Lenze ECSxK User Manual

EDBCSXKXXX

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Ä."t<ä

Operating Instructions

ECS

Capacitor module of ECSxK series



This documentation is valid for ECS capacitor modules as of version:

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c

ECS x K xxx x 4 B xxx 1A

Type

Design

E=EnclosureIP20 D = Push-through technique (thermally separated) C=Coldplate

Capacity

001 = 705 µF (±20 %) 002 = 1410 µF (±20 %)

Voltage class

4 = 400 V/480 V

Technical version

B=Standard

Variant

L

Input

Output

Overload

Type

Id.-No.

Id.-No. xxxxxxxx

xxxxxxxx

ECSEAxxxC4BXXXXXVA02

EKZ

A-SW

h.h

ATTENTION

L ´appareil est sous tension

pendant 180s après la coupure

de la tension rèseau

WARNING

Deviceisliveupto180s

after removing

mains voltage

Hans-Lenze-Straße1

Hans-Lenze-Straße1 D-31855 Aerzen

D-31855 Aerzen

D-31855 Aerzen Made in Germany

Made in Germany

2/PE DC a-aaa/aaaV

2/PE DC a-aaa/aaaV bb.b/bb.bA

bb.b/bb.bA

bb.b/bb.bA 3/PE AC c-ccc/cccV

3/PE AC c-ccc/cccV

3/PE AC c-ccc/cccV dd.d/dd.dA 0-fffHz

dd.d/dd.dA 0-fffHz

ee.eA

1

ttttttttttt

Ser.-No.

Prod.-No.

Prod.-No. yyyyyyyy

yyyyyyyy

zzzz

Parameter

B-SW

H.H

1D74

For detailed information refer

to the Instruction Manual

Hardware version

1A or higher

 Tip!

Current documentations and software updates for Lenze products can be found on the Internet in the ”Downloads” area under

http://www.Lenze.com

© 2004 Lenze Drive Systems GmbH, Hans-Lenze-Straße 1, 31855 Aerzen No part of this documentation may be reproduced or made accessible to third parties without written consent by Lenze Drive Systems GmbH. All information given in this documentation has been selected carefully and complies with the hardware and software described. Nevertheless, deviations cannot be ruled out. We do not take any responsibility or liability f or damages which might possibly occur. Necessary corrections will be included in subsequent editions.

+UG +UG -UG -UG PE PE

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X23

0

1

2

X26

 Capacitor module ECSxK  Accessory kit with fixing material  Safety instructions for modules of the ECS series

X23 Connections:

- DC-bus supply

-PE

X26 Control connection for bridging the charging current limitation

ECSXK001

EDBCSXKXXX EN 1.0

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EDBCSXKXXX EN 1.0

Contents i

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1 Preface and general information 7............................................

1.1 About these Operating Instructions 7.....................................

1.2 Terminology used 7....................................................

1.3 Legal regulations 8.....................................................

2 Safety instructions 9.........................................................

2.1 General safety and application information for Lenze capacitor modules 9......

2.2 Residual hazards 12.....................................................

2.3 Safety instructions for the installation according to UL or UR 13................

2.4 Definition of notes us ed 14...............................................

3 Technical data 15............................................................

3.1 General data/operating conditions 15......................................

3.2 Rated data 16..........................................................

4 Mechanical installation 17.....................................................

4.1 Important notes 17......................................................

4.2 Mounting with fixing rails (standard) 18....................................

4.3 Thermally separated mounting (”push-through technique”) 19.................

4.4 Mounting in ”cold plate” technique 21.....................................

5 Electrical installation 23.......................................................

5.1 Important notes 23......................................................

5.1.1 Protection of persons 23..........................................

5.1.2 Device protection 24.............................................

5.1.3 Electrical isolation 24............................................

5.2 Drive system on the mains 25.............................................

5.2.1 Supply form/electrical supply conditions 25.........................

5.2.2 Operation on public supply systems (compliance with EN 61000-3-2) 25.

5.3 Installation of a DC-typical drive system 26.................................

5.4 Power connections 28...................................................

5.4.1 Terminal assignment of the power connections 28...................

5.4.2 Fusing the DC-bus supply 28......................................

5.4.3 Specification of the cables used 28.................................

5.5 Control connection 30...................................................

5.6 Wiring 31..............................................................

5.6.1 Operation with ECSxE power supply module 31......................

5.6.2 Operation with another supplier 33................................

EDBCSXKXXX EN 1.0

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Contentsi

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6 Commissioning 34...........................................................

7 Appendix 35................................................................

7.1 Overview of accessories 35...............................................

7.1.1 Connectors 35..................................................

7.1.2 DC bus fuses 35.................................................

7.2 Index 36...............................................................

6

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EDBCSXKXXX EN 1.0

Preface and general information

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1 Preface and general information

1.1 About these Operating Instructions

These Operating Instructions assist you in connecting and commissioning the ECSxKxxx capacitor modules. They include safety instructions which must be observed.

All personsworking on and with the ECSxKxxxcapacitormodules musthavetheOperating Instructions available a nd must observe the information and notes relevantfor their work.

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

1.2 Terminology used

Term In the following text used for

Power supply module

ECSxExxx ECSxExxx power supply module

Capacitor module Any type of capacitor module

ECSxKxxx ECSxKxxx capacitor module

Axis module Controller

ECSxAxxx ECSxAxxx axis module

Drive system Drive systems with:

24 V supply Low-voltage supply

KSB Short-circuit braking: Quick discharge of the DC bus via the brake resistor

AIF AutomationInterFace

Cxxxx/y Subcode y of code Cxxxx (e. g. C0470/3 = Subcode 3 of code C0470)

Xk/y Terminal y on the terminal strip Xk (e. g. X6/B+ = terminal B+ on the terminal strip X6)

Anytypeofpowersupplymodule

Any axis module

z

ECSxAxxx axis modules

z

ECSxExxx power supply modules

z

ECSxKxxx capacitor modules

z

Other Lenze drive components

24 V DC supply

z

of the control card in a voltage range of 20 ... 30 V DC (±0V)

z

of ”Safe standstill” in a voltage range of 18 ... 30 V DC (±0V)

z

of the motor holding brake in a voltage range of 18 ... 30 V DC (±0V)

1

About these Operating Instructions

EDBCSXKXXX EN 1.0

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1

g

p

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Preface and general information

Legal regulations

1.3 Legal regulations

Labelling

Application as directed

Liability

Warranty

Disposal Material recycle dispose

Nameplate CE-identification Manufacturer

Lenze capacitor modules are clearly designated by the date on the nameplate.

ECSxKxxx capacitor modules

z

must only be operated under the conditions prescribed in these Instructions.

z

are components – for backing up the DC-bus voltage for the drive system. – for installation into a machine – for assembly with other components to form a machine.

z

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

z

comply with the requirements of the Low-Voltage Directive.

z

are not machines for the purpose of the Machinery Directive.

z

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

Drive systems with ECSxKxxx capacitor modules

z

comply with the EMC Directive ”Electromagnetic compatibility” if they are installed according to the guidelines of CE-typical drive systems.

z

can be used – for operation on public and non-public mains – in industrial areas.

z

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

Any other use shall be deemed inappropriate!

z

The information, data, and notes in these Instructions met the state of the art at the time of printing. Claims on modifications referring to capacitor modules and components which have already been supplied cannot be derived from the information, illustrations, and descriptions.

z

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

z

Lenze does not accept any liability for damage and operating interference caused by: – Disregarding the Operating Instructions – Unauthorised modifications to the capacitor modules – Operating errors – Improper working on and with the capacitor module

z

Terms of warranty: See terms of sales and delivery of Lenze Drive Systems GmbH.

z

Warranty claims must be made to Lenze immediately after detecting the deficiency or fault.

z

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

Metal D -

Plastic D -

Assembled PCBs - D

Conforms to the EC Low-Voltage Directive

Lenze Drive Systems Gmb H Postfach 101352 D-31763 Hameln

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EDBCSXKXXX EN 1.0

Safety instructions

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General safety and application information for Lenze capacitor modules

2 Safety instructions

2.1 General safety and application information for Lenze capacitor modules

(according to Low-Voltage Directive 73/23/EWG)

General

During operation, Lenze capacitor modules can include live parts, depending on their type of protection. Surfaces can be hot.

If the required cover is removed or the modules are used inappropriately or installed or operated incorrectly, severe damage to persons or material can occur.

For more information please see the documentation.

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

2

According to this basic safety information, qualified, skilled personnel are persons who are familiar with the assembly, installation, commissioning, and operation of the product and who have the qualifications necessary for their occupation.

Application as directed

Capacitor modules are components which are designed for the installation into electrical systems or machinery. They are not to be used as domestic appliances, but only for industrial purposes according to EN 61000-3-2. The documentation contains information about the compliance with the limit values to EN 61000-3-2.

When installing capacitor modules into machines, commissioning of the drive controllers (i.e. the starting of operation as directed) is prohibited until it is proven that the machine corresponds to the regulations of the EC Directive 98/37/EG (Machinery Directive); EN 60204 (VDE 0113) must be observed.

Commissioning (i.e. starting of operation as directed) is only allowed when there is compliance with the EMC Directive (89/336/EEC).

The capacitor modules meet the requirements of the Low-Voltage Directive 73/23/EWG. The harmonised standards of EN 50178 / DIN VDE 0160 apply to the capacitor modules.

The technical data and information on the connection conditions can be obtained from the nameplate and the documentation. The instructions must be strictly observed.

Warning: The capacitor modules are products with restricted availability according to EN 61800-3. These products can cause interferences in residential premises. If capacitor modules are used in residential premises, corresponding measures are required.

EDBCSXKXXX EN 1.0

Transport, storage

The notes on transport, storage and appropriate handling must be observed.

Observe the climatic conditions required to EN 50178.

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Safety instructions

General safety and application information for Lenze capacitor modules

Installation

The capacitor modules must be installed and cooled according to the regulations given in the corresponding Instructions.

Ensure careful handling and avoid mechanical stress. Do not bend any components and do not change the insulation distances during transport and handling. Do not touch any electronic components and contacts.

Capacitor modules contain electrostatic sensitive devices which can easily be damaged by inappropriate handling. Do not damage or destroy any electrical components since this means hazards for your health!

Electrical connection

When working on live capacitor modules, the valid national regulations for the prevention of accidents (e. g. VBG 4) m ust be observed.

The electrical installation must be carried out in compliance with the corresponding regulations (e. g. cable cross-sections, fusing, PE connection). Additional information can be obtained from the documentation.

The documentation contains notes for EMC-compliant installation (shielding, earthing, filters and cable routing). These notes must also be observed when using CE-marked capacitor modules. The manufacturer of the system or machine is responsible for the compliance with the limit values required by the EMC legislation.

Operation

If necessary, systems including capacitor modules must be equipped with additional monitoring and protection devices according to the corresponding safety regulations (e. g. law on technical equipment, regulations for the prevention of accidents). The capacitor module can be adapted to your application. Please observe the corresponding information given in the documentation.

After the capacitor module has been disconnected from the supply voltage, live components and power connections must not be touched immediately because capacitors can be charged. Please observe the corresponding labels on the capacitor module.

All protection covers and doors must be shut during operation.

Note for UL-approved system with integrated capacitor modules:

UL warnings are notes which only apply to UL systems. The documentation contains special UL-related information.

Maintenance and servicing

The capacitor modules are free of maintenance if the prescribed conditions of operation are observed.

10

In operating areas with polluted ambient air, the cooling surfaces of the capacitor module can get dirty or the cooling openings can block. Under these conditions a regular cleaning of the cooling surfaces and cooling openings is essential. Do not use sharp or pointed objects for this purpose!



EDBCSXKXXX EN 1.0

Safety instructions

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General safety and application information for Lenze capacitor modules

Disposal

Recycle metals and plastics. Dispose of printed circuit board assemblies according to the state of the art.

The product-specific safety and application notes in these Instructions must also be observed!

2

EDBCSXKXXX EN 1.0

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2.2 Residual hazards

Safety instructions

Residual hazards

Protection of persons

ƒ Before working on the capacitor module, check that no voltage is applied to the

power terminals, – because the power terminals +UG and -UG at the supply module remain live for at

least 3 minutes after mains switch-off.

– because the power terminals +UG and -UG remain live when the motor is stopped.

ƒ If an error occurs (short circuit to frame or earth fault) a DC residual current may

occur in the PE conductor. If an earth-leakage circuit breaker (residual current device) is used to protect against direct or indirect c ontact, only the use of an earth-leakage circuit breaker of type B is permissible on the current supply side. If not, another protective measure is to be used, as for example, separation from the environment by double or reinforced insulation or separation from the mains by using a transformer.

Device protection

ƒ All pluggable connection terminals must only be connected or disconnected when

no voltage is applied.

ƒ The power terminals +UG, -UG and PE are not protected against polarity reversal.

– When wiring, observe the polarity of the power terminals.

ƒ The power may only be converted if the power supply module in the power system

is ready for operation and the charging current limitation i s bridged. Otherwise the charging current limitation can be destroyed.

ƒ If the charging current limitation is active, a cyclic switching of the mains voltage at

the power supply module can overload and destroy the capacitor. Therefore, at least three minutes have to pass between two starting operations in case of cyclic mains switching over a longer period of time.

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EDBCSXKXXX EN 1.0

Safety instructions

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Safety instructions for the installation according to UL or UR

2

2.3 Safety instructions for the installation according to ULor U

 Warnings!

General markings:

ƒ

Use 60/75 °C or 75 °C copper wire only.

ƒ

Maximum ambient temperature 55 °C, with reduced output current.

Terminal tightening torque of lb-in (Nm)

ƒ

x23 – 10.6 ... 13.3 lb-in (1.2 ... 1.5 Nm)

ƒ

x26 – 4.4 ... 7.1 lb-in (0.5 ... 0.8 Nm)

Wiring diagram AWG

ƒ

x23 – AWG 12 ... AWG 8

ƒ

x26 – AWG 24 ... AWG 12

R

EDBCSXKXXX EN 1.0

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2.4 Definition of notes used

Safety instructions

Definition of notes used

The following signal words and symbols are used in this documentation to indicate dangers and important information:

Safety instructions

Structure of safety instructions:



Pictograph and signal word Meaning

 Danger!

 Danger!

 Stop!

Application notes

Pictograph and signal word Meaning

 Note!

Danger!

(characterises the type and severity of danger)

Note

(describes the danger and gives information about how to prevent dangerous situations)

Danger of personal injury through dangerous electrical voltage.

Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken.

Danger of personal injury through a general source of danger

Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken.

Danger of property damage.

Reference to a possible danger that may result in property damage if the corresponding measures are not taken.

Important note to ensure trouble-free operation

14

 Tip! 

Special safety instructions and application notes for UL and UR

Pictograph and signal word Meaning

 Warnings!

 Warnings!

Useful tip for simple handling

Reference to another documentation

Safety or application note for the operation of a UL-approved device in UL-approved systems.

Possibly the drive system is not operated in compliance with UL if the corresponding measures are not taken.

Safety or application note for the operation of a UR-approved device in UL-approved systems.

Possibly the drive system is not operated in compliance with UL if the corresponding measures are not taken.



EDBCSXKXXX EN 1.0

Technical data

p

y

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General data/operating conditions

3 Technical data

3.1 General data/operating conditions

Standards and operating conditions

Conformity CE

Approvals

Vibration resistance Accelerational stability up to 0.7 g (Germanischer Lloyd, general conditions)

Climatic conditions Class 3K3 to EN 50178 (without condensation, relative humidity 30 ... 95 %)

Degree of pollution VDE 0110 part 2 pollution degree 2

Packaging (DIN 4180) Delivery packing

Permissible Transport -25 ... +70 °C temperature range

Permissible installation height 0 ... 4000 m amsl reduce rated AC current by 5%/1000 m above 1000 m amsl

Installation Installation into control cabinet

Mounting position Vertically suspended

Free space Above/below ≥ 50 mm

Storage

Operation 0 ... +55 °C reduce the rated AC current by 2 %/°C above +40°C

To the sides Side-by-side mounting without any clearance

UL 508C Power Conversion Equipment

-25 ... +55 °C

Low-Voltage Directive (73/23/EWG)

Underwriter Laboratories (File No. E132659) for USA and Canada

3

General electrical data

EMC Compliance with EN 61800-3

Noise emission Compliance with limit value class A to EN 55011

(achieved with application-specific collective filter)

Noise immunity Requirements to EN 61800-3

Requirements Standard Severity

1)

ESD

High frequency in cables EN 61000-4-6 10 V; 0.15 ... 80 MHz

RF interference (enclosure) EN 61000-4-3 3, i. e. 10 V/m;

Burst EN 61000-4-4 3/4, i. e. 2 kV/5 kHz

Surge (on mains cable) EN 61000-4-5 3, i. e. 1.2/50 µs

Insulation resistance Overvoltage category III to VDE 0110

Discharge current against PE (to EN 50178) > 3.5 mA AC for operation with corresponding controllers

Enclosure

Protective insulation of control circuits Safe disconnection from supply: Double/reinforced insulation to EN 50178;

1)

Noise immunity in the above-mentioned seve rities must be guaranteed through the control cabinet! The user must check the compliance with the seve rities!

z

IP20 for standard mounting

z

IP20 for mounting in cold-plate technique

z

IP20 for mounting in push-through technique; IP54 on the heatsink side

Rated insulation voltage 300 V x √2

EN 61000-4-2 3, i. e.

z

8 kV with air discharge

z

6kVwithcontactdischarge

80 ... 1000 MHz

z

1 kV phase-phase

z

2kVphasePE

EDBCSXKXXX EN 1.0

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Technical data

Rated data

3.2 Rated data

Rated data Type ECSxK001xxx ECSxK002xxx

Data for operation with upstream supply module on mains voltage

DC-bus voltage UDC[V] 0 ... 770

Rated AC current Ir[A] 17,5 35

Rated power PB[kW] 10 20

Rated power with mains choke PBN[kW] 14 28

Capacity C[µF] 705 (±20 %) 1410 (±20 %)

Time constant for charging the capacitors

Charging time after mains connection t

Weight

Dimensions

ECSEKxxx m[kg] 2.1 3.2

ECSDKxxx m[kg] 2.1 3.2

ECSCKxxx m[kg] 2.4 3.4

ECSEKxxx (WxHxD)

ECSDKxxx (WxHxD)

ECSCKxxx (WxHxD)

U

[V] 400 480 400 480

mains

τ

[ms]

C_charging

[mm]

[s] 1

88.5 x 247 x 176 132 x 247 x 176

88.5 x 282 x 123 132 x 282 x 123

150

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EDBCSXKXXX EN 1.0

4 Mechanical installation

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4.1 Important notes

ƒ ECSxKxxx capacitor modules are provided with IP20 protection and can therefore

only be used for installation into control cabinets. – For thermally separated mounting (ECSDKxxx): IP54 on the heatsink side

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

– Take suitable preventive measures , e.g. separate air duct, installation of filters,

regular cleaning.

ƒ Ensure free space!

– Ensure unimpeded ventilation of cooling air and outlet of exhaust air. – You can install several capacitor modules next to each other without any clearance

in a control cabinet.

– Allow a free space of 50 mm above and below other i nstallations or limitations.

Mechanical installation

Important notes

4

ƒ The mounting plate of the control cabinet must be electrically conductive.

ƒ In case of continuous vibrations or shocks use shock absorbers.

Possible mounting positions

Vertically on the mounting plate with DC-bus connections at the top

Mounting techniques

ƒ With fixing rails (standard,  18)

ƒ Thermal separation (”push-through technique”,  19)

ƒ In ”cold plate” technique ( 21)

EDBCSXKXXX EN 1.0

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Mechanical installation

Mounting with fixing rails (standard)

4.2 Mounting with fixing rails (standard)

Type ECSEKxxx

For standard mounting into the control cabinet the capacitor module types ECSEKxxx must be used. The accessories required for mounting are included in the scope of supply.

Dimensions

gg

³ 50 mm

b

³ 50 mm

Fig.4-1 Dimensions for standard mounting with fixing rails, ECSEKxxx type

Capacitor modules Dimensions [mm]

Type Size O B D E g h

ECSEK001 1 88.5

ECSEK002 2 132

e

276 260 176

h

d

g

a

h

d

b

6.5

(M6)

g

a

ECSXK005

10

18

Mounting

For mounting the capacitor module ECSEKxxx proceed as follows:

1. Prepare the fixing holes (see drawing)

2. Take the fixing rails from the accessory kit in the cardboard box.

3. Push the rails into the slots of the heatsink: – From above: push in the long side. –Frombelow:pushintheshortside.

4. Fix the capacitor module onto the mounting plate.

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EDBCSXKXXX EN 1.0

Mechanical installation

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Thermally separated mounting (”push-through technique”)

4.3 Thermally separated mounting (”push-through technique”)

Type ECSDKxxx

For thermally separated mounting the capacitor modules of ECSDKxxx type must be used. The accessories required for mounting are included in the scope of supply.

ƒ Protection class of the separated cooler: IP54

ƒ When using the push-through technique the pack panel of the control cabinet must

be a steel plate with a thickness of 3 mm. The plate must be flat or slightly arched inwards (to the capacitor module). This applies to the transverse and lengthwise direction.

Dimensions

4

a1

³ 50 mm

Fig.4-2 Dimensions for thermally separated mounting, ECSDKxxx type

Capacitor modules Dimensions [mm]

Type Size O A1 B b1 c1 D E e1 g h

ECSDK001 1 88.5 78.5

ECSDK002 2 132 121.5

ee1

Z Mounting cutout (a1 x b1)

g

b

b1

c1

a

240 197 75 250 116 58 M5 10.5

Z Z

h

d

g

b

b1

a1

g

c1

a

h

d

g

ECSXK007

EDBCSXKXXX EN 1.0

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Mechanical installation

Thermally separated mounting (”push-through technique”)

Dimensions of mounting cutout

a1

g

³ 60 mm

b1

³ 90 mm

Fig.4-3 Dimensions of mounting cutout for thermally separated mounting, ECSDKxxx type



 Mounting cutout for ECSDK001  Mounting cutout for ECSDK002

g

Mounting plate

c1

0

1

a1

h

c1

2

b1

d

ECSXK063

Capacitor modules Dimensions [mm]

Type Size A1 b1 c1 D g h

ECSDK001 1 78.5

ECSDK002 2 121.5

197 75 250 M5 10.5

Mounting



Stop!

When boring through the rear panel of the control cabinet:

Seal the fixing screws with a liquid thread seal to ensure the protection class IP54 for the separated heatsink.

For mounting the capacitor module ECSDKxxx proceed as follows:

1. Prepare fixing holes for the clips (see drawing).

2. Prepare mounting cutout.

3. Fix the clips.

4. Push the capacitor module into the mounting cutout.

5. Let the capacitor module snap into place at the top and bottom.

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EDBCSXKXXX EN 1.0

4.4 Mounting in ”cold plate” technique

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Type ECSCKxxx

It is possible to mount the capacitor modules in cold-plate technique, for instance, onto collective coolers. For this mounting, the capacitor modules type ECSCAxxx must be used.

Dimensions

³ 50 mm

Mechanical installation

Mounting in ”cold plate” technique

a

g

a1

g

4

a

a1

d

³ 50 mm

e

Fig.4-4 Dimensions for mounting in ”cold plate” technique, ECSCKxxx type

Capacitor modules Dimensions [mm]

Type Size O A1 B c1 D E g

ECSCK001 1 88.5 60 ECSCK002 2 132 90

b

g

c1

282 50 286 123 M6

b

 Stop!

Penetration depth of the screws into the cooler: Approx. 15 mm!

g

c1

ECSXK009

EDBCSXKXXX EN 1.0

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Mechanical installation

Mounting in ”cold plate” technique

Mounting

ÀÁÂ

ECSXK030

Fig.4-5 Mounting in ”cold plate” technique

For mounting the capacitor module ECSCKxxx proceed as follows:

1. Prepare the fixing holes (see drawing)

2. Clean and degrease the contact area of cooler and heatsink (e. g. with methylated spirit).

3. Screw the support onto the cooler.

4. Insert the capacitor module from above c into the support d and fasten both studs with 3.5 ... 4.5 Nme.

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EDBCSXKXXX EN 1.0

5 Electrical installation

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5.1 Important notes

Electrical installation

Important notes

Protection of persons

5



5.1.1 Protection of persons



Stop!

The capacitor module contains electrostatically sensitive components. Prior to assembly and service operations, the personnel must be free of

electrostatic charge.

Danger!

ƒ

Before working on the capacitor module, check that no voltage is applied to the power terminals,

– because the power terminals +UG and -UG remain live for at least three

minutes after mains switch-off.

– because the power terminals +UG and -UG remain live when the motor is

stopped.

ƒ

If an error occurs (short circuit to frame or earth fault), a DC residual current may occur in the PE conductor. If an earth-leakage circuit breaker (residual current device) is used to protect against direct or i ndirect contact, only the use of an earth-leakage circuit breaker of type B is permissible on the current supply side. If not, another protective measure is to be used, as for example, separation from the environment by double or reinforced insulation or separation from the mains by using a transformer.

EDBCSXKXXX EN 1.0

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5.1.2 Device protection

Electrical installation

Important notes Device protection



5.1.3 Electrical isolation

Stop!

ƒ

All pluggable connection terminals must only be connected or disconnected when no voltage is applied.

ƒ

The power terminals +UG, -UG and PE are not protected against polarity reversal.

– When wiring, observe the polarity of the power terminals!

ƒ

The power may only be converted if the power supply module in the power system is ready for operation and the charging current limitation is bridged. Otherwise the charging current limitation can be destroyed.

ƒ

If the charging current limitation is active, a cyclic switching of the mains voltage at the power supply module can overload and destroy the capacitor. Therefore, at least three minutes have to pass between two starting operations in case of cyclic mains s witching over a longer period of time!

Bridging of the charging current limitation

X26 X23/+UG, -UG

Double insulation

DC bus

Fig.5-1 Electrical isolation

24



EDBCSXKXXX EN 1.0

Supply form/electrical supply conditions

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5.2 Drive system on the mains

These information apply to the drive system, consisting of:

ƒ ECSxExxx power supply module

ƒ ECSxKxxx capacitor module

ƒ ECSxAxxx axis module

ƒ Motor

ƒ Accessories

ƒ Wiring

5.2.1 Supply form/electrical supply conditions

Please observe the restrictions for the respective supply forms.

Mains Operation of the capacitor modules Notes

With earthed neutral (TT/TN systems)

With isolated neutral (IT systems)

DC-supply via +UG/-UG

No restrictions The capacitor module will be destroyed if

The operation on symmetrical IT systems with PE is permitted.

Permitted if the DC voltage is symmetrical with PE.

Electrical installation

Drive system on the mains

+UG conductor or -UG conductor are earthed.

The capacitor module will be destroyed if +UG conductor or -UG conductor are earthed.

5

5.2.2 Operation on public supply systems (compliance with EN 61000-3-2)

The European standard EN 61000-3-2 specifies limit values for limiting harmonic currents in the supply system. Non-linear loads (e. g. frequency inverters) create harmonic currents, which impair the supply system and thus may disturb other loads. The objective of this standard is to ensure the quality of the public supply systems and reduce the mains load.



Note!

This standard only applies to public supply systems. Supply systems with an own transformer station which are standard in industrial firms are not public and are out of the scope of the standard.

If a device or machine consists of several components, the limit values of the standard are applied to the entire unit.

EDBCSXKXXX EN 1.0



25

5

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5.3 Installation of a DC-typical drive system

Electrical installation

Installation of a DC-typical drive system

General notes

ƒ The electromagnetic compatibility of a machine depends on the type of installation

and care taken.Especially consider the following: – Structure – Filtering – Shielding –Earthing

ƒ For diverging installations, the conformity to the CE EMC Directive requires a check

of the machine or system regarding the EMC limit values. This is valid, for instance, when:

– Using unshielded cables – Using collective suppression filters in place of the assigned RFI filters – Operating without RFI filters

ƒ The compliance of the machine application with the EMC Directive is in the

responsibility of the user. – If you observe the following measures, you can assume that the m achine will

operate without any EMC problems caused by the drive system and that compliance with the EMC Directive and the EMC law is achieved.

– If devices which do not comply with the C E requirement concerning noise

immunity EN 61000-6-2 are operated close to the axis modules, these devices may be disturbed electromagnetically by the axis modules.

Structure

ƒ Install the capacitor module between the power supply module and the axis

module(s).. – For cable lengths > 5 m we recommend to install the capacitor module as close as

possible to the axis module with the highest power.

ƒ Connect power supply modules, capacitor modules, axis modules, RFI filters, and

mains choke to the earthed mounting plate with a large surface: – Mounting plates with conductive surfaces (zinc-coated or stainless steel) allow

permanent contact.

– Painted plates are not suitable for the installation in accordance with the EMC.

ƒ If you use several mounting plates:

– Connect the mounting plates electrically with a large surface (e.g. with copper

bands).

26

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

ƒ Do not use the same terminal strip for mains input and motor output.

ƒ Lay the cables as close as possible to the reference potential. Freely suspended

cables act like aerials.



EDBCSXKXXX EN 1.0

Electrical installation

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Installation of a DC-typical drive system

Filtering

ƒ Use RFI filters and mains chokes which are assigned to the power supply modules:

– RFI filters reduce impermissible high-frequency interferences to a permissible

value.

– Mains chokes reduce low-frequency interferences which depend on the motor

cable and its length.

Shielding

ƒ Connect the motor cable shield to the axis module

– with the EMC accessories ECSZS000X0B. – to the mounting plate below the axis module with a large surface. – Recommendation: For the shield connection, use earthing clamps on bare metal

mounting surfaces.

ƒ If contactors, motor-protecting switches or terminals are located in the motor cable:

– Connect the shields of the connected cables to the mounting plate, too, with a

surface as large as possible.

5

ƒ Connect the shield in the motor terminal box or on the motor housing to PE:

– Metal glands at the motor terminal box ensure a connection of the shield and the

motor housing.

ƒ Shield the control cables:

– Connect both shields of the digital control cables. – Connect one shields of the analog control cables. – Always connect the shields to the shield connection at the controller over the

shortest possible distance.

ƒ Using the axis modules in residential areas:

– Additionally dampen the shield in order to limit the interfering radiation: ≥ 10 dB .

This can be realised by using s tandard, closed, metallic, and earthed control cabinets or boxes.

Earthing

ƒ Earth all metallically conductive components (power supply module, capacitor

module, axis module, RFI filter, motor filter, mains choke) using suitable cables connected to a central point (PE bar).

ƒ Maintain the minimum cross-sections prescribed in the safety regulations:

– For the EMC, not the cable cross-section is important, but the surface and the

contact with a cross-section as large as possible, i.e. large surface.

EDBCSXKXXX EN 1.0



27

5

V

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Electrical installation

Power connections Terminal assignment of the power connections

5.4 Power connections

5.4.1 Terminal assignment of the power connections

Terminal Function Electrical data

X23 Connection of DC-bus voltage

X23/+UG

X23/-UG

X23/PE

Positive supplyofDC-bus voltage

Negative supplyofDC-bus voltage

Earth connection

5.4.2 Fusing the DC-bus supply

When ECSxE power supply modules with a mains-side protection are used, the DC-bus cables do not need to be fused.

Dependent on application and type 0 ... 770

When using capacitor modules in the DC-bus connection with basic devices of the 82xx and 93xx series, use the following fuses:

Fuse Support

Value [A] Lenze type Lenze type

50 EFSGR0500ANIN EFH20007

 Warnings!

ƒ

Use UL-approved cables, fuses and fuse holders only.

ƒ

UL fuse:

– Voltage 500 ... 600 V – Tripping characteristic ”H”, ”K5” or ”CC”

5.4.3 Specification of the cables used

The cables used must comply with the required approvals at the place of installation (e.g.UL).

Installation of the cables to EN 60204-1 (1998)

Shielded cables

28

Observe the following to increase the effect of shielded cables:

ƒ A good shield connection:

– Ensure a contact surface as large as possible

ƒ Low shield resistance:

– Only use shields with tin-plated or nickel-plated copper braids (shields with steel

braids cannot be used).

ƒ High contact ratio of the shield braid:

– At least 70 ... 80 % with 90 ° overlap angle



EDBCSXKXXX EN 1.0

Cable cross-sections

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Electrical installation

Power connections

Specification of the cables used

5

Terminal Function Screw tightening torques Possible cable

X23 Connection of D C-bus voltage

X26

Control connection for bridging the charging current limitation

1.2 ... 1.5 Nm

10.6 ... 13.3 lb-in

0.5 ... 0.8 Nm

4.4 ... 7.1 lb-in

cross-sections

z

rigid –0.2...10mm – AWG 24 ... 8

z

flexible –0.2...10mm – AWG 24 ... 10

z

With wire end ferrule – 0.25 ... 6 mm – AWG 22 ... 10

z

With TWIN wire end ferrule – 0.25 ... 4 mm – AWG 22 ... 12

z

flexible – 0.2 ... 2.5 mm – AWG 24 ... 12

2

EDBCSXKXXX EN 1.0



29

5

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Electrical installation

Control connection

5.5 Control connection

Terminal Function Electrical data

X26

Connection for bridging the charging current limitation

The polarity does not influence the function of the charging current limitation.

21.8 ... 30 V DC, max. 1.5 A

30



EDBCSXKXXX EN 1.0

Operation with ECSxE power supply module

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5.6 Wiring

5.6.1 Operation with ECSxE power supply module

Install the capacitor module ECSxKxxx between the power supply module and the axis module(s).

If the total cable length in the DC-bus connection is longer than 5 m, install the capacitor module as close as possible to the axis module with the highest power.

Electrical installation

Wiring

5



Stop!

ƒ

Permanently bridge the charging current limitation (X26) of the capacitor module(X26=HIGH).

ƒ

Only release the controller (X6/SI1 = HIGH) if the power supply module ECSxE displays ”Ready for operation” (X6/DO1 = HIGH).

K1

L1 L2

L3

N

PE

GND

F1...F3

-

+

Z1

PES

L1 L2

T1

K1

L3

PE

X21

ECSxExxx

X6

DI2

DO1

T2

DI1

+UG

X22

PE

-UG

+UG

PE

-UG

PE

-UG

X23

BR0

+UG

BR1

ECSxKxxx

D24

+24V

GND

X26

+UG

B1 B2

PES

Ctrl. enable

F4

Off

On

K1

24VDC

Fig.5-2 Wiring of the capacitor module ECSxK with power supply module ECSxE

-UG

+UG

-UG

X23

ECSxAxxx

X25

U

PE

...

X24

V

M

3~

X7

W

PE

*1

6

R

J

2

ECSXX004

EDBCSXKXXX EN 1.0

HF shield termination by large-surface PE connection

Twisted cables

*1 System cable - feedback Ctrl.

enable

Terminal X6/SI1 of the connected axis modules (controller enable)



31

5

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Electrical installation

Wiring Operation with ECSxE power supply module

ECSxA: X6/SI1 (CINH)

HIGH (1)

ECSxE: X6/DO1

LOW (0)

100 %

U

ZK

0%

ECSxK: X26 (24 V DC)

HIGH (1)

ECSxE: X6/DI1 ECSxE: X6/DI2

LOW (0)

HIGH (1)

K1

LOW (0)

Fig.5-3 Level/time diagrams for operation with ECSxE power supply module

t [s]

ECSXK010

32



EDBCSXKXXX EN 1.0

5.6.2 Operation with another supplier

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Electrical installation

Wiring

Operation with another supplier

5



Stop!

ƒ

After mains connection, wait at least one second before bridging the charging current limitation (X26 = HIGH).

ƒ

Only release the controller (X6/SI1 = H IGH) if the charging current limitation is bridged.

1 (HIGH)

ECSxA: X6/SI1 (CINH)

U

ECSxK: X26 (24 V DC)

0(LOW)

100 %

ZK

0%

1 (HIGH)

0(LOW)

t [s]

1 (HIGH)

K1

0(LOW)

Fig.5-4 Level/time diagrams for operation with other supplier

1

t [s]

ECSXK011

EDBCSXKXXX EN 1.0



33

Commissioning6

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6 Commissioning

Before you start

Prior to initial switch-on of the drive system, check the wiring of the capacitor module for completeness, short-circuit, and earth fault:

ƒ Power connection (X23):

– Polarity of the DC-bus voltage supply via terminals +UG and -UG

ƒ Control connection (X26):

– Wiring adjusted to the signal assignment of the control terminals.



Further information on commissioning the drive system can be obtained from the documentations for the power supply module and axis module.

34



EDBCSXKXXX EN 1.0

7 Appendix

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7.1 Overview of accessories

The accessories are not included in the scope of supply. The capacitor module and accessories are carefully coordinated.

7.1.1 Connectors

Inorderto provide a flexible purchasing,theconnectorsareavailable as a separate delivery unit.

ƒECSZK000X0B (connectors for capacitor modules)

7.1.2 DC bus fuses

Appendix

Overview of accessories

7

The DC bus must only be fused when using the capacitor module with ba sicdevice of 82xx and 93xx series. Here, the following fuses must be used:

Fuse Support

Value [A] Lenze type Lenze type

50 EFSGR0500ANIN EFH20007

EDBCSXKXXX EN 1.0



35

7

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Appendix

Index

7.2 Index

A

Accessories, 35

- connectors, 35

- DC bus fuses, 35

Appendix, 35

Application as d irected, 8

Approvals, 15

B

Bridging of charging current limitation, connection, 30

C

Cable cross-sections, 29

Capacitor module, 7

- application as directed, 8

- labelling, 8

- type ECSCKxxx, mounting in ”cold plate” technique, 21

- type ECSDKxxx, thermally separated mounting, 19

- type ECSEKxxx, mounting with fixing rails, 18

Capacitor module, connection, 31

Capacity, 16

CE-typical drive system, 26

-earthing, 27

- filtering, 27

- installation, 26

- shielding, 27

- structure, 26

Charging current limitation, bridging, connection, 30

Charging time, capacitors, 16

Climatic conditions, 15

Commissioning, 34

Conformity, 15

Connection - bridging of charging current limitation, 30

Connection of D C bus voltage, 28

Connection, capacitor module, 31

Connectors, 35

Control connection (X26), terminal assignment, 30

Controller, 7

D

DC bus fuses, 28

DC bus supply, fusing, 28

DC bus voltage, 16

DC bus voltage, connection, 28

DC-bus fuses, 35

Definition of notes used, 14

Definitions, 7

Degree of pollution, 15

Device protection, 12

Dimensions, 16

Discharge current against PE, 15

Disposal,8,11

Drive system, 7

Drive system on the mains, 25

- operation on public supply systems, EN 61000-3-2, 25

- supply forms / electrical supply conditions, 25

E

Earthing, EMC, 27

Electrical data, general, 15

Electrical installation, 23

- control connection (X26), terminal assignment, 30

- drive system on the mains, 25 operation on public supply systems, 25 supply forms / electrical supply conditions, 25

- important notes, 23 electrical isolation, 24 protection of persons, 23

- installation of a CE-typical drive system, 26 earthing, 27 filtering, 27 shielding, 27 structure, 26

- power connections connection of capacitor module, 31 DC bus supply, fusing, 28 specification of cables used, 28

- power connections (X23), terminal assignment, 28

Electrical isolation, 24

Electromagnetic compatibility, 15

EMC, 15

-earthing, 27

- filtering, 27

- shielding, 27

EN 61000-3-2, operation on public supply systems, 25

Enclosure, 15

F

Filtering, EMC, 27

36

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EDBCSXKXXX EN 1.0

Appendix

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Index

7

Free space, 15

Fuses, 28 , 35

G

General electrical data, 15

I

Installation, 15

Installation height, 15

Installation of a CE-typical drive system, 26

-earthing, 27

- filtering, 27

- shielding, 27

- structure, 26

Installation, electrical, 23

- control connection (X26), terminal assignment, 30

- drive system on the mains, 25 operation on public supply systems, 25 supply forms / electrical supply conditions, 25

- important notes, 23 electrical isolation, 24 protection of persons, 23

- installation of a CE-typical drive system, 26 earthing, 27 filtering, 27 shielding, 27 structure, 26

- power connection, connection of capacitor module, 31

- power connections DC bus supply, fusing, 28 specification of cables used, 28

- power connections (X23), terminal assignment, 28

Installation, mechanical, 17

- important notes, 17

- mounting in ”cold plate” technique, type ECSCKxxx, 21

- mounting with fixing rails, type ECSEKxxx, 18

- thermally separated mounting, type ECSDKxxx, 19

Insulation resistance, 15

M

Manufacturer, 8

Mechanical installation, 17

- important notes, 17

- mounting in ”cold plate” technique, type ECSCKxxx, 21

- mounting with fixing rails, type ECSEKxxx, 18

- thermally separated mounting, type ECSDKxxx, 19

Mounting in ”cold plate” technique, type ECSCKxxx, 21

Mounting position, 15

Mounting with fixing rails, type ECSEKxxx, 18

N

Noise emission, 15

Noise immunity, 15

Notes, definition, 14

O

Operating conditions, 15

Operation on public supply systems, EN 61000-3-2, 25

P

Packaging, 15

Power, 16

Power connection, connection of capacitor module, 31

Power connections, 28

- DC bus supply, fusing, 28

- specification of cables used, 28 cable cross-sections, 29 shielded cables, 28

Power connections (X23), terminal assignment, 28

Power reduction, 15

Power supply module, 7

Protection of persons, 12

L

Labelling, capacitor module, 8

Legal regulations, 8

Liability, 8

Low-voltage supply, 7

EDBCSXKXXX EN 1.0

R

Rated current, 16

Rated data, 16

Rated power, 16

Residual hazards, 12



37

7

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Appendix

Index

S

Safety instructions, 9

- definition, 14

-design,14

- device protection, 12

- general, for Lenze capacitor modules, 9

-protectionofpersons, 12

Shielded cables, 28

Shielding, EMC, 27

Specification of cables used, 28

- cable cross-sections, 29

-shieldedcables,28

Standards, 15

Supply forms / electrical supply conditions, 25

T

Technical data, 15

- general electrical data, 15

- operating conditions, 15

-rateddata,16

-standards,15

Temperature range, 15 Terminal assignment

- control connection (X26), 30

- power connections (X23), 28

Thermally separated mounting, type ECSDKxxx, 19

V

Vibration resistance, 15

W

Warranty, 8 Weight, 16 Wiring, 31

38



EDBCSXKXXX EN 1.0

Appendix 7

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EDBCSXKXXX EN 1.0



39



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Lenze Drive Systems GmbH Hans-Lenze-Straße 1 31855 Aerzen Germany

 

Service 0080002446877(24hhelpline)

¬

Service +49 (0) 51 54 82-1112

E-Mail Lenze@Lenze.de Internet www.Lenze.com

EDBCSXKXXX 1.0 09/2004 TD14

 2004

+49 (0) 51 54 82-0

10987654321

Lenze ECSxK User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents i

1 Preface and general information

1.1 About these Operating Instructions

1.2 Terminology used

1.3 Legal regulations

2 Safety instructions

2.1 General safety and application information for Lenze capacitor modules

2.2 Residual hazards

Safety instructions for the installation according to UL or UR

2.4 Definition of notes used

3 Technical data

3.1 General data/operating conditions

3.2 Rated data

4 Mechanical installation

4.1 Important notes

4.2 Mounting with fixing rails (standard)

5 Electrical installation

5.1 Important notes

5.1.1 Protection of persons

5.1.2 Device protection

5.1.3 Electrical isolation

5.2 Drive system on the mains

5.2.1 Supply form/electrical supply conditions

5.2.2 Operation on public supply systems (compliance with EN 61000-3-2)

5.3 Installation of a DC-typical drive system

5.4 Power connections

5.4.1 Terminal assignment of the power connections

5.4.2 Fusing the DC-bus supply

5.4.3 Specification of the cables used

5.5 Control connection

5.6 Wiring

5.6.1 Operation with ECSxE power supply module

5.6.2 Operation with another supplier

6 Commissioning

7 Appendix

7.1 Overview of accessories

7.1.1 Connectors

7.1.2 DC bus fuses

7.2 Index