Lenze EDB9300UES User Manual

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

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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.

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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.

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Fig. 9: 8230 frequency inverter BDE control unit

Note:

The menu label is removable.

Technical Data

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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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