Lenze 8230, 8231, 8234, 8232, 8233 Operating Instructions Manual

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EDB9300UES

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00402016

Operating Instructions

23(1

Global Drive Frequency inverters 8230 series

Power range 110 ... 250 kW

Contents

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Contents i1

Comments i4

1 Brief description 1

1.1 General 1

1.2 Basic operation 2

1.3 Main features 3

2 Technical Data 5

2.1 Key to types, rating plate 5

2.2 Series of types 6

2.2.1 Technical data at rated current 7

2.2.2 Technical data at basic load current 8

2.2.3 Power loss and cooling air volume 9

2.3 System data 10

2.3.1 Standards, operating conditions and certificates 15

2.3.1.1 Standards applicable 15

2.3.1.2 Certificate 16

2.3.1.3 CE Certificate 16

2.3.2 CE mark 17

2.4 Supply components 19

2.4.1 Components for 3AC supply 19

2.4.1.1 Fuses for 3AC mains connection 19

2.4.1.2 Mains chokes (3-phase chokes) 21

2.4.1.3 Line fuses for operation class gL and cable cross-sections 23

2.4.1.4 Fuse circuit breakers 23

2.4.1.5 Mains contactor 23

2.5 Options 24

2.5.1 Control unit (BDE) 24

2.5.2 Brake chopper and braking resistors 26

2.5.2.1 Brake chopper 27

2.5.2.2 Braking resistors 28

2.5.3 RFI filters 30

2.5.4 Motor filters and output chokes 31

2.5.4.1 Motor filters 31

2.5.4.2 Motor choke 34

2.5.6 Option boards for Alspa MD2000 36

2.5.6.1 Encoder interface 37

2.5.6.2 Operation on a mains supply with no earth 43

2.6 Summary circuit diagrams 44

2.6.1 Summary circuit diagram, 8230 frequency inverter 44

2.7 Connection, terminal wiring 45

2.7.1 Power stack 45

2.7.1.1 3AC supply 45

2.7.2 Electronics section, A10 control board 48

2.7.2.1 Terminal strip wiring :X15 and signal functions 49

2.7.2.2 Description of terminal strip inputs / outputs 54

Contents

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2.8 Dimensions, Installation drawing, weights 58

2.8.1 8230 frequency inverter build-in units 58

2.8.2 Mains chokes for 8230 frequency inverter 60

2.8.3 Installation drawing for control unit 61

2.8.4 Dimensions and installation dimensions Base for semiconductor fuses of operating class gR with 110 mm length 63

2.8.7 Dimensions and installation dimensions Braking resistor 64

2.8.8 Dimensions and weights motor filters 65

2.8.9 Motor choke 66

2.8.10 Dimensions and weights 67

3 Transport, Installation and Connection 68

3.1 Safety instructions 68

3.2 Storage 69

3.3 Transport 69

3.4 Installation 69

3.5 Connection and wiring 70

3.5.1 Potential separation 77

3.6 Installation and connection instructions for EMC 79

3.7 Specific measures for ensuring electromagnetic compatibility (EMC) 88

4 Operation and Software 90

4.1 Unit operation 90

4.1.1 Control philosophy 92

4.2 Parameter adjustment 93

4.3 Menu 95

4.4 Description of parameters and displays 100

4.4.1 Display 100

4.4.2 Application parameter 101

4.4.3 Configuration parameters 105

4.4.4 Parameters for analog I/O 113

4.4.5 Parameters for digital I/O’s 119

4.4.6 Ratings 123

4.4.7 Control parameters 128

4.4.8 Diagnosis 131

4.4.9 Password 131

4.4.10 Language 133

5 Commissioning 134

5.1 Safety instructions for com m iss ionin g 134

5.2 Commissioning sequence diagram, 8230 frequency inverter build-in unit 136

5.3 General 140

5.4 Mains and motor connection 140

5.5 Commissioning Report 141

Contents

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5.6 First commissioning with the 8230 frequency inverter BDE control unit 148

5.6.1 Language Select 148

5.6.2 Ratings 149

5.6.3 Control structure 152

5.6.4 Speed adjustment/speed limit 152

5.6.5 Field weakening 152

5.6.6 Multiple motor operation/Group supply 153

5.6.7 Motor potentiometer function 154

5.7 Terminal strip wiring 154

5.8 Configuring the drive 156

5.9 Demand selection 157

5.10 Control structure 158

5.10.1 Frequency control 158

5.10.2 Control without encoder 158

5.10.3 Control with encoder 159

6 Help in the event of errors 160

6.1 First value log for error messages 160

6.2 Switching sequence on errors 160

6.3 Event log 160

6.4 Events 160

6.5 Error log 163

6.6 Errors 163

7 Maintenance 167

7.1 Battery for RAM and clock 167

7.1.1 Battery change 167

7.1.2 Technical data of battery 167

7.2 Fans 167

7.3 Power connections 167

7.4 Reforming the link capacitors 168

Declaration of Conformity AAS-KE 001/9.95 170

Comments

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Expressions used Note:

A note shows important or additional information separately from the text.

Important!

Important means that the instructions given must be followed precisely in order to prevent any loss of data or damage.

Warning! Warning means that the operator may be injured if the relevant instructions are

not followed.

Limitation of liability Unless agreed elsewhere the latest issue of the “General Supply Conditions for

Products and Services of the Electrical Industry” applies accordingly. We are not obliged to make software updates or upgrades available to users. Modifications to improve handling and updates for new types of equipment can only

be offered to registered users at preferential prices.

Data, illustrations, amendments Data and illustrations are approximate only and subject to modification without notice.

Please advise if you have any suggestions for improving or otherwise amending the documentation. A printed form is provided on the last few pages of this document.

Training Lenze GmbH & Co KG offers training seminars to provide additional system

knowledge.

Without prior permission this document may not be duplicated or otherwise made available to third parties. It may not be misused in any way by the recipient or third parties. Translation into a foreign language is not permitted. All data, dimensions, weights, illustrations and other technical details may be subject to modification without notice, in particular for further development of our equipment. The information agreed in an order is final and binding.

1 Brief description

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1.1 General 8230 frequency inverter are processor-c ontrolled pulse inverters with a field-orientated control concept for continuous low-loss speed adjustment of AC motors.

The power stack consists of a diode rectifier in a 3-phase bridge circuit on the mains side and an IGBT inverter on the motor side.

The basic inverter models are designed for standard applications. Through suitable options (eg. bus couplers, encoder interface) the units can be integrated into automation systems and can also fulfil highly dynamic requirements.

Operation of all units is identical throughout the entire type range. Easy familiarisation and operation as well as maximum flexibility were the prime objectives during development.

The inverters are operated and parameters adjusted by means of a control unit (BDE).

Connection to automation systems is po ssi ble throu gh conv en tional bus systems (see field bus coupler options).

With a mains voltage range from 380 to 480 V build-in units cover the power range from 144 kVA to 330 kVA.

In conjunction with standard asynchronous motors the drive capacities provided are therefore as follows:

- At unit rated current

110 kW to 200 kW, 400 V

- At unit 1.5 x rated current

132 kW to 250 kW, 400 V

Note:

This operating manual applies to the following units: 8230 frequency inverter Software version: V2.0

Important!

8230 frequency inverter are designed as standard for operating on earthed networks.

BA8230 1

Brief description

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1.2 Basic operation The link voltage is generated from the mains supply through the mains rectifier. A 3phase choke connected to the mains supply reduces harmonic currents and serves to decouple the unit from other converters (consumers) on the same supply network. 8230 frequency inverter are connected as standard to an earthed network. The link voltage is smoothed by high quality electrolytic capacitors. With the motor converter these provide the magnetising reactive power required by the motor and decouple the converter on the mains side from the inverter on the motor side.

Through optimised pulse width modulation the motor converter generates from the link voltage a sinusoidal 3-phase system with variable frequency and voltage.

A power dump (option) in conjunction with a braking resistor allows braking energy to be used in regenerative operation.

Control and regulation of the 8230 frequency inverter are fully digital. Different control structures such as, frequency control, speed control with or without encoder and torque control with or without encoder can be selected, depending on the application requirements. The field-orientated control concept provides control dynamics directly comparable to those of a DC drive.

In addition, various inputs and outputs can be connected individually according to the task involved. Thus the drive system can very easily be customised for the requirements of the specific application.

2 BA8230

Fig. 1: Summary circuit diagram, basic layout, operation

1.3 Main features • Consistent range of Types for drives from 110 kW to 250 kW with

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IGBT inverters

• Supply voltage ranges:

- 3AC 380 V ... 460 V +10 %/ -15 % ... 480 V +6 %/ -15 %

• Standard design for connection to earthed networks

• Output frequency range: 0 ... 300 Hz

• 120% overload capacity for 60 s related to 1.2 rated controller current

(Applications with medium overload)

• 150% overload capacity for 60 s related to 1.5 rated controller current (Applications with high overload)

Brief description

• Standard asynchronous motors can be used without power reduction

• High dynamics: Torque rise time: t

= 2 to 8 ms

• 8230 frequency inverter units are resistant to idling, short circuit and earth fault

• DC system bus supply for several 8230 frequency inverter through

DC link connection (option)

• 4Q operation (option) through power dump with braking resistor

• Mains supply power connections at top and motor connections at foot

• Motor temperature monitoring by thermistor processing electronics (PTC)

• Easy, user-friendly system structure

• Consistent and easily learned operation via control unit (option) with plain

text display (various languages available)

• Extensive additional operating facilities via PC, for example menu control, user-controlled commissioni ng, os cilloscope function

• Control structures available:

- Frequency control

- Speed control with or without incremental rotation encoder

- Torque control with or without incremental rotation encoder

BA8230 3

Brief description

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• Kinetic back-up on mains failure Back-up operation of the control electronics using the kinetic energy in the drive systems at speeds close to zero, also suitable for flow machines

• Capture without torque surge (the inverter is applied to the de-excited motor while the motor is running)

• Automatic restart facility after mains failure (Parameter-adjustable up to 15 s as standard)

• Conventional drive through standard terminal strip

- 12 digital potential-separated inputs for control signals (eg. Start, Stop etc.), of which 3 inputs are parameter-adjustable through sel ection list

- 4 digital potential-free outputs for messages (On, Ready, Error, free output parameter-adjustable through selection list, 1 output

"Ready” can be re-assigned via technology)

- 2 free adjustable and scaleable analog outputs

- 2 scaleable analog demand inputs

- 2 parameter sets switchable via control unit or terminal strip

• Expansion of standard terminal strip (I/O interface option)

- 20 configurable digital inputs with separate potential

- 8 configurable digital outputs with separate potential

- 2 configurable analog demand inputs

- 2 configurable analog outputs

• Comprehensive testing and diagnostics facilities:

- Self-test on control electronics and hardware

- Event memory with timings of all binary events with first value error message and documentation

- Error log with timing details

- Protocol log for documenting all parameter changes

• Comprehensive protection and monitoring facilities.

4 BA8230

2 Technical Data

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2.1 Key to types, The type data includes the following information. An example: rating plate



Hans-Lenze-Strasse 1 D-31855 Aerzen Made in Germany

Global Drive 8230

Type Id.-No. Input Output Overload

Fig. 2: 8230 frequency inverter rating plate

EVF8234BE 00395613 3/PEAC 400/460V 360/430A 50/60Hz 3/PEAC 0-460V 400/483A 200/250kW 0-300Hz 600A / 60s (400V) 520A / 60s (460V)

Sach.-No. Ser.-No.

The following details are required for identifying the unit:

- Type No :

- Serial No :

029. 206879 00001

BA8230 5

Technical Data

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2.2 Series of types 8230 frequency inverter for 3-phase AC connection

8230 frequency inverter 150 ... 275 kVA, 3AC 380 ... 480 V Processor-controlled pulse inverter with field-orientated control concept for continuous low-loss speed adjustment of standard AC motors.

8230 frequency inverter

8231 8 195 (230) 257 216 324 3 AC 50/60Hz 8232 8A 230 (270) 304 257 365 380 ... 460 V 8233 9 290 (360) 396 325 488 +10/-15 % 8234 9A 360 (430) 483 400 600 ...480 V

Frame

size

Unit input current, Unit output current

mains current

1.2 x rated

current

1.5 x rated

current

Max. current

60 s

Supply voltage

eff [A] [A] [A] [A]

+6/-15 %

Table 1: 8230 frequency invert er series

Rated current with overload capacity 1.2 x rated current

Rated current with overload capacity 1.5 x rated current

Max. current for max. 60 s overload, cycle time 600 s

Mains commutation choke not included in scope of supply.

The details for the mains current with the standard mains choke are based on a mains short circuit capacity in relation to the inverter power of 100 : 1 at unit output current = rated current. Values in brackets are valid for 1.2 rated current.

Frame size Dimensions Weight

H x W x D [mm] ca. [kg]

8 1049 x 495 x 419 90 8A 1224 x 495 x 419 90 9 1499 x 495 x 419 140 9A 1674 x 495 x 419 140

6 BA8230

Table 2: 8230 frequency invert er frame sizes

Scope of supply: Build-in unit, IP20

2.2.1 Technical data Overload capacity 1.2 x rated current

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at rated current

The technical data shown in Table 3 applies at a pulse frequency of f as supplied ex works, and a maximum air supply temperature up to 40 °C.

Technical Data

= 3 kHz,

8230 frequency inverter

Rated current Max. current

for max. 60 s

Unit rated current [kVA] at rated current

[A] [A] 400 V 415 V 460 V 480 V 400 ... 415 V 460 ... 480 V

8231 257 324 178 185 205 214 132 151 8231 304 365 211 218 241 252 160 172 8231 396 488 275 285 316 330 200 230 8231 483 600 335 347 385 400 250 285

Table 3: Technical data at rated current with overload capacity 1.2 x rated current

120 % overload for total max. 60 s on a load cycle of 1 : 10 / cycle time 600 s

motor rating based on standard 2, 4 and 6 pole motors at

400 ... 415 V or 460 ... 480 V rated voltage.

motor rating

[kW]

Fig. 3

8230 frequency inverter Overload capacity 1.2 x rated current

BA8230 7

Technical Data

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2.2.2 Technical data Overload capacity 1.5 x rated current at rated current 1.5

The technical data shown in Table 4 applies at a pulse frequency of f

as set ex works, and a maximum air supply temperature up to 50 °C.

= 3 kHz

8230 frequency inverter

Rated current Max. current

for max. 60 s

Unit rated current [kVA] at rated current

[A] [A] 400 V 415 V 460 V 480 V 400 ... 415 V 460 ... 480 V

8231 216 324 150 155 172 180 110 126 8231 325 365 178 185 205 214 132 151 8231 396 488 225 234 259 270 160 184 8231 400 600 275 287 318 333 200 230

Table 4: Technical data at rated current with overload capacity 1.5 x rated current

150 % overload for total max. 60 s on a load cycle of 1 : 10 / cycle time 600 s

motor rating based on standard 2, 4 and 6 pole motors at

400 ... 415 V or 460 ... 480 V rated voltage.

motor rating

[kW]

8 BA8230

Fig. 4: 8230 frequency inverter Overload capacity 1.5 x rated current

Technical Data

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2.2.3 Power loss and The rise in temperature of the cooling air at rated current is ∆ϑ ≤ 16 °C for the cooling air volume cooling air volume stated and when the installation clear anc es are mai ntai ned.

8230 frequency inverter Frame size Cooling air

volume

[m³/h] [A] 400 V 460 V 480 V

8331 8 580 257 3,73 3,84 3,88 8232 8A 730 304 4,45 4,63 4,70 8233 9 950 396 5,55 5,80 5,88 8234 9A 1100 483 6,50 6,80 6,88

Table 5: Power loss and cooling air volume at rated current

The values stated apply to a pulse frequency of fp = 3 kHz

The values apply to a static pressure increase of ∆p ≈ 32 Pa between cooling air inlet and outlet.

8230 frequency inverter Frame size Cooling air

volume

[m³/h] [A] 400 V 460 V 480 V

8331 8 580 216 3,14 3,22 3,24 8232 8A 730 257 3,78 3,94 4,00 8233 9 950 325 4,54 4,74 4,83 8234 9A 1100 400 5,60 5,85 5,96

Rated current Power loss1) [kW]

at rated current and 3AC supply voltage

Rated current Power loss1) [kW]

at rated current and 3AC supply voltage

Table 6: Power loss and cooling air volume at 1.5 x rated current

The values stated apply to a pulse frequency of fp = 3 kHz

The values apply to a static pressure increase of ∆p ≈ 32 Pa between cooling air inlet and outlet.

BA8230 9

Technical Data

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2.3 System data • Mains supply voltage 3AC 400 ... 460 V; +10/-15 % ... 480 V; +6/-15 %

• Mains frequency 50 ... 60 Hz ±5 %

• Power factor

- Mains base frequency cos ϕ

> 0.97

- Total at rated current depending on mains impedance λ

» 0.88 ind - 0.93 ind

• Output voltage 3AC 0 ... U

mains

• Approvals prEN50178:1994/VDE0160 CE mark according to low voltage directive

• Efficiency

at rated power ≥0.97

• Overload factor 1.2 for max. 60 s at rated current 1.2

1.5 for max. 60 s at rated current 1.5 cycle time ≥10 min

• Min. operating frequency

With encoder 0 Hz Without encoder motor: 1 Hz

regenerative: 2.5 Hz

• Max. operating frequency 300 Hz

• Speed adjustment range for speed control

without encoder with encoder

1:50

The adjustment range is 1:20 in regenerative

>1:1000

operation using the control structure “Speed control without encoder”

• Speed accuracy for speed control without encoder with encoder

with digital demand preset

0.5 % 0.05 %

10 BA8230

• Torque rise times For speed control with or without encoder 2 ... 8 ms

• Frequency resolution 10 mHz standard adjustable with parameter f

• Frequency stability for

frequency control <0.01 % standard

<0.001 % option, on application

100

• Frequency accuracy for

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frequency control <0.01 %

• Temperature response of analog demand <0.01 %/°C

• Speed encoder incremental encoder

see encoder interface option

• Noise A-weighted sound pressure level

frame size 8 <70 dB(A) frame size 8A <73 dB(A) frame size 9 <72 dB(A) frame size 9A <74 dB(A)

• Overtemperature shutdown frame size 8 at >95 °C

frame size 8A at >105 °C frame size 9 at >105 °C frame size 9A at >105 °C

Technical Data

• Ambient temperature

Operation 0 ... +55 °C

Storage -25 °C ... +65 °C

• Cooling corced air cooling

see section 2.2.3 for cooling air volumes

• Coolant temperature 0 ... 40 °C at rated current, overload factor 1.2

for 60 s every 10 minutes up to max. 55 °C with power reduction 2 % per 1 °K

0 ... 50 °C at rated current, overload factor 1.5 for 60 s every 10 minutes up to max. 55 °C with power reduction 2 % per 1 °K

• Installation altitude ≤1000 m above MSL, up to max. 2200 m with

power reduction 1.2 % per 100 m

• Storage time Without reforming the capacitors: 2 years, 5 months

of which at temperatures over 40°C

• Protection classes Build-in units IP20

Cubicle-mounted units IP21 Standard

IP31, IP43, IP54 Option

• Environment class DIN EN 60721 Part 3-3

3K3 / 3M2 / 3C2

/ 2K2

- Max. relative humidity 85 % at 28 °C, condensation not permitted

- Insulation Contamination Class II to DIN VDE 0110

• Permitted switching Precharging circuit duty cycle = 2 %/180 s, frequency max. 20 per hour

• Power loss of control ca. 130 W electronics with control board, no additional options

BA8230 11

Technical Data

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• Mechanical use prEN50178:1994/IPA90 DIN IEC86 (Vibration) T.2-6 10 ... 150 Hz

• Electromagnetic compatibility3) :

- Interference resistance To IEC1800-3 (IEC22G/21/CDV), EN50082-2,

suitable for use in an industrial environment

- Radiated interference To IEC1800-3 (IEC22G/21/CDV)

- industrial mains supply AC mains choke

- public supply network Additional RFI filter

EN50081-2, limit to EN55011 Group 1 Class A: Mains choke and RFI filter EN50081-1, limit to EN55011 Group 1 Class B: Mains choke, RFI filter and Motor filter

Adequate convection cooling must be provided for the 8230 freq ue ncy inv erter control

electronics. No heat build up inside the 8230 frequency inverter.

No salt spray mist.

Connection to earthed network

see section 3.7 for optional measures

• Pulse frequency adjustable

- Standard 3 kHz

- Maximum Up to 6 kHz For a chopping frequency of f

=6 kHz, a power reduction to 1.5 rated current is

required.

• Servicing Data memory battery replacement required,

see section 7.1 Fan replacement recommended, see section 7.2 Check power connection screws, see section 7.3

12 BA8230

Power reduction curves

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Technical Data

Fig. 5: Power reduction curves (De ratin g ) 823 0 freq ue ncy inve rte r

BA8230 13

Technical Data

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Efficiency curves

Fig. 6: 8230 frequency inverter Efficiency curves

The curves in Fig. 6 apply to pulse frequency 3 at a 400 ... 460 V supply voltage.

14 BA8230

Technical Data

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2.3.1 Standards, operating conditions and certificates

2.3.1.1 Standards applicable As per 06.1996

VDE 0100-540 Installation of heavy current systems with rated voltages up to 1000 V; selection and

installation in electrical equipment, earthing, protective conductor, potential compensation conductor

VDE 0106-100 Protection against electric shock; configuration of actuator components close to parts

which are dangerous to touch

VDE 0110 Insulation coordination for electrical equipment in low voltage systems.

Rating of air gaps and creepage distances VDE 0160/pr EN50178 Installing electronic equipment on heavy current systems DIN EN 60146-1-1 (IEC 146-1-1) Semiconductor converters; general requirements and mains-fed converters;

basic requirements (DIN VDE 0558 Part 11: 1994-03) DIN EN 60146-1-3 (IEC 146-1-3) General requirements and mains-fed converters,

transformers and choke coils (DIN VDE 0558 Part 8: 1994-03) IEC 1000-4-2 Resistance to electrostatic discharge,

requirements and test methods (conversion IEC 801-2) IEC 1000-4-3 Resistance to electromagnetic HF fields,

requirements and test methods IEC 1000-4-4 Resistance to fast electrical transients and bursts (conversion IEC 801-4) IEC 801-5 Resistance to surge voltages on mains supply cables (surge pulses) IEC 1000-4-5 Resistance to voltage peaks DIN EN 55011 Radio interference suppression of electrical plant and equipment;

(VDE 0875 Part 11), limits and test methods for radio interference suppression of

industrial, scientific and medical high frequency equipment DIN EN 55022 Electromagnetic compatibility of equipment in information processing and

telecommunications technology (VDE 0878 Part 3), limits and test methods for radio

interference suppression on technical information equipment IEC1800-3/prEN61800-3:1995 EMC product standard for variable speed drives

(IEC22G/21/CDV) EMC interference resistance and radiated interference Anforderungen und

Meßverfahren DIN EN 50081-1 Electromagnetic compatibility (EMC); specialist basic standard for radiated

interference;

Part 1: Residential, business and light industry DIN EN 50081-2 Electromagnetic compatibility (EMC); specialist basic standard, radiated interference;

Part 2: Industrial DIN EN 50082-1 Electromagnetic compatibility (EMC); specialist basic standard, interference

resistance;

Part 1: Residential, business and light industry DIN EN 50082-2 Electromagnetic compatibility (EMC); specialist basic standard, interference

resistance,

Part 2: Industrial (VDE 0839 Part 82-2)

BA8230 15

Technical Data

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DIN EN 60204-1 (IEC 204-1) Machine safety; electrical equipment on machines;

Part 1: General requirements (VDE0113 Part 1: 1993-06)

DIN EN 60249-2 Basic materials for printed circuits;

Part 2: Individual conditions DIN EN 60529 Protection classes by enclosure (IP Code) DIN EN 60721-3 Classification of environmental conditions

- Classes of environ ment al influe nces and limits IEC 68-2 Electrical technology; basic environmental test methods; tests IEC 364-5-54 DIN VDE 0110 TS10: 1995-12 DIN EN 60439-1:1994 Low voltage switchgear combinations

VDE 0660 Part 500 1994-04

2.3.1.2 Certificate

DIN EN ISO 9001 Model for quality assurance in development, design, production, assembly, testing,

sales and maintenance.

UL/CSA Certification in preparation

2.3.1.3 CE Certificate

CE mark CE mark to low voltage directive 73/23 EC 1995

See appendix for EC Certificate of Conformity.

VDE0160/prEN50178 Fitting heavy current systems with electronic equipment

16 BA8230

Technical Data

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2.3.2 CE mark The 8230 frequency inverter frequency inverter carries the CE mark. This confirms for monitoring authorities responsible in the European Union (EU) that the unit complies with the low voltage guideline 73/23 EC and the CE mark guideline 93/68/EC. The certificate of conformity with the low voltage guideline is available on request.

The 8230 frequency inverter frequency inverter is completed into a drive system by the connection of an AC motor and electrical components, safety equipment and external radio interference suppression components. Installation must be carried out by experienced personnel in compliance with the relevant rules and regulations.

No certificate of conformity is required for the 8230 frequency inverter as an

“independently operated unit” in the sense of EMC Directive 89/336/EC. The 8230 frequency inverter is classified according to CEMEP2 for use and supply through the industry, trade and other users experienced in the field of electromagnetic compatibility (EMC).

Type tests on electromagnetic compatibility (EMC) were carried out to demonstrate compliance with the documented EMC-relevant IEC standards, DIN EN standards, EMC installation guidelines and specified combinations with optional radio interference suppression components in this operating manual when connected to an earthed mains supply. Compliance with the EMC installation instructions in section 3.6 is essential. Section 3.7 provides optional measures for guaranteeing EMC.

IEC 22G/21/CDV EMC product standard including specific test methods for power drive systems; EMC product standard for drive converters; EMC radiated interference and interference resistance.

DIN EN 50082

Electromagnetic compatibility (EMC) Specialist basic standard, interference resistance Part 1: Residential, business and light industry connected to the public electricity supply network (VDE 0839 Part 82-1) Part 2: Industrial

VDE 0839 Part 82-2).

DIN EN 50081 Electromagnetic compatibility (EMC) Specialist basic standard, radiated interference Part 1: Residential, business and industrial connected to the public electricity supply network

(VDE 0839 Part 81-1). Limit to EN 55011 Group 1 Class B Part 2: Industrial

Compare ESD, burst and surge limits on the following page

(VDE 0839 Part 81-2). Limit to EN 55011 Group 1 Class A

BA8230 17

Technical Data

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EMC interference resistance IEC1800-3/prEN61800-3 (IEC224/21CDV); EN50082-2 The following limits for interference resistance are fulfilled when a mains choke and

screened control cables are used.

Requirement Standard Severity level

ESD

IEC1000-4-2 (IEC 801-2) (Static discharge) Burst

IEC1000-4-4 (IEC 801-4) Mains connection 2 kV, 5 kHzkap (Transients)

Surge

IEC 801-5 Mains/load connection (Surge voltages)

Limit curves, radio interference voltage

Air discharge (AD) ±8 kV Contact discharge (CD) ±6 kV

Load connection 2 kV, 5 kHzkap Demand 2 kV, 5 kHzkap General interfaces 2 kV, 5 kHzkap

1,2 / 50 µs phase - PE 2 kV 1,2 / 50 µs phase - phase 2 kV

18 BA8230

Fig. 7: Limit curves (QPK-Quasi Peak) radio interference voltage

Fig. 8: Typical interferenc e vol tag e char act eri s ti c at mai ns input

Fig. 8 shows the typical interference voltage characteristic at the mains input in the example of the 8230 frequency inverter. Differences are possible according to the connection configuration and unit inv olv ed.

Technical Data

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2.4 Supply components The 8230 frequency inverter can be supplied with power through connection of the units to a 3-phase supply.

2.4.1 Components for 3AC supply The components for connecting the 8230 frequency inverter to an AC network are determined according to the 8230 frequency inverter type rating. The basic components

- Semiconductor fuse recommended for brake chopper

- mains choke (2.4.1.2)

-mains fuse (2.4.1.3) with gL characteristic

are required to VDE and are shown in the tables below. Minimum cross-sections for mains supply cables with PVC insulation to EN 60204-

1:1992 are given at an ambient temperature of ϑ = 40 °C and laying method E.

In the event that the supply includes separation points, the additional components

- fuse isolator, 3-pole

- fuse circuit breaker (2.4.1.4)

- mains contactor / main contactor (2.4.1.3)

are to be used.

2.4.1.1 Fuses for Mains fuses with aR characteristic (semiconductor protection)

3AC mains connection

frequency inverter fuse fuse type type current rate

(A)

8231 EFSFF3750AXP 375 8232 EFSFF4500AXP 450 8233 EFSFF5500AXP 550 8234 EFSFF7000AXP 700

Table 7: Semiconductor fuses

Design to DIN 43 653

• Screw straps with 110 mm length

• Fuse indicator

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These parts are mounted on the fuse base SI DIN 110630 or are installed in conjunction with the fuse circuit breaker. See section 2.4.1.4 for fuse circuit breakers. Fuses can also be equipped with microswitches for fuse monitoring.

Accessories: Semiconductor fuse 110 mm DIN 43653

designation holder type

Single pole fuse base Length 110 mm with EFH10003 Microswitch + Indicator EFZ0007 Adapter EFZ0005

Table 8: Semiconductor fuses accessories

20 BA8230

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2.4.1.2 Mains chokes Mains choke is required in the supply cable to reduce the harmonics and

(3-phase chokes) limit commutation failures. The mains chokes for the relevant 8230 frequency inverter

types are listed in the table below. Mains chokes are not included in the 8230 frequency inverter. The mains choke must be allocated individually to each 8230 frequency inverter to

guarantee decoupling when several units are operated at the same mains supply point. A mains choke of high rating is not suitable for several low power 8230 frequency inverter units. Mains chokes improve the overvoltage protection. The impedance of the choke forms a voltage divider with the impedance on the mains side. When the choke is not saturated magnetically it limits the current rise when the voltage rises. This prevents excessive overvoltages at the 8230 frequency inverter mains input.

frequency inverter Mains choke Mains choke type with medium overload with high overload

8231 ELN3-0011H270 ELN3-0014H200 8232 ELN3-0011H270 ELN3-0011H270 8233 ELN3-0009H370 ELN3-0009H300 8234 ELN3-0006H450 ELN3-0009H370

Table 9: Mains chokes

Characteristics

Relative short circuit voltage uK = 3.8 %

(400 V supply voltage, rated output current)

Operating voltage 380 V ... 460 V +10/-15 %, 50/60 Hz ±5 %

Protection class IP 00 Mode DB Environment class DIN EN 60721 Part 3-3 3K3 / 3M2 / 3C2 / 2K2

See section 2.8.2 for dimensions, weights and installation instructions

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Harmonics

The mains converter consists of an uncontrolled 6-pulse bridge circuit (B6) with diodes. Capacitors which decouple the mains converter from the motor converter are fitted on the link and maintain the continuous flow of current to the motor converter. A varying amount of energy is taken from the link capacitor depending on the load on the motor, whereby the mains converter compensates for the reduction in charging according to the mains voltage characteristic, i.e. the phase position of the current, in contrast to the thyristor mains converter, remai ns al mos t constant and is not dependent on the momentary value. The effective mains impedance and the load conditions affect the shape of the mains current curve and therefore the harmonic content, whereby the mains choke and the ratio between the mains short-circuit voltage and the inverter apparent power are decisive for the harmonic content.

Commutation notches

If the ratio between the mains short-circuit power to the complete rated controller power is less than 30 : 1 with a standard mains choke, special mains chokes to limit commutation notches in the mains voltage at public mains according to prEN50178/VDE0160:1991 are to be used.

If the feedback is evaluated on the basis of VDEW

recommendations, the ratio must

not be smaller than approx. 100 : 1 with mains chokes.

VDEW = Association of German Electricity Supply Companies.

In large industrial plant it is possible to reduce the dominant 5th harmonic in 6-pulse mains converters by connecting some of the converter load through transformers with

a phase shift of 30° electrical in relation to the other transformers. Another transformer circuit in switching group Yy0 with a compensation winding could be implemented instead of the Dy5 circuit often used. In this configuration, for example, the 5th harmonic can be reduced by more than 50 % provided that both converters have the same overlap angle.

22 BA8230

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2.4.1.3 Line fuses for Installation instructions for a 3AC 8230 frequency inverter connection in the

operation class gL and customer’s low voltage distribution system: cable cross-sections The NH fuses recommended for operation class gL and the cable cross-sections to be

used for 8230 frequency inverter 3AC mains connections are shown in the following table. Minimum cross-sections for mains supplies cables with PVC insulation according to EN 60204-1:1992 are given for an ambient temperature of ϑ = 40 °C and laying method E.

8230 frequency inverter type

Unit output current Recommende d fuse

gL characteristics

Recommended cable cross-sections for PVC insulated copper cable

1.2 x Rated current

1.5 x Rated current

Max. current for 60 s

Type 3-phase cables

NYY/ NYM

[A] [A] [A]

8231 257 216 324 315 A Gr.2 2x3x95 mm² 8232 304 257 365 355 A Gr.2 2x3x120 mm² 8233 396 325 488 400 A Gr.2 2x3x150 mm² 8234 483 400 600 500 A Gr.3 2x3x185 mm²

Table 10: 8230 frequency inverter AC line fuses

2.4.1.4 Fuse circuit breakers The above semiconductor fuses (aR-Characteristics) with 100 mm length to DIN 43 653 can be installed as an alternative to fuse bases in conjunction with the hand-operated fuse circuit breaker. This creates a separation point in the 3AC mains supply and all poles of the semiconductor fuses can be sw itched .

2.4.1.5 Mains contactor Contactors 3 AC 400 V, 50/60 Hz On 3AC mains supplies which include (automatic) on/off switching of the mains voltage at the 8230 frequency inverter input (eg. 8230 frequency inverter units with optional brake chopper and braking resistor), 3-phase contactors according to the following tables are used.

Important! Note the mains contactor control voltage!

8230 frequency

Unit output current Contactors 3 AC

inverter type

1.2 x Rated current

1.5 x Rated current

Max. current for 60 s

Type

[A] [A] [A]

8231 257 216 324 LS247.22 8232 304 257 365

8233 396 325 488

8234 483 400 600

Table 11: Mains contactors

LS247.22

CA-5-550A

Mains contactors and accessories are stated for 400 V, 50/60 Hz mains voltage.

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2.5 Options The user can install optional assemblies and function modules to adapt the 8230 frequency inverter to many different applications.

2.5.1 Control unit (BDE) The control unit for the 8230 frequency inverter allows you to operate, control and monitor the unit. Values are displayed with the physical units of measurement used. The BDE has a 2-line, 20-character LCD display, 3 LEDs and 9 keys (5 keys for controlling the machine and 4 keys for parameter adjustment). Display contrast can be adjusted using a potentiometer on the rear (the PCB side). The BDE can be used regardless of the 8230 frequency inverter type rating and software version. It can be installed in the front door of the unit or located up to 2 m away, in the door of a another cubicle for example. If the BDE is installed in the door of a cubicle, a protection class up to IP54 is possible when the contact surface between the BDE and the door is sealed.

24 BA8230

Fig. 9: 8230 frequency inverter BDE control unit

Note:

The menu label is removable.

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If after delivery of the 8230 frequency inverter the control unit is removed and installed separately, for example in a cubicle door, the installation opening in the 8230 frequency inverter must be sealed with a blank panel.

The menu label can be replaced very easily and is available in all languag es use d for the menu.

Designation

menu label German menu label English menu label French

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2.5.2 Brake chopper The 8230 frequency inverter can additionally be equipped with a brake chopper

and braking resistors for applications involving regenerative operation, for example braking processes.

Regenerative operation of the drive occurs if negative load torque or negative acceleration torque (braking torque) occurs in the speed range. In the majority of all applications braking processes are the cause of regenerative drive operation. The 8230 frequency inverter can be equipped with a power dump for this application. Braking energy is then converted by the power dump into heat in an external resistor.

In this case the 8230 frequency inverter link voltage is limited to a fixed value, the link current is reversed and is taken off through the power dump and the external braking resistor.

You can estimate whether a 8230 frequency inverter with a power dump for braking is required if you have the following drive parameters available:

• P

• n

Motor rating [kW]

nom

Rated motor speed [rpm]

nom

• n1Motor speed before braking [rpm]

• n2Motor speed after braking [rpm]

• t

Braking time required [s]

• tcLoad cycle repeat time [s]

• MLLoad torque on the motor shaft [Nm]

• J Total inertia applied to the motor shaft [kgm²]

26 BA8230

Fig. 10: Load cycle diagram

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With this information you can calculate the rated motor torque MN and the braking torque:

9550PM∗

Motor rated torque

Braking torque

M −

nom

)n(nJ

−

t9,55

∗

The ratio between braking torque and rated motor torque determines whether a power dump is required.

At low braking torque (0.1 ... 0.2 x M

1. M

2. MB/M

≤ 0,1 ... 0.2 No power dump required

B/Mnom

> 0,1 ... 0.2 Power dump required

nom

) the drive system is braked by its own losses.

rated

2.5.2.1 Brake chopper The brake chopper is built in the 8230 frequency inverter, if version BE was ordered. The table below shows the brake chopper with the relevant technical data for the 8230 frequency inverter types.

8230 frequency

Brake chopper

inverter type

Br max

[A] [V]

R [Ω]

min

Br max

[kW]

8231 300 750 2.5 225 8232 300 750 2.5 225 8233 600 750 1.25 450 8234 600 750 1.25 450

for 750V U

min

Duty cycle = 100 %

Table 12: Brake chopper

Important!

In drive applications with a brake chopper the temperatures of the braking resistors used must be monitored! If the monitor responds, the mains voltage at the power input to the 8230 frequency inverter must be switched off, i.e. the monitor must trigger a mains contactor on the 3AC supply to the 8230 frequency inverter.

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2.5.2.2 Braking resistors The mean braking capacity and the duty cycle are determined for selecting the braking resistor (assuming braking is required). In addition, the minimum braking resistor or the maximum braking power of each 8230 frequency inverter with a power dump must be observed.

Determining the mean braking capacity:

Power: Energy content of one braking process:

WB = 0,0055 J x (n

- n

)[W

]= Ws

[J] = kgm²

, n2]= min

-1

Mean braking power for the complete braking process:

PBV = WB/t

[PBV]= W

]= s

The braking resistor is rated for the mean braking power and the duty cycle permitted according to the resistor.

If several braking processes occur during a load cycle, the individual mean braking powers P The resultant effective mean braking power P

BV1

, P

BV2

.... P

must be calculated and related to the cycle time tc.

BVn

must match the continuous capac ity

BVeff

of the braking resistor:



∗++∗+∗

tP...tPtP

BVnb2



 

BVeff



BV1



 

BV2b1

The continuous capacity of the braking resistor must at least match the mean braking capacity PBV or P

respectively as shown above.

BVeff

Important!

The brake resistors used must be monitored thermally by an overload protection. The brake resistors offered by Lenze have an integrated temperature monitoring. When using several resistors in parallel, the individual monitoring contacts must be connected in series (normally-closed contacts).

28 BA8230

Note:

When determining the rating of a braking resistor the type of load involved is an important criterion. The size of the braking resistor for a sudden load is determined only by the weight of the active material and for the theoretical continuous power only by the radiating surface of the resistor material. In discontinuous operation the rating is determined by the power permitted and the duty cycle. The values shown in Table 13 for the duty cycle are preferred and, unless stated otherwise, refer to a maximum duty cycle of 15 s.

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Example:

With a 10 % duty cycle the resistor may be switched on continuously for a maximum of 15 seconds. Also permissible, for example, would be 5 seconds on and 45 seconds off. A load cycle with 20 seconds on and then 180 seconds off would not be permissible.

Technical data of braking resistors:

8230 frequency inverter

Type ERBD015R04K0

Resistance Peak load 40 kW Duty cycle % / 150 s 10 % Max. rating 600 kWs Continuous capacity ϑ = 45 °C

Continuous current at DC 750 V 16 A Peak current at DC 750 V 50 A Permitted ambient temperature -25 ... +45 °C

Protection class IP 20

Table 13: Technical data of braking resist ors

Assignment of braking resistors

Number of parallel resistors

Total resistance

Total continuous power

[Ohm] [kW] [A] [kW] [A]

max. 55 °C: Power reduction of 1 % / 1 °C

Total continuous current

Total peak power

0.4 kW / 15 Ω

15 Ω

4 kW

Total peak current

8231 4 3.7 16 64 150 200 8232 5 3.0 20 80 187 250 8233 6 2.5 24 96 225 300 8234 8 1.9 32 128 300 400

Table 14: Assignment of braking resistors

Observe the installation notes in section 3. Dimensions and installation drawings: See section 2.8.7.

Important!

The brake resistors used must be monitored thermally by an overload protection. The alarm contact(s) are to be integrated into the control of the drive (plant) such that the mains voltage is switched off atthe power input of the 8230 frequency inverter, if the contact responds. This means that the main contactor or power switch in the 3AC supply is opened.

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2.5.3 RFI filters

frequency inverter RFI filters RFI filters type with medium overload with high overload

8231 EZF3-250A001 EZF3-250A001 8232 ELN3-320A001 EZF3-250A001 8233 ELN3-600A001 EZF3-320A001 8234 ELN3-600A001 EZF3-600A001

Table 15: RFI filters

See section 2.8.10 for dimensions and weights.

Important!

RFI filters are only used on earthed networks.

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2.5.4 Motor filters and output chokes

2.5.4.1 Motor filters The use of the latest semiconductor technology allows extremely short times for

switching the circuit breakers in frequency inverters on or off. 8230 frequency inverter are IGBT pulse inverters whose output voltage has rising or

falling flanks of approx. 2 ... 3 kV/µs. Output filters for 8230 frequency inverter units are available for unlimited use with the benefits of IGBT technology when using a wide range of asynchronous 3-phase motors with different winding insulation voltages. These filters reduce the voltage rate of rise. An excessive voltage rise at the motor terminal box is determined by the cable length and the windings on the 3-phase motor used, through capacitive coupling. 8230 frequency inverter motor filters reduce this excessive rise in voltage through their built-in attenuation circuit. The 8230 frequency inverter motor filter prevents premature ageing of the insulation and therefore early failure if insulation limits are exceeded.

In general: du/dt → The shorter the motor cable length, the more critical

the rate of rise

Excessive voltage rise → When longer motor cables are used the amplitude of

the voltage rise and fall at the motor terminal box can increase beyond the critical value for the mains supply voltage.

Higher cable inductance and capacitan ce on long er motor cab les, however, reduces the du/dt value. The maximum voltage amplitude is therefore also reduced, so that the voltage rate of rise is reduced when an inductance due to longer cables applies.

The motor du/dt filters developed for 8230 frequency inverter units reduce the output voltage rise and fall times to below 500 V/µs (VDE 0503T1 Sheet 2). At the same time the filter design limits the rise time and the amplitude of the voltages and currents occurring in comparison to earth potential.

When using screened motor cable a du/dt filter also attenuates the amplitude and rate of rise of the screen current. This significantly reduces the effects of adjacent unscreened cables. The limit for transient overvoltages is maintained when the cable lengths specified for the filter are observed.

Fig. 11: Permitted limits for motor insulation

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Application range of motor filters:

• With mains supply voltages U

≤ 460 V standard motors or motors with equivalent

insulation characteristics can be used on 8230 frequency inverter. Standard motors of 400 V ... 460 V are designed for the voltage rates of rise and fall and voltage peaks of up to 1300 V which occur during inverter operation. If other makes of motors are used, please contact the motor supplier concerning suitability for inverter operation. 8230 frequency inverter motor filters are to be used if the insulation resistance of the motors and the maximum permitted voltage in the motor terminal box does not match the required value of 1300 V and the permitted

voltage rate of rise in the winding insulation is <3 kV/µs. If the motors do not satisfy these requirements, 8230 frequency inverter motor filters or application-dependent output chokes are to be used.

• With long parallel runs of unscreened motor cables in industrial applications a

motor filter is recommended to reduce the effect of adjacent cable runs caused by direct magnetic coupling.

• Radiated interference, particularly for high frequency components in the motor

current, is reduced by limiting the voltage rate of rise when using motor cables which are not screened.

frequency inverter Motor filters Motor filters type with medium overload with high overload

8231 ELM3-0040H260 ELM3-0050H220 8232 ELM3-0030H330 ELM3-0040H260 8233 ELM3-0025H400 ELM3-0030H330 8234 ELM3-0020H500 ELM3-0025H400

Table 16: motor filters

See section 2.8.8 and 2.8.9 for dimensions, weights and power losses.

Note:

See section 3.5 “Mains and motor connection” for further information and the maximum permitted motor cable length when using filters.

32 BA8230

Motor filters are ready to connect components which contain:

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• 3-phase iron core choke

• Push-pull choke

• Pulse capacitors

• Attenuation resistors

Protection class: IP 00 Mode of operation: DB Operating frequency: max. 150 Hz

Motor filters for higher frequencies available on application

Important!

8230 frequency inverter motor du/dt filters are designed for a maximum pulse frequency of 3 kHz.

Fig. 12 shows the basic configuration and connection of motor filters with 8230 frequency inverter.

Technical Data

See section 3.5 “Mains and motor connection” for further information. See sections

2.8.8 and 2.8.9 for dimensions and weights.

Fig. 12: Circuit diagram of motor fil ter for limiting the output voltage rate of rise

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2.5.4.2 Motor choke The motor choke makes it possible to use longer cable lengths between the 8230 frequency inverter and the motor. Motor chokes reduce the output voltage rates of rise and fall and attenuate the high frequency recharging currents caused by cable capacitance. The motor choke is also to be installed in multiple motor applications. The recharging current amplitudes are higher, the higher are the pulse frequency/voltage rate of rise and the effective capacitance through the motor cables. This means on average also higher currents can be found. As fault currents occurring on the motor current circuit are also detected by earth current detection, pulses may be disabled and fault shutdowns may occur when long motor cables are used and the earth fault threshold is set too low. The motor choke reduces these fault currents and is to be used if cable length is

excessive and the 8230 frequency inverter is operated “ also Table 24.

Alternatively a 8230 frequency inverter motor filter is to be used if required for insulation protection.

without an output circuit

”, see

If an output choke is fitted, the motors used must be designed for the maximum voltage ratings since a reduction in the maximum voltage amplitude can only be expected when longer cables (approx. 150 m) are used.

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A common output choke at the inverter output is generally to be provided in multiple

motor applications.

frequency inverter Motor choke Motor choke type with medium overload with high overload

8231 ELD3-0040H260 ELD3-0050H220 8232 ELD3-0030H330 ELD3-0040H260 8233 ELD3-0025H400 ELD3-0030H330 8234 ELD3-0020H500 ELD3-0025H400

Table 17: Output chokes for 8230 frequency inverter

Characteristics

Iron core choke 3-leg configuration optimised for inverter operation

Operating voltage 400 V ... 460 V

Operating frequency max. 150 Hz

Ferrite core output chokes for higher

frequencies by request Protection class IP 00 Mode of operation DB

Environment class DIN EN 60721 Part 3-3 3K3 / 3M2 / 3C2 / 2K2

Important!

8230 frequency inverter motor filters are designed for a maximum pulse frequency of 3 kHz.

See section 3.5 for further information.

See section 2.8.10 for dimensions, weights and losses.

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2.5.6 Option boards The options encoder interface is an option board which is installed on the rack of the information electronics.

Encoder

interface

Controlboard

Fig. 13: Configurations, frame size 8 and 9

Note:

The bus terminator (included in the connection kit) must always be fitted when options are installed (64 pol.).

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EMZ8235IB

2.5.6.1 Encoder interface The encoder interface is an assembly for detecting the speed when using an incremental encoder. It is required for 8230 frequency inverter drive controls with a speed actual value encoder to achieve higher control quality and an extension of the speed adjustment range to values above 1:1000.

The assembly consists of:

• Encoder interface

• Bus adapter cable 40 mm

• Supply adapter cable 40 mm

• Mechanical fixings

• Bus terminator

Fig. 14 shows the basic configuration of the encoder interface assembly.

Fig. 14: Structure diagram of encoder interface

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The encoder interface is connected to the I/O bus through bus connector X101. The supply to the assembly is through connector X109 from the +7 V and +24 V supply voltages in the 8230 frequency inverter. The voltage controllers for the encoder interface generate the supply voltage for the core system (the logic modules) and the supply voltages for the encoder. The incremental encoder is connected through terminal strip X10. The terminal wiring for the X10 encoder connection terminal strip on the encoder interface is shown in Fig. 15.

38 BA8230

Fig. 15: Encoder interface terminal wiring

The supply voltage for the incremental encoder can be taken either internally from the encoder interface or from an external voltage source. The external voltage source is then connected according to Fig. 15 to terminals X10:17 and X10:19.

If the incremental encoder is supplied internally through the encoder interface the supply voltage can be switched to either DC +5 V, DC +15 V or DC +24 V. Switching is achieved by moving jumper X11 to the appropriate position.

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The symmetrical encoder signals (differential track signals) for Track 1, Track 1N,

Track 2, Track 2N, Track Z, Track ZN are detected and processed through differential input stages in a voltage range from approx. 3 V ... 24 V and are output to the terminals according to Fig. 15 as the signals TRACK1OUT, TRACK1NOUT, TRACK2OUT, TRACK2NOUT, TRACKZOUT, TRACKZNOUT for further use at a voltage level of DC +5 V. Output at the 15 V or 24 V voltage level is in preparation. The encoder track signals are monitored for wire break. The LEDs ARDY (Track 1 / Track 1N), BRDY (Track 2 / Track 2N), ORDY (Track Z / Track ZN) ... indicate that the track signals are intact, see Fig. 16.

If symmetrical encoder signals are connected, the two hook switches S20a and S20B are in position 1. Asymmetrical encoder signals cannot be processed directly.

The zero pulses (Track Z / Track ZN) of the incremental encoder are not processed at the present time and need not be connected.

When a 5 V encoder supply voltage is used, connection of a sense signal at E83 :X10

terminal :12/:14 allows compensation for voltage drops. Through internal calibration the voltage actual value is processed and the voltage drop is controlled within the adjustment range (TTL level).

The maximum cable length for connecting an incremental encoder however is also limited by the maximum frequency which can be transmitted. The notes on connection must be observed.

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Fig. 16: Encoder interface - indic at or s , sel ec to r swi t ch es , conn ec to rs

The input and output signals for the encoder interface are conne cted through the plug-in terminal strip X10. Connection to the A10 control board is by means of ribbon cables.

Technical data of inputs and outputs

Inputs (incremental encoder) 1 encoder input Configuration: 2 differential inputs, separate potential,

for 2 incremental encoder tracks offset

through 90° 1 differential input, separate potential, for

the zero pulse track (not essential) Input voltage level: +5 V/+15 V/+24 V adjustable Input frequency of track signals: Max. 1 MHz Loading per Differential input ≤35 mA Dimensions (width x heigth): 168 mm x 120 mm Weight: ca. 0.35 kg

40 BA8230

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Outputs (encoder interface)

1 output for encoder track signals for further processing Configuration: 2 differential outputs, separate potential

(+5 V isolated) for 2 incremental encoders

tracks offset through 90° 1 differential output, separate potential

(+5 V isolated) for the zero pulse track Voltage level: DC +5 V (15 V and 24 V in preparation) Load rating per track: 20 mA

Incremental encoder supply

Configuration: Switch controller output / internal Voltage level: 5 V / 15 V / 24 V adjustable Rating: 350 mA The supply for the incremental encoder can be switched to “external” using hook

switches S50A and S50B. The incremental encoder is then fed from an external voltage source through the “External voltage source” input. Switch position 1 = “internal”, 2 = “external”. The “external voltage source” may be max. DC +24 V.

Unit software required

From 8230 frequency inverter Unit software SW V2.0

Note:

The procedure for connecting option boards through adapter cables must be followed accurately. If several option boards are used, the following procedures must be observed:

• The encoder interface must always be connected directly at the control board,

using the shortest possible cable.

BA8230 41

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Ratings and connection To compensate for interference (push-pull interference) on cables, encoders with two

pulse tracks offset through 90° electrical and with complimentary outputs are used. To guarantee high resistance to interference it is recommended that encoders with a 24 V operating voltage are used.

The quality of the encoder cable is critical for the maximum encoder frequency which can be transmitted. Screened cables with conductors twisted in pairs are to be used. The screen is connected at both ends. In the system, encoder cables must be laid separately from power cables (spacing ≥

0.3 m for up to 200 m cable length). It is recommended that the encoder cable be connected directly to the encoder interface, without any separation points. The screen is to be fully surrounded by clamps and connected to the control electronics cassette. See section 3.6 for supplementary notes on connection.

Recommended encoder cable: LIYCY 3 x 2 x 0,75 mm² (twisted in pairs) Guideline values for possible cable lengths for incremental encoder cable

Max. encoder cable

length:

l [m]

Max. encoder frequency:

fG [kHz]

ZnImpmin

∗∗

[]

60 10

∗

−

[]

kHz

30 300

00 160 200 100 300 50

For more stringent requirements the details given by the manufacturer of incremental encoder systems for higher transmission frequencies should also be observed and matched sets of special cables should also be used.

Maximum speed of the drive:

max

=∗ ∗60 10

max

Z Encoder pulses per revolution [p/rev] n

max

Gmax

Max. motor speed [rpm] Max. encoder frequency [kHz]

Minimum speed of the drive:

∗

60 10

min

For technical reasons lower values for n

∗∗

max

with T

Max. time between 2 pulse [ms] = 25 ms

max

are interpreted as motor standstill.

min

To achieve high resolution for speed measurement the encoder should have a high number of pulses per revolution. At high motor speeds this is counteracted by the limit on transmission frequency resulting from long encoder cables and the technical data of incremental encoders. Encoders of 1000 pulses per revolution and above are recommended. Depending on the manufacturer, incremental encoders using a 24 V supply voltage operate up to a maximum sensing frequency of approx. 160 kHz.

Example configurations Cable length = 100 m, frequency limit = 100 kHz.

42 BA8230

Technical Data

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[rpm] 6000 4000 3000 2400 1670

max

[rpm] 1.2 0.8 0.6 0.5 0.4

min

Line markings [p/rev] 1000 1500 2000 2500 3600

2.5.6.2 Operation on a mains Important! supply with no earth

The limits for radio interference suppression as stated in this operating manual apply only to earthed networks. If other equipment is operated at the same mains supply point, the EMC interference resistance of the equipment used is to be checked with the mains supply operator and matched to the 8230 frequency inverter.

BA8230 43

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2.6 Summary circuit diagrams

2.6.1 Summary circuit diagram, 8230 frequency inverter

44 BA8230

Fig. 17: 8230 frequenc y in ve r ter wit h 3A C sup pl y

Technical Data

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2.7 Connection, terminal wiring

2.7.1 Power stack The power stack consists of a B6 diode input bridge, charging circuit, link and inverter. The AC bridge connections U1, V1, W1 are connected to the 3-phase AC supply

network L1, L2, and L3.

2.7.1.1 3AC supply

Connections at top Function PE Earth terminal

L2 Mains supply 3AC 400 ... 460 V

- Not used

}

RB1 Braking resistor +UG (+UG = link plus)

}

Connections at foot Function PE Earth terminal

V1 Motor connection

+UG Link plus

}

-UG Link minus PE Earth terminal

Fig. 18 shows the 8230 frequency inverter power connections for a 3AC supply. The 8230 frequency inverter supply components marked * are not essential.

Note:

In exceptional cases it can be necessary to reverse the order of components 1), see

Fig. 18. This is the case, for example, if additional auxiliary supplies such as external

motor fans are to be operated at the feed point or function earthing is not consistent.

BA8230 45

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46 BA8230

Fig. 18: 8230 frequency inverter power connection

Technical Data

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Fig. 19: 8230 frequency inverter power stack terminal wiring

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2.7.2 Electronics section, The 8230 frequency inverter is controlled via the terminal strip :X15 on A10 control board A10 control board.

Fig. 20 shows the A10 control board with the clip-on terminal strip :X15 and the various plug connections.

48 BA8230

Fig. 20: A10 Control board, control and signal connections

2.7.2.1 Terminal strip wiring :X15

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and signal functions

Technical Data

Terminal :X15 Function Comments

:1 DC +24 V Max. load: 800 mA

:2 DC 0 V Re ference potential for DC +24 V :3 PTC- Motor thermistor connection :4 Motor temperature Motor thermistor connection

Binary inputs :5 ON / STOP

Flank LOW • HIGH = ON :6 MANUAL/AUTOMATIC +24 V = Automatic; Open = Manual :7 STOP

Flank HIGH • LOW = STOP :8 FAST STOP Open = Fast Stop :9 LEFT +24 V = Left :10 INHIBIT Open = Inhibit, drive idles down :11 RIGHT +24 V = Right :12 EXTERNAL ERROR Open = Inverter disabled :13 QUIT Flank LOW ® HIGH = acknowledge :14 DIGITAL INPUT 1 Function available :15 DIGITAL INPUT 2 Function available :16 DIGITAL INPUT 3 Function available

Binary outputs :17 Relay DC 30 V; 0,5 A max.

:18 contact closed on "READY" :19 Relay DC 30 V; 0,5 A max. :20 contact closed on "ON" :21 Relay DC 30 V; 0,5 A max. :22 contact :23 Relay DC 30 V; 0,5 A max. :24 contact

READY ON

ERROR SPEED

REACHED

closed on "ERROR"

Function available

Standard: "SPEED REACHED"

3),4)

:25 DC +24 V parallel to terminal 1 :26 DC 0 V parallel to terminal 2

Demand inputs Analog outputs :27 MAIN DEMAND (-) Di fferenti al input

:28 MAIN DEMAND (+) Differential i nput :29 ADDIT. DEMAND (-) Differential input :30 ADDIT. DEMAND (+) Differential inpu t :31 DC +10 V Rating: 20 mA resistant to short

circuit

:32 DC -10 V Rating: 20 mA resistant to short

circuit

:33 A-OUTPUT 1 Rating: 3 mA :34 DC 0 V Reference potential 0 V for DC + 10 V :35 A-OUTPUT 2 Rating: 3 mA :36 DC 0 V A-OUTPUT Reference potential 0 V Analog outp.

As supplied: Terminals :7, :8, :10, :11, :12 are connected to +24 V (terminal :1). Terminals :3 and :4 are bridged. The 8230 frequency inverter can therefore be controlled directly via the control unit.

The function can be re-directed with the PC handling software if required

The function can be inverted if required

The output can be adjusted.

A-OUTPUT 1, A-OUTPUT 2

BA8230 49

Technical Data

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Motor thermistor connection PTC-MOTOR-TEMP

A PTC resistor according to DIN 44081 is used for monitoring the motor temperature.

PTC cold R PTC hot R

< 2 kΩ

PTC

> 2.4 kΩ

PTC

The comparator in the 8230 frequency inverter switches at a resistance value of 2.1 kWΩ to 2.3 kWΩ and has 0.1 kΩ hysteresis. The temperature trigger curve is very steep in this range. If a switch contact is connected here (TMA), the low contact current of 2 mA should be noted. Suitable switching contacts must be used.

Fig. 21: Motor thermistor connection

Binary inputs

Design: Optocoupler Number: 12 Input level: 24 V / 14 mA

Fig. 22: Binary signal input

The inputs can be switched with a signal level of DC +12 V ... +30 V (positive logic).

The internal DC +24 V supply voltage should be used wherever possible. The input current is 14 mA per input. The standard terminal wiring is stated in section 2.7.2.1. The binary input signals have a common reference potential at X15 :02 and X15 :26.

50 BA8230

Technical Data

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Binary outputs

Number: 4 Design: Relay, potential-free Rating: DC 30 V; 0,5 A

See section 2.7.2.1 for the standard terminal wiring.

Fig. 23: Binary signal output

Demand inputs

Number: 2 Design: Differential input Signal level: 0 ... ±10 V switchable

0 (4) ... ±20 mA

A/D resolution: 10 bit

Fig. 24: Main demand input

Fig. 25: Additional demand input

The input signal level is selected by plugging the jumpers on pins X25 or X26

(see Fig. 20).

BA8230 51

Technical Data

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Jumper setting: Input signal level:

X25:2 - X25:3 and DC -10 V ... +10 V or X26:2 - X26:3 DC 0 V ... +10 V (Parked position)

X25:1 - X25:2 DC 0 mA ... 20 mA or X26:1 - X26:2 DC 4 mA ... 20 mA (Bridged)

Analog outputs

Number: 2 Design: Operational amplifier Signal level: 0 ... ±10 V / 3 mA max.

D/A resolution: 11 bit + polarity Standard setting: Output 1 = Output frequency See section 4.4.4

} }

Output 2 = Motor current

52 BA8230

Fig. 26: Analog signal outputs

Technical Data

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Fig. 27: A10 Control board X15 terminal strip wiring

BA8230 53

Technical Data

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2.7.2.2 Description of Terminal :1/:2 5 DC +24 V terminal strip Potential-free and short-circuit resistant voltage inputs / outputs source to supply the standard terminal strip.

Terminal :2/:26 DC 0 V

Reference potential for +24 V terminal :1/:25

Terminal :3/:4 PTC MOTOR-TEMP

Connection for motor thermistor resistor for motor temperature

monitoring.If the processing electronics respond, “Motor overtemperature” is signalled. The inverter shuts down with the error message “Motor overtemperature”. If no motor thermistor resistor is connected, terminals :3 and :4 are to be bridged.

Terminal :5 ON/STOP

The inverter is switched on by the rising flank of the +24 V signal.

When the link has been precharged the internal main contactor (DC) is energised. The inverter is shut down and the drive brought to a controlled standstill at LOW level. With the drive at a standstill the pulses are disabled, the main contactor (DC) is de-energised and the link is discharged (if a brake chopper is fitted). Deenergisation of the internal main contactor and link discharge can be prevented by appropriate parameter settings (see section

4.4.3.). After an error is acknowledged, a new rising flank is required for

starting. If automatic restarting is selected, within the specified restart time no rising flank is required after the mains voltage returns if the ON/STOP signal is still HIGH.

Terminal :6 MANUAL/AUTOMATIC

Manual/Automatic changeover

LOW corresponds to manual and HIGH corresponds to automatic operation. The signal source controlling the inverter can be switched with this terminal. The source for manual or automatic operation is parameter-adjustable and can be set to terminal strip, control unit, PC serial interface, field bus 1, field bus 2.

Standard setting: Manual = Control unit Manual/automatic changeover is only possible from the terminal

strip.

Terminal :7 STOP

A flank from HIGH to LOW results in the drive being brought to a

controlled standstill at the braking ramp. On standstill, the pulses are disabled and the main contactor (DC) is de-energised. This signal takes effect from the sources terminal strip, BDE, serial interface and field bus. The stop function via the BDE control unit can be disabled using the handling software parameters.

Automatic = Terminal strip

54 BA8230

Terminal :8 FAST STOP

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Fast Stop function by a flank from HIGH to LOW.

The drive runs to zero at the parameter-adjustable “ramp fast stop”. The pulses are then disabled and the internal DC main contactor is de-energised. If the optional brake chopper with braking resistor is connected, the link is force-discharged after approx. 30 s.

Terminal :9 LEFT

Left, demand enable on HIGH

If “demand preset 0 ... +10 V" or “line current” is preset, operation in the left direction is enabled with a HIGH signal at terminal :9. Negative values at the demand input produce a demand of zero. If neither LEFT nor RIGHT is HIGH, no direction is enabled. If both LEFT and RIGHT are HIGH, the signal set first takes priority.

Terminal :10 DISABLE

Inverter disable

This disables the pulses on LOW and de-energises the internal DC main contactor. If the optional brake chopper with braking resistor is connected, the link is force-discharged after approx. 30 s.

Terminal :11 RIGHT

Right, demand enable on HIGH

If “demand preset 0 ... +10 V" or "line current” is preset, the right direction is enabled on a HIGH signal at terminal :11. Negative values at the demand input result in a demand of zero. If neither LEFT nor RIGHT is HIGH, no direction is enabled. If both LEFT and RIGHT are HIGH, the signal set first takes priority.

Technical Data

Terminal :12 EXTERNAL ERROR

Opening the external error contact causes the inverter to be

disabled and de-energises the DC contactor. The motor idles down. Restarting is only possible after an acknowledgement.

Terminal :13 ERROR RESET

Acknowledgement of an error

A change in level from LOW to HIGH is an acknowledgement.

Terminal :14 D-INPUT 1

Digital input 1

Function parameter-adjustable (05 Digital I/O →Terminal :14) Standard setting: - Motor potentiometer higher Alternatively: - Select fixed speed.1 Input resistance: 4.8 kΩ

BA8230 55

Technical Data

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Terminal :15 D-INPUT 2

Digital input 2

Function parameter-adjustable (05 Digital I/O → Terminal :15) Standard setting: - Motor potentiometer higher Alternatively: - Select fixed speed.2 Input resistance: 4.8 kΩ

Terminal :16 D-INPUT 3

Digital input 3

Function parameter-adjustable (05 Digital I/O → Terminal :16) Standard setting: - Jogging Alternatively: - Change parameter set

- Select ramp 2

- Select fixed speed 3

- Input resistance: 4.8 kΩ

Terminal :17/:18 READY

Relay “ready”

The contact closes when a voltage is applied, no errors are present and no mains supply phase failure has occurred. This function can be altered using the PC handling software (See standard technology configuration). Contact rating - as standard: 30 V, 500 mA to cos ϕ ≥ 0.9; Apply load to relay coils

Terminal :19/:20 ON

Relay “on"

This contact closes when the drive is “ready” and the inverter is pulsing. Contact rating as terminal :17/:18

Terminal :21/:22 ERROR

Relay “Error”

This contact closes after an error shutdown. Operation is only possible after an acknowledgement. Contact rating as terminal :17/:18 The function can be inverted by parameter adjustment.

Terminal :23/:24 D-OUTPUT 1

Digital output

Parameter-adjust able (05 Digital I/O → Terminal :23/:24) (Standard setting: “Speed reached” - see section 4.4.5) Contact rating as terminal:17/:18 This function can be inverted by parameter adjustment.

Terminal :27/:28 MAIN DEMAND

Differential input for MAIN DEMAND

Burden 500 Ω with a line current demand Input parameter-adjustable as speed or torque input (07 Regulation → control structure: As supplied: Speed demand) The input is designed as a differential amplifier input. Input resistance: 40 kΩ Resolution: 10 bit + polarity

56 BA8230

Technical Data

}

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Terminal :29/:30 ADDITIONAL DEMAND

Differential input, additional demand

As terminal :27/:28 Terminal :31 + 10 V/ 20 mA Supply voltage for Terminal :32 - 10 V / 20 mA Demand channels (short-circuit

resistant)

Terminal :31 DC +10 V 20 mA voltage supply for demand channels

Terminal :32 DC -10 V 20 mA voltage supply for demand channels Terminal :33 A-OUTPUT 1

Analog output for an analog value 0 ... ±10 V

Function adjustable (04 Analog I/O → Terminal :33) (Standard setting: Output frequency - see section 4.4.4) Scaling adjustable through 04 Analog I/O - Scale analog output

Rating: 3 mA; load ≥ 3.3 kΩ

D/A transformer: 12 bit accuracy, 0.3 % resolution Terminal :34 0 V Reference potential for DC ±10 V Terminal :35 A-OUTPUT 2

Analog output for an analog value 0 ... ±10 V

As analog output 1

(Standard setting: Motor current - see section 4.4.4)

Terminal :36 DC 0V A-OUTPUT

0 V for analog outputs A-OUTPUT 1 and A-OUTPUT 2

BA8230 57

Technical Data

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2.8 Dimensions, Installation drawing, weights

2.8.1 8230 frequency inverter build-in units

Fig. 28: Dimensions, 8230 frequency inverter build-in units

8230 frequency

inverter type

Frame size

Width B Depth T

[mm] [mm] [mm] [kg] [mm] [mm] [mm]

The clearances above, below and to the side must be provided. The mains choke may not be installed directly under the unit.

Enclosure dimensions Weight Installation clearances

Height H top o bottom u at side s

(Clearance for cooling air inlets)

8231 8 495 419 1049 90 300 200 0 8232 8A 495 419 1225 90 300 200 0 8233 9 495 419 1499 140 300 200 0 8234 9A 495 419 1675 140 300 200 0

The unit depth can be reduced by 19 mm by removing the decorative facia on the door.

Table 18: Dimensions, weights, installation clearances

58 BA8230

Technical Data

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Fig. 29: Installation dimensions

8230 frequency

inverter type

Frame size Installation dimens. Bolt connections, wall-mounting

Slot Steel Tightening a b c [mm] [mm] [mm] [mm] above below 8.8 [Nm]

∅

Number bolt torque

8231 8 1021 125 325 9 4 4 M8 12 8232 8A 1021 125 325 9 4 4 M8 12

8233 9 1471 125 325 9 4 4 M8 12 8234 9A 1471 125 325 9 4 4 M8 12

Table 19: Installation dimensions and bolt connections

BA8230 59

Technical Data

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2.8.2 Mains chokes for 8230 frequency inverter

Fig. 30: Dimensions, 8230 frequency inverter mains chokes

Mains choke/type Mains choke / AC choke

Dimensions Installation dimensions Weight Losses

[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] [W]

ixk

ca.

ELN3-0014H200 300 170 290 274 88 8.3 16 30 x 3 10.5 32 220 ELN3-0011H270 300 190 290 274 114 8.3 16 35 x 4 12.5 40 280 ELN3-0009H300 300 200 290 274 114 10.5 18 35 x 4 12.5 44 290 ELN3-0009H370 360 210 343 330 107 10.5 18 50 x 5 12.5 58 380 ELN3-0006H450 360 210 343 330 107 10.5 18 50 x 5 12.5 58 460

60 BA8230

Technical Data

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2.8.3 Installation drawing for The control unit BDE can also be installed in the door of the cubicle door control unit if required.

Fig. 31 shows the cut-out for installation in the cubicle door.

Cut-out for installation of 8230 frequency inverter control unit front view:

Fig. 31: Control unit BDE - door cut-out

Door panel max. 2.0 mm thick

*)Potentiometer for display contrast adjustment

BA8230 61

Technical Data

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62 BA8230

Fig. 32: Layout of BDE in the door (Cubicle earthed against HF)

Note:

When the control unit is installed in the cubicle door it is essential that the door hinges are bridged with straps to conduct HF.

Any paint on the contact points between the support frame and the door panel must be removed. We recommend the control unit should also be earthed to the frame using an earth strap

In protection classes ≥ IPx3 the contact surface 2) of the BDE is to be sealed with 1K sealant.

, e.g. copper plate 20 x 0.15 mm.

2.8.4 Dimensions and installation dimensions

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Base for semiconductor fuses of operating class gR with 110 mm length

Technical Data

Fig. 33: Fuse base SI DIN 110 630

When protecting the 8230 frequency inverter using semiconductor fuses to DIN 43653 (screw strap with 110 mm length) 3 fuse bases SI DIN 110 630 (Fig. 33) must be installed in a row.

BA8230 63

Technical Data

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2.8.7 Dimensions and installation dimensions Braking resistor

Fig. 34: Braking resistors

Braking resistor Type

ERBD015R04K0 640 265 554 240 229 526 9

Braking resistor Dimensions

abcdefg

[mm] [mm] [mm] [mm] [mm] [mm] [mm]

See installation note in section 3

64 BA8230

2.8.8 Dimensions and weights motor filters

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Motor filter 8230 frequency inverter motor filter

type Installation dimensions

Weight

[kg]

ELM3-0050H220 60 425 422 410 390 380 460 ELM3-0040H260 72 500 422 410 390 380 510 ELM3-0030H330 84 500 422 410 390 380 630 ELM3-0025H400 108 500 422 410 390 380 690 ELM3-0020H500 115 500 422 410 390 380 760

Technical Data

Width

[mm]

Depth

[mm]

Height

[mm]

Width

[mm]

Height

[mm]

Losses

[W]

Table 20: Dimensions and weig hts, motor filters

The losses stated are approximate only and refer to the rated data of the relevant unit at 400 V rated voltage and 3 kHz pulse frequency. This is based on a motor cable length of approx. 100 m NYCWY which is rated according to the connection instructions given in this operating manual.

Fig. 35: Dimensions motor filters

BA8230 65

Technical Data

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2.8.9 Motor choke

Motor choke

Type Dimensions Losses

Weight [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [W]

ELD3-0050H220 34.0 300 177 270 240 120 10.5 11 15 ELD3-0040H260 40.0 300 190 270 240 133 14 11 15 ELD3-0030H330 45.0 300 210 270 240 145 14 11 15 ELD3-0025H400 62.0 300 236 270 240 171 14 11 15 ELD3-0020H500 64.0 300 236 270 240 171 17.5 11 15

Table 34: Dimensions and weig hts, mot o r choke

ca.

∼160 ∼190 ∼240 ∼300 ∼370

66 BA8230

Fig. 36: Dimensions motor chok e

2.8.10 Dimensions and weights RFI filters

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RFI filter Width

EZF3-250A001 190 115 390 15,0 EZF3-320A001 260 115 390 21,0 EZF3-600A001 260 115 440 22,0

[mm]

Depth

[mm]

Height

[mm]

Technical Data

Weight

[kg]

Table 21: Dimensions and weig hts, R FI filte r

Fig. 37: Dimension drawing, RFI filter

RFI filter Type

EZF3-250A001 380 240 190 165 115 12 EZF3-320A001 380 240 260 235 115 12 EZF3-600A001 430 290 260 235 115 12

RFI filter Dimensions

aa1b c em

[mm] [mm] [mm] [mm] [mm] [mm]

BA8230 67

3 Transport, Installation and Connection

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3.1 Safety instructions During transport and on installation of each unit it is important to remember that the centre of gravity is not located at the centre of the unit itself. The asymmetrical loads resulting during transit and installation must therefore be taken into account accordingly.

Heavy units must always be lifted using suitable equipment and trained personnel. Units may only be transported in the correct position using the eyebolts provided. They may not be placed on their side for transportation purposes. A pallet must be used for transport with a forklift truck. Uniform distribution of the load is essential when lifting. The force applied to all eyebolts must be equal. The support cables may not vary more than 30 degrees from the vertical. Heavy vibration and severe shock must be avoided during transport and when lifting and lowering. After installation the eyebolts should be removed and stored safely in case they are needed in the future. Incorrect lifting and transportation of the units can cause severe or even fatal physical injury and extensive material damage. Build-in units are designed for wall-mounting. The securing bolts to be used must always be of the correct size (see section 3.4).

Please note the following when connecting inverters:

• All work on the unit and its installation must be executed in accordance with the

national and local electrical regulations and conditions. This means that the inverter must be earthed correctly at the protective earth connections to ensure that no easily accessible part of the unit is at mains potential or carries any other dangerous voltage.

Attention! If inverters are not earthed it is possible for the casing to carry dangerous voltages

which can cause fatal or severe physical injury or extensive material damage.

• Check that the load connected, i.e. the cables and motors, are not earthed.

• Check the rated supply voltage and current as well as the motor data

according to the 8230 frequency inverter rating plate.

• Build-in units must be installed in panelled cubicles or rooms which are only

accessible to trained personnel.

• The user is responsible for ensuring that inverters and other equipment are

installed and connected in accordance with the accepted rules of technology and the local regulations in the country concerned. This must take into account the cable dimensions, fusing, earthing, isolation, separation, insulation monitoring and overcurrent protection in particular.

The safety instructions given inside the cover and in section 5.1 must be observed.

68 BA8230

Transport, Installation and Connection

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3.2 Storage 8230 frequency inverter are packed according to the climatic and other conditions expected in transit and in the country for which they are intended. All notes on the packaging concerning transport, storage and correct handling must be observed. The consignment may not be stored outdoors. Stacking is prohibited! Storage rooms must be dry and well ventilated.

Permitted storage temperature -25 ... +65 °C 8230 frequency inverter units contain high quality aluminium electrolytic capacitors.

Their reliability may be affected if they are stored in the uncharged condition for longer periods, particularly at high temperatures. 8230 frequency inverter can be stored without charge for at least 2 years, of which max. 5 months may be at storage temperatures of over 40 °C. The 8230 frequency inverter should be checked after this storage period has elapsed. The aluminium electrolytic capacitors should be reformed by suitably trained personnel before charging at the rated voltage. Please refer to section 7.4 for instructions on forming.

3.3 Transport The units may only be transported with forklift trucks when standing vertically on a pallet and in their cardboard packaging. When unpacked, transport is also possible using the eyebolts provided on the inverter. Uniform distribution of the load is essential. When lifting using the eyebolts the force on all bolts must be equal and vertical. Heavy vibration and severe shocks are to be avoided, for example when lowering. Always check the unit for completeness and any evidence of damage when unpacking.

If damage in transit is discovered, it must be recorded and reported immediately to the carriers.

3.4 Installation According to their protection class IP 20 all 8230 frequency inverter units are to be installed in clean dry rooms ventilated with sufficient clean cooling air according to the power losses involved. The rated 8230 frequency inverter data may vary in other protection classes. The volume of cooling air required for the power losses is to be provided, i.e. adequate ventilation must be ensured. The coolant temperature may not fall below 0 °C. If the coolant temperature is above 40 °C or 50 °C respectively at constant load torque and 150 % overload, the current must be reduced by 2 % per Kelvin up to max. 55 °C and if the unit is installed above 1000 m to max. 2200 m above mean sea level an additional current reduction of 1.2 % per 100 m must be taken into account accordingly. 8230 frequency inverter are designed for vertical wall mounting in switchgear cubicles, booths and boxes.

The following bolt connections (bolt sizes) are to be used for securing build-in units to the wall:

8230 frequency

inverter

Table 22: Bolt sizes and tightening torque for securing 8230 frequency inverter units

Top: Bottom: Tightening

torque

4 x M8 4 x M8 12 Nm

BA8230 69

Transport, Installation and Connection

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Cooling is fan-assisted. An adequate clearance above the unit (see section 2.8) is to

be provided to prevent heat build-up. Cooling air is fed in from below, where adequate clearances are also to be provided (see section 2.8). Internal air circulation must generally be prevented. Unsatisfactory ducting and air flow will result in overheating in the switchgear cubicle.

3.5 Connection and wiring We recommend that 3-phase cables with the cross-sections stated in Table 23 below should be used for the power connections (the motor and mains supply). For reasons of electromagnetic compatibility the motor connection cable used should be a 3-phase cable with a concentric protective conductor. This protective conductor (screen sleeve) in the motor cable is to be earthed at both ends. A connection bracket (option) is available for connecting several cables to a power connection strap.

The screw connections are to be secured to prevent loosening through vibration and temperature fluctuation, using a suitable spring component. The bolt sizes and tightening torque levels are given in Table 23. Power cables must be secured to suitable cable brackets for strain relief purposes. The PE connection on the unit must be connected to a good earth. Mains supply cables and motor cables are to be laid separately according to the EMC connection instructions. When connecting the motor to the 8230 frequency inverter it is important to ensure that no other power circuit (e.g. reactive power compensation) is connected to the motor connection. This is particularly important when upgrading an existing system. The motor star point may not be earthed. Control and signal cables for the control electronics are to be laid and connected in accordance with the EMC connection instructions.

Connecting signal leads Electronic control circuits are considered low power circuits (< 2 A) according to DIN

EN 60204 Part 1 (VDE 0113 Part 1, 6). In approximation to this standard we recommend the following cross-sections for terminal strip wiring on fixed indoor systems for reasons of the mechanical strength and interference resistance:

• Single core, multi-wire (stranded) cables at least 1 mm²,

in switchgear cubicles at least 0.5 mm²

• Multi-wire screened cable at least 0.75 mm²

in switchgear cubicles at least 0.5 mm²

70 BA8230

Transport, Installation and Connection

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Note:

The cable cross-sections stated in Table 23 can only be considered general guidelines. The cable dimensions must satisfy the regulations and any works standards applicable at the installation.

8230 frequency inverter

Type

8231 2 x 3 x 95 315 A 2 x 3 x 95 M12 92 200 8232 2 x 3 x 120 355 A 2 x 3 x 120 M12 92 200 8233 2 x 3 x 150 400 A 2 x 3 x 150 M12 92 200 8234 2 x 3 x 185 500 A 2 x 3 x 185 M12 92 200

Mains connection Motor connection Screw connection

Recommended

copper cable

cross-sections

[mm²] [mm²] [Nm] [mm²]

Applicable

overload

protection NH

fuse

Table 23: Cable connections

Recommended

copper cable

cross-sections

Steel screw

Strength class 8.8,

not greased

Note concerning motor connection

The following main factors must be taken into consideration for connecting motors to the 8230 frequency inverter:

• 8230 frequency inverter unit type: As standard the response threshold for earth fault detection on the motor side is 10 % IN.

• 8230 frequency inverter pulse frequency

• Motor insulation system: Details from the motor manufacturer concerning the max. motor voltage/current in the motor terminal box, suitability for inverter operation

• Cable type: Screened, with armouring or without screen

• Effective cable length: Parallel cables, group supply

• Cable cross-section: Voltage drop ≤ 1.75 % or ≤ 3 %

Motor + Mains connection

Tightening

torque

Max. direct

single

connection

cross-section

at the unit

Suitable screened heavy current cable 0.6/1 kV

Cross-section [mm

to 25 Ölfex-Servo - 730 CY Lappkabel 10 ... 120 Protoflex-EMV-CY

10 ... 185 NYCWY 3x XX/Y

Type Manufacturer

]

2YSLCY-J

(für Y jeweils größter Wert)

Siemens

Normkabel

BA8230 71

Transport, Installation and Connection

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The recommended guidelines for copper cable cross-sections guarantee a voltage

drop of <3 % up to conductor temperatures of 50 °C. The values stated apply to a 400 V supply at rated current for frame size 1 up to approx. 80 m and for frame sizes 2, 3 and 4 up to approx. 160 m.

The maximum permitted cable lengths for connecting 3-phase asynchronous motors

to the 8230 frequency inverter are stated in Table 24.

Max. permissable motor cable lengths of the 8230 frequency inverter

8230 frequency inverter Type

8231 300 400 400 300 250 350 300 200

8232 300 450 450 350 250 350 350 250

8233 300 450 450 350 250 350 350 250

8234 300 450 450 350 250 350 350 250

Max. suitable motor cable lengths, 8230 frequency inverter

Unscreened cable NYY/NYM

no circuit2)with motor

choke

2) 4)

with motor

filter

UN=400 V

=3 kHz

with motor

filter

=460 V

=3 kHz

Screened cable NYCWY

No circuit

with motor

choke

with motor

filter

UN=400 V

=3 kHz

[m] [m] [m] [m] [m] [m] [m] [m]

150

Table 24: Max. permitted motor cable lengths

120

200

with motor

filter

UN=460 V

=3 kHz

150

72 BA8230

Notes:

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PVC insulated 3-phase cable 0.6/1 kV to DIN/VDE 0271.

Cables with a braided screen providing a high degree of cover (comparable to

control cables) are not required for supplying frequency inverters with regard to the EMC characteristics. These cables increase the capacitive load on the inverter so that it becomes necessary to reduce the cable lengths stated for NYCWY by approx. 40 %. Repeated parallel connection of these types of cables to increase the cross-section, if not stated expressly in Table 23, is only permitted with a proportional reduction in the lengths stated.

At an inverter pulse frequency of 6 kHz the resulting permitted cable length is

reduced by 30 %.

If very high control dynamics are required, e.g. an enclosed control surface of

≤0.25 %/sec at a ±50 % change in load at rated speed (VDI/VDE 2185), a direct

connection between the 8230 frequency inverter and the motor must be taken into consideration during the design stage. The maximum voltage drop over the motor cable may not exceed 1.75 %. This value also applies to lifting equipment. A 5 % reserve in the mains voltage is to be taken into account with regard to the given dynamic control characteristics over 95 % of the motor type point. In addition, if necessary, the drive characteristics in the event of mains undervoltage are to be taken into account (IEC 34.1: Requirements concerning electronic equipment).

The output choke is used with the cable lengths stated in order to reduce the

capacitive load caused by the motor cable and also reduces the voltage rate of

rise. With cable lengths <150 m the motors used must be designed for the

maximum voltage loads stated in this section under “Notes: Winding insulation”.

Compliance with the motor insulation limits according to DIN VDE 0530 Part 1,

Supplement 2: 1991

Typically U frequency inverter supply possess very high reserves in the insulation system by comparison to this limit.

Transport, Installation and Connection

= 1000 V; du/dt = 500 V/µs. Modern asynchronous motors for

max

The overall length is decisive in group drives or multiple motor supplies. The voltage

drop across motor cables should not exceed 1.75 %. With lower dynamic drive requirements the guideline value for the voltage drop over

the motor cable is ≤3.0 % (DIN 18015). The cable lengths stated are maximum values. No increase in the cross-section to reduce the voltage drop over long motor cables has been taken into account and should be determined if necessary, taking the motor power factor into consideration.

Voltage drop e [%]:

= sinXcosR

∗

()

U10

ϕ∗+ϕ∗

∗∗

U Linked voltage [V] I Current load [A] l Supply length [m] R Resistance [Ω/km] X Inductive resistance [Ω/km]

The inductive voltage drop should be taken into consideration particularly with

cable cross-sections A ≥ 50 mm².

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Cross-section Resistance R

[mm²]

[Ω/km] [Ω/km]

95 0.216 0.0754 120 0.171 0.0733 150 0.139 0.0733 185 0.110 0.0725

Table 25: Operating values for PVC insulated cable at 50 °C cable temperature.

To compensate for internal voltage drops 8230 frequency inverter units can simulate the output voltage in an over-modular manner. The voltage drop across the motor cable however cannot be compensated without direct measurement at the motor connection. However the motor current consumed increases almost proportionally through a reduced motor voltage at the same torque and increases the motor losses for a squared reduction in motor trip torque and a reduction in motor flux.

Inductive reactive resistance

If the values for the voltage drop are exceeded, 3-phase asynchronous motors with U

Motor

< U

are to be used. If standard 3-phase motors are used, a reduction in the

Mains

type point can be made to determine the revised rating point. Example: 50 Hz / 400 V changed to 47.5 Hz / 380 V The level of interference on the mains side which is associated with the power is

increased through longer motor cables. A mains filter is recommended if sensitive consumers are operated on the same mains supply and motor cable lengths exceed 50 m.

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Notes on motor winding insulation

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With mains supply voltages UN of up to 460 V it is possible to use standard motors or motors with equivalent insulation characteristics with the 8230 frequency inverter. The 400 ... 460 V standard motors are designed for the voltage rates of rise and voltage peaks of up to 1300 V which occur during inverter operation. When using motors from other manufacturers it may be necessary to contact the supplier concerning the suitability of motors for inverter operation. 8230 frequency inverter motor filters are to be used if the insulation resistance of the motors and the max. permitted voltage in the motor terminal box do not match the 1300 V required and the permitted voltage

rate of rise for the winding insulation is < 3 kV/µs. If the motors do not meet these requirements, 8230 frequency inverter motor filters or motor chokes are to be provided.

Installation notes, braking resistors

Transport, Installation and Connection

All braking resistors are to be connected via short cables. Cable bundles are to be laid separately from other cables. For EMC reasons we recommend using only screened cables. The screen must be earthed at both ends and connected to the casing. The cable cross-sections must be rated at least according to the overcurrent protection device. Braking resistors carry dangerous voltages to earth and must be protected so that they cannot be touched.

Braking resistors are to be installed externally so that the cooling air and the ambient

temperature for 8230 frequency inverter units are not affected by the heat generated by the braking resistors.

An unrestricted flow of cooling air is essential for the braking resistors. The waste heat

is emitted upwards. A minimum clearance of 200 mm is to be provided from adjacent components, walls, roofs or similar. As electrical energy is converted in braking resistors the air and certain parts of the casing will inevitably become hot. The temperature may rise to 150 °K above the ambient temperature.

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Notes on encoder connection

In the modes of operation “Speed control with encoder” and “Torque control with encoder” highly accurate speed actual value detection is necessary and incremental encoders must be used.

To compensate for the effects of interference (inphase interference) on the cables the encoders to be used have two pulse tracks offset through 90° electrical and complimentary outputs. To guarantee adequate interference resistance we recommend encoders with a 24 V operating voltage.

The quality and length of the encoder cable are criteria for the maximum encoder

transmission frequency. Screened cables with the conductors twisted in pairs are to be used. The screen is to be connected at both ends.

These cables must be laid in the system so that they are separate from power cables. We recommend the encoder cable should run directly to the encoder interface, i.e. with no interruptions. The screen is to be surrounded fully using the screen clamps supplied, to ensure a firm connection at the control electronics cassette.

Recommended encoder

cable:

LIYCY (TP) 3 x 2 x 0.75 mm² (Data cable with copper braid, twisted in pairs)

Example configurations, cable length = 100 m

[rpm] 6000 4000 3000 2400 1670

max

[rpm] 1.2 0.8 0.6 0.5 0.4

min

No. of markings [pulses per revolution]

1000 1500 2000 2500 3600

When using an incremental encoder with 1000 pulses per revolution the example for digital demand preset therefore results in a speed control accuracy of 0.05 % at n

max

The accuracy of the encoder and an undisrupted transmission capability particularly

for 5 V encoders due to their low interference resistance play a major part in determining the accuracy of speed detection.

See section 2.5.6.1, Encoder interface, for using encoders and the technical data of the encoder input.

76 BA8230

3.5.1 Potential separation

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Transport, Installation and Connection

Fig. 38: 8230 frequency inverter potential separation concept

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Potential

Legend

A Power potential B Electronics potential, earthed DC ±15 V, +7 V, +5 V C Auxiliary potential DC ±27 V, +24 V D Potential island for

RS422 serial interface DC + 5 V

E External potential / customer potential

M Mains voltage detection

Link voltage detection

Z Link charging G IGBT control SNT Switch mode power supply K1 Link contactor L Fan and fan control I Digital inputs P Motor thermistor (PTC) connection S DC +24 V and short circuit monitor

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3.6 Installation and connection Fig.39 shows an example of an ideal layout for a 8230 frequency inverter with instructions for EMC EMC components.

Fig.39: Example of cubicle layout, 8230 frequency inverter

Note:

The overview in Fig.39 illustrates the ideal position of components relevant to EMC. In order to achieve good EMC in the drive system the following basic rules are

recommended for cubicle construction, installation and layout. These measures are to be considered part of industrial EMC installation practice and are summarised here.

• Function earth All inactive metal parts are to be well connected. Inactive metal parts are all conducting parts which are electrically separated from active parts by at least basic insulation and can only carry a voltage if a fault occurs. The function earth for the 8230 frequency inverter cubicle is most effectively provided by low-impedance connection (bare metal, low HF resistance, generous connections) of cubicle parts with the frames and inactive parts of the building (armouring and steel supports) which are to be included in potential compensation of the entire system. In addition to the screw connections for parts, broad flat bands with a large surface area are suitable as low-impedance connections. As far as possible parts made of aluminium should be used only to a limited extent and fitted using contact protection grease.

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• A central connection is to be made between ground and the operating earth / protective conductor system to IEC 364-5. DIN VDE 0100 also applies.

• Uniform reference potential should preferably be provided and all electrical equipment is to be earthed. It must be ensured that no external equipment can be damaged by the earthing of the control electronics in the 8230 frequency inverter.

• Parts of the system and cubicles containing other 8230 frequency inverter units, control cubicles, construction and machine parts etc. are always to be connected in a star configuration to the earth/protective conductor system to prevent loops. If the system mainly involves drive cubicles, a method of earthing which is more efficient as far as EMC is concerned should be used on installation, i.e. earthing via a grid system.

• Induced interference is to be dispersed over large metal surfaces. All equipment such as RFI filters (including standard profile parts as well as PE and screen rails) are to be fixed to metal component parts to ensure low impedance. The PE / screen rail is the central earthing point in the 8230 frequency inverter cubicle and in cubicles of 600 mm width and above is to be secured to the cubicle frame or the mounting plate through at least three electrical contact points. A metal rear panel onto which all units are mounted is particularly reco mme nded in a switchgear cubicle. If mounting plates are used whose surfaces are not good conductors, for example painted, anodised or yellow chromated, the surface coating must be removed at equipment contact points. Galvanised component parts for the cubicle and metal parts at contact points are ideal from the viewpoint of EMC. To achieve good EMC these components must be screened together directly to provide good contact. Cubicles in which the complete edge of side and rear panels is in contact with the cubicle frame are recommended. The door is to be included using a connection method which is effective at HF.

• Screw connections on metal parts which are painted and anodised are to be fitted with special contact washers or the insulating coatings are to be removed. Low impedance contact surfaces must be cleaned thoroughly to remove paint before assembly. Protect all connection points against corrosion, using contact protection grease for example.

• According to the concept of EMC protection zones all signal leads are to be fed into the cubicle at just one level, if possible, not at several different levels.

• All switchgear cubicles involved in linked drives are to be connected with a potential

compensation cable of at least 25 mm² if they do not include a screen rail or this rail is not continuous.

• No unswitched contactors, relays, solenoid valves, electromechanical meters, counters etc. may be used in a switchgear cubicle with the 8230 frequency inverter. All inductances installed on the same current circuit are to be connected with surge supressors. DC-activated coils are to be connected with a diode or Z diode and AC-operated coils are damped using a varistor or an RC component. If contactors without with surge supressors are used in an adjacent cubicle, the cubicles are to be separated by a metal partition.

• Cables to the 8230 frequency inverter control electronics must be scr eened.

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Transport, Installation and Connection

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• Ideally the wiring should be divided into groups: Power cables, power supply cables, analog signal leads, digital signal leads and the bus or data leads. Power cables and the signal and data leads should be placed in separate ducts or bundles. Signal and data leads should preferably run clos e to grou nded surfaces, e.g. support beams, metal rails, mounting plates or cubicle panelling. These

measures are intended to suppress any “crosstalk” between parallel cables. Cables which hang unsupported may act as passive or active antennas and can cause interference. Motor cables, mains supply cables and signal leads for the control electronics are to be spaced at least 0.2 m apart inside the switchgear cubicle. This spacing can be reduced where cables cross. Outside the switchgear cubicle the motor cables should be laid in separate bundles spaced at a distance of at least 0.3 m - and more when using longer parallel runs involving unscreened motor cables. No other current circuits may be fed through or on the motor cable. The following guidelines can be given as the minim um spa cing (a) between parallel screened signal leads and motor cables:

Up to 200 m a ≥ 0.3 m Up to 300 m a ≥ 0.5 m Up to 500 m a ≥ 1.2 m

It is always better to use a separate metal cable track for laying control cables.

• Signal leads for the control electronics and control cables outside the switchgear cubicle are best laid on separate cable tracks to provide sufficient spacing to avoid interference. If no separate cable track can be provided, signal leads are to be partitioned off from power cables using chambers in the cable tracks and the chamber are to be fitted with covers. Cables for processing the motor temperature using thermistors are to be laid separately and never together with motor power circuits.

• Mains and motor cables are to be PVC insulated 3-phase cables according to DIN VDE 0271 1986-06. If single conductors are used they should preferably be twisted at 1 turn per 5 m and bundled in groups of three. If this is not the case, current distribution may be disrupted and in extreme ca ses, in addition to cable overloading, the drive system may malfunction.

• Practical experience with EMC has shown that motor connection cables with copper armouring or concentric corrugated protective conductors, for example NYCWY (3-core) should be used. If the screen is connected in a low-impedance configuration at both ends the screen sleeve / protective conductor guarantees good attenuation to reduce the HF interference radiated from the motor cable through high frequency recharging currents. The ground wiring should always have the maximum possible cross-section. Steel armoured motor cables are unsuitable for reasons of EMC.

• To ensure a good EMC connection the motor cable at the frequency inverter side is to be connected using pipe clamps, terminal clamps or screw connections which surround the cable fully at the contact point to provide a good connection to the screen bus or mounting plate.

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• If contactors, motor protection switches or terminals are located on the screened motor cable, the screens of the cables connecte d at that point ar e to be cont inuo us and of low impedance. In the motor terminal box the screen is to be connected with the PE / PA. Metal cable screw connections (nickel plated brass) at the metal connection box (do not use a plastic connectio n box ) provides a very good connection between the screen and the motor casing. On the inverter side the screen is to be connected to the central screen rail and not directly to the unit.

• For reasons of EMC the motor cable should be as short as possible. The frequency inverter should preferably be located close to the motor. Additional radio interference suppression measures may be necessary in systems which are physically very large, depending on the situation. In particular improvements in potential compensation may be necessary. The motor cable lengths stated in this section were calculated on the basis of trials and are the maximum guideline values with regard to the inphase current occurring. The inphase current limits the dynamics and causes additional losses in the inverter. With dynamic direction changes at the zero cro ssov er point it may be necessary to adjust some control parameters when commissioning drives without speed actual value detection, due to longer cables.

• Analog and digital control leads for the 8230 frequency inverter control electronics and data leads are to be laid using screened cable. The screen is to be connected firmly at both ends for good potential compensation. Good potential compensation will be achieved if a star or grid type earth system is used consistently. Applying the screen twice on short spacing distances in the cubicle increases the interference resistance. When transferring analog signals of low amplitudes in the mV range a single-sided application of the screen in the switchgear cubicle may only be

necessary close to strong radiation fields, due to a low frequency “50 Hz hum”. Generally cable screens are always connected at both ends. This is the only way to ensure good interference resistance at high frequencies throughout the entire range of interference frequencies. Without pote nti al com pen sa ti on the screen on control cables should only be connected at one end, however, but this is always a compromise. The cable screens are to be applied directly after they enter the cubicle, as this is where the highest interference amplitudes occur. Apply the screen generously to the screen / protective conductor rail and secure the screen with cable clamps, screen connection terminals or hose clamps, depending on the system involved. Continue the screen up to the terminal strip or, if necessary, up to the assembly at the 8230 frequency inverter or external modules, without any interruptions. The internal screen contacting facilities on the aluminium slide-in rack for the control electronics, which use round clamps, are always to be used for making contact with the screen. So-called "pigtails” or similar must never be used for control leads. Such a path would be low impedance and the flow of the screen current close to signal conductors would allow the screen current to act as an interference current. The cable screen must always be connected directly at the end. The cables at the 8230 frequency inverter terminal block are to be divided into analog input and output cables and digital input and output cables and these groups are to be laid separately using screened cables with both ends of the screen connected. Alternatively a double screen control / data cable is possible. In this case the outer screen is earthed to the side of the unit and the inner screen is earthed at the other end. As these cables generally have screens made of foil, mechanical damage can occur easily, even with just slight bending and pressure. An additional compensation cable is always particularly recommended if the potential difference between the relevant earthing points is > 5 V. 25 mm² Cu is sufficient as an equalizer up to acable of 200 m. For longer cables, at least 35 mm² Cu are recommended.

82 BA8230

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Above that length two separate compensator cables of 16 mm² copper should be

used for reasons of EMC. The potential compensation cable should be laid so that the surface area enclosed between the signal cable and the compensation cable is as small as possible. In difficult cases where additional radio interference suppression measures are needed, twisting with the cable affected by interference is a very efficient method for effectively suppressing malfunctions.

Fig. 40: Efficiency of screen contact for induced effects

• When the 8230 frequency inverter is supplied by an external 24 V auxiliary voltage this voltage may not supply several consumers in different cubicles. Ideally each 8230 frequency inverter should have power supplies of separate potential.

• The quality of the signal cable to the encoder is a critical factor for the maximum possible encoder frequency. Screened encoder cables with the conductors twisted in pairs, for example LIYCY 3 x 2 x 0.75 mm² at least, should always be used. The screen is to be connected well at both ends. Signal cables should preferably always be connected directly at the encoder interface, with no further terminals or separation points. Unused signal conductors are to be grounded.

• Only signal cables with a tinned copper screen braid should be used. The braid should provide at least 85 % cover. Cables with a foil screen are less suitable as they are easily damaged by bending and pressure.

• The screen is to be continuous to peripheral equipment such as demand potentiometers etc. Only one additional interruption point is permitted. This is to be such that less than 2 cm of the cable remain unscreened. The screens at both ends of the cable are to be connected through the screen rail (see Fig. 43). Various different round cable clamps are supplied with the unit for securing cable screens to the aluminium slide-in rack in the 8230 frequency inverter. It is to be secured using a M4 screw (see Fig. 44).

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• If a RFI filter is used it should be installed as close as physically possible to the cubicle feed point, taking the cooling air requirements into account. With this installation the inverter cubicle may not contain any other unfiltered current circuits to the motor, e.g. cables for external fans, as otherwise the inverter radio interference suppression will be limited. The filtered sections of the cable between the RFI filter and the commutation choke / supply terminals in the cubicle are to be screened or laid in armoured steel pipes or metal ducts (see Fig. 39) to avoid extraneous interference, for example through the motor cable if closely spaced and ≥ 30 cm in length. Under no circumstances may the RFI filter supply and return leads be placed in the same cable duct. RFI filters generate currents. According to prEN50178/VDE0160 a PE connection of at

least 10 mm² is required. If other unswitched auxiliary power circuits are included, separate filtering is to be provided (Example: Uninterruptable auxiliary voltage, auxiliary supply).

• To prevent bridging of the RFI filter in the HF range the protective conductor may not be laid past the RFI filter to PE1 on the 8230 frequency inverter mains connection. The protective conductor is then connected to the lower terminal PE2 (see Fig. 39).

• If a mains contactor is fitted, the contactor control cables must be laid separately from other control cables in the cubicle.

• The 8230 frequency inverter has a built-in mains rectifier. After a short circuit a DC fault current can prevent the ELCB-protection switch from being triggered. Additional measures such as zeroing are therefore necessary or ELCB-protection switches which are sensitive to all currents can be used (VDE 0160 5.88). When rating the release current it is important to note that capacitive compensation currents occurring during operation can cause the interference suppression filters and cable screens to produce triggers in error. Depending on the filters involved, currents of up to approx. 300 mA can occur.

Important!

Operation of radio transmitters and radio telephones with a transmitter output capacity of >2 W is not permitted in the direct proximity of 8230 frequency inverter.

With lower power radio communication equipment and radio telephones operation is permitted when the 8230 frequency inverter is not open.

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Fig. 41: Cable clamps used for earthing a continuous screen or at the screen end

Fig. 42: Recommended cable earthing rail, 8230 frequency inverter cubicle

Fig. 43: Layout of a separation point in a screen cable, e.g. transfer terminal strip in cubicle

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86 BA8230

Two clamps each of 3 mm, 4 mm and 5 mm are included in the scope of supply. They can be ordered under Ref. No. 029.145 173.

Fig. 44: Handling cable screens at terminal block

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Connection instructions, control cables

The correct EMC connection of control cables to the 8230 frequency inverter control board is to be made as shown in Fig. 45.

Fig. 45: Control connection, terminal strip A10 : X15 (Control board)

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3.7 Specific measures for Depending on the environment, optional measures are necessary to ensuring electromagnetic comply with the EMC radiated interference conditions for drive converters. compatibility (EMC)

IEC1800-3/prEN61800-3 (IEC 22G/21/CDV); Industrial:

To comply with the EMC requirements, no further options are required for radio interference suppression in addition to special consideration of the installation regulations and the instructions given in this documentation together with installation of mains chokes (3-phase chokes) and the use of screened control cables. A RFI filter is recommended when using screened motor cables of above 50 m in length. If other equipment which does not meet the interference resistance requirements of this product standard or the values according to EN50082-2 is installed on the same mains supply, radio interference measures are to be co-ordinated with the mains operator (IEC1800-3 / prEN61800-3 / IEC 22G/21/CDV).

Increasing the interference resistance of low power equipment is often far less complex or expensive. In industry it is therefore more economical to increase interference resistance than to reduce the radiated interference. In industry the EMC of the units should be based on a balanced mix of radiated interference and interference resistance.

IEC1800-3/prEN61800-3 (IEC 22G/21/CDV)

Residential, business and trade facilities as well as small businesses on the public electricity supply network. A RFI filter is required in addition to the measures described for industry. Only the RFI filters stated in this operating manual guarantee compliance with the radio interference voltage according to limit EN55011 Class A (CISPR11 Class A). To meet these limits for radiated interference it is assumed that the cubicles used for the 8230 frequency inverter provide direct contact with the cubicle frame over the entire circumference of the side and rear panels. High coupling attenuation resistance is achieved by the cubicle function earth. In general no HF seals are required in cubicle doors for standard applications since the wavelength of the relevant radiated interference to be screened is approx. 0.5 ... 10 m. Screened copper-armoured motor cables of type NYCW Y or -730CY with a good, low-impedance earth at both ends are to be used. The length of this motor connection cable may not exceed 150 m without taking into account further ancillary factors such as earth fault conditions and the system configuration. The cables to the braking resistor are to be screened.

EMC radiated interference to DIN EN 50081 Part 2: Limit EN55011 Group 1, Class A (CISPR11 Class A)

The measures stated in the last section to meet the limits for the public electricity supply network are required for compliance with this basic EMC standard.

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EMC radiated interference to DIN EN50081 Part 1: Limit EN55011 Group 1 Class B (CISPR11 Class B)

Compliance with the measures stated for CISPR11 Class A is assumed. In addition an inphase choke is to be used at the inverter output.

Compliance with the interference voltage limit to EN55011 Class B (CISPR11 Class B) is achieved with these measures. The length of the motor cables is limited to max. 60 m. In comparison to CISPR11 Class A, further measures relating to the design and layout of the switchgear cubicle are necessary for compliance with the interference limit CISPR11 Class B for radiated interference (30 MHz - 1000 MHz). In particular the switchgear cubicle must be fully sealed. Cubicles are to be designed to guarantee good HF protection, if necessary using adapter kits after consultation with the manufacturer.

High EMC efficiency of the design in this frequency range is generally only possible by means of earthing. All measures for function earthing must be executed with great care. Metal PG screw connections (nickel plated brass) are to be used for the screen contacts when feeding the screened control and power cables into the cubicle and the motor terminal box.

Installation close to sensitive measurement and detection systems

A motor du/dt filter, if not already used for motor insulation protection, can be installed to further reduce any interference radiated by the motor cable, in addition to the measures stated for public electricity supply networks or the residential sector. A du/dt filter is particularly recommended near sensitive measurement or detection equipment, sensors or comparable sensitive control units. This also applies particularly if radio signals in the long and medium wave band are used during operation for controlling the plant, e.g. transponder signals.

Important!

The classification of the measures stated here applies only to connection to an earthed network.

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4 Operation and Software

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4.1 Unit operation The 8230 frequency inverter is normally operated through the BDE control unit. The following section describes operation using the control unit.

Fig. 46: 8230 frequencyinverter control unit BDE

90 BA8230

Operation and Software

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4.1.1 Software structure For operation with the control unit the user interface is divided into 2 levels. Level 1 contains the main menu.

Level 2 is used to select the parameters required.

Mainmenu Parameter

01 DIPSPLAY Output frequency

02 APPLICATION Speed limit PAR. Ref.overspeed

03 CONFIGURATION Reaktion OFF

04 ANALOG I/O’s Main demand 27/28

05 DIGITAL I/O’s D-Input 1:14

06 RATINGS Motor-type

07 CONTROL Control structure

08 DIAGNOSTICS First Fault

09 PASSWORD Protection Level

10 LANGUAGE SEL. Language

Speed Motor current

...............

Ramp up

...............

Auto Testart Time RS422: Baudrate

...............

Add. demand 29/30 A-output 1:33 A-output 2:35

................

D-Input 2:15 D-Input 3:16 D-Output 1:23/24

................

Nom. motor power Nom. motor voltage

.................

Speed cntrl. Kp

..................

Event Nr.

..................

Password Level 1 Password Level 2

................

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All options on the main menu are listed with the relevant codes on a label on the back of the control unit.

See section 4.3 for the full menu.

Operation and Software

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4.1.2 Control philosophy Operation of the unit with the 8230 frequency inverter control unit is divided into 3 control levels:

1) "Select main menu"

2) "Select Parameter"

3) "Select from list” or “Adjust a parameter value"

You move to the next lower control level using the “Enter” (4) key. You move back to the next higher level with the “Menu” key (3).

Select  Enter → Select  Enter → Select list Hauptmenu ← Menü  Parameter ← Menü  Adjust value

• In the “Select main menu” or “Select parameter” mode you can select a main menu

option for the parameter using the “Up” (5) and "Down" (6) keys.

• In the “Select list / Adjust value” mode you can either select from a list

(Example: Language: German / English / French) or adjust parameter values (eg. maximum speed: 1270 rpm → 1480 rpm).

• Parameters from the Select list are selected using the “Up” (5) and "Down" (6)

keys. If you select “Adjust a parameter value” using “Enter” (4), the number before the decimal point is selected first. This can then be adjusted with the Up(5) or Down (6) keys. When you have selected the right-hand number you can save your entry by pressing the “Enter” (4) key.

• If you made an adjustment in the “Select list/Adjust value” mode and saved it,

this is indicated by the message “Info: Parameter adjusted” (the word “Info” will flash). This message will disappear after 2 seconds. It tells the operator that a change was made on this level.

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Operation and Software

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4.2 Parameter adjustment Key control Selection in the relevant control level is with the “Up(5) and “Down” (6) keys. You move one level lower or save or confirm a value by pressing “Enter” (4). You move back up one level using the “Menu” key (3).

Display control The flashing cursor indicates your present level and the item

you can select using the “Up” (5) and “Down” (6) keys.

- The code and the relevant menu option appears on the first line in the “main

menu” level. The second line is blank.

02 = APPLIKATION PAR.

A cursor flashes to the left next to the code. This indicates that you can change

the code (= Menu block) using the “Up” (5) and “Down” (6) keys.

- After selecting the menu block required (in this case 02 Application parameter) using the “Up” (5) / “Down” (6) keys you can return to the “Select parameter” level using “Enter” (4).

The display then appears as follows:

02 Speed limit 5 1/min

1. line: The “02” indicates the code for the menu block (in this case the

application parameter). It no longer flashes as the menu block is already selected.

The first parameter of the relevant menu block (in this case “Speed limit”) appears to the right next to the code. The flashing cursor is positioned on the first letter of the parameter. It indicates that you are now on the “Select parameter” level. The parameter for the menu block already selected can now be selected with the “Up” (5) and “Down” (6) keys.

2. line: The value of the relevant parameter is displayed here. It has not yet

been selected. When you have selected the parameter required using the

“Up” (5) / “Down” (6) keys, you can move to the “Adjust value” level by pressing the “Enter” (4) key.

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The display then appears as follows:

02 Speed limit 1490 1/min

The first line shows the menu block you are in (in this case 02 = Speed limit) and the parameter you selected (in this case, maximum speed).

The flashing cursor on the second line is now located on the “1” as the highest value digit. The cursor indicates that this value can be adjusted using the “Up” (5) / “Down” (6) keys. The digits are selected with the “Enter” (4) key and are adjusted with the keys “Up” (5) / “Down” (6). When you have selected or adjusted the lowest value digit the value is saved when you press the “Enter” (4) key . This is conf irm ed by the display “Info: Parameter adjusted”. This mes sa ge disa ppe ars automatically after 2 seconds.

If the control level “Change select list” does not contain a value as described above but a select list instead (eg. German, English, French under the “Language” parameter you can select a parameter by pressing the “Up” (5) / “Down” (6) keys and save it using “Enter” (4). This is also followed by the message “Info: “Parameter adjusted”) for approx. 2 seconds.

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4.3 Menu

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Operation and Software

01 DISPLAY

02 APPLICATION PAR.

Protection Level 1 Ref. overspeed 1800 1/min

Protection Level 2

Output frequency 50.0 Hz Speed 1460.0 1/min

Motor current 34.5 A Motor voltage 400.0 V Torque 120.0 Nm Motor power 18.5 kW

DC link voltage 530.0 V Temp. heatsink. 25 °C

Working time 49.50 h Date, Time 01.06.95 10:30:10 Software ID 29152712 Software Version Lenze 8230 V2.0 Drive Name

Speed limit 1500 1/min

Crnt.lmt.max.mot.. 150 % Crnt.lmt.max.gen.. 100 % Crnt.lmt.nom.mot. 100 % Crnt.lmt.nom.gen. 100 % Ramp up 2.000 s Rampe down 5.000 s Ramp fast stop 0.200 s Motpot ramp up 10.000 s Motpot ramp down 10.000 s Motpot n-max 3000 1/min Motpot n-min 0.01 1/min Jogging speed 30.00 1/min Fixed speed 1 150.00 1/min Fixed speed 2 300.00 1/min Fixed speed 3 450.00 1/min Fixed speed 4 600.00 1/min Skip speed 1 750.0 1/min Skip band 1 0.0 1/min Skip speed 2 1500.0 1/min Bandbreite 2 0.0 1/min Skip speed 3 2250.0 1/min Skip band 3 0.0 1/min

No display at control structure = f-control

BA8230 95

Lenze 8230, 8231, 8234, 8232, 8233 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Comments

1 Brief description

1.1 General 8230 frequency inverter are processor-c ontrolled pulse inverters with a field-orientated control concept for continuous low-loss speed adjustment of AC motors.

1.3 Main features • Consistent range of Types for drives from 110 kW to 250 kW with

2 Technical Data

2.2 Series of types 8230 frequency inverter for 3-phase AC connection

2.3 System data • Mains supply voltage 3AC 400 ... 460 V; +10/-15 % ... 480 V; +6/-15 %

2.3.1 Standards, operating conditions and certificates

2.3.1.1 Standards applicable As per 06.1996

2.3.1.2 Certificate

2.3.1.3 CE Certificate

2.4 Supply components The 8230 frequency inverter can be supplied with power through connection of the units to a 3-phase supply.

2.4.1 Components for 3AC supply The components for connecting the 8230 frequency inverter to an AC network are determined according to the 8230 frequency inverter type rating. The basic components

2.5 Options The user can install optional assemblies and function modules to adapt the 8230 frequency inverter to many different applications.

2.5.2.1 Brake chopper The brake chopper is built in the 8230 frequency inverter, if version BE was ordered. The table below shows the brake chopper with the relevant technical data for the 8230 frequency inverter types.

2.5.2.2 Braking resistors The mean braking capacity and the duty cycle are determined for selecting the braking resistor (assuming braking is required). In addition, the minimum braking resistor or the maximum braking power of each 8230 frequency inverter with a power dump must be observed.

2.5.3 RFI filters

2.5.4 Motor filters and output chokes

2.5.4.1 Motor filters The use of the latest semiconductor technology allows extremely short times for

2.5.6 Option boards The options encoder interface is an option board which is installed on the rack of the information electronics.

2.6 Summary circuit diagrams

2.6.1 Summary circuit diagram, 8230 frequency inverter

2.7 Connection, terminal wiring

2.7.1 Power stack The power stack consists of a B6 diode input bridge, charging circuit, link and inverter. The AC bridge connections U1, V1, W1 are connected to the 3-phase AC supply

2.7.1.1 3AC supply

2.8 Dimensions, Installation drawing, weights

2.8.1 8230 frequency inverter build-in units

2.8.2 Mains chokes for 8230 frequency inverter

2.8.8 Dimensions and weights motor filters

2.8.9 Motor choke

2.8.10 Dimensions and weights RFI filters

3 Transport, Installation and Connection

3.1 Safety instructions During transport and on installation of each unit it is important to remember that the centre of gravity is not located at the centre of the unit itself. The asymmetrical loads resulting during transit and installation must therefore be taken into account accordingly.

3.5.1 Potential separation

4 Operation and Software

4.1 Unit operation The 8230 frequency inverter is normally operated through the BDE control unit. The following section describes operation using the control unit.

4.1.1 Software structure For operation with the control unit the user interface is divided into 2 levels. Level 1 contains the main menu.

4.1.2 Control philosophy Operation of the unit with the 8230 frequency inverter control unit is divided into 3 control levels:

4.2 Parameter adjustment Key control Selection in the relevant control level is with the “Up(5) and “Down” (6) keys. You move one level lower or save or confirm a value by pressing “Enter” (4). You move back up one level using the “Menu” key (3).

4.3 Menu