation

- speed-synchronous operation

- synchronous speed ratio

Technical Data

( Increase of the max. armature voltage to 115 % ôV

to 2Q operation (with 49XX)

( Speed accuracy better than 0.5‰ at 100% changing load with resolver

feedback or incremental encoder

( Speed setting range 1:1000 at constant load with resolver feedback or

incremental encoder

( Current setting range 1:300 by means of pulse current adaptation and

bridge modulation

( Speed-dependent armature current limitation

( Adjustable max. armature current from 112,5 % to 180 % rated current

(depending on the size)

( Freely connectable process controller, e.g. for dancer position control or

tension control

( Integrated field current control for large speed setting range

( 4 customer-specific parameter sets can be saved and changed via digital

input terminals

Operation

( On-line changes of control parameters

by changing from 4Q

mains

( Parameter setting and diagnosis via

- keypad with two-line LCD in German, Englisch and French

- serial interface and PC

- fieldbus module (as option): PROFIBUS, InterBus

( Fault messages plain text

48XX/49XXSHB0399

3-1

Technical Data

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Speed feedback systems

( Resolver feedback with encoder emulation for superimposed systems

(synchronizing systems, positioning controls, etc.)

( Incremental encoder feedback

( DC tacho feedback

( Armature voltage feedback

Inputs

( Digital

- 8 isolated inputs (24 V level), 5 of them freely assignable

- 1 serial interface RS 485 or RS 232 (1200 ... 9600 baud)

( Analog

- 4 freely assignable inputs (13 bit resolution) e.g. for main setpoint, additional setpoint, torque limitation, etc.

Outputs

( Digital

- 8 isolated outputs (24 V level), 5 of them freely assignable

- Another 7 free outputs can be evaluated via the LECOM interface

- 1 relay output (50V; 0,5A), freely assignable

( Analog

- 2 reference voltages ( 10V, 7mA)

- 1 monitor output, with I

act

- 2 monitor outputs, freely assignable (37 different signals with 11 bit resolution selectable)

- 1 frequency output, freely assignable

Monitoring

( Monitoring functions of the system and controller components

( Controller protection (Iôt function)

( Motor overload protection (I

ôt function)

( Monitoring of frequency and mains voltage

( Self-synchronisation for mains frequencies from 50 to 60Hz

3-2

48XX/49XXSHB0399

( Safe operation with CW or CCW direction of rotating field input

( Monitoring of the act.-value encoder feedback

( Display of the sources of controller inhibit via a code

( Classifiable monitoring (TRIP, message or warning)

( Monitoring of the cooling air stream with 4X08 to 4X13

( Monitoring of the semiconductor fuses with 4X11 to 4X13

Technical Data

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3.2 General data / application conditions

Field Values

Type of protection IP20 to DIN40050, steel sheet housing Permissible humidity Relative humidity 90%, no condensation Temperature ranges

Stora ge

Tr a ns p o rt -25 C...+ 70 C

Influence of the installation height h $ 1000m : 100% rated armature current

Degree of pollution VDE 0110, part 2, degree of pollution 2

Noise emission Requirements to EN 50081-2, IEC 22G

Noise immunity Limit values maintained with RFI filter.

-25 C...+ 55 C

h $ 2000m : 95% rated armature current h $ 3000m : 90% rated armature current h $ 4000m : 85% rated armature current

Controllers must not be exposed to a corrosive or explosive atmo-sphere.

Limit-value class A (EN 55011; industrial premises) with RFI filter

Requirements to EN 50082-2, IEC 22G Requirements ESD EN 61000-4-2 3, i.e. 8kV air discharge

RF interference IEC 1000-4-3 3, i.e. 10 V/m (e ncl os ure ) Burst EN 61000-4-4 3/4, i.e. 2kV / 5kHz Surge EN 61000-4-5 3, i.e. 1.2 / 50

Standard Severi ty

6 kV contact discharge

1kV phase - phase 2kV phase - PE

48XX/49XXSHB0399

3-3

Technical Data

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3.3 Rated data

3.3.1 Mains voltage 400V

( Controllers 4902 to 4907 (4Q controllers)

Typ e 4902 4903 4904 4905 4906 4907

Output power

Ma ins v olt age V Armature voltage V Rated armature current

(continuous operation) Ma ximum c urr ent

(short-time operation) Field voltage

Max. field current, controlled

Power loss

Ambient temperature in operation

Weight approx. [kg ] 9,2 13,1 13,8 18 22 23

Order No. EVD 4902-E EVD 4903-E EVD 4904-E EVD 4905-E EVD 4906-E EVD 4907-E

mai ns

Arated

Amax

loss

amb

[kW] 6.7 10.5 23.1 46.2 84 105

3 ¼340...460 V~ á0%, 50...60Hz

420V if V

= 400V (1.05 ¼V

mai ns

[A] 16 25 55 110 200 250

[A] 29 45 90 150 240 300

[A] 3.5

Fmax

= 0.875 ¼V

L1-L3

[W] 60 108 185 288 577 650

[C] 0...+ 45 0...+ 35

)

( Controllers 4908 to 4913 (4Q controllers)

Typ e 4908 4909 4911 4912 4913

Output power

Ma ins v olt age V Armature voltage V Rated armature current

(continuous operation) Maximum current (short-time

operation) Field voltage

Max.field current, controlled I Power loss

Ambient temperature in operation

Weight approx. [kg] 28 28 60 60 60

Order No. EVD 4908-E EVD4909-E EVD4911-E EVD 4912-E EVD 4913

mai ns

Arated

Amax

loss

amb

[kW] 139 210 294 420 504

3 ô 340 ... 460 V~á0%, 50...60Hz

420 V if V

= 400V (1.05ôV

mai ns

)

[A] 330 500 700 1000 1200

[A] 400 600 840 1200 1350

= 0,875 ¼V

Fmax

L1-L3

[A] 15 30 [W] 840 1220 2100 2850 3400

[C] 0...+35

3-4

48XX/49XXSHB0399

Technical Data

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( Controllers 4808 to 4813 (2Q controllers)

Typ e 4808 4809 4811 4812 4813

Output power

Ma ins v olt age V Armature voltage V Rated armature current

(continuous operation) Ma ximum c urr ent (short-time operation) Field voltage

Max. field current, controlled Power loss

Ambient temperature in operation

Weight approx. [kg] 28 28 60 60 60

Order No. EVD 4808-E EVD 4809-E EVD 4811-E EVD 4812-E EVD 4813

[kW] 152 230 322 460 552

mai ns

Arated

Amax

loss

amb

[A] 330 500 700 1000 1200

[A] 400 600 840 1200 1350

[A] 15 30

[W] 830 1220 2100 2850 3400

[C] 0...+35

3 ô 340...460 V~á0%, 50...60Hz

460 V if V

= 400 V (1.15 ¼ V

mai ns

= 0.875 ¼ V

Fmax

L1- L3

mai ns

)

1) referred to a mains voltage of 3

400V

2) The field is controlled as a current source, i.e. the field voltage depends on the field resistance.

3) at rated armature current

4) T

35°C: no power derating, 35°C T

amb

45°C: power derating 1%/K

amb

48XX/49XXSHB0399

3-5

Technical Data

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3.3.2 Mains voltage 500V (Variant V014)

( Controllers 4903 to 4907 (4Q controllers)

Typ e 4903 4904 4905 4906 4907

Order No. EVD

Output power

Ma ins v olt age V Armature voltage V Rated armature current

Arated

mai ns

4903-E-V014

[kW] 13.1 28.8 57.7 105 131

[A] 25 55 110 200 250

(continuous operation) Maximum current (short-time

Amax

[A] 45 90 150 240 300

operation) Field voltage Max. field current, controlled I Power loss Ambient temperature in

P T

loss

amb

[A] 3.5 10

108 185 288 577 650

[C] 0...+ 45 0...+35

operation Weight approx. [kg] 13.1 13,8 18 22 23

EVD

4904-E-V014

EVD

4905-E-V014

3ô410...550 V~0%, 50...60 Hz

525 V if V

mai ns

Fmax

= 0.875 ¼ V

= 500V (1.05 ¼ V

4906-E-V014

mai ns

L1- L3

EVD

4907-E-V014

)

EVD

( Controllers 4908 to 4913 (4Q controllers)

Typ e 4908 4909 4911 4912 4913

Order No.

Output power Ma ins v olt age V

mai ns

Armature voltage V Rated armature current

Arated

[kW] 173 262 367 525 630

[A] 330 500 700 1000 1200

EVD

4908-E-V014

(continuous operation) Maximum current (short-time

Amax

[A] 400 600 840 1200 1350

operation) Field voltage Max. field current, controlled I Power loss Ambient temperature in

P T

loss

amb

[A] 15 30 [W] 840 1220 2100 2850 3400

[C] 0...+35

operation Weight approx. [kg] 28 28 60 60 60

EVD

4909-E-V014

EVD

4911-E-V014

3ô 410...550 V~á0%, 50...60Hz

525 V if V

= 500 V (1.05 ¼ V

mai ns

= 0.875 ¼ V

Fmax

L1- L3

EVD

4912-E-V014

)

mai ns

EVD

4913-E-V014

3-6

48XX/49XXSHB0399

Technical Data

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( Controllers 4808 to 4813 (4Q controllers)

Typ e 4808 4809 4811 4812 4813

Order No.

Output power

Ma ins v olt age V Armature voltage V Rated armature current

Arated

mai ns

[kW] 189 287 402 575 690

[A] 330 500 700 1000 1200

EVD

4808-E-V014

(continuous operation) Maximum current (short-time

Amax

[A] 400 600 840 1200 1350

operation) Field voltage Max. field current, controlled I Power loss Ambient temperature in

loss

amb

[A] 15 30

[W] 830 1220 2100 2850 3400

[C] 0...+35

operation Weight approx. [kg] 28 28 60 60 60

EVD

4809-E-V014

EVD

4811-E-V014

3ô 410...550 V~á0%, 50...60Hz

575 V if V

= 500 V (1.15 ¼ V

mai ns

= 0.875 ¼ V

Fmax

L1- L3

EVD

4812-E-V014

)

mai ns

EVD

4813-E-V014

1) referred to a mains voltage of 3

500V

2) The field is controlled as a current source, i.e. the field voltage depends on the field resistance.

3) at rated armature current

4) T

35°C: no power derating, 35°C T

amb

45°C: power derating 1%/K

amb

48XX/49XXSHB0399

3-7

Technical Data

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3.4 Dimensions

3.4.1 Controller 4902 to 4X09

a c



”A”

X10 X1 1 V1 V2

”A”

4900

Typ e

4902 / 4903 / 4904 269 415 242 395 222 360 6.5 8 30 26 175 4905 / 4906 / 4907 269 525 242 505 222 466 6.5 8 30 26 175 4808 / 4809 / 4908 / 4909 322 550 288 525 335 497 6.5 8 30 34 295

3-8

48XX/49XXSHB0399

X1 X2

FIG4-1 Dimensions of the controllers 4902 to 4907, 4X08 and 4X09

X3 X4 X5 X6 X7

a b c d e f g h i k l

X8 X9

4900Str001

all dimensions in mm

3.4.2 Controllers 4811 to 4813, 4911 to 4913

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Technical Data



FIG4-2 Dimensions of the controllers 4X11 to 4X13

Typ e

4811 - 4813 / 4911 - 4913 322 800 292 740 390 9 30 15 9

a b c d e g h m n

4900

c a

all dimensions in mm

4900Str002

48XX/49XXSHB0399

3-9

Technical Data

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3-10

48XX/49XXSHB0399

4 Installation

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4.1 Mechanical installation

4.1.1 Important notes

( Ensure free installation space above and below the controller:

- 100 mm for 4902...4907

- 150 mm for 4X08...4X13

( Ensure unimpeded ventilation of cooling air and outlet of exhaust air.

( If the cooling air contains pollutants (dust, fluff, grease, aggressive gases),

which may impair the function of the controller:

- Take suitable preventive measures , e.g. separate air duct, installation of filters, regular cleaning, etc.

Installation

( Do not exeed the ambient temperature permissible during operation:

- 4902...4906: to 45 °C: without power derating

- 4907, 4X08...4X13: to 35 °C: without power derating

35 °Ctomax.45 °C: power derating 1% / K

Possible mounting positions

( Only vertical controller installation:

- 4902 ... 4907, 4X08 and 4X09 with mains connections on top

- 4X11 ... 4X13 with mains connections at bottom

48XX/49XXSHB0399

4-1

Installation

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4.2 Electrical installation

For information on the installation according to EMC, see chapter 4.4

4.2.1 Protection of persons

( Protection of persons and animals according to DIN VDE 0100 with

current-operated protective devices: The inverters are equipped with a mains rectifier. After a short-circuit to frame, a DC fault current may prevent the tripping of the current-operated protective device. Additional measures, such as protective multiple earthing or universal current sensitive current-operated e.l.c.b., should therefore be taken.

( When dimensioning the tripping current of the current-operated e.l.c.b. it

must be observed that false tripping may occur under the following conditions:

- In the event of capacitive leakage currents between the cable screens (especially with long screened motor cables).

- If several controllers are connected to the mains at the same time.

- If you use RFI filters.

( Comment on the application of universal-current sensitive current-operated

e.l.c.b.: The preliminary standard prEN50178 (previously VDE0160) on the application of universal-current sensitive current-operated e.l.c.b. has passed the German Committee K226. The final decision about this standard will be made by CENELEC/CS (European Committee for Electrotechnical Standardization) in Brussels. For further information on the application of universal-current sensitive current-operated e.l.c.b., can be obtained from the supplier.

( Replace defective fuses with the prescribed type only when no voltage is

applied. The fuses protect the controller from impermissible operating conditions. After tripping, the controller or the system should be checked for possible faults or errors before replacing the fuse.

( The controller can be safely disconnected from the mains via a contactor on

the input side.

Electrical isolation

There is an electrical isolation (insulating distance) between power and control terminals:

( The reference potential GND of the control electronics is connected to PE

viaabridge(bridgetoX4;term.90 term. FE)

4-2

48XX/49XXSHB0399

( The control electronics has a basic isolation (single insulating distance).

( The protection against contact, if the insulating distance is defective, can

only be ensured by additional measures.

4.2.2 Protection of the controller

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Stop!

The controllers contain electrostatically sensitive components: Prior to assembly and service operations, the personnel must be free of electrostatic charge, e.g. by touching the PEfixing screw or other grounded metal surfaces in the control cabinet.

( In the event of condensation, connect the controller to the mains voltage

only after the visible humidity has evaporated.

( The controllers are designed for operation with a neutral earth mains

voltage.

( For separate supply of the field controller:

- Ensure correct phase connection of the terminals L1.1 and L3.1. The PEN conductor must never be connected!

Installation

( The power outputs of the controller for the armature circuit (A, B) and the

field circuit (I, K) must only be disconnected when no voltage is applied.

( Use the prescribed semiconductor fuses to protect the thyristors in the

power stage (see chapter 13.1).

( For speed control with incremental encoder:

- Only use incremental encoders with pulse tracks shifted by 90.

( For speed control with tacho:

- Only use DC tacho generators.

4.2.3 Screening of the control cables

Wire the screening and the GND and PE connections very carefully to avoid interference. Interference in the control cables can interrupt operation, because it disturbs the controller program (fault message ’CCr’).

( Screening of control cables.

- Connect the screen of the control cables to the screen connections of the controller or via the isolated earthing bus in the control cabinet (e.g. PE terminals).

( Prevent breaks in the screening:

- In the event of interruption, screening must be connected to protective buses (terminal strips, relays, fuses).

- Low-resistance connection between buses (at least 10 mm the supply.

)and PEof

( Control cables must not be installed parallel to motor cables carrying

interference.

- If it is not possible to ensure an installation distance between control and motor cables, the motor cables should be screened.

48XX/49XXSHB0399

4-3

Installation

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4.2.4 Earthing of the control electronics

Single drives

( With factory setting, the reference potential GND of the control electronics is

joined to PE. Additional earthing measures are not required.

Group drives

( Ensure that earthing the control electronics does not cause any damage to

external controllers.

( Ensure to avoid ground loops when the ground is connected (GND):

- Remove the bridge to X4 from terminal 90 to terminal FE.

- All ground cables must be connected to externally isolated buses which are as close to the controllers as possible.

- Make a low-resistance connection between the buses (at least 10 mm and PE of the supply.

)

4.2.5 Mains types and conditions

Please observe the restrictions for each mains type!

Mains Operation of the controller Notes

With grounded neutral No restrictions Observe controller ratings With grounded phase Operation is impossible. With isolated neutral (IT mains) Operation with the recommended RFI filter

is only possible if an isolating transformer is preconnected. The neutral of the secondary circuit must be earthed secondarily.

Interaction with compensation equipment

For reactive-power compensation of mains with an inverter controller load, the compensation unit should be equipped with a choke, since the controller generates harmonic currents. These harmonic currents could excite oscillating circuits which consist of mains impedance and capacitor reactance. Capacitors, transformers, switching units, etc. could be destroyed by these reactance effects.

In this case, please contact the supplier of your compensation equipment.

Contact Lenze. The RFI filter will be destroyed when directly connected to the IT mains and fault “earth fault”.

4-4

48XX/49XXSHB0399

Installation

0.5...0.6Nm2.0...2.4N

64N

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4.3 Connection

Connection between controller and motor

Lenze c ont roller Motor (to DIN 42017/ VDE 0530 part 8) Function Ter m in al Te rm in al Oth ers Motor type

Armature voltage

Excitation voltage

Armature voltage

Excitation voltage

Armature voltage +-A

DC tacho +-3

Te mp . sw i t c h S1 , S2 Thermal contact T1, T2

1B1 2B2

F1 F2

1C1 2C2

F1 F2

A1 A2

2A1 2A2

A1 B2, A2

F5, (for higher connection voltages) F2

A1 C2

F5, (for higher connection voltages) F2

DC motor uncompensated with commutating winding

DC motor compensated with commutating winding

Permanent-magnet mot or

Screw-tightening torques

Typ e 4902 4903 - 4904 4905 - 4907 4X08 - 4X09 4X11 - 4X13

L1,L2,L3,A,B A, B L1.1, L3.1, I, K 0.5 ... 0.6 Nm 1.2 ... 1.5 Nm L1.2, L2.2, L3.2 0.5 ... 0.6 Nm L1.3, L2.3, L3.3, 86 - 89 - 0.5 ... 0.6 Nm

Terminal strip X1 - X4 0.5 ... 0.6 Nm

1) Rated tightening torque for the connection of terminal ends to busbars

0.5 ... 0.6 Nm 2.0 ... 2.4 Nm 37 Nm

(VDE 0220 part 1/11.71)

When continued with busbar see DIN43673 part 1/02.82

37 Nm

15 ... 20 Nm

64 Nm

The following circuit diagrams show the electrical wiring of the power connections.

48XX/49XXSHB0399

4-5

Installation

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4.3.1 Power connection of standard controller

F1 F2

FF16A

500V

BR1

BR2

BR5

BR3

BR4

4902/3/5LP 4902VP

M0,5A 500V

F’1...F’3

F’’ 1...F’’ 3

L1 L2 L3PE B

L1 L2 L3

L’1L’2L’3

L1 L2 L3

FIG4-3 Power connection of controllers 4902 to 4907

K1 Mai ns contactor F’1...F’4 Semiconductor fuses for controller protection F’’ 1...F’’ 3 Line protection fuses L

Z1 RFI filter

BR1 - BR5 0W wire bridge

¥ ¦

mai ns

Co mmuta ti ng chok e (ma ins c hoke )

Field controller

Power sta ge

Auxiliary starting circuit

L3. 1L1. 1

F’4

= 340 ... 460 V~  0% 50 ... 60 Hz

IKL1. 2L2 .2 L3.2

IKAB S1 S2

4900Str003

With field voltages > 300V and field currents < 200mA an auxiliary starting circuit should be used.

Recommended dimensioning: R = 330 W/20W; C=0.22mF/400V AC.

4-6

48XX/49XXSHB0399

Installation

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L1 L2 L3

PE B

L1 L2 L3

L'1 L'2 L'3

FF16A 500V

FF32A

F''5F''4

V = 200...240 V ~ 50...6 0 H z

600V

L1 N

BR5

BR3

BR4

F1 F2

L2.3L1.3

L3.1L1.1

0,6A

M 0,5A 500V

L1.2 L2.2 L3.2

4908LP

4902VP

F'4

S1 S2

F '1 ...F '3

F ''1 ...F ''3

L1 L2 L3

= 3 4 0 ... 460 V ~ ±0 % 50 ... 6 0 H z

mains

FIG4-4 Power connection of controllers 4X08 to 4X09

K1 Mains contactor F’1...F’4 Semiconductor fuses for the protection of controllers F’’ 1...F’’ 5 Line protection fuses L

Co mmuta ti ng chok e (ma ins c hoke ) Z1 RFI filter Z2 RFI filter for separate fan supply

BR3 - BR5 0W wire bridge

¥ ¦

Field controller

Power sta ge

Fan

4900Str128

48XX/49XXSHB0399

4-7

Installation

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F3.1F2.1F1.1

L1 L2 L3

PE B

F1.2 F2.2 F3.2

K2LK2

F''4 F''5

M ~

FF16A 500V

V = 200...240 V ~ 50...6 0 H z

FF32A

600V

L1 N

BR5

BR3

BR4

F1 F2

L2.3L1.3

0,3 A

4911LP

M 0,5A 500V

L3.1L1.1

L1.2 L2.2 L3.2

4902VP

S1 S2

4900Str129

F ''1 ...F ''3

L1 L2 L3

L'1 L'2 L'3

L1 L2 L3

= 3 4 0 ... 460 V ~ ±0 % 50 ... 6 0 H z

mains

FIG4-5 Power connection of controllers 4X11 to 4X13

K1 Mai ns contactor F1.1 ... F3.2 Semiconductor fuses for controller protection F’’ 1...F’’ 5 Line protection fuses L

Z1 RFI filter

Co mmuta ti ng chok e (ma ins c hoke )

Z2 RFI filter for separate fan supply

BR3 - BR5 0W wire bridge

¥ ¦

Power sta ge Field controller Fan

It is not necessary to protect mains and armature cables by semiconductor fuses, because the thyristors are already protected by internal cell fuses.

4-8

48XX/49XXSHB0399

Installation

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4.3.2 Separate supply of the field-current bridge at a high motor field voltage

Stop!

Ensure correct phase connection of the separate field supply. Incorrect connection leads to blown fuses. Thephaseshift of the voltages from the power stage to the control electronics must be smaller than 2 °(electrically).

To reduce the mains feedback, separate mains chokes are required for the field supply (chapter 13.2.2).

The fuses F’’4andF’’5 are cable protection fuses. They must be matched to the cross section of the cables used and dimensioned for at least I

In weak mains supplier, field-current fluctuations may occur and thus the torque can be reduced. For rated field voltages V supply for the field bridge.

> 210V, werecommend aseparate

Frated

The armature current control circuit and the field current control circuit are electrically decoupled by an external supply for the field controller with voltage pick-off before the mains choke.

Remove the wire bridges BR1 and BR2 of the controllers 4902 to 4907 (4902LP, 4903LP or 4905LP) when no voltage is applied. The bridges can be easily accessed:

1. Open the controller cover (4 mounting screws)

2. Unbolt the 2 mounting screws for the cover of the control electronics

3. Open the cover.

48XX/49XXSHB0399

4-9

Installation

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FF16A

500V

BR1

BR2

F1 F2

BR5 BR3 BR4

4902/3/5LP 4902VP

M0,5A 500V

F4 F3

L1 L2 L3PE B

L1 L2 L3

L’1L’2L’3

F’1...F’3

F’’ 1...F’’ 3

L1 L2 L3

FIG4-6 Power connection for controllers 4902 to 4907

F’’ 4F’’ 5

= 340 ... 460 V~ 0% 50 ... 60 Hz

mai ns

L3. 1L1. 1

F’4

IK L1. 2 L2. 2 L3 .2

IKAB S1 S2

4900Str006

4-10

48XX/49XXSHB0399

K1 Mains contactor F’1...F’4 Semiconductor fuses for controller protection F’’ 1...F’’ 5 Line protection fuses L

Z1 RFI filter

BR3 - BR5 0W wire bridge

¥ ¦

Co mmuta ti ng chok e (ma ins c hoke )

Power sta ge

Field controller

4.3.3 Separate supply for the control electronics

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Stop!

Ensure correct phase connection of the separate mains supply. Incorrect connection leads to blown fuses.

( The phase shift of the voltages from the power stage to the control

electronics must be smaller than 2°(electrically).

( The controller must be inhibited via the function ”Controller enable” (C tr l.

enable) before the contactor can be opened or closed. If the switching sequence is not observed, the fuses will blow or fault messages ACI or FCI will be indicated.

( The electronics remains supplied after K1 has been opened. The mains is

completely separated via the main switch.

Installation

48XX/49XXSHB0399

4-11

Installation

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L1 L2 L3

PE B

4902/3/5/8/11LP 4902VP

M 0,5A 500V

BR5

BR3

BR4

A L1.2 L2.2 L3.2

F '1 ...F '3

F ''1 ...F ''3

F ''6 ...F ''8

L1 L2 L3

L'1 L'2 L'3

L1 L2 L3

= 3 4 0 ... 460 V ~ ±0 % 50 ... 6 0 H z

mains

FIG4-7 Power connection for controllers 4902 to 4907 and 4X08 to 4X13

K1 Mains contactor F’1...F’3 Semiconductor fuses for controller protection F’’ 1...F’’ 3 Line protection fuses F’’ 6...F’’ 8 Cable protection fuses 4A L

Commutating choke Z1 RFI filter Q1 Main switch

¥ ¦

Power sta ge

Field controller

4900Str130

4-12

48XX/49XXSHB0399

4.3.4 Control connections

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Installation

915

X10

12345678910

40 41 44 45 K11K14A1 A2 A3 A4

FIG 4-8 Control connections for the controller

X1 - X4 Control t erminals X5 Digital frequency/incrementa l encoder input (Dig_In_1) X6 LECOM1 interface (RS 232 / 485) X7 Resolver connection X8 Digital frequency output X9 Digital frequency/incrementa l encoder input (Dig_In_2) X10, X11 Fieldbus connnections (as option e.g. 2110 for InterBus) V1, V2 Displays for fieldbus options (option)

915

X11

20 21 22 28 E1 E2 E3 E4 E5 39

A5 59 60 61 62 63 80VE990 FE

V1 V2

961596

X6 X7

4900Str008

Switch on the control module

Some function of inputs and outputs can be changed via the switches on the control module 4902MP. For settings ensure

- that no voltage is applied

- the cover is removed (4 mounting screws)

4902MP.xx.xx

S1 S2

onon

X2A X2 B

4900Str009

FIG 4-9 Positions of switches S1 to S4 on the control module

48XX/49XXSHB0399

4-13

Installation

onito

out

put

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4.3.4.1 Connection of analog signals

S3/ 2

8x 3,3nF

S4/ 5

168 k

GND

47 k

168 k

GND

168 k

S3/ 1

250 R

-10 V/ 7 mA

+10 V/ 7 mA

234165 78 109 61 62 6360

R> 1,5k

GND

IUIU

S2 S1

R> 3k

FIG 4-10 Analog inputs and outputs



















The analog signals are contacted via the terminal blocks X1 and X4. FIG 4-10 shows the function assignment according to factory setting.

External torque limitation Setpoint 2 Actual value signal with tacho feedback Additional setpoint Setpoi nt 3 Main setpoint as digital master voltage/current Setpoint 1 Main setpoint as unipolar setpoint Main setpoint as bipolar setpoint Armature current I Current setpoint C063 Actual speed value C051

act

Analog input

4900Str010

4-14

48XX/49XXSHB0399

Installation

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Analog inputs

Ter m in al Switch position Use Level Resolut ion

1, 2

3, 4

OFF

ON OFF

OFF

Setpoint 2

-10V...+10V 12 bit + sign with ground reference (factory setting)

Setpoint 2

-10V...+10V 12 bit + sign differential input

Actual value -10V...+10V 12 bit + sign

Actual value -30V...+30V 12 bit + sign

Actual value -60V...+60V 12 bit + sign

Actual value (factory setting) -73V...+ 73V 12 bit + sign

Actual value -90V...+90V 12 bit + sign

Actual value -99V...+99V 12 bit + sign

Actual value -120V...+ 120V 12 bit + sign

Actual value -180V...+ 180V 12 bit + sign

Actual value

12 bit + sign

with ground reference

Actual value differential input

12 bit + sign

6 Setpoint 3 with ground reference -10V...+10V 12 bit + sign 7 Internal ground, GND 8

OFF

Setpoint 1, Master voltage (factorysetting)

Setpoint 1, Master current

-10V...+10V 12 bit + sign

-20mA...+ 20mA

-20 mA...-4 mA

+4 mA...+ 20 mA 9 Voltage supply for + 10V/7mA 10 Setpoint selection via potentiometer -10V/7mA

48XX/49XXSHB0399

4-15

Installation

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Analog outputs (monitor outputs)

Ter m in al Switch position Use Level Resolution

60 Internal ground, GND 61 Actual current value -5 V...+5 V

correspond to the rated current of the controller

For changing the factory setting of switch S4, jumper 5 to ON (actual value with

ground reference), observe the following:

- Bridge terminals 4 and 5 externally.

- Set DIP switch S4, jumper 1-4 (preselected actual value) to double tacho voltage.

Moni tor 1 Output voltage(factory setting)

Moni tor 1 Output current

Moni tor 2 Output voltage(factory setting)

Moni tor 2 Output current

-10V...10V 11 bit

-20mA...+ 20mA 11 bit

-10V...+10V 11 bit

-20mA...+ 20mA 11 bit

The max. possible tacho voltage is 90 V!

4-16

48XX/49XXSHB0399

4.3.4.2 Connection of digital signals

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( All digital inputs and outputs are PLC compatible and separated from the

rest of the control module when operated with an external voltage supply (24 V).

( The diagrams show the function assignments according to the factory

setting.

( For switching the signal cables, only relays with contacts for low- level

switching should be used. We recommend using relays with gold contacts.

( Voltage supply

- external 24 V to terminals X2/39 and X4/59 or

- internal 15 V to terminal X2/20

Stop!

Installation

( Maximum permissible load of the internal 15 V supply : 100 mA.

( For operation with internal voltage: Bridge terminals X2/39 and X3/40

externally.

( Digital inputs unused should be connected!

Inputs:

Input voltage 0...+30 V

LOW level: 0...+5V HIGH level: +13...+30V

Input current: 24 V:

15 V:

8 mA per input 5 mA per input

Outputs:

Output current: Max. 50 mA per output

(external resistance min. 480W at 24V,

e. g. relay, order designation EK0005)

The input and output signals are in average read, processed and updated every 4mseconaverage.

48XX/49XXSHB0399

4-17

Installation

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GND e xt.

22 k

10 k

10 R

+15 V / 100 mA

3k3k3k3k3k3k3k

50 mA

GND

X3 X4

21 22 2820 E2E1 E3 E4 39E5 41 44 4540 A2A1 A3

QSP

CCW

1 2 3

4 5 6

7 8910

FIG 4-11 Digital inputs and outputs with external voltage supply (24 V)

GND e xt.

22 k

+15 V / 100 mA

3k3k3k3k3k3k3k

50 mA

GND

X3 X4

21 22 2820 E2E1 E3 E4 39E5 41 44 4540 A2A1 A3 A4 59A5

50 mA

A4 59

50 mA

10 k

10 R

50 mA

4900Str011

4-18

48XX/49XXSHB0399

CCW

QSP

1 2 3

7 8

9 10 11

FIG 4-12 Digital inputs and outputs with internal voltage supply (15 V)

12 13

4900Str012

Digital inputs

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Installation

Name Ter m in al Use

(factory setting)

20 Voltage supply 15V, 100mA

CW 21 Removal of qui ck stop, CW rotation HIGH

CCW 22 Remove quick stop, CCW rotation HIGH 1 28 Controller enable - Ctrl. enable HIGH 2 E1 Freely assignable input

(TRIP se t)

3 E2 Freely assignable input

(TRIP reset)

4 E3 Freely assignable input

(Inhibit additional setpoint)

5 E4, E5 Freely assignable input

(Enable JOG values, three JOG values)

Level for activation Programming

HIGH

Digital outputs

Name Te rm in al Use

39 Ground of the digital inputs and outputs, external GND 40 Internal ground, GND

6 41 TRIP HIGH LOW

7 44 Ready for operation - RDY HIG H HIGH 8 45 Pulse inhibit - IMP HIGH LOW

9 A1 Freely assignable output

10 A2 Freely assignable output

11 A3 Freely assignable output

12 A4 Freely assignable output

13 A5 Freely assignable output

59 Supply input of the digital outputs:

(factory setting)

(n-controller = M

(Setpoint reached, RFG

24 V external or 15 V internal

act<nx

=0)

act

act=nset

)

max

output

)

=RFG

input

)

Message Programming

1) 2)

HIGH LOW

LOW HIGH

HIGH HIGH

HIGH LOW

HIGH HIGH

see chapter

1) Message in stationary controller operation

2) Message, if the function is active

48XX/49XXSHB0399

4-19

Installation

+Vcc158

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Relay output

Ter m in al Use

(factory setting)

4908LP

4911LP

4900Str063

K11, K14 Floating relay output, conta ct load capacitiy: 50V / 0.5A (TRIP)

Additional digital inputs and outputs with 4X08...4X13

The controllers 4X08...4X13 are equipped with additional control terminals to monitor the fuses. Thefollowing current flow charts show the factorysetting of the internal wiring and give suggestions on how to include an external fuse monitoring.

4902MP

88 89 28

86 87 88 89 28

Ctrl. enable

FIG4-13 4808...4809 and 4908...4909

Ctrl. enable

+ Vcc15

4902MP

+ Vcc15

External fuse monitoring

Without external fuse monitoring, terminal 20 can be directly connected with the

4900Str013

switch Ctrl. enable.

Internal fuse monitoring

4900Str_01

4-20

FIG4-14 4811...4813 and 4911...4913

For monitoring, the terminals 86 and 89 should be connected in series with the controller enable contact Ctrl. enable.

( For internal voltage supply (15 V), bridge the following terminals:

- X2/20 to 86

- X2/28 to 89

( For external voltage supply (24 V):

- Apply supply voltage to terminal 86.

- Bridge terminals 28 and 89.

Danger! (especially for hoist applications)

Please observe when connecting the fuse monitoring: No torque is generated when the controller is inhibited.

48XX/49XXSHB0399

4.3.5 Feedback systems

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Several feedback systems can be connected to the controller and configured:

( Armature voltage control

( DC tacho feedback

( Resolver feedback

( Encoder feedback

- Incremental encoder TTL

- Incremental encoder HTL

DC tacho feedback

Tacho signals are connected via term. 3/4 of terminal block X1. The controller processes rated tacho voltages of 10...180V (chapter 4.3.5.1).

Installation

Resolver feedback (X7)

( 2-pole resolver (V = 10 V, f = 5 kHz)

( Connection to a 9-pole Sub D socket X7

- We recommend to use the pre-cut Lenze system cable (see chapter 13.3).

( Resolver cable and resolver are monitored for wire breakage (fault message

”Sd2”)

=50m

ma x

+REF

-REF

+COS

-COS

+SIN

-SIN

4900Str015

FIG 4-15 Resolver connection (9-pole Sub D socket)

Pin assignment of socket X7:

Pin 1 2 3 4 5 6 7 8 9 Signal +REF -REF GND +COS -COS +SIN -SIN --- ---

Cross section 0.5 0.14

48XX/49XXSHB0399

4-21

Installation

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The resolver signal or encoder signal can be output for following drives at the digital frequency output X8.

( Connection as shown in the connection diagrams:

- Use cables twisted and screened in pairs.

- Connect both screen ends.

- Use cable cross-sections indicated.

( The feedback system can be activated under C005.

( If resolvers are used which are not specified by Lenze are used, contact

your Lenze representative.

Incremental encoder feedback

( Incremental encoders with two 5 V complementary signals electrically

shifted by 90(TTL encoders) or HTL encoders can be connected.

( Connection to a 9-pole Sub D socket X5 or X9, depending on the

configuration of C005

- Maximum input frequency: 420 kHz with TTL encoder

- Current consumption per channel: 6 mA

100 kHz with HTL encoder

( With HTL signal:

- If there is no inverse track available, the inputs A

and B (with zero track also Z ) must be connected to the

encoder supply potential.

=50m

ma x

B A

VE9

GND



FIG 4-16 Incremental encoder connection (9-pole Sub D socket)

A A

Z Z

4900Sttr016

4-22

48XX/49XXSHB0399

Installation

TerminalsAand

TerminalsIand

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Pin assignment of socket X5/X9:

Pin 1 2 3 4 5 6 7 8 9 Signal B

Pin 8, LC ( ¥)

- For encoders without lamp control, assign +5 V...+30V. Otherwise, the controller will indicate fault ”Sd3” or ”Sd4”.

Pin 4, VE9

- Is connected to the terminal of the external incremental encoder supply X4/ VE9.

A VE 9 GND

X5, X9 Pin 4

GND

Z LC

90 FE

VE9

FIG 4-17 Connection of the incremental encoder supply

VE9 External supply for incremental encoder to X5/X9 90 Internal ground GND FE Functional earth

4.3.6 Change of the direction of rotation in 2Q operation

In 2Q operation (controller 48XX or C180 = -1-), only one thyristor bridge of the controller is active, i.e. the output terminal A can only carry positive voltage referred to terminal B, on the condition that no active loads occur.

The direction of rotation of the motor is determined by the connection of the armature cable to A and B and of the field cable to I and K. If the opposite direction of rotation is required, take the following steps (depending on the actual value feedback system):

4900Str017

Act. speed feedback system Directionofrotationchangedby: Additional measures

Armature voltage None Ta c h o

Re sol ver

Incremental encoder

Exchange connection:

Connection tacho signal exchange term. 3 and 4

Signal cable resolver exchange track +sin and -sin

Invert act. speedsgnal via C205 / C027

48XX/49XXSHB0399

4-23

Installation

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4.3.7 Digital frequency selection and encoder emulation

Digital frequency input

( Possible digital frequency signals:

- Incremental encoder with two 5 V complementary signals electrically

shifted by 90(TTL encod ers) or HTL encoder

- Encoder emulation of the host (master)

( Connection to a 9-pole Sub D socket X5 or X9, depending on the

configuration of C005

- max. input frequency: 420 kHz for TTL encoders 100 kHz for HTL encoders

- Current consumption per channel: 6 mA

Digital frequency selection via the digital frequency output of the master drive

B A

GND

X8 X5 /X9

FIG4-18 Digital frequency selection for the slave ¦ via digital frequency output (master ¥)

GND

B A

4900Str018

Pin assignment of socket X5/X9:

Pin 1 2 3 4 5 6 7 8 9 Signal 6.5

A VE 9 GND

Z LC

Pin 8, LC (lamp control of the encoder):

- With digital frequency coupling, pin 8 is deactivated in the factory setting

(configuration C005= -5X-, -6X-, -7X-)

Pin 4, VE9

- Is connected to the terminal of the external incremental encoder supply

X4/ VE9.

4-24

48XX/49XXSHB0399

Installation

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Digital frequency output / encoder emulation

The output signal of the Sub-D socket X8 can be used for superimposed control circuits to feed back actual values (synchronous running, digital frequency coupling or positioning control). Depending on the configuration under C005, it is assigned as a digital frequency output or as an output for the encoder emulation.

Features:

( Two 5V complementary signals (TTL signal), electrically shifted by 90°

( Current capacity 20mA per channel

( Current capacity at PIN 8 (+5V): max. 5mA

The output signal is internally derived from the resolver or incremental encoder signal.

Resolver f eedback Incremental encoder feedback

Resolut ion 2048 increments per revolution Constant of the incremental encoder

Signal type

FIG 4-19 Signal of digital frequency or encoder output X8 assignment of plug X8

4900Str019

4900Str020

Pin assignment of socket X8:

Pin 1 2 3 4 5 6 7 8 9 Signal B

A NC GND

Z +5V

Note!

If fault messages occur at the encoder monitoring during resolver feedback to superimposed systems:

( Exchange tracks A and B

( Use inverse tracks

48XX/49XXSHB0399

4-25

Installation

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4.3.8 Serial interface RS232/485

Danger!

The interface RS232C/RS485 is not isolated, i.e. an additional electrical isolation (double basic insulation) to VDE 0106, part 1, (protection against electric shock) and to VDE 0160 (reduction of interference) is required for host connection.

LECOM-A: with 2 Lenze level converters 2101IB connected to the host or

another RS 232C electrical isolation. LECOM-B: with Lenze level converter 2101IB connected to the host LECOM-LI: no additional electrical isolation required

Ensure electrical isolation of the voltage supply!

Thecontrollers can communicate with the host (PLC or PC) via the serialinterface LECOM1 or an operating keypad that works according to the LECOM protocol.

The LECOM1 interface (X6) processes the LECOM-A/B protocol. The LECOM-A/B protocol is based on the standard ISO 1745 and can be used with up to 90 controllers. It detects faults and avoids the transmission of faulty data.

Controllers to standard RS232C (LECOM-A) or RS485 (LECOM-B) can be connected to the LECOM1 interface. The interface can be used for parameter setting, monitoring, analysis and simple control tasks.

With the RS232C interface, it is possible to create point-to-point connections with a cable length of up to 15 m. Most PCs or other hosts are equipped with this interface.

For multiple drives and distances >15m, use the RS485 interface. With only 2 wires it is possible to connect up to 31 controllers and communicate over a cable length of max. 1,200 m.

Pin assignment of socket X6:

Pin Name Input/output Explanation

1 + VCC15 Output Supply voltage + 15V / 50mA 2 RxD Input Receive data cable RS232C 3 TxD Output Transmit data cable RS232C 4 DTR Output Transmission control RS232C 5 GND Controller reference potential 6 DSR Input (not used) RS232C 7 T/R (A) Output/ input RS485 8 T/R (B) Output/ input RS485 9 + VCC5 Output Supply voltage + 5V

4-26

48XX/49XXSHB0399

The baud rate can be changed under C125 (1200/2400/4800/9600 baud).

Protocol: LECOM-A/B V2.0

4.3.9 Fieldbus connection

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Note!

Special features of the controller variants V011 and V013:

1. The interface module 2110IB or 2130IB is integrated into the controller.

2. In the factory setting, the controllers are prepared for the separate mains supply of power stage and control electronics:

- The bridges BR3, BR4, BR5 are not installed!

( Variant V011 with InterBus interface module

The interface module type 2110IB connects Lenze controllers with the fast serial communication system InterBus. The module enables the highly dynamic transfer of process data (e. g. setpoints and actual values) and access to all parameters of the controller according to the DRIVECOM profile.

Installation

The InterBus communication is based on a ring concept. All bus participants are required for communication. For applications which require a volt- free power stage, a separate mains supply must be provided to ensure communication (see chapter 4.3.3).

4900Str117

FIG4-20 Front view 2110IB

X10 X11 Output InterBus peripheral bus V1 LED green, bus supply V2 LED yellow, communication

Input InterBus peripheral bus

48XX/49XXSHB0399

4-27

Installation

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( Variant V013 with PROFIBUS interface module

The interface module type 2130IB connects Lenze controllers to the fast serial communication system PROFIBUS. With PROFIBUS it is possible to parameterize and control a controller via a host.

FIG4-21 Front view 2130IB

4900Str116

Connection

X12 RS485 bus

connection

X13-W30 Optical fibre

receiver

X13-W31 Optical fibre

sender

V1 2130IB supply OFF:

V2 Communicatio

n 2130IB

9-pole SubD socket

(only 2130IB, V002)

Module is not supplied. Controller is switched off or connection is interrupted(X4). ON: Module is supplied.

OFF: No supply or 2130IB and controller not yet initialised. ON: Module 2130IB and basic unit are initialised but the PROFIBUS-DP communication is still not working. FAST BLINKING (4x pe r se cond): PROFIBUS-DP communication with user data SLOW BLINKING (1x pe r se cond): PROFIBUS-DP communication initialised

Explanations

If the interface module 2130IB is no longer supplied, the bus system will not stop working. However, the connected controller cannot be addressed by the host.

If necessary, the control stage of the controller should be supplied separately (see chapter 4.3.3).

4-28

48XX/49XXSHB0399

4.4 Installation of a CE-typical drive system

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4.4.1 General notes

( The electromagnetic compatibility of a machine depends on the type of

installation and care taken. Please observe:

- Assembly

- Filters

- Screening

- Grounding

( For diverging installations, the conformity to the CE EMC Directive requires

a check of the machine or system regarding the EMC limit values. E.g. with:

- the use of unscreened cables

- the use of group RFI filters instead of the assigned RFI filters

- Operation without mains choke

- Multi-motor drive systems

Installation

The user of the machine is responsible for compliance with the EMC Directive.

If you observe the following measures, you can assume that the machine will operate without any EMC problems caused by the drive system, and that compliance with the EMC Directive and the EMC law is achieved.

If devices which do not comply with the CE requirement concerning noise immunity EN 50082-2 are operated close to the controller, these devices may be interfered electromagnetically by the controllers.

Because of the earth-potential reference of the RFI filters, the CE-typical drive systems which are described are not suitable for the connection to IT- mains (mains without earth- reference potential).

For the use of 48XX/ 49XXdrive systems in residential areas observe the following:

( Check that the radio interference suppression level at the supply to the site

of operation complies with the standard (EN55022 class B).

( Check that the permissible level for radio interference (EN55022 class B) is

not exceeded around the site of operation.

48XX/49XXSHB0399

4-29

Installation

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4.4.2 Components of the CE-typical drive system

System c omponent Specification

Controller 4800/4900 DC controllers RFI filter For data and filters see chapter 13.4 Ma ins c hok e For assignment and technical data see chapter 13.2 Armature and field cable Unscreened power cable

Control cables Screened signal cable type LIYCY Encoder cable for digital frequency Lenze system cable or screened signal cable, twisted in pairs, tin plated E-CU braid

Encoder cable for resolver Lenze systemcable type EWLR or screened signal cable, twisted in pairs, tin plated

Mot or Separately excited DC motor

Accessories InterBus module 2110IB

Rated max. length: 50m

with 75% optical overlay

E-CU braid with 75% optical overlay

Lenze series MGFQ, MGFR or similar

Profibus module 2130IB

Controller, RFI filter and mains choke are mounted on the same assembly board inside a standard control cabinet.

4.4.3 Measures required

Control cabinet assembly board

( For HF grounding, only use mounting plates with an excellent conductive

surface (e.g. zinc-coated surface).

( If you use mounting plates with badly conductive surfaces (e.g. painted,

anodized, yellow passivated):

- Remove the paint or coating from the contact surface of the mains filters, controllers, and screen connections, to provide a large and conductive connection.

( When using several mounting plates, connect them with a surface as large

as possible (e.g. using copper bands).

( Connect the controller, RFI filter and mains choke to the grounded

mounting plate with a surface as large as possible.

Power connection

4-30

48XX/49XXSHB0399

( Avoid unnecessarily long cables

( Ensure the separation of motor cable and signal or mains cable.

( Ensure separation of unscreened and screened cables (distance > filter

length)

( Ensureadistanceasshortaspossiblebetweentheconductors

(single-c or es)

( Both ends of unused cores should be connected to ground/PE.

Installation

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Signal cables

( Always screen digital and analog signal cables.

- Always connect the signal cables over the shortest possible distance with the screen connections provided at the controller:

- Connect both screen ends of digital signal cables.

( If potential differences are to be expected, lay an additional compensation

cable.

( For long signal cables, provide additional screening points:

- Connect the screen at the control cabinet input with a suitable clamp to the conductive mounting plate of the control cabinet.

Remove the coating

Screen braid

Cont act the sc reen withasurfaceaslargeaspossible

FIG 4-22 Additional screening connection on a mounting plate of the control cabinet

K35.0098

Filters

( Only use the mains filters and RFI filters which are designated for the

controller:

- RFI filters reduce impermissible high-frequency interference to a permissible value.

- Mains chokes reduce low-frequency interference which depend on the motor cable and its length.

Screening

Wire the screening and the GND and PE connections very carefully, to avoid interference.

( All signal cables should be screened.

( Avoid a common terminal board for mains input and motor output.

( Route cable as close as possible to the reference potential. Free-hanging

cables have the same effect as aerials.

48XX/49XXSHB0399

4-31

Installation

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Grounding

( Ensure a good equipotential bonding of all system parts (controller, RFI filter,

mains choke, etc.) by cables to a central earthing bus (PE busbar). The prescribed minimum cross-sections must be observed in all cases.

( To comply with the EMC Directive, not the cross-section but the contact

surface is decisive.

( Ensure that grounding of the control electronics does not cause any

damage to external controllers.

4-32

48XX/49XXSHB0399

Installation

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PEPE I K A B

108

FIG4-23 Part of the CE-typical drive systemwith 4902 ... 4907 on a mounting plate

1 Connection mains fuse 2 RFI filter 3 Uncoated, bare metal contact surfaces 4 Commutating choke 5 Armature fuse 6 Metal plug-in casing connected to screen or Lenze system cable 7 Uncoated surface for screen connection 8 PE connection

9 Screenedsignal cables 10 Screened cables for act. value encoder or setpoint encoder 11 Motor connection

4900Str021

48XX/49XXSHB0399

4-33

Installation

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2 3

L1L2L3

FIG 4-24 Part of the CE-typical drive system with 4X08/4X09 on a mounting plate

1 Connection mains fuse 2 Connection fan supply L1/N 3 RFI filter 4 Armature fuses 5 Screenedsignal cables 6 Metal plug-in casing connected to screen or Lenze system cable 7 Uncoated surface for screen connection 8 Mains choke field supply

9 Line protection fuses for field supply 10 Motor connection with screened cable for act. value encoder 11 Commutating choke 12 PE connection 13 RFI filter 14 Uncoated, bare metal contact surfaces

4900Str022

4-34

48XX/49XXSHB0399

Installation

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2 3

L1L2L3

FIG 4-25 Part of the CE-typical drive system with 4X11 ... 4X13 on a mounting plate

1 Connection mains fuse 2 Connection fan supply L1/N 3 RFI filter 4 Uncoated surface for screen connection 5 Metal plug-in casing connected to screen or Lenze system cable 6 Screenedsignal cables 7 Motor connection with screened cable for act. value encoder 8 Commutating choke

9 Line protection fuses for field supply 10 Mains choke field supply 11 PE connection 12 RFI filter 13 Uncoated, bare metal contact surfaces

4900Str023

48XX/49XXSHB0399

4-35

Installation

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4-36

48XX/49XXSHB0399

EDS4900U--C

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00408852

Manual Part C

Commissioning

DC speed controller 4800/4900

The features, data and versions indicated in this Manual met the state of the art at

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thetimeofprinting.

(Printing date: inner cover pages of the parts).

In the event of deviations, please see the Operating Instructions or contact Lenze.

Edition of: 01/03/1999

revised

5 Commissioning

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5.1 Initial switch-on

Stop!

Prior to initial switch-on of the controller, check the wiring for completeness, short-circuit, and earth fault:

( Power connection:

- Supply via terminals L1, L2 and L3

- Separate field supply (if available)

( Field connection

Commissioning

( Armature connection

( Feedback system (resolver, incremental encoder, ¡)

( Control terminals:

- Controller enable: Terminal X2/28 (reference potential: X2/39)

- Selection of direction of rotation Terminal X2/21 or X2/22 (reference potential: X2/39)

- Setpoint selection

- with internal voltage supply: bridge between X2/39 and X3/40

( Maintain the switch-on sequence!

Note!

( All controllers described are factory set. A DC shunt motor with attached

tacho can be driven as a speed-controlled drive with tacho feedback without further settings after entering the rated field current (see nameplate). The motor must comply with the following:

-V

-n

-V

( Simple adaptation to other machine data or special requirements: Use the

following for commissioning:

- Operating unit of the controller or

- LEMOC2 (PC program by LENZE)

= 420V

mains

= 3000 rpm

rated

= 20V / 1000 rpm

tacho

48XX/49XXSHB0399

5-1

Commissioning

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Wiring recommendation for speed control with tacho

F’’ 1...F’’3

F’1...F’3

L1 L2 L3

L10

L11

S2 K2

K2. 1

td > tbr.

K2K3

L’1L’2L’3

K2 K2 .1 K1

L20

L1 L2 L3PE

4900

X1 X2 X3 X4

I K 20B

IK AB

F’4

43 5 22

nset

FIG5-1 Flow chart section: Speedcontrol with tacho

F’’ 1...F’’ 3

Cable protection fuse L11 ”Emergency stop” cable F’1...F’3 Semiconductor fuse LK Ma ins c hoke F’4 Armature fuse M1 Mot or K1 Ma ins contactor nset Setpoint potentiometer K2 QSP relay CW CW rotation K2. 1 Delay timer Ctrl. enable Controller enable K3 Motor standstill Q1 Main switch

CCW CCW rotation QSP Quick stop function L10 Direct cable from the control cable ”ON” Z1 RFI filter

21 28 3940 59 90FE8 97

CCW

Ctrl.

enable

QSP nact = 0

4900Str024

5-2

48XX/49XXSHB0399

With a tacho voltage to ground: bridge terminals X1/ 4 and X1/5 and configure the switch S4 on the control module for the operation with a tacho signal to ground (chpt. 4.3.4.1).

Commissioning

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The following table describes briefly how to commission a DC shunt motor with an attached tacho according to the example in FIG 5-1(see chapter 15).

Section Activity see also

Switch-on sequence 1.X2/28 (Ctrl. enable) must be opened (LOW)

2. Connect the mains Approx. 0.5sec after mains connection the controller is ready for operation. The time t

depends on the initial response

of the field current

Typical values: t

= 300ms ...600ms

t2=t1+ 20ms

FIG: Signal flow after mains connection (see fig. on the right)

Input of the mot or da ta

3. Input of the motor nameplate data

- C083 Rated field current

- C084 Armature circuit time constant

- C088 Rated motor current

- C090 Rated motor vol tage

adaptation of tacho constants

4. Set S4 before adapting the tacho voltage

- C025 -2- Select adjustment of terminals 3, 4

- C029 Adjustment of actual speed

Set the current limit 5 . Max . mot or c urre nt

Ad justme nt o f max . speed

Select direction of rotation

- C022 + I

- C023 -I

6.Select the reference value for 100% setpoint

- C011 max. speed

7.CW rotation: HIGH signal at X2/21 (+13...+30 V) CCWrotation: HIGH signal at X2/22 (+13...+ 30 V)

Amax

Main s on

TRIP

field

RDY

Armature current

50 ms

Controller enable

90 %of the rated curre n

Integration of the armature cont roller in its operating point

Time

4900Str025

Chapter 5.2

Chapter 7.1.2.2

Chapter 5.4

Setpoint selection 8.Apply a voltage higher than 0V (max. 10V)

- do not achivate JOG setpoint (LOW signal at X2/E4 and X2/E5)

Check whether LED

9. If RDY is off and C067 is blinking, remove TRIP first. Chapter 8.1 ff.

’RDY’ ison Controller enable 10. AssignHIGH-signal to X2/28 (+13...+ 30 V)and do not press STP

The motor will now run with the selected setpoint and in the selected direction of rotation. If necessary, adapt the controller to your application.

Additional settings 11. Further setting required for LECOM operation

Stop!

( Do not change the switch-off sequence

The controller must only be disconnected from the mains when it is inhibited or the motor is in standstill (for mains switch-off logic see chapter 15.9.2).

Chapter 5.3

48XX/49XXSHB0399

5-3

Commissioning

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5.2 Input of the motor data

Note

For internal calculations with field-weakening control, the exact input of the following data is required. See indications on the nameplate of the connected motor.

( C022, C023 Adapt maximum motor current I

( C081 Rated motor power for the power display

( C087 Rated motor speed for the power display

( C083 Rated field current for the field controller

( C084 L/R armature time constant for uncompensated motors

( C088 Rated motor current for ”I

( C090 Rated motor voltage for armature voltage limitation

Under C084 the controller can be adjusted to different armature time constants T = L/R. The values can be set between 0 ms and 30 ms.

Common armature time constants: (see motor catalog, section I)

- compensated machines 0 ms to 10 ms

- uncompensated machines 15 ms to 30 ms.

¼t monitoring” (armature circuit)

max

5-4

48XX/49XXSHB0399

5.3 Controller enable

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For controller enable, the following conditions must be fulfilled:

( Controller enable via terminal:

- Independently of the operating mode, apply a voltage of V = +13...+30 V to X2/28. (Reference potential: X2/39).

( Controller enable via LECOM interface

- For the operating modes C001 = -3-, -5-, -6- and -7- (LECOM control), the controller must be additionally enabled via the LECOM interface.

( Stop function

- The controller can be inhibited by pressing the STP key. The stop function can only be reset via the enable command SH + STP or mains switching.

( TRIP reset

- If a monitoring system sets TRIP the controller will be inhibited immediately. The internal controller inhibit will be reset when resetting the fault (C067).

Commissioning

Since the controller inhibit can be caused by many different reasons, the origin of the controller inhibit is displayed under C183.

Ctrl. enable

FIG 5-2 Signal flow when enabling the controller

50 ms

4900Str026

48XX/49XXSHB0399

5-5

Commissioning

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5.4 Selection of direction of rotation and quick stop

Direction of rotation

The polarity of the output voltage V

and thus the direction of rotation of the motor

depends on the signs of the setpoint, the control of the digital inputs X2/21 and X2/22, and the polarity of the field voltage.

Quick stop (QSP)

Independently of the setpoint selection and because of the quick stop function, the controller can be stopped within a time selectable under C105.

( The quick stop function is active:

- when the mains is switched on, if X2/21= HIGH and X2/22 = HIGH

- during operation with X2/21 = LOW and X2/22 = LOW The speed is reduced to zero within the deceleration time set under C105.

( Quick stop

- sets the additional setpoint integrator to 0.

- decelerates the drive to 0 according to the deceleration ramp set under C105.

- is detected internally if no signal has been applied to X2/ 21, X2/22 for more than approx. 6 ms.

( The drive starts running again

- if a HIGH signal is applied to one of the inputs (also for keypad or interface operation).

CCW

QSP

FIG 5-3 Selection of direction of rotation

4900Str027

5-6

48XX/49XXSHB0399

¥ CW/CCW not overlapping ¦ CW/CCW overlapping

When the threshold n

= 0 (C019) is reached, the integral action component of

act

the speed controller will be switched off (onlyif C005 = -10-, -11-, -40-, -41-). With all other configurations, the I-component of the n-controller will only be switched off, if the angle controller is not active (C254 = 0). The drive cannot generate a torque when stopped by a brake.

Commissioning

CodeNam

control

C041and

thes

tatusof

terminals

C04

rotationo

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With the configurations C005 = -X2- or -X3- and activated angle controller (C254 > 0), the drive will be decelerated to speed = 0 and angle-controlled (drift-free). The drive can thus generate its maximum torque (independently of the current limit C022, C023).

Code Name

C105 Dec ele -

ration time for quick stop

Possible settings Lenze Selection Info

0.00s 0s {0.01s} 1s 1 s {0.1s} 10s 10 s {1 s} 100 s 100 s {10 s} 990 s

Time referred to the speed change

0...n

max

( Configuration possibilities for the selection of the direction of rotation and

quick stop

Operating

mode

Te r mi n a l

C041 and C042 display

X2/ 21 a nd X2/ 22

Keypad / LECOM

C041 and C042 determine the direction of

quick stop, in addition LOW signal X2/21 and X2/22 activates quick stop.

Setpoint to

X1/8

positive HIGH LOW -0- -0- cw

negative LOW HIGH -1- -0-

positive LOW HIGH -1- -0- ccw

negative HIGH LOW -0- -0pos. / neg. HIGH HIGH -0- / -1- -0- unchanged pos. / neg. LOW LOW -0- / -1- -1- Quick stop

positive HIGH/L OW LOW/ HIGH -0- -0- cw

negative HIGH/ LOW LOW/HIGH -1- -0-

positive HIGH/L OW LOW/ HIGH -1- -0- ccw

negative HIGH/ LOW LOW/HIGH -0- -0-

pos. / neg. LOW LOW -0- / -1- -1- Quick stop

X2/21 X2/22 C041 C042 Direction of

rotation

(View

towards

motor shaft)

active

48XX/49XXSHB0399

5-7

Commissioning

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5.5 Changing the internal control structure

The internal control structure is adapted to the control task (e. g. speed control,

torque control, angle control, ¡) via code C005 (see chapter 7.9). The controller

must however be inhibited first.

Stop!

It is possible that the terminal assignments change when the internal control structure is changed.

5.6 Changing the terminal assignment

Note!

A function, which is already assigned to an input, can only be assigned to another terminal if the input used before is assigned with a new function. If you reassign an input, the function assigned before will be overwritten.

Freely assignable digital inputs

Except for the functions ”Enable JOG setpoints”, ”Enable additional acceleration and deceleration times”, ”Enable fix setpoints” and ”Select parameter set”, each function can only be assigned to one input.

It is possible to determine a priority for each input: The function can either be switched via a terminal, or depending on the selected operating mode.

Changing the assignment

1. Select the input to be assigned under C112.

2. Select the function for the input under C113.

3. Determine the polarity under C114 (HIGH-active or LOW-active).

4. Determine the priority under C115.

5-8

48XX/49XXSHB0399

Repeat steps 1. to 4. to assign all inputs.

5 freely assignable inputs are available at the terminals.

Commissioning

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Freely assignable digital outputs

The controller provides 12 freely assignable digital outputs and a relay output.

Thefreedigitaloutputs 1to 5 areassigned to terminalsX3/A1 to X3/A4 and X4/A5. The relay output is assigned to terminals X3/K11 and X3/K14. The polarity can be determined (HIGH-active, LOW-active) and the output can be delayed.

The free digital outputs 6 to 12 can only be evaluated via the LECOM interface. They are always HIGH-active.

Changing the assignment

1. Select the output to be assigned under C116.

2. Select the function for the output under C117.

Only for outputs A1 to A5 and relay output:

3. Determine the polarity under C118 (HIGH-active or LOW-active).

4. Determine the signal delay under C128.

Repeat steps 1. to 4. until all outputs are assigned.

Freely assignable ”analog” inputs

The term “freely assignable analog inputs” comprises the analog (terminals) and digital (X5, X7 and X9) setpoint and actual value inputs.

If you change the configuration under C005, the assignment of the free analog inputs will be overwritten with the corresponding factory setting. If necessary, adapt the function assignment to the wiring.

It is possible to determine the priority for terminals X1/1, X1/2, X1/3, X1/4, X1/6, X1/8, X5, X7 and X9. Thanksto the priority function, the terminalcan be switched indendently of the the operating mode.

Changing the assignment

1. Select the input to be changed under C145.

2. Select the function for the input under C146.

Only for inputs X1/1, X1/2, X1/3, X1/4, X1/6, X1/ 8, X5, X7, X9:

3. Determine the priority under C147.

Repeat steps 1. to 3. until all inputs are assigned.

48XX/49XXSHB0399

5-9

Commissioning

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Freely assignable analog monitor outputs

Via the monitor outputs X4/62, X4/63 und X8, internal signals can be output as voltage signals, current signals or frequency signals (See chapter 4.3.4.1).

With C108 and C109 (C109 is not effective for the digital frequency output), the outputs can be adapted, for instance, to a measuring unit or a slave drive.

Changing the assignment

1. Select the output to be assigned under C110.

2. Select the function for the output under C111.

3. Set the offset under C109 (not for the digital frequency output).

4. Determine the gain under C108.

Repeat steps 1. to 4. until all outputs are assigned.

Special feature of the freely assignable digital frequency output

With theselection of a configurationunder C005, the output X8 already has a basic assignment. The assignment can only be changed afterwards.

If the digital frequency output X8 is assigned to another signal than indicated in the basic assignment of the configuration (C005),then the output frequency can only be adapted via code C108.

With signal sources with a reference value of 100% (see C111, except: DF and resolver inputs) a signal of 100% at the output X8 with a gain factor of C108 = 1.00 corresponds to a frequency of 250 kHz.

5-10

48XX/49XXSHB0399

Commissioning

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48XX/49XXSHB0399

5-11

Commissioning

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5-12

48XX/49XXSHB0399

6 During operation

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This chapter is part of the Lenze documentation structure. It remains free for the 48XX/49XX DC speed controller.

During operation

48XX/49XXSHB0399

6-1

EDS4900U--D

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00408853

Manual Part D

Configuration

Code table

DC speed controller 4800/4900

The features, data and versions indicated in this Manual met the state of the art at

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thetimeofprinting.

(Printing date: inner cover pages of the parts).

In the event of deviations, please see the Operating Instructions or contact Lenze.

Edition of: 01/03/1999

revised

7 Configuration

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7.1 Speed controlled operation

For standard applications, the drive can be immediately commissioned with the default settings. To adapt the drive to special requirements, please observe the notes in the following chapters.

7.1.1 Set-valueselection

CW CCW

Configuration C005 = -1x-

offset

C 025/C 026

set'

-10 V ... +10 V

Additional

setpoint

-10 V ... +10 V

Tacho

±180 V

Increm ental

encoder

Resolver

A r m a tu re v o lta g e

Torque reduction

0 V = no reduction

1 0 V = m a x . re d u c tio n

C 025/C 027

offset

C 025/C 026

C 025/C 027

offset

3 4

Enc.

const.

2 1

C 145/C 146

C 025/C 026

C 145/C 146

C 025/C 027

C 027 C 028C025/C026

C 025/C 027

set

C 046

C 049

act

C 025/C 026

C 025/C 027

max

C 011

JO G 1 JO G 2

JO G x

C 0 0 5 C o n fig u ra tio n

C 232

I · R - com pensation

C 145/C 146

E4 E5

Enable

Z o ff

set

21 22

±1

C 041 CW /CCW

act

C 051

C 012 T C 013 T

C 134QSP

RFG stop

RFG zero

QSP

SW I

C 220, C 221

n-controller

C 070 V

C 071 T

C 072 K

100 %

ir if

C 047

Configuration

C 042

QSP

C 190

C46

100% - C 49

QSP

C 105

·+ /-

C 286 C 287

in % o f n

n at n-controller

set

in % o f n

Fact

C310 C311 C312 C313 C314

max

C 022, C 023

max

C 050

M in %

set

of M

Main si

max

C 056

nal path

set

C 063

4900Str028

FIG 7-1 Signal-flow chart showing the set-value processing for speed control with addition setpoint

(C005 = -1X-) default setting

48XX/49XXSHB0399

7-1

Configuration

CodeNam

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7.1.1.1 Main set-value

The speed is determing via via the set-value value n

(C011). The set-value can be selected as analog value using the input

max

X1/8, as dig. frequency using X5 or X9, as well as via keypad or LECOM interface. Which input is activated depends on the operating mode set under C001 and the signal priority set under C145/C147. The set- value channel is determined via the configuration. A change to other signal sources is possible via the codes C145 / C146.

7.1.1.2 Additional set-value

Also with keypad or interface operation, the additional analog set- value can be set via the input X1/6 (or another signal source). The additional set-value (C049 / set-value2) is internallysent to aramp function generator before it iscombined with the main set-value in a ”fixed” arithmetic block.The additional set-value can be switched off via X2/E3 (C280).

With thisfunction it ispossible, for instance, to deactivatea correctionsignalduring set-up (dancer position, etc.).

Code Name

C220* Acceleration

time T the additional set-value

C221* Decelerat ion

time T the additional set-value

Possible settings Lenze Selection Info

0.00 s 0.00 s {0.01 s} 1 s

1s {0.1s} 10s 10 s {1 s} 100 s 100 s {10 s} 990 s

0.00 s 0.00 s {0.01 s} 1 s 1s {0.1s} 10s 10 s {1 s} 100 s 100 s {10 s} 990 s

(C046)and related to theadjustable

set

7-2

7.1.1.3 JOG set-values

If you need certain fixed settings as main set-values, it is possible to retrieve set-values, which can be parameterised, from the memory using the JOG inputs. JOG set- values replace the main set-value. Enter JOG set-values as relative values in % of n

Parameter setting for JOG set-values

JOG set-values are set in two steps:

( Select a JOG set-value under C038.

( Enter the value selected for the JOG set-value under C039.

Repeat these two steps if you need several JOG set-values. Up to max. 15 JOG set-values can be programmed.

48XX/49XXSHB0399

max

Configuration

CodeNam

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Code Name

C038¤ Input

preselection: JOG set-value

C039 JOG speed

for C038

Assignment of the digital inputs

The number of inputs to be assigned with the function ”enable JOG set- value”, depends on the number of JOG set-values required.

Possible settings Lenze Selection Info

1 -1- Selection JOG1

-2- Selection JOG2 ...

-15- Selection JOG15

-100 % n

100.0% JOG1

75.0% JOG2

50.0% JOG3

25.0% JOG4

0.0 % JOG5

.. ...

0.0 % JOG15

Number of JOG set -values required Number of inputs required

8...15 4

{0.1 %} + 100.0 % n

max

1 at least 1

2...3 at least 2

4...7 at least 3

max

Select JOG setpoint to be set under C039.

Enable JOG set-values via the digital inputs or via C045.

This function can be assigned to up to four inputs. For input assignment, observe the notes in chapter 5.6.

JOG set-value enabling with terminal control

The assigned digital inputs must be controlled according to the table below to enable JOG set-values.

2. input 3. input 4. input JOG 1 1 0 0 0 JOG 2 0 1 0 0 JOG 3 1 1 0 0 JOG 4 0 0 1 0 JOG 5 1 0 1 0 JOG 6 0 1 1 0 JOG 7 1 1 1 0 JOG 8 0 0 0 1 JOG 9 1 0 0 1

JOG 10 0 1 0 1 JOG 11 1 1 0 1 JOG 12 0 0 1 1 JOG 13 1 0 1 1 JOG 14 0 1 1 1 JOG 15 1 1 1 1

The input with the lowest figure is the first input, the input with the next higher figure is the second input, and so on (e. g. E4 = 1. input, E5 = 2. input).

C045 indicates the active set-value.

48XX/49XXSHB0399

7-3

Configuration

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JOG set-value enabling with control via keypad or LECOM interface

Active the JOG set-values under C045.

Code Name

C045¤ JOG enable 0 -0- Main set-value (C046)active

Possible settings

Lenze Selection Info

-1- Set-value JOG1 active ...

-15- Set-value JOG15 active

7.1.1.4 Master current

If the analog set-value is to be entered via X1/8 as master current, the current setting range can be selected under C034:

( For -20mA...+20mA: C034 = -0-

( For 4...20mA: C034 = -1- (only unipolar)

If range 4...20mA is selected and the current is less than 2mA, the fault ”Sd5” is indicated.

Spannungsleitwert auf Stromleitwert (Strombürde 250W)mitdemSchalterS3/1

auf der Steuerbaugruppe 4902MP umschalten:

( Master voltage/potentiometer: S3/1 = OFF

(Default setting)

( Master current: S3/1 = ON

(see chapter 4.3.4)

With terminal control only display

7.1.1.5 External torque reduction

With a potentiometer, it is possible, for instance, to apply a voltage externally to terminal 2. This voltage has a direct influence on the I and C023.

Note!

A voltage of 0V at terminal X1/2 corresponds to I

-72-.

The corresponding speed set-value is to be applied via terminal X1/8.

Alternatively to the set-value potentiometer, the current limitation can also be under linear influence from an external control voltage.

values set under C022

max

if C005 = -1X-, -5X-, -6X- or

max

7-4

48XX/49XXSHB0399

Configuration

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S3/2

+10VRef.

9521

(lin.)

10 k

min max

V = + 10 ... 0 V

Ise t

FIG7-2 Connection diagramfor external torque reduction via potentiometer or master voltage

4900Str029

Code Name

C282*¤ Function

for C047

Note!

The terminal input is inverted and assigned with 100 % I for standard applications without external torque limitation.

For torque limit inputs (e. g. via master frequency), the function C047 = 100% |terminal (1,2)| can be changed to function C047 = |terminal (X5)|.

Possible settings

Lenze Selection Info

0 -0- Function C047 = 100% - |input source|

-1- Function C047 = |input source|

to reduce the wiring

max

48XX/49XXSHB0399

7-5

Configuration

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7.1.1.6 Acceleration and deceleration times Tir,T

Each acceleration or deceleration time refers to a speed change from 0 to n (C011). The times Tirand Tifto be set can be calculated as follows:

act

[rp m ]

max

FIG7-3 Calculation of acceleration and decelerationtime

Here tirand tifcorrespond to the times desired for the change from n1to n2and vice versa. The times T

and Tifcalculated are setting values for the controller.

( Acceleration and deceleration time C012 and C013

The ramp function generator of the main set-value (n the times T

and Tifunder C012 and C013.

( Additonal acceleration and deceleration times

set

max

T = t

ir ir

T = t

if if

max

n - n

2 1

max

n - n

2 1

4900Str030

or JOG set-value)is set via

Alternaltively to the acceleration and deceleration times under C012 and C013, additional T

and Tiftimes can be retrieved from the memory, for instance, to

change the drive acceleration from a certain speed on.

Programming of additional acceleration and deceleration times

Set the additionalT

times in two steps. The selection under C100 is valid for a pair

of acceleration and deceleration times:

( Select additional acceleration/ deceleration times under C100.

( Enter the required acceleration time under C101, and the deceleration time

under C103.

For several additional T

times repeat these two steps as often as required.

A maximum of 15 additional acceleration and deceleration times can be programmed.

7-6

48XX/49XXSHB0399

Configuration

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Code Name

C100*¤ Input:

Additional acceleration/ deceleration times for ma in set-value

C101* Acceleration

time for C100

C103* Decelerat ion

time for C100

Assignment of the digital inputs

The of inputs to be assigned with the function ”enable additional acceleration and deceleration times”, depends on the number of additional T

Number of additional acceleration and deceleration times

Possible settings

Lenze Selection Info

-1- Acceleration time T

-2- Acceleration time T ...

-15- Acceleration time T

0.00s 0s {0.01s} 1s 1 s {0.1s} 10s 10 s {1 s} 100 s 100 s {10 s} 990 s

required

1 at least 1

2...3 at least 2

4...7 at least 3

8...15 4

/deceleration time T

ir1

/deceleration time T

ir2

/deceleration time T

ir15

Extends Tir(C012) and Tif(C013) by max.

if1

15 value pairs. Can be changed under

if2

C130:

1. Select additional times under C100.

if15

2.Set C101 (T

Time refers to speed change 0...n

) or C103 (Tif).

times.

Number of inputs required

max

This function can be assigned to up to four inputs. For input assignment, observe the notes in chapter 5.6

48XX/49XXSHB0399

7-7

Configuration

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Enable of additional acceleration and deceleration times

With terminal control, the inputs must be assigned according to the table below to enable the additional acceleration and deceleration times. T activated in pairs.

ir1,Tif1

ir2,Tif2

ir3,Tif3

ir4,Tif4

ir5,Tif5

ir6,Tif6

ir7,Tif7

ir8,Tif8

ir9,Tif9

ir10,Tif10

ir11,Tif11

ir12,Tif12

ir13,Tif13

ir14,Tif14

ir15,Tif15

times can only be

input 2. input 3. input 4. input

1 0 0 0 0 1 0 0 1 1 0 0 0 0 1 0 1 0 1 0 0 1 1 0 1 1 1 0 0 0 0 1 1 0 0 1 0 1 0 1 1 1 0 1 0 0 1 1 1 0 1 1 0 1 1 1 1 1 1 1

The input with the lowest figure is the first input, the input with the next higher figure is the second input, and so on (e. g. E4 = 1. input, E5 = 2. input).

C130 displays the momentarily active T

With control via keypad or LECOM interfaces, C130 is used for the activation of the T

Code Name

C130*¤ Enable of

additional

times

times.

times in pairs.

Possible settings

Lenze Selection Info

0 -0- Tir(C012) / Tif(C013) active

-1- T ...

-15- T

ir1/Tif1

ir15/Tif15

active

If t he Titimes are enabled via terminal, C130 is for display only.

7-8

48XX/49XXSHB0399

7.1.1.7 Limitation of the speed set- value

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Main and additional set-values are lined via the arithmetic block 1 and then limited via a limitation element with adjustable limits (C286, C287). This function can be used if certain negative or positive values must not be exceeded during operation.

21 22

C041 CW/CCW

CCW

C012 T C013 T

FDE

RF G s top

FDE

RF G z e ro

QSP

SPI

C220, C221

ir if

C134QSP

Configuration C005 = -10- ... -53-

set 1

C046



100 %

max

C011

JOG 1 JOG 2 JOG x

set 2

C049

C145/C146

FDE

Enable

FDE

Zoff

set

C182

C190

C46

100%- C49

Configuration

C042

QSP

C105

·+ /-

C286 C287

in % of n

max

C050

n a t n-controll er

set

in % of n

max

n-controller

4900Str031

FIG7-4 Signal-flow chart for speed set-value selection with limitation element

Code

Name

C286*¤ Upper limit

of the speed

setpoint

C287*¤ Lower limit

of the speed

set-value

Possible settings

Lenze Selection Info

180% -100.0 % {0.1 %} + 100.0 %

-180 % {1 %} + 180 %

-180% -100.0 % {0.1 %} + 100.0 %

-180 % {1 %} + 180 %

Upper limit of the speed setpoint for C050 C286 must be higher than C287!

Upper limit of the speed setpoint for C050 C287 must be smaller than C286!

48XX/49XXSHB0399

7-9

Lenze 4800, 4900 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

1 Preface and general information

1.1.1 Terminology used

1.2 Scope of delivery

1.3 48XX/49XX controller

1.3.1 Labelling

1.3.2 Application as directed

1.3.3 Legal regulations

1.4 EC Directives/Declaration of Conformity

1.4.1 What is the purpose of EC directives?

1.4.2 What does the CE mark imply?

1.4.3 EC Low-Voltage Directive

1.4.4 EC Directive Electromagnetic Compatibility

1.4.5 EC Machinery Directive

2 Safety information

2.1 Persons responsible for the safety

2.2 General safety information

2.3 Residual hazards

2.4 Layout of the safety information

3 Technical data

3.1 Features

3.2 General data / application conditions

3.3 Rated data

3.3.1 Mains voltage 400V

3.3.2 Mains voltage 500V (Variant V014)

3.4 Dimensions

3.4.1 Controller 4902 to 4X09

3.4.2 Controllers 4811 to 4813, 4911 to 4913

4 Installation

4.1 Mechanical installation

4.1.1 Important notes

4.2 Electrical installation

4.2.1 Protection of persons

4.2.2 Protection of the controller

4.2.3 Screening of the control cables

4.2.4 Earthing of the control electronics

4.2.5 Mains types and conditions

4.3 Connection

4.3.2 Separate supply of the field-current bridge at a high motor field voltage

4.3.4 Control connections

4.3.4.1 Connection of analog signals

4.3.4.2 Connection of digital signals

4.3.5 Feedback systems

4.3.6 Change of the direction of rotation in 2Q operation

4.3.7 Digital frequency selection and encoder emulation

4.3.8 Serial interface RS232/485

4.4 Installation of a CE-typical drive system

4.4.1 General notes

4.4.2 Components of the CE-typical drive system

4.4.3 Measures required

5 Commissioning

5.1 Initial switch-on

5.2 Input of the motor data

5.3 Controller enable

5.4 Selection of direction of rotation and quick stop

5.5 Changing the internal control structure

5.6 Changing the terminal assignment

6 During operation

7 Configuration

7.1.1.4 Master current

7.1.1.5 External torque reduction