Lenze EDS4900U-REG User Manual

EDS4900U-REG

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00408862

Table of contents Preface and general

information Safety information

Technical data Installation

Commissioning During operation

Manual

Configuration Code table

Troubleshooting and fault elimination

Maintenance

DC bus connection

Application of brake units

Automation

Accessories and motors

Selection aid Application examples

Signal-flow charts

Glossary Table of keywords

DC speed controller 4800/4900

Manual 4800 / 4900

ATableofcontent

Prefaceandgeneralinformatio

BTechnicaldat

CCommissionin

DConfiguratio

ETroubleshootingandfaultelimination

FDC

KSelectionaid

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Part Content Notes A

B Technical data

C Commissioning

D Configuration

E Troubleshooting and fault elimination

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

L Signal-flow charts M Glossary

able of contents Preface and general information Safety information

Installation

During operation

Code table

Maintenance

us connec

Application examples

Ta bl e of k e yw o r ds

Explanation: - in the Manual.

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

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

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Part A

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Part B

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

4.3.2 Separate supply of the field-current bridge at

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Part C

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

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

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

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

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

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

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

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

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

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

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

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

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

6 During operation

48XX/49XXSHB00399

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Part D

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

7.5.3.2 Memory function of the

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

48XX/49XXSHB00399

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Part E

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Part F

10 DC-bus operation

Part G

11 Application of brake units

48XX/49XXSHB00399

Contents

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Part H

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

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

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

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

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

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

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

Part I

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

48XX/49XXSHB00399

Contents

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Part K

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Part L

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

Part M

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

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

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

48XX/49XXSHB00399

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Contents

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viii

48XX/49XXSHB00399

EDS4900U--A

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00408849

Manual Part A

Contents

Preface and general information

Safety information

DC speed controller 4800/4900

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

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thetimeofprinting.

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

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

Edition of: 01/03/1999

revised

Preface and general information

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1 Preface and general information

1.1 About these Operating Instructions ...

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

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

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

1.1.1 Terminology used

Controller

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

Drive system

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

1.2 Scope of delivery

- The scope of delivery includes:

- 1 48XX/49XX DC controller

- 1 Operating Instructions

- 1 Accessory kit with plug-in terminals

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

- visible transport damage immediately to the forwarder.

- visible deficiencies/incompleteness immediately to your Lenze

representative.

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Preface and general information

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1.3 48XX/49XX controller

1.3.1 Labelling

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

- CE mark:

- Conformity with the Low-Voltage Directive

- Conformity with the EMC Directive

- Manufacturer

-LenzeGmbH&CoKG

Postfach 101352 D-31763 Hameln

1.3.2 Application as directed

48XX/49XX controllers

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

- are components

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

separately excited DC motors.

- to be installed into a machine.

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

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

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

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

Drive systems with 48XX/49XX controllers

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

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- can be used

- on public and non-public mains.

- in industrial premises.

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

Any other use shall be deemed inappropriate!

1.3.3 Legal regulations

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Liability

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

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

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

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

- disregarding these Operating Instructions

- unauthorized modifications to the controller

- operating errors

- improper working on and with the controller

Preface and general information

Warranty

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

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

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

Disposal

The controller consists of different materials.

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

Material recycle dispose

Me tal - Plastic - Printed-board assemblies - -

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Preface and general information

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1.4 EC Directives/Declaration of Conformity

1.4.1 What is the purpose of EC directives?

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

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

1.4.2 What does the CE mark imply?

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

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

1.4.3 EC Low-Voltage Directive

(73/23/EEC)

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

General

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

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48XX/49XXSHB0399

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

Preface and general information

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EC Declaration of Conformity ’99

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

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

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

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

Considered standards:

Standard

DIN EN 50178 Classification VDE 0160 / 04.98

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

Electronic equipment for use in electrical power installations

Hameln, 01/03/1999

(i.V.Schäfer) (i.A.Tolksdorf)

Product Manager Commissioned for CE

48XX/49XXSHB0399

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1.4.4 EC Directive Electromagnetic Compatibility

(89/336/EEC)

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

CE Mark Directive (93/68/EEC)

General

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

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

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

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

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

- The user himself can determine the system components and their

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

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

manufacturer has already proved the conformity.

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Preface and general information

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

on Electromagnetic compatibility (89/336/ EEC)

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

CE Mark Directive (93/68/EEC)

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

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

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

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

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

Generic standards considered:

Generic standard

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

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

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

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

Generic standards considered for the test of noise emission:

Generic standard Tes t Limit value

EN 55011 7/92 Radio interferences, housing and mains

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

Class A for use in industrial premises

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Generic standards considered for the test of noise emission:

Basic standard Tes t Limit value

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

IEC 1000-4-3 2/95 Electromagnetic fields

Frequency range 26-1000MHz

ENV 50140 8/93 High-fre quency field

Frequency range 80-1000MHz, 80% amplitude modulated

Fixed frequency 900MHz with 200Hz, 100 %modulated

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

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

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

Mains cable

6kV for contact, 8kV clearance

Seve rity 3 10V/m

10V/m

Seve rity 3 2kV/5kHz

2kV/5kHz Installation class 3

Hameln, 01/03/1999

(i.V.Schäfer) (i.A.Tolksdorf)

Product Manager Commissioned for CE

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48XX/49XXSHB0399

Preface and general information

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1.4.5 EC Machinery Directive

(89/392/EEC)

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

Second Amendment Directive (93/ 44/EEC)

CE Mark Directive (93/68/EEC)

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

EC M anufacturer’s Declaration

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

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

Second Amendment Directive (93/ 44/EEC)

CE Mark Directive (93/68/EEC)

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

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

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

Hameln, 01/03/1999

(i.V.Schäfer)

Product Manager

48XX/49XXSHB0399

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2 Safety information

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Safety and application notes for controllers

Safety information

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

1. General

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

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

Further information can be obtained from the documentation.

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

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

2. Application as directed

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

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

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

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

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

3. Transport, storage

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

Climat ic condit ions must b e observed according to prEN

50178.

4. Erection

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

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

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

5. Electrical connection

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

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

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

6. Operation

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

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

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

7. M aintenance and servicing

The manufacturer’s documentation must be observed.

The safety information must be preserved!

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

48XX/49XXSHB0399

2-1

Safety information

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2.1 Persons responsible for the safety

Operator

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

behalf of whom the drive system is used.

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

- all relevant regulations, notes and laws are observed

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

- the personnel have the Operating Instructions available for all

corresponding operations and

- unqualified personnel are prohibited from working with and on the

controller.

Qualified personnel

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

2-2

48XX/49XXSHB0399

2.2 General safety information

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

problems please contact your Lenze representative.

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

basically safe operation.

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

hardware and software versions of the controller.

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

property of the operator, if

- unqualified personnel work on and with the drive system.

- the controller is used inappropriately.

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

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

Safety information

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

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

( Take additional measures to limit consequences of malfunctions which may

cause hazards to personnel or damage to properties:

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

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

- measures covering the complete system

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

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

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

2.3 Residual hazards

Excessive speed

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

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

conditions. Use additional components for this.

48XX/49XXSHB0399

2-3

Safety information

hazardouselectrical

ons

sifdisr

ded

generaldanger

Possiblecons

sifdisr

ded

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2.4 Layout of the safety information

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

layout:

Signal word

Note

- The icon characterizes the type of danger.

- The signal word characterizes the severity of danger.

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

Warning of danger for persons

Icons used Signal words

Wa rn i ng o f

volta ge

Wa rn i ng o f a

eneral dange

Danger! Wa rn s o f impending dangeU.

equence

Death or very severe injuries.

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

Possible consequences if disregarded: Death or very severe injuries.

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

equence

Light or minor injuries.

ega

Warning of damage to material

Icons used Signal words

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

Other notes

Icons used Signal words

Note! Designates a general, useful tip.

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

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

2-4

48XX/49XXSHB0399

EDS4900U--B

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00408850

Manual Part B

Technical Data

Installation

DC speed controller 4800/4900

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

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thetimeofprinting.

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

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

Edition of: 01/03/1999

revised

3 Technical data

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3.1 Features

Controller and system features

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

( Digital speed feedback with resolver or incremental encoder

( Torque control with superimposed speed monitoring for winding drives

( Phase control for drift-free positioning

( Digital frequency coupling as setpoint bar or setpoint cascade for

- phase synchronisation

- speed-synchronous operation

- synchronous speed ratio

Technical Data

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

to 2Q operation (with 49XX)

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

feedback or incremental encoder

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

incremental encoder

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

bridge modulation

( Speed-dependent armature current limitation

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

(depending on the size)

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

tension control

( Integrated field current control for large speed setting range

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

input terminals

Operation

( On-line changes of control parameters

by changing from 4Q

mains

( Parameter setting and diagnosis via

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

- serial interface and PC

- fieldbus module (as option): PROFIBUS, InterBus

( Fault messages plain text

48XX/49XXSHB0399

3-1

Technical Data

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Speed feedback systems

( Resolver feedback with encoder emulation for superimposed systems

(synchronizing systems, positioning controls, etc.)

( Incremental encoder feedback

( DC tacho feedback

( Armature voltage feedback

Inputs

( Digital

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

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

( Analog

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

Outputs

( Digital

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

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

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

( Analog

- 2 reference voltages ( 10V, 7mA)

- 1 monitor output, with I

act

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

- 1 frequency output, freely assignable

Monitoring

( Monitoring functions of the system and controller components

( Controller protection (Iôt function)

( Motor overload protection (I

ôt function)

( Monitoring of frequency and mains voltage

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

3-2

48XX/49XXSHB0399

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

( Monitoring of the act.-value encoder feedback

( Display of the sources of controller inhibit via a code

( Classifiable monitoring (TRIP, message or warning)

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

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

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