Moeller DF5 Hardware And Engineering
Hardware and Engineering
DF5-...
09/01 AWB8230-1412GB
1st published 2001, edition 09/01
© Moeller GmbH, Bonn
Author: Holger Friedrich, Jörg Randermann
Editor: Michael Kämper
Translator: David Long
All brand and product names are trademarks or registered
trademarks of the owner concerned.
All rights reserved, including those of the translation.
No part of this manual may be reproduced in any form
(printed, photocopy, microfilm or any otherprocess) or processed,
duplicated or distributed by means of electronic systems without
written permission of Moeller GmbH, Bonn.
Subject to alterations without notice.
Warning!
Dangerous electrical voltage!
Before commencing the installation
• Disconnect the power supply of the device.
• Ensure that devices cannot be accidentally restarted.
• Verify isolation from the supply.
• Earth and short circuit.
• Cover or enclose neighbouring units that are live.
• Follow the engineering instructions (AWA) of the
device concerned.
• Only suitably qualified personnel in accordance with
EN 50 110-1/-2 (VDE 0105 Part 100) may work on this
device/system.
• Before installation and before touching the device ensure
that you are free of electrostatic charge.
• The functional earth (FE) must be connected to the protective
earth (PE) or to the potential equalisation. The system installer
is responsible for implementing this connection.
• Connecting cables and signal lines should be installed so
that inductive or capacitive interference do not impair the
automation functions.
• Install automation devices and related operating elements in
such a way that they are well protected against unintentional
operation.
• Suitable safety hardware and software measures should be
implemented for the I/O interface so that a line or wire
breakage on the signal side does not result in undefined
states in the automation devices.
• Ensure a reliable electrical isolation of the low voltage for the
24 volt supply. Only use power supply units complying with
IEC 60 364-4-41 (VDE 0100 Part 410) or HD 384.4.41 S2.
• Deviations of the mains voltage from the rated value must
not exceed the tolerance limits given in the specifications,
otherwise this may cause malfunction and dangerous
operation.
• Devices that are designed for mounting in housings or control
cabinets must only be operated and controlled after they have
been installed with the housing closed. Desktop or portable
units must only be operated and controlled in enclosed
housings.
• Measures should be taken to ensure the proper restart of
programs interrupted after a voltage dip or failure. This should
not cause dangerous operating states even for a short time.
If necessary, emergency-stop devices should be implemented.
• Wherever faults in the automation system may cause
damage to persons or property, external measures must be
implemented to ensure a safe operating state in the event of
a fault or malfunction (for example, by means of separate limit
switches, mechanical interlocks etc.).
• According to their degree of protection frequency inverters may
feature during operation live, bright metal, or possibly moving,
rotating parts or hot surfaces.
• The impermissible removal of the necessary covers, improper
installation or incorrect operation of motor or frequency
inverter may cause the failure of the device and may lead to
serious injury or damage.
• The relevant national regulations apply to all work carried on
live frequency inverters.
• The electrical installation must be carried out in accordance
with the relevant regulations (e. g. with regard to cable cross
sections, fuses, PE).
• All work relating to transport, installation, commissioning and
maintenance must only be carried out by qualified personnel.
(IEC 60 364 and HD 384 and national work safety regulations).
• Installations fitted with frequency inverters must be provided
with additional monitoring and protective devices in
accordance with the relevant safety regulations etc.
Modifications to the frequency inverters using the operating
software are permitted.
• Emergency stop devices complying with IEC/EN 60 204-1 must
be effective in all operating modes of the automation devices.
Unlatching the emergency-stop devices must not cause restart.
Moeller GmbH
Safety instructions
I
• All shrouds and doors must be kept closed during operation.
• In order to reduce hazards to persons or equipment, the user
must include in the machine design measures that restrict the
consequences of a malfunction or failure of the drive
(increased motor speed or sudden standstill of motor).
These measures include:
– Other independent devices for monitoring safety-related
variables (speed, travel, end positions etc.).
– Electrical or non-electrical system related measures
(interlocks or mechanical interlocks).
– Live parts or cable connections of the frequency inverter
must not be touched after it has been disconnected from the
power supply due to the charge in capacitors. Appropriate
warning signs must be provided.
II
09/01 AWB8230-1412GB
Contents
About this Manual 5
Abbreviations and symbols 5
1 About DF5 series frequency inverters 7
System overview 7
Type code 8
Inspecting the items supplied 9
Layout of the DF5 10
– Frequency inverter characteristics 11
Selection criteria 11
Intended use 12
Service and guarantee 12
2 Engineering 13
Features of the DF5 13
Connection to the mains 14
– Electrical grid types 14
– Mains voltage, Mains frequency 14
– Interaction with compensation devices 15
– Fuses and cable cross-sections 15
– Protection of persons and domestic animals
with residual-current protective devices 15
– Mains contactor 16
– Current peaks 16
– Mains choke 16
– Line filter, Radio interference filter 16
EMC guidelines 17
– EMC interference class 17
3 Installation 19
DF5 Installation 19
– Mounting position 19
– Installation dimensions 20
– DF5 attachment 21
EMC compliance 22
– EMC compliant installation 22
– Radio interference filter usage 22
– EMC measures in the control panel 23
– Grounding 24
– Screening 24
Electrical connection 26
– Connecting the power section 28
– Connecting the signalling relay 36
– Connecting the control signal terminals 38
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Contents
09/01 AWB8230-1412GB
4 DF5 Operation 43
Initial startup 43
LCD keypad 44
Operation with LCD keypad 44
– Menu overview 44
– Changing display and basic parameters 45
– Changing the parameters of the extended
parameter groups 46
Display after the supply voltage is applied 47
Operational warning message 48
5 Programming the control signal terminals 49
Overview 49
Frequency display FM 52
– Analog frequency display 52
– Digital frequency display 53
Programmable digital inputs 1 to 5 54
Start/Stop 55
Fixed frequency FF1 to FF4 selection 56
– Current setpoint value AT (4 to 20 mA) 58
– Second time ramp 2CH 59
– Controller inhibit and coasting of the
motor FRS (free run stop) 60
– External fault message EXT 61
– Restart inhibit USP 62
– Reset: RST 63
–Jog mode (JOG) 64
– PTC thermistor input: PTC 65
– Software protection SFT 66
Programmable digital outputs 11 and 12 67
Frequency value messages FA1/FA2 68
– RUN operational 70
– Overload message OL 71
– PID controller deviation message OD 72
– Error message AL 73
Signalling relay terminals K11, K12, K14 74
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09/01 AWB8230-1412GB
Contents
6 Setting Parameters 75
Setting the display parameters 75
Basic functions 76
– Input/display frequency value 76
– Acceleration time 1 76
– Deceleration time 1 77
– Direction of rotation 77
Setting the frequency and start command parameters 78
– Definition of frequency setpoint value 78
– Start command 78
– Base frequency 79
– Maximum end frequency 79
Analog setpoint value matching 80
Voltage/frequency characteristics and boost 81
DC braking (DC-Break) 82
Operating frequency range 83
PID controller 84
– The PID closed-loop control 84
– Structure and parameters of the PID controller 87
– Example for setting K
and T
p
i
92
– Application examples 93
Automatic voltage regulation (AVR) 95
Time ramps 96
Automatic restart after a fault 97
Electronic motor protection 98
Current limit 99
Parameter protection 100
Magnetizing current 100
Other functions 101
– Carrier frequency 101
– Initialization 101
– Country version 101
– Frequency factor for display via PNU d07 101
– Inhibit of the OFF key 102
– Motor restart after cancellation of the FRS signal 102
– Display when a remote operating unit is used 102
7 Messages 103
Fault messages 103
Other messages 104
8 Fault correction 105
3
Contents
09/01 AWB8230-1412GB
Appendix 107
Technical Data 107
Dimensions and weights 111
Cables and fuses 112
Mains contactors 113
Radio interference filter 115
Mains choke 116
Connection examples 117
– Operation through an external potentiometer 117
– Operation through an analog setpoint value 117
– Operation with fixed frequencies 118
Abbreviations of parameters and functions 119
Standard form for user defined parameter settings 120
®
UL
Caution, Warnings and Instructions 125
– Preparation for Wiring 125
– Determination of Wire and Fuse Sizes 125
– Terminal Dimensions and Tightening Torque 126
Index 127
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09/01 AWB8230-1412GB
About this Manual
This manual describes the frequency inverters of the DF5 series.
This manual contains special information which is required for
engineering, installation and operation of the DF5 series frequency
inverters. The features, parameters and functions are described in
detail and illustrated by the use of examples for the most important applications. All the details stated relate to the hardware and
software versions specified.
Abbreviations and symbols
Abbreviations and symbols with the following meanings are
described in this manual:
EMC: Electro Magnetic Compatibility
ESD: Electro static discharge
(Electro Static Discharge)
HF: High Frequency
IGBT: Insulated Gate Bipolar Transistor
PES: PE – connection (earth) of the screen (cable)
PNU: Parameter Number
WE: Factory default setting
All measurements are in millimeters unless otherwise stated.
In some of the illustrations, the enclosure of the frequency inverter
as well as other safety relevant parts may be omitted for the
purpose of improved visualization. However, the frequency
inverter must always be operated in the enclosure with all necessary safety relevant parts and components.
Read the manual carefully before you install and operate the
frequency inverter. We assume that you have a good knowledge
of engineering fundamentals and that you are familiar with the
electrical systems and the principles which apply, and are able to
read, understand and apply information contained in technical
drawings.
X indicates instructions to be followed
Makes you aware of interesting tips and additional
h
information
Caution!
warns about the possibility of minor material damage.
Warning!
warns about the possibility of major material damage and
minor injury.
Warning!
warns about the possibility of major material damage and
severe injury or death.
In order to improve the readability, the title of the chapter is indicated on the top of the left-hand page and the current section is
indicated on the top of the right-hand page. Pages where chapters
commence and blank pages at the end of the chapter are an
exception.
5
09/01 AWB8230-1412GB
6
09/01 AWB8230-1412GB
1 About DF5 series frequency inverters
System overview
a
b
g
f
c
d
e
Figure 1: System overview
a DF5 series frequency inverters-...
b DE5-LZ... RFI filter
c DE5-CBL-...-ICL connection cable
d DEX-CBL-...-ICS connection cable
e DE5-NET-DP interface module for PROFIBUS-DP
f DEX-DEY-10 external keypad
g DE5-KEY-RO3 external display module
7
About DF5 series frequency
inverters
Type code
Type code and type designation of the DF5 series frequency
inverter:
09/01 AWB8230-1412GB
DF5-xxx-yyy
Motor rating code
Incoming supply: EU rated voltage (230 V/400 V)
Version and model number
0 = basic version
1 = system devices
2 = voltage code suffix
Supply connection, voltage code (EU rated value)
2 = 230 V (180 V – 0 % to 252 V + 0 %)
4 = 400 V (342 V – 0 % to 506 V + 0 %)
Supply connection, phase code
1 = single-phase
3 = three-phase
Family name:
Drives Frequency Inverter, Generation 5
Figure 2: Type code DF5 series frequency inverters
Examples:
DF5-322-075
DF5-340-5K5
Frequency inverters of the DF5 series
Single-phase or three-phase supply: 230 V
Assigned motor rating: 0.75 kW at 230 V
Frequency inverters of the DF5 series
Three-phase mains supply voltage: 400 V
Assigned motor rating: 5.5 kW at 400 V
8
09/01 AWB8230-1412GB
Inspecting the items supplied
Inspecting the items supplied
Frequency inverters of the DF5 series frequency inverters are carefully packed before delivery. The device may be transported only in
its original packaging with a suitable transport system (see weight
details). Observe the instructions and the warnings on the side of
the packaging. This also applies after the device is removed from
the package.
Open the packaging with suitable tools and inspect the contents
immediately after delivery to ensure that they are complete and
undamaged. The package must contain the following items:
• a DF5 series frequency inverter,
• the installation instructions AWA8230-1935,
• a CD with:
– this manual in PDF format as well as in further languages
– the parameter definition software;
the requirements are: A PC with Windows 95, 98, ME, 2000,
NT and the DEX-CBL-2M0-PC connection cable
Figure 3: Equipment supplied
Using the nameplate attached to the frequency inverter,
h
check to ensure that the frequency inverter is the type
which you have ordered.
9
About DF5 series frequency
inverters
Layout of the DF5
09/01 AWB8230-1412GB
m e
Figure 4: Designations of the DF5
a Front cover, can be opened without tools
b Integrated keypad
c Terminal shroud
d Front cover flap with keypad
e Signalling relay terminals
f Heat sink
g Optional radio interference filter
e
j
k
l
cab
i
h
h Power terminals
i Screw for opening the front enclosure
j Control signal terminals
k Enclosure
l Earth connection (PE)
m Interface connection
e
d
f
g
10
09/01 AWB8230-1412GB
Selection criteria
Frequency inverter characteristics
The DF5 series convert the voltage and frequency of an existing
three-phase supply to a DC voltage and use this voltage to generate a three-phase supply with adjustable voltage and frequency.
This variable three-phase supply allows stepless variability of
three-phase asynchronous motors.
f
h
a
bc d
Figure 5: Functional diagram of the frequency inverter
a Supply via an interference suppressor
Mains voltage U
-322 1/3 AC 230 V, 50/60 Hz
DF5
-340 3 AC 400 V, 50/60 Hz
DF5
b The bridge rectifiers convert the AC voltage of the electrical supply to
a DC voltage.
c The DC link contains a charging resistor, smoothing capacitor and
switched-mode power supply unit. It enables coupling of the DC bus
voltage and the DC current supply:
DC bus voltage (U
d IGBT power inverter:
The power inverter converts the DC voltage of the DC link to a variable
three-phase alternating voltage with variable frequency.
e Output voltage (U
three-phase, variable AC voltage, 0 to 100 % of the input voltage
)
(U
LN
Output frequency (f
Variable frequency, 0.5 to 360 Hz
Output rated current (I
1.8 to 22.5 A with about 1.5 times the starting current for 60 s, with
a switching frequency of 5 kHz and with an ambient temperature of
40 °C
Motor connection, assigned shaft output (P
0.18 to 2.2 kW at 230 V
0.37 to 7.5 kW at 400 V
f Programmable control section with keypad and interface.
(EU-rated voltage):
LN
) = W2 x mains voltage (ULN)
ZK
), motor connection:
2
):
2
):
2N
2
M
3
˜
e
):
Selection criteria
The frequency inverter is selected to suit the rated motor current.
The output rated current of the frequency inverter must however,
be greater than or equal to the rated motor current.
The following drive data is assumed to be known:
• type of motor (three-phase asynchronous motor),
• mains voltage = supply voltage of the motor (e.g. 3 ~ 400 V),
• rated motor current (guide value, dependent on the circuit type
and the supply voltage),
• load torque (quadratic, constant, with 1.5-times the starting
torque),
• ambient temperature (maximum temperature 40 °C).
With the parallel connection of multiple motors to the
h
output of a frequency inverter, the motor currents are
subject to vector addition, i.e. the active in-phase current
and reactive current components are added separately.
Select the frequency inverter rating to ensure that the
total current can be supplied by the frequency inverter.
If a motor switches during operation on the output of a
h
frequency inverter, the motor draws a multiple of its rated
current. Select the rating of the frequency inverter to
ensure that the starting current plus the sum of the
currents of the running motors does not exceed the rated
output current of the frequency inverter.
The rated output current of the frequency inverter can be found in
the technical data in the Appendix from Page 107.
11
About DF5 series frequency
inverters
09/01 AWB8230-1412GB
Intended use
The DF5 series frequency inverters are not domestic appliances.
They are designed only for industrial use as system components.
The DF5 series frequency inverters are electrical apparatus for
controlling variable speed drives with three-phase motors. They
are designed for installation in machines or for use in combination
with other components within a machine or system.
After installation in a machine, the frequency inverters must not be
taken into operation until the associated machine has been
confirmed to comply with the safety requirements of Machinery
Safety Directive (MSD) 89/392/EEC and meets the requirements of
EN 60204. The user of the equipment is responsible for ensuring
that the machine use complies with the relevant EU Directives.
The CE-mark attached to the DF5 series frequency inverters
confirm that, when used in a typical drive configuration, the
apparatus complies with the European Low Voltage Directive
(LVD) and the EMC Directives (Directive 73/23/EEC, as amended
by 93/68/EEC and Directive 89/336/EEC, as amended by 93/68/
EEC).
Frequency inverters of the DF5 series are suitable for use in public
and non-public networks in the described system configuration.
Depending on their location of use, external filtering may be
necessary.
Service and guarantee
In the unlikely event that you have a problem with your Moeller
frequency inverter, please contact your local sales office.
Please have the following data and information concerning the to
hand:
• exact frequency inverter type designation (a nameplate)
• date of purchase
• exact description of the problem which has occurred with the
frequency inverter.
If some of the information printed on the nameplate is not legible,
please state only the information which is clearly legible.
Information concerning the guarantee can be found in the Moeller
General Terms and Conditions of Sale.
Connection to IT networks (networks without a ground potential
reference point) is not permitted as the devices internal filter capacitors connect the network to the ground potential (enclosure). On
earth free networks, this can lead to dangerous situations or
damage to the device (isolation monitoring required).
On the output of the frequency inverter (terminals U, V, W) you
may not:
• connect a voltage or capacitive loads (e.g. phase compensation
capacitor),
• connect multiple frequency inverters in parallel,
• make a direct connection to the input (bypass).
Observe the technical data and terminal requirements. Refer to the
equipment nameplate or label and the documentation for more
details.
Any other usage constitutes improper use.
12
09/01 AWB8230-1412GB
2 Engineering
This chapter describes the ”Features of the DF5” as well as guidelines and regulations concerning the following subjects:
• Connection to the mains
• EMC guidelines
Features of the DF5
Ambient temperatures
Operation
Storage Ta = –25 to +70 °C
Transport
Permissible ambient influences
Resistance to vibration Vibrations and shaking: maximum 5.9 m/s2 (0.6 g) at 10 to 55 Hz
Pollution degree
Packaging
Climatic conditions
Installation altitude
Mounting position
Free surrounding areas
Electrical data
Emitted interference IEC/EN 61800-3 (EN 55011 group 1, class B)
Noise immunity
Insulation resistance
Leakage current to PE
Degree of protection
Protection against direct contact
Protective isolation against switching circuitry
Protective measures
Control/regulation
Modulation method Pulse width modulation (PWM), V/f-predetermined control (linear,quadratic)
Switching frequency
Torque
Output frequency
Relay
1)
Range 0.5 to 360 Hz
Frequency resolution
Error limit at 25 °C g10 °C
Changeover contact • AC 250 V, 2.5 A (resistive load)
Ta = –10 to +40 °C with rated current Ie without derating,
up to +50 °C with reduced carrier frequency of 2 kHz and reduced output current to 80 % I
Ta = –25 to +70 °C
VDE 0110 Part 2, pollution degree 2
Dust proof packaging (DIN 4180)
Class 3K3 according to EN 50178 (non-condensing, average relative humidity 20 to 90 %)
Up to 1000 m above sea level
Vertically suspended
100 mm above and below device
IEC/EN 61800-3, industrial environment
Overvoltage category III according to VDE 0110
Greater than 3.5 mA according to EN 50178
IP20
Finger and back-of-hand proof (VBG 4)
Safe isolation from the mains. Double basic isolation according to EN 50178
Overcurrent, earth fault, overvoltage, undervoltage, overload, overtemperature, electronic motor
protection: I
5 kHz (WE), can be selected between 0.5 and 16 kHz
At start 1.5 x MN for 60 s with assigned motor rating, every 600 s
0.1 Hz, at digital setpoint, maximum frequency/1000 with analog setpoint
Digital setpoint definition g0.01 % of the maximum frequency
Analog setpoint definition g0.2 % of the maximum frequency
• AC 250 V, 0.2 A (inductive load, cos v = 0.4)
• AC 100 V, minimum 10 mA
• DC 30 V, 3 A (resistive load)
• DC 30 V, 0.7 A (inductive load, cos v = 0.4)
• DC 5 V, minimum 100 mA
2
t monitoring and PTC input (thermistor or temperature contacts)
e
13
Engineering
Internal voltages
Control 24 V DC, maximum 30 mA
Setpoint value definition
Analog and digital actuation
Analog inputs • 1 input, 0 to 10 V, input impedance 10 kO
Digital inputs/outputs
Monitor output
Keypad (integrated)
Operation 6 function keys for control and parameter definition of the DF5
Display
Potentiometer
1) If the frequency inverter is to be installed in a control panel, enclosure or similar installation, the prevalent ambient temperature within these enclosures or control panels is considered to be the ambient temperature T
remains within permissible limits.
10 V DC, maximum 10 mA
• 1 input, 4 to 20 mA, load impedance 250 O
5 Freely programmable inputs
2 Outputs, open collector (maximum 27 V DC, 50 mA)
1 output for frequency or current, 10 V, maximum 1 mA
Four character 7 segment display and seven LEDs (status messages)
Setpoint definition (0 to 270°)
. The use of fans should be considered to ensure that the ambient temperature
a
09/01 AWB8230-1412GB
Connection to the mains
The DF5 series frequency inverters can be used without limitation
with every type of electrical grid (Electrical grids according to
IEC 364
-3).
Electrical grid types
Electrical grids with a direct earthing point (TT/TN
-systems):
• Operation of the frequency inverters of the DF5 series with TT
-systems is possible without limitation. Adhere to the rated
TN
data of the DF5 series frequency inverters.
If many frequency inverters with a single-phase supply are
h
connected to the mains, the symmetric distribution on all
three mains poles should be considered as well as the
loading of the common neutral pole (mains r.m.s current).
If necessary, the cross-section of the neutral pole must be
increased, if it conducts the total current of all singlephase devices.
Grids with isolated centre point (IT
-systems):
• Operation of the frequency inverters of the DF5 series with
IT
-systems is only conditionally possible. A prerequisite is a
suitable device (isolation monitoring), which monitors earth
faults and isolates the frequency inverter from the mains.
Caution!
With an earth fault in an IT
-system, the capacitors of the
frequency inverter which are switched to earth are subject
to a very high voltage. Therefore, safe operation of the
frequency inverter cannot be guaranteed. The situation
can be remedied with an additional isolating transformer
with an earthed centre point on its secondary, which is
then used to supply the input of the frequency inverter.
This constitutes an individual TN-system for the frequency
-/
inverter.
Mains voltage, Mains frequency
The rated data for the frequency inverters of the DF5 take the
European and American standard voltages into account:
• 230 V, 50 Hz (EU) and 240 V, 60 Hz (USA) with DF5-322,
• 400 V, 50 Hz (EU) und 460 V, 60 Hz (USA) with the DF5-340
The permitted mains voltage range is:
• 230/240 V: 180 V – 0% to 252V+0%
• 400/460 V: 342 V – 0% to 506V+0%
The permissible frequency range is 47 Hz – 0% to 63Hz+0%.
The device assignment of the motor rating to the mains voltage is
listed in Section ”Technical Data”, Page 107 in the Appendix.
14
09/01 AWB8230-1412GB
Connection to the mains
Interaction with compensation devices
The DF5 series frequency inverters only accept a minimal fundamental reactive power from the AC voltage supply. Compensation
is therefore unnecessary.
Caution!
Operation of the frequency inverters of the DF5 series on
the mains with p.f. correction equipment is only permitted
when this equipment is dampened with chokes.
Fuses and cable cross-sections
When the devices are connected to the mains, the fuses and cable
cross-sections which are required are dependent on the rating of
the frequency inverter and the operation mode of the drive.
Caution!
The voltage drop under load conditions should be considered when selecting the cable cross-section. Compliance
to further standards (e.g. VDE 0113, VDE 0289) is the
responsibility of the user.
The recommended fuses and the assignment of the DF5 series
frequency inverters are listed in Section ”Cables and fuses”,
Page 112 in the Appendix.
The national and regional standards (e.g. VDE 0113, EN 60204)
must be observed and the necessary approvals (e.g. UL) at the site
of installation must be fulfilled.
When the device is operated in a UL
-approved fuses, fuse bases and cables can be used.
UL
-approved system, only
Protection of persons and domestic animals with residualcurrent protective devices
Residual-current circuit-breakers RCCB (according to VDE 0100,
also referred to as ELCBs). Universal current sensitive ELCBs according to EN 50178 and IEC 755.
Identification on the residual-current circuit-breakers
Logo
Type alternating
current sensitive
(RCCB, Type AC)
pulse current
sensitive
(RCCB, Type A)
universal current
sensitive
(RCCB, Type B)
The frequency inverter is internally equipped with a mains rectifier.
With a short circuit to an exposed conductive part, a fault DC
current can block the trip of the alternating current sensitive or
pulse current sensitive residual-current circuit-breaker and thus
eliminate the protective function. We therefore recommend the
use of:
•“Pulse current sensitive residual-current circuit-breakers” with
a rated current f 30 mA with frequency inverters with a singlephase supply ( .
•”Universal current sensitive residual-current circuit-breakers”
with a rated current f 300 mA with frequency inverters with a
single-phase supply on frequency inverters with three-phase
supply .
The fault current recommended values of the DF5 series frequency
inverters and the assigned radio interference filter are listed in
Section ”Radio interference filter”, Page 115 in the Appendix.
The leakage currents to ground (according to EN 50178) are
greater than 3.5 mA. The PE terminal and the enclosure must be
connected to the earth-current circuit.
Caution!
The prescribed minimum cross-sections of PE-conductors
(EN 50178, VDE 0160) must be observed. Select the
cross-section of the PE
-conductor as least as large as the
terminal capacity of the power terminals.
Spurios tripping of a residual-current circuit-breaker can be
activated by the following:
• by capacitive compensation currents of the cable screens,
particularly with long screened motor cables,
• by simultaneous connection of multiple frequency inverters to
the mains supply,
• with the use of additional chokes and filters (radio interference
filter, line filter).
Caution!
Residual-current circuit-breakers may only be installed on
the primary side between the incoming supply and the
frequency inverter.
Warning!
Only use cables, residual-current circuit-breakers and
contactors which have a suitable rating. Otherwise there
is a danger of fire.
15
Engineering
09/01 AWB8230-1412GB
Mains contactor
The mains contactor is connected to the mains side input cables
L1, L2, L3 (type dependant). It allows the operational switch on
and off of the DF5 series frequency inverters from the mains supply
as well as shutdown during a fault.
Mains contactors and the assignment with the DF5 series
frequency inverters are listed in Section ”Mains contactors”,
Page 113 in the Appendix.
Current peaks
In the following cases, a relatively high peak current can occur on
the primary side of the frequency inverter (i.e. on the supply
voltage side), which under certain conditions, can destroy the
input rectifier of the frequency inverter:
• Imbalance of the voltage supply greater than 3 %.
• The maximum power output of the supply point must be at least
10 times greater than the maximum frequency inverter rating
(approx 500 kVA).
• If sudden voltage dips in the supply voltage are to be expected,
e.g. :
– a number of frequency inverters are operated on a common
supply voltage.
– a Thyristor system and a frequency inverter or operated on a
common supply voltage.
– power factor correction devices are switched on or off.
In the cases mentioned, a mains choke with approx. 3 % voltage
drop at rated operation should be installed.
Mains choke
The mains choke (also referred to as a commutating choke or line
reactor) is connected to the mains side input cables L1, L2, L3 (type
dependent). It reduces the harmonics and leads to a reduction of
the apparent mains current by up to 30 %.
A mains choke also limits current peaks which occur, caused by
potential dips (e.g. caused by p.f. correction equipment or earth
faults) or switching operations on the mains.
The mains choke increases the lifespan of the DC link capacitors
and consequently the lifespan of the frequency inverter. Its use is
also recommended:
• with a single-phase supply (DF5-322),
• with derating (temperatures above +40 °C, sites of installation
which are more than 1000 m above sea level),
• with parallel operation of multiple frequency inverters on a
single mains supply point,
• with DC link coupling of multiple frequency inverters
(interconnected operation).
Mains chokes and the assignment to DF5 series frequency inverters are listed in Section ”Mains choke”, Page 116 in the
Appendix.
Line filter, Radio interference filter
Line filters are a combination of mains chokes and radio interference filters in a single enclosure. They reduce the current harmonics and dampen high frequency radio interference levels.
Radio interference filters only dampen high frequency radio interference levels.
16
Caution!
When line filters or radio interference filters are used, the
leakage current to earth increases. Observe this point
when residual-current circuit-breakers are used.
09/01 AWB8230-1412GB
EMC guidelines
EMC guidelines
The limit values for emitted interference and immunity with variable speed drives are described in the IEC/EN 61800
-3 product
standard.
When operating the frequency inverters of the DF5 series in coun-
tries which are part of the European Union (EU), the EMC guideline
89/336/EEC must be observed. The following conditions described
must be observed in order to comply with this guideline:
Supply voltage (mains voltage) for the frequency inverter:
• voltage fluctuation g10 % or less
• voltage imbalance g3% or less
• frequency variation g4 % or less
If the above mentioned conditions are not fulfilled, the respective
mains choke must be installed (a Section ”Mains choke” in the
Appendix, Page 116).
EMC interference class
When installation is completed according to the Section ”Installa-
tion”, described in ”EMC guidelines” Page 17 and with the use of
a radio interference filter, the frequency inverters of the DF5 series
comply to the following standards:
• Emitted interference:
IEC/EN 61800-3 (EN 55011 group 1, class B)
• Noise immunity:
EN 61800-3, industrial environment
Noise immunity
DF5 series frequency inverters conform with the requirements of
the EC/EN 61800
-3 EMC-product standard for industrial use
(second environment), and the higher interference immunity
values in domestic environments (first environment) with the
assigned radio interference filters.
A domestic environment can be understood to be a connection
point (transformer feeder) to which domestic households are also
connected.
The EMC
-guideline for an industrial system requires electromag-
netic compatibility with the environment as a whole. The product
standard examines a typical drive system in principle as a complete
system, i.e. the combination of frequency inverter, cables and
motor.
Emitted interference and radio interference suppression
DF5 series frequency inverters conform with the requirements of
the EC/EN 61800
-3 EMC-product standard for domestic use (first
environment), and therefore also with the higher interference
immunity values in industrial environments (second environment)
with the assigned radio interference filters.
Ensure compliance to the limit values with the following points:
• reduction of performance related interference with line filters
and/or radio interference filters including mains chokes.
• reduction of the electromagnetic emission interference by
screening motor cables and signal cables.
• compliance with installation guidelines (EMC compliant
installation).
With frequency inverters, performance related and emitted interference increase with the switching frequency. The frequency of
occurrence of performance related interference also increase with
longer motor cables. When the respective radio interference filter
is used, the EN 61800-3 standard is complied to as follows:
Conformity
General Limited
First environment
(Public power grid)
Second environment (Industrial)
1) This is a product with limited conformity according to IEC/
EN 61800-3. This product can cause radio frequency interference in
domestic environments. In this case, it is necessary that the user
undertakes the required protection measures.
Up to 10 m motor cable
lengths with 16 kHz
(maximum switching
frequency)
Up to 20 m motor cable
lengths with maximum
5 kHz switching frequency
Up to 50 m Up to 50 m
Up to 50 m
1)
17
09/01 AWB8230-1412GB
18
09/01 AWB8230-1412GB
3 Installation
The DF5 series frequency inverters should be installed in a control
panel or in a metal enclosure (e.g. IP54).
During installation or assembly operations on the
h
frequency inverter, all ventilation slots and openings
should be covered to ensure that foreign bodies and
objects do not penetrate the device.
DF5 Installation
The DF5 series frequency inverters must be installed vertically on a
non-flammable base.
Mounting position
F 30˚
F 30˚
Figure 6: Mounting position
F 30˚
F 30˚
19
Installation
09/01 AWB8230-1412GB
Installation dimensions
A free space of 100 mm minimum is required above and below the
device (thermal air circulation).
f 100f 100
f 100f 100
f 80
f 120
Please ensure that the front cover of the enclosure can always be
opened and closed without impediment to ensure that the control
terminals can be connected.
f 100
Figure 7: Installation dimensions
Dimensions and weights of the DF5 can be found in the Appendix
Section ”Dimensions and weights” from Page 111.
f 100
f 10f 10
20
09/01 AWB8230-1412GB
DF5 attachment
Install the DF5 series frequency inverter according to Fig. 8 and
tighten the screws with the following torques (a Table 1):
o
DF5 Installation
Figure 8: DF5 attachment
Table 1: Tightening torque's of the attachment screws
o
[mm]
5 M4 3 Nm 26 lbin
7
M6 4 Nm 35 lbin
21
Installation
EMC compliance
09/01 AWB8230-1412GB
EMC compliant installation
The frequency inverter operates with fast electronic switching
devices e.g. transistors (IGBT). For this reason, radio interference
can occur on the output of the frequency inverter, which may
effect other electronic devices located in the direct vicinity such as
radio receivers or measurement instruments. In order to offer
protection against this radio frequency interference (RFI), the
devices should be screened and installed as far away as possible
from the frequency inverters.
We recommend the following measures for EMC compliant installation:
• installation of the frequency inverter in a metallic, electrically
conducting enclosure with a good connection to earth.
• installation of a radio interference filter on the input of the
frequency inverter in its direct vicinity
• screened motor cables (short cable lengths).
Z1
Uh
G1
6
Radio interference filter usage
The RFI filter should be installed in the direct vicinity of the
frequency inverter. The connection cable between the frequency
inverter and filter should be as short as possible. Screened cables
are required if the length exceeds 30 cm.
The radio interference filters assigned for the DE5-LZ... series
(a Section ”Radio interference filter” in the Appendix,
Page 115) enable the installation below (foot-print) or on the side
(book-type) of the DF5 series frequency inverters.
3h
a
M
E
E
Figure 9: DF5 and radio interference filter in a sealed enclosure
Z1: RFI filter
G1:frequency inverter
a Screened motor cable
X Ground the metallic enclosure via a cable which should be as
short as possible (a Fig. 9).
Figure 10: foot-print-Aufbau
Figure 11: Seitlicher Anbau
22
Radio interference filters produce leakage currents which can be
significantly larger than the rated values in the event of a fault
(phase failure, load unbalance). The filters must be earthed before
use in order to avoid dangerous voltages. As the leakage currents
09/01 AWB8230-1412GB
EMC compliance
are high frequency interference sources, the earthing measures
must be undertaken with low resistance's on surfaces which as
large as possible.
Z1 G1
R2
L1
L2
L3
PE
L1
L2
L3
L/L1
S2
L2
T2
N/L3
e
U
V
W
3h
M
E
E
Figure 12: Earthing measures
Z1: EMC filter
G1:frequency inverter
With leakage currents f 3.5 mA, the VDE 0160 and EN 60335
stipulate that either:
• the protective conductor must have a cross-section f 10 mm
• the protective conductor is monitored to ensure continuity or
• an additional protective conductor is also installed.
For the frequency inverters of the DF5 series use the assigned filter
DE5-LZ....
EMC measures in the control panel
To ensure EMC-compliant setup, connect all metallic components
of the devices and of the control cabinet with each other using a
large cross-section conductor with good HF conducting properties.
Do not make connections to painted surfaces (Eloxal, yellow chromated). If there is no alternative, use contact and scraper washers
to ensure contact with the base metal. Connect mounting plates
to each other, and the cabinet doors with the cabinet using
contacts with large surface areas and short HF wires.
An overview or all EMC measures can be seen in the following
figure.
2
,
PE
Figure 13: EMC-compliant setup
15
PES
W2
U2
V2
U1
W1
V1
PES
PES
PE
23
Installation
09/01 AWB8230-1412GB
Fit additional RFI filters or mains filters and frequency inverters as
closely as possible to each other and on a single metal plate
(mounting plate).
Lay cables in the control cabinet as near as possible to the ground
potential. Cables that hang freely act as antennae.
To prevent transfer of electromagnetic energy, lay interferencesuppressed cables (e.g. mains supply before the filter) and signal
lines as far away as possible (at least 10 cm) from HF-conducting
cables (e.g. mains supply cable after a filter, motor power cable).
This applies especially where cables are routed in parallel. Never
use the same cable duct for interference-suppressed and HF
cables. Where unavoidable, cables should always cross over at
right angles to each other.
Never lay control or signal cables in the same duct as power
cables. Analog signal cables (measured values, setpoints and
correction values) must be screened.
Z1G1 Gn Zn
M1
3h
Grounding
Connect the ground plate (mounting plate) with the protective
earth using a short cable. To achieve the best results, all conducting components (frequency inverter, mains filter, motor filter,
mains choke) should be connected by an HF wire, and the protective conductor should be laid in a star configuration from a central
earthing point. This produces the best results.
Ensure that the earthing measures have been correctly implemented (a Fig. 14). No other device which has to be earthed
should be connected to the earthing terminal of the frequency
inverter. If more than one frequency inverter is to be used, the earthing cables should not form a closed loop.
Mn
M
PE
M
3h
PE
Figure 14: Star-type point to point earthing
PE
Screening
Unscreened cables behave like antennae, i.e. they act as transmitters and receivers. To ensure EMC-compliant connection, screen
all interference-emitting cables (frequency inverter/motor output)
and interference-sensitive cables (analog setpoint and measured
value cables).
The effectiveness of the cable screen depends on a good screen
connection and a low screen impedance. Use only screens with
tinned or nickel plated copper braiding, braided steel screens are
unsuitable. The screen braid must have an overlap ratio of at least
85 percent and an overlap angle of 90°.
PE PE
e
a
e
Figure 15: Sample motor cable
a CU screen braid
b PVC outer sheath
c Strands (CU-strands)
d PVC core insulation
3 x black, 1 x green/yellow
e Textile braid and PVC inner material
b
c
d
24
09/01 AWB8230-1412GB
EMC compliance
The screened cable between frequency inverter and motor should
be as short as possible. Connect the screen to earth at both ends
of the cable using a large contact surface connection.
Lay the cables for the supply voltage separately from the signal
cables and control cables.
Never unravel the screening or use pigtails to make a connection.
Figure 16: Inadmissible screen grounding (pigtails)
If contactors, maintenance switches, motor protection relays,
motor reactors, filters or terminals are installed in the motor
cabling, interrupt the screen near these components and connect
it to the mounting plate (PES) using a large contact surface
connection. The free, unscreened connecting cables should not be
longer then about 100 mm.
Example: Maintenance switch
In an EMC-compliant control cabinet (metal-enclosed, damped to
about 10 dB), the motor cables do not need to be screened
provided that the frequency inverter and motor cables are spatially
separated from each other and arranged in a separate partition
from the other control system components. The motor cable screening must then be connected via a large surface area connection
at the control cabinet (PES).
The control cable and signal (analog setpoint and measured value)
cable screens must be connected only at one cable end. Connect
the screen to ground using a large-area contact surface; ensure
that the connection has a low impedance. Digital signal cable
screens must be connected at both cable ends with large-surface,
low-resistance connections.
a
PES
b
PES
Figure 17: Maintenance switch, e.g. T… in an enclosure
a Metal plate
b Insulated PE-terminal
25
Installation
Electrical connection
In this section, you will find information for connection of the
motor and the supply voltage to the power terminals, and the
signal cables to the control terminals and signalling relay.
Warning!
The wiring stages may only commence after the frequency
inverters have been correctly installed and attached.
Otherwise, there is a danger of electrical shock or injury.
Warning!
Wiring may only be carried out under no voltage
conditions.
Warning!
Only use cables, residual-current circuit-breakers and
contactors which have a suitable rating. Otherwise there
is a danger of fire.
09/01 AWB8230-1412GB
An overview of the connections can be found in the following
illustration.
26
09/01 AWB8230-1412GB
a
L1
L2
L3
PE
Electrical connection
3 h 400 V, 50/60 Hz
b
I > I > I >
j
T1 T2 PE
i
DE4-BM4...
–UG
+UG
PES
c
d
e
f
PES
DC+ DC–
i
L1 L2
PE
FI
U
L3 PE
VW
M
3
˜
K14 K12 K11
#
L5
g
PES
h
PES
i
Figure 18: Power connection, example with 400 V
a Network configuration, mains voltage, mains frequency
interaction with p.f. compensation systems
b Fuses and cable cross-sections
c Protection of persons and domestic animals with residual-current
protective devices
d Mains contactor
e Mains choke, radio interference filter, line filter
f Mounting, installation
power connection
EMC measures
example of circuits
g Motor filter
dv/dt filter
sinusoidal filter
h Motor cables, cable length
i Motor connection
parallel operation of multiple motors on an single frequency inverter
j Braking resistors, braking units
DC link coupling
DC supply
27
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