Lenze MC1000 User Manual

MC1000 Series

Installation and Operation Manual

NOTE!

The manual covers software version M108314 and above.

Refer to parameter 63 for the software version of the drive you are working with.

If you are working with an earlier software release, you will not have all of the functionality described in this manual. However, the full functionality of the drive is documented in this manual.

If you are working with M108313 or earlier, parameters 69 and 70 are described in this manual as parameters 98 and 99.

Table of Contents

1 GENERAL........................................................................... 1

1.1 PRODUCTS COVERED IN THIS MANUAL........................................1

1.2 PRODUCT CHANGES ......................................................... 1

1.3 WARRANTY ..................................................................1

1.4 RECEIVING ................................................................... 1

1.5 CUSTOMER MODIFICATION ...................................................1

2 MC1000 SPECIFICATIONS ...........................................................2

3 MC1000 MODEL DESIGNATION CODE ............................................... 3

4 MC1000 DIMENSIONS .............................................................. 4

4.1 TYPE 1 DIMENSIONS: MODELS RATED UP TO 30 HP ............................ 4

4.2 TYPE 1 DIMENSIONS: MODELS RATED ABOVE 30 HP ...........................6

4.3 TYPE 4, 4X & 12 DIMENSIONS: MODELS RATED UP TO 30HP .................... 7

4.4 TYPE 12 DIMENSIONS: MODELS RATED ABOVE 30 HP . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5 MC1000 RATINGS..................................................................10

6 THEORY...........................................................................14

6.1 DESCRIPTION OF AC MOTOR OPERATION.....................................14

6.2 DRIVE FUNCTION DESCRIPTION.............................................. 16

7 INSTALLATION.....................................................................17

7.1 INSTALLATION AFTER A LONG PERIOD OF STORAGE ..........................18

7.2 EXPLOSION PROOF APPLICATIONS...........................................18

8 INPUT AC REQUIREMENTS .........................................................19

8.1 INPUT AC POWER REQUIREMENTS ...........................................19

8.2 INPUT FUSING AND DISCONNECT REQUIREMENTS ...........................19

9 VOLTAGE SELECTION ..............................................................20

10 POWER WIRING....................................................................21

10.1 WIRING FOR SINGLE PHASE OR THREE PHASE INPUT..........................21

11 MC1000 POWER WIRING DIAGRAM.................................................22

12 INITIAL POWER UP.................................................................23

13 KEYPAD CONTROL.................................................................24

13.1 KEYPAD FUNCTIONS (IN LOCAL MODE).......................................24

13.2 MC1000 DISPLAY............................................................25

14 CONTROL WIRING .................................................................29

14.1 GENERAL ...................................................................29

14.2 START/STOP AND SPEED CONTROL ..........................................29

15 MC1000 CONTROL WIRING DIAGRAMS .............................................34

15.1 MC1000 TERMINAL STRIP ....................................................34

15.2 TWO-WIRE START/STOP CONTROL ...........................................35

15.3 THREE-WIRE START/STOP CONTROL..........................................36

15.4 SPEED POT AND PRESET SPEED CONTROL....................................37

16 PROGRAMMING THE MC1000 DRIVE ...............................................38

16.1 PROGRAMMING THE PARAMETERS........................................... 38

16.2 PARAMETER ACCESS USING SPEED DIAL .....................................40

17 PARAMETER MENU ................................................................41

18 DESCRIPTION OF PARAMETERS ....................................................44

19 MC1000 PID SET POINT CONTROL..................................................70

19.1 FEEDBACK DEVICES .........................................................70

19.2 THE SYSTEM - DIRECT AND REVERSE ACTING .................................71

19.3 PID CONTROL - DIRECT AND REVERSE ACTING................................71

19.4 SET POINT REFERENCE SOURCES.............................................72

19.5 TUNING THE PID CONTROL ..................................................72

19.6 MC1000 DISPLAY IN PID MODE ..............................................73

20 TROUBLESHOOTING............................................................... 74

21 USER SETTING RECORD ............................................................76

APPENDIX...............................................................................78

A SINGLE PHASE DATA SELECTED MODELS ...........................................78

A-1 WIRING .....................................................................78

A-2 DERATING...................................................................78

13435742_EDBM101_v24 1

2 MC1000 SPECIFICATIONS

Storage Temperature -20° to 70° C

Ambient Operating Temperature Chassis (w/o cover) -10° to 55° C

(With 2.5, 6, and 8 kHz carrier, Type 1 (IP 31) -10° to 50° C

derate for higher carriers) Type 4 (IP 65) -10° to 40° C

Type 12 (IP 54) -10° to 40° C

Ambient Humidity Less than 95% (non-condensing)

Altitude 3300 feet (1000 m) above sea level

without derating

Input Line Voltages 240/120 Vac, 240/200 Vac,

480/400 Vac, and 590/480 Vac

Input Voltage Tolerance +10%, -15%

Input Frequency Tolerance 48 to 62 Hz

Output Wave Form Sine Coded PWM

Output Frequency 0-120 Hz, Optional up to 1000 Hz

Carrier Frequency 2.5 kHz to 14 kHz

Frequency Stability +0.00006% / °C

Service Factor 1.00

Eciency > 97% throughout speed range

Power Factor (displacement) > 0.96

Overload Current Capacity 150% of output rating for 60 seconds

180% of output rating for 30 seconds

Speed Reference Follower 0-10 VDC, 4-20 mA

Control Voltage 15 VDC

Analog Outputs 0 - 10 VDC, or 2 - 10 VDC

Proportional to speed and load

Digital Outputs Form C relay: 2 A at 28 VDC or 120 Vac

Open-collector outputs: 40 mA at 30 VDC

2 13435742_EDBM101_v24

3 MC1000 MODEL DESIGNATION CODE

The model number of an MC1000 Series drive gives a full description of the basic drive unit (see example below).

EXAMPLE: M1450BP

(MC1000, 480 Vac, 5 HP, Type 1 Enclosure, with a Remote Keypad Assembly)

M1 4 50 B P

Series:

M1 = M1000 Series Variable Speed AC Motor Drive

Input Voltage:

1 = 240/120 Vac (For 110, 115, 120, 230 and 240 Vac; 50 or 60 Hz)

2 = 240/200 Vac (For 208, 230, and 240 Vac; 50 or 60 Hz)

4 = 480/400 Vac (For 380, 415, 440, 460 and 480 Vac; 50 or 60 Hz)

5 = 590/480 Vac (For 440, 460, 480, 575 and 600 Vac; 50 or 60 Hz)

Rating:

03 = ¼ HP (0.18 kW ) 75 = 7½ HP (5.5 kW) 500 = 50 HP (37.5 kW)

05 = ½ HP (0.37 kW ) 100 = 10 HP (7.5 kW) 600 = 60 HP (45 kW )

10 = 1 HP (0.75 kW ) 150 = 15 HP (11 kW) 750 = 75 HP (55 kW)

15 = 1½ HP (1.1 kW ) 200 = 20 HP (15 kW) 1000 100 HP (75 kW )

20 = 2 HP (1.5 kW ) 250 = 25 HP (18.5 kW) 1250 = 125 HP (90 kW)

30 = 3 HP (2.2 kW ) 300 = 30 HP (22 kW) 1500 = 150 HP (110 kW)

50 / 51 = 5 HP (3.7 kW ) 400 = 40 HP (30vkW)

Input Phase:

S = Single phase input only.

No character indicates three phase input only

Enclosure Type:

B = NEMA 1 - General Purpose, vented

C = NEMA 4 - Water-tight and Dust-tight

D = NEMA 12 - Oil-tight and Dust-tight

E = NEMA 4X - Water-tight, Dust-tight, and Corrosion Resistant (Stainless Steel)

Standard Options:

H = Additional Form C Relay circuit board

J = D ynamic Braking circuit board

K = D ynamic Braking & Additional Form C Relay board (not available on all HP sizes - consult factory)

No character when this type of option is not specied

Interface Options:

P = Remote keypad assembly

No character when this type of option is not specied

13435742_EDBM101_v24 3

4 MC1000 DIMENSIONS

4.1 TYPE 1 DIMENSIONS: MODELS RATED UP TO 30 HP

AT 240/200 Vac AND 60 HP AT 590/480/400 Vac

Q Q

(kW)

0.25

(0.18)

(0.37)

INPUT

VOLTAGE

240 / 120 M1103SB 7.50 4.70 3.33 2.35 1.60 1.37 5.50 0.88

240 / 120 M1105SB 7.50 6.12 3.63 3.77 1.80 1.37 5.50 0.88

0.5 240 M1205SB 7.50 4.70 3.63 2.35 1.90 1.37 5.50 0.88

240/200 M1205B 7.50 4.70 3.63 2.35 1.90 1.37 5.50 0.88

Conduit Holes:

S Dia.

0.88" Dia.

S Dia.

Dia. Slot

MODEL H W D N P Q R S

1.00"

Mounting Tab Detail

240 / 120 M1110SB 7.50 6.12 4.22 3.77 2.40 1.37 5.50 0.88

(0.75)

240 M1210SB 7.50 4.70 4.33 2.35 2.60 1.37 5.50 0.88

240 / 200 M1210B 7.50 4.70 4.33 2.35 2.60 1.37 5.50 0.88

480 / 400 M1410B 7.50 4.70 3.63 2.35 1.90 1.37 5.50 0.88

590 M1510B 7.50 4.70 3.63 2.35 1.90 1.37 5.50 0.88

240/120 M1115SB 7.50 6.12 4.22 3.77 2.40 1.37 5.50 0.88

1.5

(1.1)

240 M1215SB 7.50 6.12 4.22 3.77 2.40 1.37 5.50 0.88

240/200 M1215B 7.50 4.70 4.33 2.35 2.60 1.37 5.50 0.88

240 M1220SB 7.50 6.12 5.12 3.77 3.30 1.37 5.50 0.88

240 / 200 M1220B 7.50 6.12 5.12 3.77 3.30 1.37 5.50 0.88

(1.5)

480/400 M1420B 7.50 6.12 4.22 3.77 2.40 1.37 5.50 0.88

590 M1520B 7.50 6.12 4.22 3.77 2.40 1.37 5.50 0.88

IF W < 7.86" T = 0.20" U = 0.34" V = 0.19"

IF W = 10.26" T = 0.28" U = 0.44" V = 0.24"

4 13435742_EDBM101_v24

TYPE 1 DIMENSIONS (continued)

(kW)

(2.2)

(3.7)

(5.5)

(7.5)

(11)

(15)

(18.5)

(22)

(30)

(37.5)

(45)

INPUT

VOLTAGE

240 M1230SB 7.50 6.12 5.12 3.77 3.30 1.37 5.50 0.88

240 / 200 M1230B 7.50 6.12 5.12 3.77 3.30 1.37 5.50 0.88

480 / 400 M1430B 7.50 6.12 5.12 3.77 3.30 1.37 5.50 0.88

590 M1530B 7.50 6.12 5.12 3.77 3.30 1.37 5.50 0.88

240 / 200 M1250B 7.88 7.86 5.94 5.13 3.95 1.50 5.88 1.13

480 / 400 M1450B 7.50 6.12 5.12 3.77 3.30 1.37 5.50 0.88

590 M1551B 7.88 7.86 5.94 5.13 3.95 1.50 5.88 1.13

240 / 200 M1275B 9.38 7.86 6.84 3.93 4.19 2.00 5.88 1.13

7.5 480 / 400 M1475B 9.38 7.86 6.25 5.13 3.95 1.50 7.38 1.13

590 M1575B 9.38 7.86 6.25 5.13 3.95 1.50 7.38 1.13

240 / 200 M12100B 11.25 7.86 6.84 3.93 4.19 2.00 7.75 1.38

480 / 400 M14100B 9.38 7.86 6.84 3.93 4.19 2.00 5.88 1.13

590 M15100B 9.38 7.86 7.40 3.93 4.19 2.00 5.88 1.13

240/200 M12150B 12.75 7.86 6.84 3.93 4.19 2.00 9.25 1.38

480/400 M14150B 11.25 7.86 6.84 3.93 4.19 2.00 7.75 1.38

590 M15150B 12.75 7.86 6.84 3.93 4.19 2.00 9.75 1.38

240 / 200 M12200B 12.75 10.26 7.74 5.13 5.00 2.50 9.25 1.38

480/400 M14200B 12.75 7.86 6.84 3.93 4.19 2.00 9.25 1.38

590 M15200B 12.75 7.86 7.40 3.93 4.19 2.00 9.25 1.38

240 / 200 M12250B 15.75 10.26 8.35 5.13 5.00 2.50 12.25 1.38

480/400 M14250B 12.75 10.26 7.74 5.13 5.00 2.50 9.25 1.38

590 M15250B 12.75 10.26 7.74 5.13 5.00 2.50 9.25 1.38

240 / 200 M12300B 15.75 10.26 8.35 5.13 5.00 2.50 12.25 1.38

480/400 M14300B 12.75 10.26 7.74 5.13 5.00 2.50 9.25 1.38

590 M15300B 12.75 10.26 8.25 5.13 5.00 2.50 9.25 1.38

480/400 M14400B 15.75 10.26 8.35 5.13 5.00 2.50 12.25 1.38

590 M15400B 15.75 10.26 8.35 5.13 5.00 2.50 12.25 1.38

480/400 M14500B 19.75 10.26 8.55 5.13 5.75 2.50 16.25 1.75

590 M15500B 19.75 10.26 8.55 5.13 5.75 2.50 16.25 1.75

480/400 M14600B 19.75 10.26 8.55 5.13 5.75 2.50 16.25 1.75

590 M15600B 19.75 10.26 8.55 5.13 5.75 2.50 16.25 1.75

MODEL H W D N P Q R S

13435742_EDBM101_v24 5

4.2 TYPE 1 DIMENSIONS: MODELS RATED ABOVE 30 HP

AT 240/200 Vac AND 60 HP AT 590/480/400 Vac

0.44" Dia.

0.68"

0.31"

1.50"

1.36"

0.92"

0.43"

1.50"

3.00"

1.36"

HP/kW

INPUT

VOLTAGE

IF W = 13.00"

Conduit Holes:

1.13" Dia.

S Dia.

0.36"

Dia.

Mounting Tab Detail

IF W > 16.64"

MODEL H W D N C P Q S

40/30 240 / 200 M12400B 25.00 13.00 10.50 5.56 6.50 6.50 2.62 1.38

60/45 240 / 200 M12600B 47.00 16.64 11.85 See below

75/55 480 / 400 M14750B 29.00 16.64 11.85 7.14 6.88 6.88 3.12 1.75

100/75 480 / 400 M141000B 29.00 24.42 11.85 11.12 7.25 6.50 4.50 2.50

125/90 480 / 400 M141250B 29.00 24.42 11.85 11.12 7.25 6.50 4.50 2.50

150/110 480 / 400 M141500B 29.00 36.66 11.85 See below

CONDUIT HOLES FOR M12600B

4.26"

4.00" 4.00"

6.88"

Conduit Holes: Large holes = 1.75"

Small hole = 1.13"

CONDUIT HOLES FOR M141500B

7.45" 9.00"

7.25"

Conduit Holes: Large holes = 3.00"

Small holes = 1.13"

7.00" 9.00"

6.50"

6 13435742_EDBM101_v24

4.3 TYPE 4, 4X & 12 DIMENSIONS: MODELS RATED UP TO 30HP

AT 240/200 Vac AND 60 HP AT 590/480/400 Vac

(kW)

0.25

(0.18)

(0.37)

INPUT

VOLTAGE

240 / 120 M1103S 7.88 6.12 3.63 3.06 2.00 1.37 5.88 0.88

240 / 120 M1105S 7.88 7.86 3.75 4.80 2.10 1.37 5.88 0.88

0.5 240 M1205S 7.88 6.12 4.35 3.06 2.70 1.37 5.88 0.88

240/200 M1205 7.88 6.12 4.35 3.06 2.70 1.37 5.88 0.88

Conduit Holes:

S Dia.

0.88" Dia. S Dia.

Dia. Slot

Mounting Tab Detail

MODEL H W D N P Q R S

1.00"

240 / 120 M1110S 7.88 7.86 4.90 4.80 3.25 1.37 5.88 0.88

(0.75)

240 M1210S 7.88 6.12 4.35 3.06 2.70 1.37 5.88 0.88

240 / 200 M1210 7.88 6.12 4.35 3.06 2.70 1.37 5.88 0.88

480 / 400 M1410 7.88 6.12 4.35 3.06 2.70 1.37 5.88 0.88

590 M1510 7.88 6.12 4.35 3.06 2.70 1.37 5.88 0.88

240/120 M1115S 7.88 7.86 4.90 4.80 3.25 1.37 5.88 0.88

1.5

(1.1)

240 M1215S 7.88 7.86 4.90 4.80 3.25 1.37 5.88 0.88

240/200 M1215 7.88 6.12 5.25 3.06 3.60 1.37 5.88 0.88

240 M1220S 7.88 7.86 4.90 4.80 3.25 1.37 5.88 0.88

240 / 200 M1220 7.88 7.86 4.90 4.80 3.25 1.37 5.88 0.88

(1.5)

480/400 M1420 7.88 7.86 4.90 4.80 3.25 1.37 5.88 0.88

590 M1520 7.88 7.86 4.90 4.80 3.25 1.37 5.88 0.88

240 M1230S 7.88 7.86 5.90 4.80 4.25 1.37 5.88 0.88

240 / 200 M1230 7.88 7.86 5.90 4.80 4.25 1.37 5.88 0.88

(2.2)

480 / 400 M1430 7.88 7.86 4.90 4.80 3.25 1.37 5.88 0.88

590 M1530 7.88 7.86 4.90 4.80 3.25 1.37 5.88 0.88

IF W < 7.86" T = 0.20" U = 0.34" V = 0.19"

IF W > 10.26" T = 0.28" U = 0.44" V = 0.24"

13435742_EDBM101_v24 7

DIMENSIONS - TYPE 4, 4X, AND 12 ENCLOSED (continued)

(kW)

(3.7)

(5.5)

(7.5)

(11)

(15)

(18.5)

(22)

(30)

(37.5)

(45)

*Models available in NEMA 12 only.

INPUT

VOLTAGE

240 / 200 M1250 9.75 10.26 7.20 5.13 5.25 2.00 7.75 1.13

480 / 400 M1450 7.88 7.86 5.90 4.80 4.25 1.37 5.88 0.88

590 M1550 7.88 7.86 5.90 4.80 4.25 1.37 5.88 0.88

240 / 200 M1275 11.75 10.26 8.35 5.13 5.75 2.00 9.75 1.13

7.5 480 / 400 M1475 9.75 10.26 7.20 5.13 5.25 2.00 7.75 1.13

590 M1575 9.75 10.26 7.20 5.13 5.25 2.00 7.75 1.13

240 / 200 M12100 13.75 10.26 8.35 5.13 5.75 2.00 11.75 1.38

480 / 400 M14100 11.75 10.26 8.35 5.13 5.75 2.00 9.75 1.13

590 M15100 11.75 10.26 8.35 5.13 5.75 2.00 9.75 1.13

240/200 M12150 15.75 10.26 8.35 5.13 5.75 2.00 13.75 1.38

480/400 M14150 13.75 10.26 8.35 5.13 5.75 2.00 11.75 1.38

590 M15150 13.75 10.26 8.35 5.13 5.75 2.00 11.75 1.38

240 / 200 M12200D* 15.75 10.26 8.35 5.13 5.75 2.00 11.75 1.38

480/400 M14200 15.75 10.26 8.35 5.13 5.75 2.00 13.75 1.38

590 M15200 15.75 10.26 8.35 5.13 5.75 2.00 13.75 1.38

240 / 200 M12250D* 20.25 10.26 8.35 5.13 5.75 2.00 16.25 1.38

480/400 M14250D* 15.75 10.26 8.35 5.13 5.75 2.00 11.75 1.38

590 M15250D* 15.75 10.26 8.35 5.13 5.75 2.00 11.75 1.38

240 / 200 M12300D* 20.25 10.26 8.35 5.13 5.75 2.00 16.25 1.38

480/400 M14300D* 15.75 10.26 8.35 5.13 5.75 2.00 11.75 1.38

590 M15300D* 15.75 10.26 8.35 5.13 5.75 2.00 11.75 1.38

480/400 M14400D* 20.25 10.26 8.35 5.13 5.75 2.00 16.25 1.38

590 M15400D* 20.25 10.26 8.35 5.13 5.75 2.00 16.25 1.38

480/400 M14500D* 21.00 13.72 8.35 5.13 6.10 2.00 16.25 1.38

590 M15500D* 21.00 13.72 8.35 5.13 6.10 2.00 16.25 1.38

480/400 M14600D* 21.00 13.72 8.35 5.13 6.10 2.00 16.25 1.38

590 M15600D* 21.00 13.72 8.35 5.13 6.10 2.00 16.25 1.38

MODEL H W D N P Q R S

8 13435742_EDBM101_v24

4.4 TYPE 12 DIMENSIONS: MODELS RATED ABOVE 30 HP

AT 240/200 Vac AND 60 HP AT 590/480/400 Vac

0.68"

1.36"

1.50"

IF W = 14.00"

Mounting Tab Detail

0.92"

0.43"

1.36"

3.00"

1.50"

HP/kW

INPUT

VOLTAGE

0.36" Dia.

Conduit Holes:

1.13" Dia.

S Dia.

0.44" Dia.

IF W > 18.00"

MODEL H W D N P Q R S

75/55 480 / 400 M14750D 37.00 18.00 13.30 7.50 8.00 3.13 7.14 1.75

0.31"

100/75 480 / 400 M141000D 39.00 26.00 13.30 11.50 9.00 4.50 9.14 2.50

125/90 480 / 400 M141250D 39.00 26.00 13.30 11.50 9.00 4.50 9.14 2.50

13435742_EDBM101_v24 9

5 MC1000 RATINGS

The following tables indicate the input and output ratings of the MC1000 Series.

NOTE: The output current ratings are based on operation at carrier frequencies of 8 kHz and below. At full ambient temperature, operation at carrier frequencies above 8 kHz require derating the drive by multiplying the output current rating by the following factors: 0.94 at 10 kHz, 0.89 at 12 kHz, and 0.83 at 14 kHz. Refer to Parameter 23 - CARRIER in Section 18 - DESCRIPTION OF PARAMETERS.

NOTE

Refer to Appendix A for derated single phase ratings on selected models.

M1100 SERIES RATINGS

MODEL

(120/240 Vac, 50 - 60 Hz) (0 - 230 Vac)

INPUT OUTPUT

FOR MOTORS NOMINAL NOMINAL

MODEL

NUMBER

RATED INPUT CURRENT

POWER CURRENT POWER

HP kW PHASE (AMPS) (K VA) (AMPS) (KVA)

M1103S 0.25 0.18 1 6.0 / 3.0 0.72 1.4 / 1.4 0.56

M1105S 0.5 0.37 1 9.2 / 4.6 1.1 2.2 / 2.2 0.88

M1110S 1 0.75 1 16.2 / 8.1 1.9 4.0 / 4.0 1.6

M1115S 1.5 1.1 1 21 / 10.4 2.5 5.2 / 5.2 2.1

Refer to Section 3 for model number breakdown.

Refer to Section 8 for recommended fuse type.

10 13435742_EDBM101_v24

M1200 SERIES RATINGS

MODEL

(200/240 Vac, 50 - 60 Hz) (0 - 200/230 Vac)

INPUT OUTPUT

FOR MOTORS NOMINAL NOMINAL

MODEL

NUMBER

RATED INPUT CURRENT2POWER CURRENT POWER

HP kW PHASE (AMPS) (K VA) (AMPS) (KVA)

M1205S 0.5 0.37 1 5.8 / 5.0 1.2 2.5 / 2.2 0.9

M1205 0.5 0.37 3 3.1 / 2.7 1.1 2.5 / 2.2 0.9

M1210S 1 0.75 1 10.4 / 9.0 2.2 4.6 / 4.0 1.6

M1210 1 0.75 3 5.5 / 4.8 2.0 4.6 / 4.0 1.6

M1215S 1.5 1.1 1 13.3 / 11.6 2.8 6.0 / 5.2 2.1

M1215 1.5 1.1 3 7.1 / 6.2 2.6 6.0 / 5.2 2.1

M1220S 2 1.5 1 17.1 / 14.9 3.6 7.8 / 6.8 2.7

M1220 2 1.5 3 9.3 / 8.1 3.4 7.8 / 6.8 2.7

M1230S 3 2.2 1 24 / 21 5.0 11.0 / 9.6 3.8

M1230 3 2.2 3 13.0 / 11.3 4.7 11.0 / 9.6 3.8

M1250 5 3.7 3 20 / 17.7 7.4 17.5 / 15.2 6.1

M1275 7.5 5.5 3 30 / 26 10.6 25 / 22 8.8

M12100 10 7.5 3 37 / 32 13.2 32 / 28 11.2

M12150 15 11 3 55 / 48 19.8 48 / 42 16.7

M12200 20 15 3 70 / 61 25.3 62 / 54 21.5

M12250 25 18.5 3 89 / 77 32.0 78 / 68 27.1

M12300 30 22 3 104 / 90 37.6 92 / 80 31.9

M12400

40 30 3 119 / 99 41.0 120 / 104 41.4

M12600 360 45 3 174 / 145 60.5 177 / 154 61.3

Refer to Section 3 for model number breakdown.

Refer to Section 8 for recommended fuse type.

For branch circuit protection, the 40HP and 60HP 230V models must only be

installed with the appropriately rated UL Listed fuses.

13435742_EDBM101_v24 11

M1400 SERIES RATINGS

MODEL

(400/480 Vac, 50 - 60 Hz) (0 - 400/460 Vac)

INPUT OUTPUT

FOR MOTORS NOMINAL NOMINAL

MODEL

NUMBER

RATED INPUT CURRENT2POWER CURRENT POWER

HP kW PHASE (AMPS) (K VA) (AMPS) (KVA)

M1410 1 0.75 3 2.8 / 2.4 2.0 2.3 / 2.0 1.6

M1420 2 1.5 3 4.7 / 4.1 3.4 3.9 / 3.4 2.7

M1430 3 2.2 3 6.6 / 5.7 4.7 5.5 / 4.8 3.8

M1450 5 3.7 3 10.2 / 8.9 7.3 8.7 / 7.6 6.1

M1475 7.5 5.5 3 14.7 / 12.8 10.6 12.6 / 11.0 8.8

M14100 10 7.5 3 18.3 / 15.9 13.2 16.0 / 14.0 11.2

M14150 15 11 3 28 / 24 19.8 24 / 21 16.7

M14200 20 15 3 36 / 31 25.3 31 / 27 21.5

M14250 25 18.5 3 44 / 38 31.9 39 / 34 27.1

M14300 30 22 3 52 / 45 37.6 46 / 40 31.9

M14400 40 30 3 68 / 59 49.0 60 / 52 41.4

M14500 50 37.5 3 85 / 74 61.5 75 / 65 51.8

M14600 60 45 3 100 / 87 72.3 88 / 77 61.3

M14750 75 55 3 109 / 91 75.5 110 / 96 76.5

M141000 100 75 3 139 / 116 96.4 143 / 124 98.8

M141250 125 90 3 175 / 146 121.4 179 / 156 124.3

M141500 150 110 3 202 / 168 139.7 207 / 180 143.4

Refer to Section 3 for model number breakdown.

Refer to Section 8 for recommended fuse type.

12 13435742_EDBM101_v24

M1500 SERIES RATINGS

MODEL

(480/590 Vac, 50 - 60 Hz) (0 - 460/575 Vac)

INPUT OUTPUT

FOR MOTORS NOMINAL NOMINAL

MODEL

NUMBER

RATED INPUT CURRENT2POWER CURRENT POWER

HP kW PHASE (AMPS) (K VA) (AMPS) (KVA)

M1510 1 0.75 3 1.9 / 1.9 1.9 1.6 / 1.6 1.6

M1520 2 1.5 3 3.3 / 3.3 3.4 2.7 / 2.7 2.7

M1530 3 2.2 3 4.6 / 4.6 4.7 3.9 / 3.9 3.9

M1550/51 5 3.7 3 7.1 / 7.1 7.3 6.1 / 6.1 6.1

M1575 7.5 5.5 3 10.5 / 10.5 10.7 9.0 / 9.0 8.8

M15100 10 7.5 3 12.5 / 12.5 12.8 11.0 / 11.0 11.0

M15150 15 11 3 19.3 / 19.3 19.7 17.0 / 17.0 16.9

M15200 20 15 3 25 / 25 25.4 22 / 22 21.5

M15250 25 18.5 3 31 / 31 31.2 27 / 27 26.9

M15300 30 22 3 36 / 36 37.1 32 / 32 31.9

M15400 40 30 3 47 / 47 47.5 41 / 41 40.8

M15500 50 37.5 3 59 / 59 60.3 52 / 52 51.8

M15600 60 45 3 71 / 71 72.5 62 / 62 61.7

Refer to Section 3 for model number breakdown.

Refer to Section 8 for recommended fuse type.

13435742_EDBM101_v24 13

6 THEORY

6.1 DESCRIPTION OF AC MOTOR OPERATION

Three phase AC motors are comprised of two major components, the stator and the rotor. The stator is a set of three electrical windings held stationary in the motor housing. The rotor is a metal cylinder, xed to the motor drive shaft, which rotates within the stator. The arrangement of the stator coils and the presence of three phase AC voltage give rise to a rotating magnetic eld which drives the rotor. The speed at which the magnetic field rotates is known as the synchronous speed of the motor. Synchronous speed is a function of the frequency at which the voltage is alternating and the number of poles in the stator windings.

The following equation gives the relation between synchronous speed, frequency, and the number of poles:

Ss = 120 f/p

Where: Ss = Synchronous speed (rpm ), f = frequency (Hz),

p = number of poles

In three phase induction motors the actual shaft speed diers from the synchronous speed as load is applied. This difference is known as “slip”. Slip is commonly expressed as a percentage of synchronous speed. A typical value is three percent at full load.

The strength of the magnetic field in the gap between the rotor and stator is proportional to the amplitude of the voltage at a given frequency. The output torque capability of the motor is, therefore, a function of the applied voltage amplitude at a given frequency. When operated below base (rated) speed, AC motors run in the range of “constant torque”. Constant torque output is obtained by maintaining a constant ratio between voltage amplitude (Volts) and frequency (Hertz). For 60 Hz motors rated at 230, 460, and 575 Vac, common values for this V/Hz ratio are 3.83, 7.66, and 9.58 respectively. Operating with these V/Hz ratios generally yields optimum torque capability. Operating at lower ratio values results in lower torque and power capability. Operating at higher ratio values will cause the motor to overheat. Most standard motors are capable of providing full torque output from 3 to 60 Hz. However, at lower speeds, where motor cooling fans become less effective, supplemental cooling may be needed to operate at full torque output continuously.

If the frequency applied to the motor is increased while the voltage remains constant, torque capability will decrease as speed increases. This will cause the horsepower capability of the motor to remain approximately constant. Motors run in this mode when operated above base speed, where drive output voltage is limited by the input line voltage. This operating range is known as the “constant horsepower” range. The typical maximum range for constant horsepower is about 2.3 to 1 (60 to 140 Hz). The diagram below depicts the characteristics of a typical AC induction motor with a 60 Hz base speed.

WARNING!

Consult motor manufacturer before operating motor and/or driven equipment above base speed.

14 13435742_EDBM101_v24

150

130

CONSTANT TORQUE CONSTANT HP

110

TORQUE (%)

TORQUE HORSEPOWER

HORSEPOWER

20 40

60 80 100 120

FREQUENCY (Hz)

TORQUE

6.1.1 VARIABLE TORQUE VS. CONSTANT TORQUE

Variable frequency drives, and the loads they are applied to, can generally be divided into two groups: constant torque and variable torque. Constant torque loads include: vibrating conveyors, punch presses, rock crushers, machine tools, and just about every other application that is not considered variable torque. Variable torque loads include centrifugal pumps and fans, which make up the majority of HVAC applications.

Variable torque loads are governed by the anity laws, which dene the relationships between speed, ow, torque and horsepower. The diagram below illustrates these relationships:

100%

75%

50%

% FLOW

25%

% TORQUE

% HORSEPOWER

100%75%50%25%0%

% SPEED

“Variable torque” refers to the fact that the torque required varies with the square of the speed. Also, the horsepower required varies with the cube of the speed, resulting in a large reduction in horsepower for even a small reduction in speed. It is easily seen that substantial energy savings can be achieved by reducing the speed of a fan or pump. For example, reducing the speed to 50% results in a 50 HP motor having to produce only 12.5% of rated horsepower, or 6.25 HP.

Variable torque drives usually have a low overload capacity (110% - 120% for 60 seconds), because variable torque applications rarely experience overload conditions. To optimize efficiency and energy savings, variable torque drives are usually programmed to follow a variable V/Hz ratio.

13435742_EDBM101_v24 15

The term “constant torque” is not entirely accurate in terms of the actual torque required for an application. Many constant torque applications have reciprocating loads, such as vibrating conveyors and punch presses, where the rotational motion of the motor is being converted to a linear motion. In such cases, the torque required can vary greatly at different points in the cycle. For constant torque loads, this uctuation in torque is not a direct function of speed, as it is with a variable torque load. As a result, constant torque drives typically have a high overload rating (150% for 60 seconds) in order to handle the higher peak torque demands. To achieve maximum torque, constant torque drives follow a constant V/Hz ratio.

Both MC Series product lines (MC1000 and MC3000) have full overload capacity (150% for 60 seconds, 180% for 30 seconds), so that either one can be used for either type of application. The V/Hz ratio can also be changed to optimize performance for either type of application.

6.2 DRIVE FUNCTION DESCRIPTION

The MC Series is a 16 bit microprocessor based, keypad programmable, variable speed AC motor drive. There are four major sections: an input diode bridge and lter, a power board, a control board, and an output intelligent power module.

6.2.1 DRIVE OPERATION

Incoming AC line voltage is converted to a pulsating DC voltage by the input diode bridge. The DC voltage is supplied to the bus lter capacitors through a charge circuit which limits inrush current to the capacitors during power-up. The pulsating DC voltage is ltered by the bus capacitors which reduces the ripple level. The ltered DC voltage enters the inverter section of the drive, composed of six output intelligent insulated gate bi-polar transistors (IGBTs) which make up the three output legs of the drive. Each leg has one intelligent IGBT connected to the positive bus voltage and one connected to the negative bus voltage. Alternately switching on each leg, the intelligent IGBT produces an alternating voltage on each of the corresponding motor windings. By switching each output intelligent IGBT at a very high frequency (known as the carrier frequency) for varying time intervals, the inverter is able to produce a smooth, three phase, sinusoidal output current wave which optimizes motor performance.

6.2.2 CIRCUIT DESCRIPTION

The control section consists of a control board with a 16 bit microprocessor, keypad and display. Drive programming is accomplished via the keypad or the serial communications port. During operation the drive can be controlled via the keypad, by control devices wired to the control terminal strip, or by the serial communications port. The Power Board contains the control and protection circuits which govern the six output IGBTs. The Power Board also contains a charging circuit for the bus lter capacitors, a motor current feedback circuit, a voltage feedback circuit, and a fault signal circuit. The drive has several built in protection circuits. These include phase-to-phase and phase-to-ground short circuit protection, high and low line voltage protection, protection against excessive ambient temperature, and protection against continuous excessive output current. Activation of any of these circuits will cause the drive to shut down in a fault condition.

16 13435742_EDBM101_v24

6.2.3 MC1000 INPUTS AND OUTPUTS

The drive has two analog inputs (0-10 VDC and 4-20 mA) that can be used for speed reference, PID set point reference, or PID feedback. A speed potentiometer (10,000 Ohm) can be used with the 0-10 VDC input.

There are also two analog outputs: one is proportional to speed (frequency), and the other is proportional to load.

The drive has three programmable outputs for status indication: one Form C relay and two open-collector outputs.

NOTE: Models rated above 30 Hp at 200/240 Vac and 60 Hp at 400/480 Vac have a second Form C relay.

Refer to Sections 14 - CONTROL WIRING and 15 - CONTROL WIRING DIAGRAMS for more information.

7 INSTALLATION

WARNING! Drives must not be installed where subjected to adverse environmental conditions! Drives must not be installed where subjected to: combustible, oily, or hazardous vapors or dust; excessive moisture or dirt; strong vibration; excessive ambient temperatures. Consult Lenze AC Tech for more information on the suitability of a drive to a particular environment

The drive should be mounted on a smooth vertical surface capable of safely supporting the unit without vibrating. The LCD display has an optimum eld of view, this should be considered when determining the mounting position.

Chassis models must be installed in an electrical enclosure that will provide complete mechanical protection and maintain uniform internal temperature within the drive’s ambient operating temperature rating. All drive models MUST be mounted in a vertical position for proper heatsink cooling.

Maintain a minimum spacing around the drive as follows:

SPACING REQUIREMENTS

0.25 - 5 2 50

7.5 - 25 4 100

30 - 60 6 150

75 - 150 8 200

All drive models MUST be mounted in a vertical position for proper heatsink cooling. Fans or blowers should be used to insure proper cooling in tight quarters. mount drives above other drives or heat producing equipment that would impede the cooling of the drive. Note the ambient operating temperature ratings for each drive model.

13435742_EDBM101_v24 17

SPACING

INCHES mm

Do not

If it is necessary to drill or cut the drive enclosure or panel, extreme care must be taken to avoid damaging drive components or contaminating the drive with metal fragments (which cause shorting of electrical circuits). Cover drive components with a clean cloth to keep out metal chips and other debris. Use a vacuum cleaner to clean drive components after drilling, even if chips do not appear to be present. Do not attempt to use positive air pressure to blow chips out of drive, as this tends to lodge debris under electronic components. Contaminating the drive with metal chips can cause drive failure and will void the warranty. The MC1000 Series is UL approved for solid state motor overload protection. Therefore, a separate thermal overload relay is not required for single motor applications. In applications where one drive is operating more than one motor, a separate thermal overload relay is required for each motor per NEC.

7.1 INSTALLATION AFTER A LONG PERIOD OF STORAGE

WARNING!

Severe damage to the drive can result if it is operated after a long period of storage or inactivity without reforming the DC bus capacitors!

If input power has not been applied to the drive for a period of time exceeding three years (due to storage, etc), the electrolytic DC bus capacitors within the drive can change internally, resulting in excessive leakage current. This can result in premature failure of the capacitors if the drive is operated after such a long period of inactivity or storage.

In order to reform the capacitors and prepare the drive for operation after a long period of inactivity, apply input power to the drive for 8 hours prior to actually operating the drive/motor system.

7.2 EXPLOSION PROOF APPLICATIONS

Explosion proof motors that are not rated for inverter use lose their certication when used for variable speed. Due to the many areas of liability that may be encountered when dealing with these applications, the following statement of policy applies:

“Lenze AC Tech Corporation inverter products are sold with no warranty of fitness for a particular purpose or warranty of suitability for use with explosion proof motors. Lenze AC Tech Corporation accepts no responsibility for any direct, incidental or consequential loss, cost, or damage that may arise through the use of its AC inverter products in these applications. The purchaser expressly agrees to assume all risk of any loss, cost, or damage that may arise from such application."

18 13435742_EDBM101_v24

8 INPUT AC REQUIREMENTS

WARNING!

Hazard of electrical shock! Disconnect incoming power and wait three minutes before servicing the drive. Capacitors retain charge after power is removed.

8.1 INPUT AC POWER REQUIREMENTS

8.1.1 VOLTAGE

The input voltage must match the drive’s nameplate voltage rating. Voltage uctuation must not vary by greater than 10% over voltage or 15% under voltage.

NOTE: Drives with dual rated input voltage must be programmed for the proper supply voltage. Refer to Parameter 0 - LINE VOLTS in Section 18 - DESCRIPTION OF PARAMETERS.

The UL file for this drive shows that it is suitable for use on a circuit capable of delivering not more than 200,000 RMS symmetrical amperes, at the drive’s rated voltage. The CSA file identifies a short-circuit withstand rating of 5,000 RMS symmetrical amperes at the drives rated voltage.

Three phase voltage imbalance must be less than 2.0% phase to phase. Excessive phase to phase imbalance can cause severe damage to the drive’s power components.

Motor voltage should match line voltage in normal applications. The drive’s maximum output voltage will equal the input voltage. Use extreme caution when using a motor with a voltage rating which is dierent from the input line voltage.

8.1.2 SUPPLY TRANSFORMER kVA RATINGS

If the kVA rating of the AC supply transformer is greater than ten times the input kVA rating of the drive, a drive isolation transformer, or a 2 - 3% input line reactor (also known as a choke) must be added.

8.2 INPUT FUSING AND DISCONNECT REQUIREMENTS

A circuit breaker or a disconnect switch with fuses must be provided in accordance with the National Electric Code (NEC) and all local codes.

The MC1000 drive is capable of withstanding up to 150% current overload for 60 seconds. Select a fuse or magnetic trip circuit breaker rated at 1.5 times the input current rating of the drive (the minimum size should be 10 amps, regardless of input current rating). Refer to Section 5 - MC1000 RATINGS. Minimum voltage rating of the protection device should be 250 Vac for 240/120 Vac and 240/200 Vac rated drives, and 600 Vac for 480/400 Vac and 590/480 Vac drives.

Use UL Class CC or Class T current-limiting type fuses with low I at 200,000 AIC. Recommended fuses are Bussman type KTK-R, JJN, and JJS, or equivalent.

T values, rated

WARNING! Per UL requirements, use a FUSE (not a circuit breaker) for 240VAC drives requiring >40A protection and for 480VAC & 600VAC drives requiring >32A protection.

13435742_EDBM101_v24 19

9 VOLTAGE SELECTION

240 / 480 / 590 Vac INPUT

200 / 400 / 480 Vac INPUT

PL2 PL2

M1100 Series drives are rated for 240/120 Vac, 50-60 Hz input. The drive will function with input voltage of 120 Vac (+ 10%, -15%) at 48 to 62 Hz when wired for 120 Vac input, or with input voltage of 240 Vac (+ 10%, - 15%), at 48 to 62 Hz, when wired for 240 Vac input.

M1200 Series drives are rated for 240/200 Vac, 50-60 Hz input. The drive will function with input voltages of 200 to 240 Vac (+ 10%, - 15%), at 48 to 62 Hz.

M1400 Series drives are rated for 480/400 Vac, 50-60 Hz input. The drive will function with input voltages of 400 to 480 Vac (+ 10%, - 15%), at 48 to 62 Hz.

M1500 Series drives are rated for 590/480 Vac, 50-60 Hz input. The drive will function with input voltages of 480 to 590 Vac (+ 10%, - 15%), at 48 to 62 Hz.

To select the proper input voltage on 240/200 VAC 40-60 Hp models, 400/480 VAC 75-150 Hp and 480/590 VAC 75-150 Hp models the PL2 plug must be in the correct position. PL2 is located either at the lower right corner, or upper right corner of the power board, depending on horsepower. The PL2 plug is used to select the correct input voltage. Plug PL2 into the top and middle pins to select 240, 480, or 590 VAC or the middle and bottom pins to select 200, 400, or 480.

NOTE:

In addition to the voltage plug selection, Parameter 0 – LINE VOLTS must also be programmed for the proper voltage. Refer to Section 18 - DESCRIPTION OF PARAMETERS.

Voltage Selection Plug (PL2)

MODEL

CODE

1200 1400 1500

200V 400V 480V

240V 480V 590V

MODEL

CODE

1200 1400 1500

200V 400V 480V

20 13435742_EDBM101_v24

240V 480V 590V

10 POWER WIRING

WARNING!

Hazard of electrical shock! Wait three minutes after disconnecting incoming power before servicing drive. Capacitors retain charge after power is removed.

Note drive input and output current ratings and check applicable electrical codes for required wire type and size, grounding requirements, over current protection, and incoming power disconnect, before wiring the drive. Size conservatively to minimize voltage drop.

Input fusing and a power disconnect switch or contactor MUST be wired in series with terminals L1, L2, and L3 (L1 and L2 if input is single phase). If one has not been supplied by Lenze AC Tech Corporation, a disconnect means must be wired during installation. This disconnect must be used to power down the drive when servicing, or when the drive is not to be operated for a long period of time, but should not be used to start and stop the motor.

Repetitive cycling of a disconnect or input contactor (more than once every two minutes) may cause damage to the drive.

10.1 WIRING FOR SINGLE PHASE OR THREE PHASE INPUT

If the drive is name plated for 240/120 Vac single phase input, wire the input to terminals L1 and N and jumper terminals L1 to L2 for 120 Vac input voltage, or wire to terminals L1 and L2 (do not wire to N) for 240 Vac input voltage. Refer to Section 11 - MC1000 POWER WIRING DIAGRAM.

If the drive is name plated for three phase input only, wire the input to terminals L1, L2, and L3.

NOTE: Refer to Appendix A for alternate single wiring conguration on selected models.

All three power output wires, from terminals T1, T2, and T3 to the motor, must be kept tightly bundled and run in a separate conduit away from all other power and control wiring.

Do not install contactors or disconnect switches between the drive and motor. Operating such devices while the drive is running can potentially cause damage to the drive's power components. If such a device is required, it should only be operated when the drive is in a STOP state. If there is potential for the device to be opened while the drive is running, the drive must be programmed for COAST TO STOP (see Parameter 26 - STOP), and an auxiliary contact on the device must be interlocked with the drive's run circuit. This will give the drive a stop command at the same time the device opens, and will not allow the drive to start again until the device is closed.

13435742_EDBM101_v24 21

11 MC1000 POWER WIRING DIAGRAM

T1 T2

L1 L2 L3

L1L2N

120 Vac SINGLE

PHASE INPUT

WIRING DIAGRAM

L1 L2 N

240 Vac SINGLE

PHASE INPUT

WIRING DIAGRAM

THREE PHASE

AC MOTOR

GND

GNDGND

FUSED INPUT

VOLTAGE

DISCONNECT

MEANS

(REQUIRED)

WARNING!

Do not connect incoming AC power to output terminals T1, T2, or T3! Severe damage to the drive will result.

INSTALL, WIRE, AND GROUND IN ACCORDANCE WITH ALL APPLICABLE CODES.

NOTES:

1. Wire the motor for the proper voltage per the output rating of the drive. Motor wires MUST be run in a separate steel conduit away from control wiring and incoming AC power wiring.

2. Do not install contactors between the drive and the motor. Damage to the drive may result. Refer to Section 10.1.

3. Remove any existing, and do not install, power factor correction capacitors

between the drive and the motor. Failure to do so will result in drive damage.

4. Use only UL and CSA listed and approved wire.

5. Minimum wire voltage ratings: 300 V for 120, 200 and 240 Vac systems,

and 600 V for 400, 480, and 590 Vac systems.

6. Wire gauge must be based on a minimum of 125% of the rated input/output

current of the drive, and a minimum 75°C insulation rating. Use copper wire only.

7. Wire and ground in accordance with NEC or CEC, and all applicable local

codes.

8. Refer to Appendix A for alternate single phase wiring configuration on

selected models.

22 13435742_EDBM101_v24

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