Moeller DF5 Hardware And Engineering

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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.

(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

• 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.

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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

Contents

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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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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

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

Contents

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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

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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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

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.

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1 About DF5 series frequency inverters

System overview

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

About DF5 series frequency inverters

Type code

Type code and type designation of the DF5 series frequency inverter:

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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

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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,

check to ensure that the frequency inverter is the type which you have ordered.

About DF5 series frequency inverters

Layout of the DF5

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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

cab

h Power terminals i Screw for opening the front enclosure j Control signal terminals k Enclosure l Earth connection (PE) m Interface connection

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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.

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

)

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):

) = W2 x mains voltage (ULN)

), motor connection:

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

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

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.

About DF5 series frequency inverters

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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.

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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

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

t monitoring and PTC input (thermistor or temperature contacts)

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

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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

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.

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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.

-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.

Engineering

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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.

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.

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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

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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

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˚

Figure 6: Mounting position

F 30˚

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 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

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DF5 attachment

Install the DF5 series frequency inverter according to Fig. 8 and tighten the screws with the following torques (a Table 1):

DF5 Installation

Figure 8: DF5 attachment

Table 1: Tightening torque's of the attachment screws

[mm]

5 M4 3 Nm 26 lbin 7

M6 4 Nm 35 lbin

Installation

EMC compliance

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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).

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.

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

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

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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

L1 L2 L3

L/L1

N/L3

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.

Figure 13: EMC-compliant setup

PES

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

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.

M 3h

Figure 14: Star-type point to point earthing

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

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

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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.

PES

Figure 17: Maintenance switch, e.g. T… in an enclosure

a Metal plate b Insulated PE-terminal

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.

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An overview of the connections can be found in the following illustration.

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L1 L2 L3 PE

Electrical connection

3 h 400 V, 50/60 Hz

I > I > I >

T1 T2 PE

DE4-BM4...

–UG

+UG

PES

DC+ DC–

L1 L2

L3 PE

K14 K12 K11

PES

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

Installation

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Connecting the power section

The flap on the front enclosure must be opened in order to connect the cables to the supply voltage and signal relay terminals.

Complete the following steps with the tools stated and

without the use of force.

Open the front cover and the front of the enclosure

X First of all open the front cover

X Loosen the screw

MIN

PRG

MAX

ENTER

POWER

RUN

PRG

MIN

MAX

ENTER

Figure 19: Opening the front cover

Figure 20: Loosen the screw

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X Flap open the front cover and remove the terminal shroud. Power terminal arrangement

The arrangement of the power terminals can be seen in the following figure.

L+

DC+ DC–

Electrical connection

Figure 21: Open the front cover and remove the terminal shroud a Power terminals

Table 2: Description of the power terminals

Terminal designation

L, L1, L2, L3, N Supply voltage (mains

U, V, W Frequency inverter

L+, DC+

DC+, DC–

e, PE

Function Description

• Single-phase mains voltage: Connection to L and N

voltage)

• Three-phase mains voltage: Connection to L1, L2, L3 Connection of a three-phase motor

output External DC choke Normally, the terminals L+ and DC+ are assigned with a

jumper. If a d.c.-link choke is used, the jumper must be removed.

DC link These terminals are used for the connection of an optional

braking resistor as well as for DC linking and DC feed of multiple frequency inverters.

Earthing Enclosure earthing (prevents the presence of dangerous

voltages on the enclosure with a malfunction)

L/L1 L2 U V WN/L3

L1 L2 L3

3 h

Figure 22: Arrangement of the power terminals a Internal connection. Remove if a d.c.-link choke is used.

N/L3L2L/L1 U V W

3 h

Installation

Power terminal connection Laying the cables

Warning!

The supply voltage must suit the frequency inverter which is selected (a Section ”Appendix”, Page 107):

• DF5-322: Single-phase or three-phase: 230 V (180 to 264 V g 0%)

• DF5-340: three-phase 400 V (342 to 506 V g 0%)

Lay the cables for the power section separately from the signal cables and control cables.

The motor cables which are to be connected must be screened. The maximum cable length must not exceed 50 m. With larger cable lengths, a motor choke is required for dv/dt-limitation

If the cable leading from the frequency inverter to motor is longer than approx. 10 m, it is possible that the available thermal relays

Warning!

The mains voltage may not be connected for any reason to the output terminals U, V and W. Danger of electrical

(bimetallic relays) will malfunction due to high frequency harmonics. Install a motor filter on the output of the frequency inverter in this case.

shock or fire.

Warning!

Each phase of the supply voltage for the frequency inverter must be protected by a fuse (danger of fire).

Do not connect cables to the terminals in the power section which are not designated. These terminals are partially without function (dangerous voltages) or are reserved for DF5 internal purposes.

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Warning!

Ensure that all power cables are correctly tightened on the

Tightening torques and conductor cross-sections

power section.

Warning!

The frequency inverter must be earthed. Danger of electrical shock or fire.

Table 3: Tightening torque's and conductor cross-sections for the power terminals

L, L1, L2, L3, N L+, DC+, DC– U, V, W, PE

DF5- mm

322-018 322-037

322-055 340-037 340-075 340-1K5 340-2K2

322-075 322-1K1 340-3K0 340-4K0

322-1K5 322-2K2 340-5K5 340-7K5

AWG mm mm Nm

1.5 16 6 to 8 7.1 M3.5

1.5 16 8 to 10 9 M4 1.2 to 1.3 1

2.5 14 8 to 10 9 M4 1.2 to 1.3 1

4 12 12 to 14 13 M5 2 to 2.2 2

X Screw on the cables tightly according to Table 3.

M4 (PE)

Warning!

Tighten the screws on the terminals correctly (a Table 3), so that they do not come loose unintentionally.

0.8 to 0.9 1

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PES

Figure 23: Cable connection to the power terminals

Connecting the supply voltage

X Connect the supply voltage to the power terminals:

– Single-phase supply voltage: L, N and PE – Three-phase supply voltage: L1, L2, L3 and PE

Electrical connection

Installation

Connecting the motor cable

X Connect the motor cable to the U, V, W and PE terminals:

L1 L N PE

PE PE

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F1, Q1 =

III

K1M

DF5-322... 1 h 230 V, 50/60 Hz

K1M

V2U2

L1 L2 L3

W1V1U1

L1 L2 L3

DF5-322... 3 h 230 V, 50/60 Hz

DF5-340... 3 h 400 V, 50/60 Hz

DC+

DC–L+U

PES

3 ~

Figure 24: Power terminal connection example F1, Q1:Line protection

K1M: Mains contactor L1: Mains choke Z1: RFI filter

Observe the electrical connection data (rating data) on

the rating label (nameplate) of the motor.

The stator winding of the motor can be connected as a star or delta configuration in accordance with the rating data on the nameplate.

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Electrical connection

U1 V1 W1

W2 U2 V2

Figure 25: Connection types

/ 400 V230

0,75S1

rpm

1410 50 Hz

Figure 26:

Frequency inverter

Mains voltage Single-phase

Mains current Motor circuit Motor current Motor voltage

Example of a motor nameplate

DF5322--075 DF5340--075

230 V 9 A 3.3 A Delta Star 4 A 2.3 A 3 AC 0 to 230 V 3 AC 0 to 400 V

Warning!

If motors whose insulation is not suitable for operation with frequency inverters are used, the motor may be destroyed.

U1 V1 W1

W2 U2 V2

4.0 / 2.3

cos

3-phase 400 V

0.67

U1 V1 W1

W2 U2 V2

FWD

Figure 27: Direction of rotation, change of rotation direction

U1 V1 W1

W2 U2 V2

REV

You reverse the direction of rotation of the motor shaft with frequency inverter operation on the DF5 by:

• exchanging two of the phases connected to the motor.

• triggering terminal 1 (FWD = clockwise) or

2 (REV = anticlockwise).

• applying a control command via the interface or fieldbus interface connection.

The speed of a three-phase motor is determined by the number of pole pairs and the frequency. The output frequency of the DF5 series frequency inverter can be varied infinitely in the range from

0.5 to 360 Hz.

Connection of pole-changing three-phase motors (Dahlander changing pole motors), rotor-fed three-phase commutator shunt motors (slipring rotor) or reluctance motors, synchronous motors and servo motors is possible, when they are approved for use with frequency inverters by the motor manufacturer.

Warning!

The operation of a motor with speeds higher than the rated speed (nameplate) can cause mechanical damage to the motor (bearings, unbalance) and the machinery to which it is connected and can lead to dangerous operating conditions!

If you use a motor filter or a sinusoidal filter here, the rate of voltage rise can be limited to values of approx. 500 V/ms (DIN VDE 0530, IEC 2566).

In the factory default setting, frequency inverters of the DF5 series have a clockwise rotating field. Rotation of the motor shaft to the right is achieved by connecting the motor and frequency inverter terminals as follows:

Motor DF5

U1 V1 W1

U V W

Caution!

Uninterrupted operation in the lower frequency range (less than approx. 25 Hz) can lead to thermal damage (overheating) with self-ventilated motors. Possible counter-measures include: Over-dimensioning or external cooling independant of motor speed.

Observe the manufacturers recommendations for operation of the motor.

Installation

Parallel connection of motors on a frequency inverter

The DF5 series frequency inverters can control multiple motors connected in parallel. If differing motor speeds are required, they must be selected via the number of pole pairs and/or the gear transmission ratio.

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K1M

Figure 28: Parallel connection of multiple motors

U1 V1 W1

K2M

Caution!

If a frequency inverter controls a number of motors in parallel, the contactors for the individual motors must be designed for AC

-3 operation. You may not use the mains

contactors from the table in the Appendix Section ”Mains contactors”, Page 113. These mains contactors are only designed for the mains (primary) currents of the frequency inverter. If they are used in the motor circuit, the contacts could weld.

The load resistance on the output of the frequency inverter is reduced by parallel connection of the motors. The total stator inductivity is reduced and the leakage capacitance increases. As a result, the current distortion is larger when compared to operation with a single motor load. In order to reduce the current distortion, chokes or sinusoidal filters can be used on the frequency inverter output.

The current consumption of all the connected motors may

not exceed the rated output current I

of the frequency

inverter.

It is not possible to use electronic motor protection when

operating the frequency inverter with a number of connected motors. You must however, protect each motor with Thermistors and/or overload relays.

K3M

U1 V1 W1

If motors with large differences in output power (e.g. 0.37 kW and

2.2 kW) are connected in parallel to the output of a frequency inverter, problems can occur during the start phase and at low speeds. It is possible, that motors with a low motor rating are unable to develop the required torque. This is due to the relatively high ohmic resistance's in the stators of these motors. They require a higher voltage during the start phase and at low speeds.

Motor cable

Only screened motor cables may be used for EMC related compatability. The length of the motor cable and the associated use of further components has an influence on the operating mode and the operational behaviour. With parallel operation (multiple motors connected to the frequency inverter output) the resulting cable lengths l

= SlM x Wn

res

SlM: Sum of all motor cable lengths

: Number of motor circuits

With long motor cables, the leakage currents can cause

must be calculated:

res

the “earth fault” fault indication due to parasitic cable capacities. In this case, motor filters must be used.

Keep the motor cables as short as possible as it will positively influence the drive behaviour.

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Electrical connection

Motor filters, dv/dt-filters, sinusoidal filters

Motor filters (chokes) compensate for capacitive currents with long motor cables and with grouped drives (multiple connection of parallel drives to a single inverter).

The use of motor filters is recommended (observe the manufacturers instructions):

• with grouped drives

• with the operation of three-phase current asynchronous motors

with maximum frequencies greater than 200 Hz,

• with the operation of reluctance motors or permanently-excited synchronous motors with maximum frequencies greater than 120 Hz.

With dv/dt filters, the voltage on the motor terminals are limited to values less than 500 V/ms. They should be applied with motors with unknown or insufficient withstand voltage for the insulation.

Caution!

During the engineering phase, the voltage drop associated with motor filters and dv/dt filters must be considered as it can be up to 4 % of the frequency inverter output voltage.

When sinusoidal filters are used, the motors are supplied with voltage and current which is almost sinusoidal.

Bypass operation

If you want to have the option of operating the motor with the frequency inverter or directly from the mains supply, the incoming supplies must be locked mechanically:

Caution!

Switch-over between the frequency inverter and the mains supply must be undertaken in a no voltage state.

Warning!

The frequency inverter outputs (U, V, W) may not be connected to the mains voltage (destruction of the device, danger of fire).

I>I>I

K1M

L1 L2 L3

Caution!

During the engineering phase, it is necessary to consider that the sinusoidal filter on the output voltage and the switching frequency of the frequency inverter must be adapted to suit each other.

The voltage drop on the sinusoidal filter can be up to 15 % of the frequency inverter output voltage.

Figure 29: Bypass motor control

UVW

M 3h

Installation

Connecting the signalling relay

The following figure indicates the position of the signalling relay.

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Figure 30: Connecting the signalling relay a Signalling relay terminals

When connecting the signalling relay, support the open

enclosure front.

Table 4: Description of the signalling relay terminals

Terminal designation

K11 Default settings: K12 K14

Table 5: Signalling relay conductor cross-sections and tightening torques

Description

• Operating signal: K11-K14 closed.

• Fault message or power supply off:

K11-K12 closed

Characteristics of the relay contacts:

• Maximum 250 V AC/2.5 A (resistive) or 0.2 A (inductive, power factor = 0.4); Minimum 100 V AC/10 mA

• Maximum 30 V DC/3.0 A (resistive) or 0.7 A (inductive, power factor = 0.4); Minimum 5 V DC/100 mA

K12K11 K14

1 x 0.14 to 1.5 6 6 to 16 0.4 x 2.5 0.5 to 0.6

0.14 to 0.75 6 – 0.4 x 2.5 0.5 to 0.6

2 x

mm AWG mm Nm

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X Fit the terminal shroud to the enclosure again and close the

enclosure front.

Electrical connection

PES

Figure 31: Close the power section

Installation

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Connecting the control signal terminals

The following figure shows the arrangement of the individual control signal terminals.

L54321P24

h O OI L FM CM2 12 11

Figure 32: Location of the control signal terminals

Function of the control signal terminals

ESD measures

Discharge yourself on an earthed surface before touching the frequency inverter and its accessories. This prevents damage to the devices through electrostatic discharge.

Table 6: Meaning of the control signal terminals

No. Function Level Default setting Technical data, description

L Common reference

potential

5 Digital input

4 Digital input

3 Digital input

2 Digital input 1 Digital input P24 Control voltage output

h Setpoint voltage output

OAnalog input

OI Analog input

L Common reference

potential

FM Analog output

0 V – Reference potential for the internal voltage sources

P24 and H

HIGH = +12 to +27 V LOW = 0 to +3 V

+24 V – Supply voltage for actuation of digital inputs 1 to 5.

+10 V – Supply voltage for external setpoint potentiometer.

0 to +10 V Frequency setpoint value

4 to 20 mA Frequency setpoint value

0V – Reference potential for the internal voltage source

0 to +10 V Frequency actual value

Reset PNP logic, configurable, Ri=33kO

Reference potential: Terminal L

FF2 (FF3) = fixed frequency 2 (3)

FF1 (FF3) = fixed frequency 1 (3)

REV = anticlockwise rotation FWD = clockwise rotation

(0 to 50 Hz)

PNP logic, configurable, Ri=5kO Reference potential: Terminal L

Load carrying capacity: 30 mA Reference potential: Terminal L

Load carrying capacity: 10 mA Reference potential: Terminal L

Ri = 10 kO

Reference potential: Terminal L

RB = 250 O

Output: Terminal L

P24 and H Configurable, monitored DC voltage; 10 V corres-

ponds to set final frequency (50 Hz). Accuracy: g5 % from final value Load carrying capacity: 1 mA Reference potential: Terminal L

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Electrical connection

No. Function

CM2 External control voltage

Level Default setting Technical data, description

Up to 27 V – Connection: Reference potential (0 V) of the

input

12 Transistor output 11 Transistor output

Up to 27 V = CM2 RUN (operation) Configurable, open collector

Frequency setpoint reached

Control signal terminal wiring

Wire the control signal terminals to suit their application. For a description of how to change the functions of the control signal terminals, see Section ”Programming the control signal terminals” from Page 49 .

Caution!

Never connect terminal P24 with terminals L, H, OI or FM.

external voltage source for the transistor outputs, terminals 11 and 12. Load carrying capacity: Up to 100 mA (sum of terminals 11 + 12)

Load carrying capacity: Up to 50 mA

Caution!

Never connect terminal H with terminal L.

Use twisted or screened cables for connecting to the control signal terminals. Earth the screen on one side with a large contact area near the frequency inverter. The cable length should not exceed 20 m. For longer cables, use a suitable signal amplifier.

The following figure shows a sample protective circuit for the control signal terminals

H O

F 20 m

4K7

R1 REV FWD

Figure 33: Control terminal connection (factory setting)

2 1

P24

PES

ZB4-102-KS1

Cu 2.5 mm

Installation

When connecting a relay to one of the digital outputs 11 or 12, connect a free-wheel diode in parallel with the relay, so that the self-induction voltage generated when the relay is switched off cannot destroy the digital outputs.

CM2 1211

+ 24 V

100 mA

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Figure 34: Relay with free-wheel diode

Use relays that switch reliably at 24 V H and a current of

about 3 mA.

Lay the control and signal cables separately from the

mains and motor cables.

f 100

Figure 35: Crossover of signal and power cables

a Power cable: L1, L2, L3 or L and N, U, V, W, L+, DC+, DC– b Signal cables: H, O, OI, L, FM, 1 to 5, 11 and 12, CM2, P24

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Example for the protective circuit of the digital inputs when the internal P24 supply voltage is used, or when a separate external 24 V power supply is used:

Electrical connection

+24 V

24 V

+24 V

Q.. Q.. Q.. Q.. Q..

0 V

24 V

Q.. Q.. Q.. Q.. Q..

P24

5 4 3 2 1

+24 V

DF5

5 4 3 2 1

Figure 36: Triggering of the digital inputs

0 V

DF5

Installation

Caution!

Before commissioning, remove the covering on the upper ventilation slots and openings, as the frequency inverter will otherwise overheat a Fig. 37.

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Figure 37: Removing the upper cover

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4 DF5 Operation

This section describes how to commission the DF5 series frequency inverters and deals with issues that need to be observed during its operation.

Initial startup

Observe the following points before you take the frequency inverter into operation:

• Ensure that the power cables L and N or L1, L2 and L3 as well as the frequency inverter outputs U, V and W are correctly connected.

• The control lines must be connected correctly.

• The earth terminal must be connected correctly.

• Only the terminals marked as earthing terminals must be

earthed.

• The frequency inverter must be installed vertically on a nonflammable surface (e.g. a metal surface).

• Remove any residue from wiring operations – such as pieces of wire – and all tools from the vicinity of the frequency inverter.

• Make sure that the cables connected to the output terminals are not short-circuited or connected to earth.

• Ensure that all terminal screws have been tightened sufficiently.

• Make sure that the frequency inverter and the motor are correct

for the mains voltage.

• The configured maximum frequency must match the maximum operating frequency of the connected motor.

• Never operate the frequency inverter with opened power section covers. The front enclosure must be closed and secured with the screw provided.

The control signal terminals are wired as follows.

F 20 m

4K7

Figure 38: Connecting control signal terminals (default settings)

X Switch on the supply voltage.

1 P24

PES

FWD

REVR1

The POWER and Hz LEDs light up (keypad). The display should indicate 0.0.

X Close switch S1 (FWD = clockwise rotation). X With potentiometer R1, you can set the frequency and therefore

the motor speed.

The motor turns clockwise and the display indicates the set frequency.

X Open switch S1.

Caution!

Do not carry out h.v. tests. Built-in overvoltage filters are fitted between the mains voltage terminals and earth, which could be destroyed.

Sparkover voltage and insulation resistance tests (megger

tests) have been carried out by the manufacturer.

The motor speed is reduced to zero (Display: 0.0).

X Close switch S2 (REV = anticlockwise rotation). X With potentiometer R1, you can set the frequency and therefore

the motor speed.

The motor turns anticlockwise and the display indicates the set frequency.

X Open switch S2.

The motor speed is reduced to zero (Display: 0.0). If both switches S1 and S2 are closed, the motor will not start. The

motor speed reduces to zero during operation if you close both switches.

DF5 Operation

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Caution!

Check the following points during or after the “initial operation” so that damage to the motor does not occur:

• Was the direction of rotation correct?

• Has a fault occurred during acceleration or

deceleration?

• Was the frequency display correct?

• Did any unusual motor noises or vibrations occur?

If a fault has occurred due to overcurrent or overvoltage, increase the acceleration or deceleration time (a Section ”Acceleration time 1”, Page 76 and Section ”Deceleration time 1” Page 77).

By default, the ON key and the potentiometer on the keypad (a Fig. 39 and a Table 7) have no functions assigned to them. For details about activating these operator controls, see Section ”Setting the frequency and start command parameters”, Page 78.

LCD keypad

The following illustration shows the LCD keypad of the DF5.

POWER

MIN

MAX

ENTER

RUN

PRG

Table 7: Explanation of the operating and indication elements

Number Name Explanation

a RUN LED LED lights up in RUN mode, if the

frequency inverter is ready for operation or operational.

j On key and

7 segment display

POWER LED LED is lit when the frequency inverter

Hz or A LED Indication in b: output frequency (Hz)

Potentiometer and LED

ENTER key The key is used for saving entered or

ENTER

Arrow keys Selecting functions, changing numeric

PRG key For selecting and exiting the program-

PRG

OFF key Stop the running motor and acknow-

LED

PRG LED LED is lit during parameterization.

Display for frequency, motor current, error messages, etc.

has power.

or output current (A) Frequency setpoint setting

LED is lit when the potentiometer is activated.

changed parameters.

values

Increase

Reduce

ming mode.

ledge a fault message. Active by default, also for actuation through terminals.

Starts the motor in the specified direction (not active by default).

hgf

Figure 39: Keypad view For an explanation of the elements, see Table 7.

Operation with LCD keypad

The functions of the DF5 are organized in parameter groups. The following sections describe how to set the parameter values and how the setting menu is structured.

For a detailed description of the parameters, see Section ”Setting Parameters”, Page 75.

Menu overview

The following figure shows the sequence in which the parameters appear on the display. Table 8 provides a brief description of the parameters.

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PRG

Operation with LCD keypad

Table 8: Explanation of the parameters

Display Explanation

Display parameter

d 01 Output frequency display

d 02

d 03

d 04

d 05

d 06

d 07

d 08

d 09

Basic parameters

F 01 Frequency setpoint adjustment

F 02

F 03

F 04

Extended parameter groups

A -- Extended functions group A

b --

C --

Output current display Direction of rotation display PID feedback display Digital inputs 1 to 5 status Status of digital outputs 11 and 12 Scaled output frequency Display of last alarm Display of second and third to last alarm

Set acceleration time 1 Set deceleration time 1 Direction of rotation adjustment

Extended functions, group B Extended functions, group C

Figure 40: Menu structure of the DF5 keypad a The display is dependant on the display parameter

(PNU d01 to d09) from which you return.

For a detailed explanation of the parameters, see Section ”Setting Parameters”, Page 75.

Changing display and basic parameters

Press the PRG key to switch from display or RUN mode to programming mode. The PRG lamp lights up in this mode.

You can access the individual parameters or parameter groups with the UP and DOWN arrow keys (a Fig. 40).

To access the programming mode, press the PRG key. You can modify the parameter values with the arrow keys. Exceptions are the display parameters PNU d01 to d09. These parameters have no values. After you have selected a display parameter with the arrow keys, you can return to the display mode with the PRG key. The display reflects the selected display parameter (a Section ”Setting the display parameters”, Page 75).

Parameter values can be accepted with the ENTER key or rejected with the PRG key.

By pressing the PRG key in the range of the display parameters PNU d01 to d09, you return to the display mode.

DF5 Operation

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Example for changing acceleration time 1: PNU F02

The frequency inverter is in the display mode and the RUN lamp is lit.

X Press the PRG key.

The frequency inverter changes to the programming mode, the PRG lamp lights up and d01 or the most recently modified para- meter appears on the display.

X Press the DOWN key six times until F02 appears on the

display.

X Press the PRG key.

The set acceleration time 1 in seconds appears on the display (WE = 10.0).

X The set value is changed with the UP and DOWN arrow keys.

There are now two possibilities:

X Accept the displayed value by pressing the ENTER key. X Reject the displayed value by pressing the PRG key.

The display responds with F02.

X Press the DOWN key six times until d01 appears on the

display.

X Press the PRG key.

The frequency inverter changes over to the display mode and displays the set frequency.

Changing the parameters of the extended parameter groups

The following example illustrates how to change PNU A03 of the extended parameter group A. You can change the parameter values of groups B and C exactly as described in the example. For a detailed description of the extended parameter groups, see from Section ”Setting the frequency and start command parameters”, Page 78.

An example of how to change the base frequency PNU A03

X Press the PRG key to change over to the programing mode.

The most recently modified parameter appears on the display and the PRG lamp lights up.

X Press the UP or DOWN key until the extended parameter group

A-- appears on the display.

X Press the PRG key.

The display indicates A01.

X Press the UP key twice until A03 appears on the display. X Press the PRG key.

The value set under PNU A03 (WE = 50.0) appears.

X You can change the value with the UP and DOWN arrow keys.

There are now two possibilities:

X Accept the displayed value by pressing the ENTER key. X Reject the displayed value by pressing the PRG key.

PRG PRG

6 x

Figure 41: Change acceleration time 1 a Display dependent on the selected display parameter PNU d01 to

d09

b Display of the most recently changed parameter

PRG

F02 = 9.9

ENTER

PRG

F02 = 10.0

The display indicates A03.

X Press the PRG key.

The display indicates A--.

X Press the DOWN key three times until d01 appears. X Press the PRG key.

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The frequency inverter changes over to the display mode and displays the current frequency.

Display after the supply voltage is applied

PRG

PRG PRG

3 x

PRG

Figure 42: Change the base frequency (example with default setting)

a Display dependent on the selected display parameter PNU d01 to d09 b Display of the most recently changed parameter

Display after the supply voltage is applied

After the supply voltage is switched on, the last screen which was visible before switch off will reappear (not, however, within the extended parameter groups).

PRG

A03 = 49.9

ENTER

PRG

A03 = 50.0

DF5 Operation

Operational warning message

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Warning!

If the supply voltage recovers after a brief failure, the motor may restart automatically if a start signal is still present. If personnel are endangered as a result, an external circuit must be provided which excludes a restart after voltage recovery.

Warning!

If the frequency inverter has been configured so that the stop command is not issued via the OFF key on the LCD keypad, pressing the OFF key will not switch off the motor. A separate Emergency-Stop switch must be provided in the case.

Warning!

Maintenance and inspection of the frequency inverter may only be undertaken at least 5 minutes after the supply voltage has been switched off. Failure to observe this point can result in electric shock as a result of the high voltages involved.

Warning!

Never pull on the cable to unplug connectors (e.g. for fan or circuit boards).

Warning!

If a malfunction is responded to by a reset, the motor will start automatically if a start signal is applied at the same time. To avoid the risk of serious or fatal injury to personnel, you must ensure that the start signal is not present before acknowledging an error message with a reset.

Warning!

When the supply voltage for the frequency inverter is applied when the start signal is active, the motor will start immediately. Make sure that the start signal is not active before the supply voltage is switched on.

Warning!

Cables or plug connectors may not be connected or disconnected during operation when the supply voltage is switched on.

Caution!

To prevent a risk of serious or fatal injury to personnel, never interrupt the operation of the motor by opening the contactors installed on the primary or secondary side.

The ON key is functional only if the corresponding para-

meters of the frequency inverter have been configured accordingly (a Section ”Setting the frequency and start command parameters”, Page 78).

Before operating motors at frequencies above the stan-

dard 50 or 60 Hz, contact their manufacturers to verify that the motors are suitable for operation at higher frequencies. The motors could otherwise incur damage.

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5 Programming the control signal terminals

This section describes how to assign various functions to the control signal terminals.

Overview

Table 9 provides an overview of the control signal terminals and a brief description of the functions which you can assign to the programmable digital inputs and outputs. For a detailed description of the individual functions, see from Page 52.

Table 9: Function description

Name Value

Digital inputs 1 to 5 Parameter definition under PNU C01 to C05

FWD 00 Clockwise

Function Description

REV

(start/stop)

FWD

P2412

REV 01 Anticlockwise

(start/stop)

FF1 02 Programmable fixed FF2 03

frequencies 1 to 4

FF3 04

FF4 05

JOG 06 Jog mode

2CH 09 Second time ramp FRS 11 Controller inhibit (free

run stop)

FWD

REV

FWD input closed: motor starts up in a clockwise direction. FWD input open: motor coasts to a stop (clockwise rotation). REV input: same case for anticlockwise rotation as with FWD FWD and REV inputs closed simultaneously: motor coasts to a stop.

Example: Four fixed frequencies

FF1

FF2

FWD

fs=0 to f

For four fixed frequency stages (three programmable fixed frequencies and a setpoint value), two fixed frequency inputs (3 = FF1 and 4 = FF2) are required (2

max

= 4).

RST

FF2

FF1

REV

FWD

P241234LOH5

The jogging mode, which is activated by switching on the JOG input, is used, for example, for setting up a machine in manual mode. When a start signal is received, the frequency programmed under PNU A38 is applied to the motor. Under PNU A39, you can select one of three different operating modes for stopping the motor.

Activates the second acceleration and deceleration with PNU A92 and PNU A93 respectively When FRS is switched on, the motor is immediately switched off and coasts to a stop.

Programming the control

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signal terminals

Name Value

Function Description

EXT 12 External fault When the EXT input is switched on, the fault signal activates PNU E12 and the motor switches off.

The fault signal can be acknowledged, for example, with the RST input.

USP 13 Restart inhibit

When the USP input is switched on, the restart inhibit is active. This prevents a motor restart when the voltage recovers after a mains failure while a start signal is present.

SFT 15 Parameter protection

Switching on the SFT input to activate the parameter protection prevents loss of the entered parameters by inhibiting write operations to these parameters.

AT 16 Setpoint input OI (4 to

When the AT input is switched on, only the setpoint value input OI (4 to 20 mA) is processed.

20 mA) active

RST 18 Reset

To acknowledge an error message, switch on the RST input. If a reset is initiated during operation, the motor will coast to a stop. The RST input is a make (NO) contact; it cannot be programmed as a break contact (NC).

PTC 19 Connection for a PTC

thermistor

P24 – +24 V H for digital

You can only program digital input 5 with PNU C05 as an input for a PTC thermistor. Use terminal L as the reference potential.

24 V H potential for digital inputs 1 to 5

inputs

Frequency setpoint definition

h – +10 V setpoint voltage

for external potentiometer

Setpoint value can be set with potentiometer:

LOIOH

Setpoint value through voltage input:

LOIO

Setpoint value through current input:

LOI

O – Analog input for

frequency setpoint (0 to +10 V)

PES

–

PES

–

OI – Analog input for

frequency setpoint (4 to 20 mA)

L – 0 V reference potential

for setpoint inputs

R: 1 to 10 kO 0 to 10 V H

Input impedance: 10 kO

The OI input for a setpoint value from 4 to 20 mA is only used when the digital input configured as the AT input is closed.

4 to 20 mA H Load resistor: 250 O

analog output

FM – Frequency monitor The frequency can be output via a connected analog or digital measurement device via this input.

As an option, the motor current can be displayed.

L – 0V

0 V reference potential for the FM output

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Name Value

Function Description

Digital outputs 11 and 12 Parameter definition under PNU C21 and C22

FA1 01 Signal when frequency is

reached or exceeded

Overview

Connection of a signal relay to digital output 11 or 12:

12CM2

24 V 50 mA

FA1

FA2

Transistor output (open collector)

fs = setpoint frequency

FA2 02 If a digital signal is configured as FA1, a signal is issued as long as

(maximum 27 V H, 50 mA)

the setpoint value is achieved. If a digital signal is configured as FA2, a signal is output as long as the frequencies defined under PNU C42

and PNU C43 are exceeded. RUN 00 RUN signal OL 03 Signal on overload

The RUN signal is output during operation of the motor.

The OL signal is output when the overload alarm threshold

(adjustable under PNU C41) is exceeded. OD 04 Signal on PID control

deviation AL 05 Signal (alarm) on fault CM2 – 0V

The OD signal is output when the PID control deviation set under PNU C44 is exceeded.

The AL signal is issued when a fault occurs. 0 V reference potential for the programmable digital outputs 11 and 12. These transistor outputs

(open collector) are controlled through optocouplers, whose reference potential is CM2. CM2 is isolated L.

Signalling relay

K11 – Signalling relay contacts During normal, healthy operation, terminals K11-K14 are closed. If a malfunction occurs or the K12 K14

supply voltage is switched off, the terminals K11-K12 are closed. Maximum permissible values:

• 250 V ~; maximum load 2.5 A (purely resistive) or 0.2 A (with a power factor of 0.4)

• 30 V H; maximum load 3.0 A (purely resistive) or 0.7 A (with a power factor of 0.4)

• Minimum values necessary: 100 V ~ with a load of 10 mA or 5 V H with a load of 100 mA

1) To activate the function, enter this value in the corresponding parameter.

Programming the control signal terminals

Frequency display FM

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The FM terminal provides the output frequency or the motor current as a frequency signal.

PNU Name Adjustable in

RUN mode

C23 Display via FM

– 00 Indication of the output frequency (analog 0 to 10 V H signal) 00

output

Value Function WE

01 Indication of motor current (analog 0 to 10 V H signal; 100 % rated

current corresponds to 5 V H)

02 Display of the output frequency (digital impulse signal)

Analog frequency display

The signal output (PNU C23 = 00 or 01) is a square-wave, with a constant period of oscillation. Its pulse width is proportional to the current frequency value (0 to 10 V correspond to 0 Hz to the end frequency).

FML

–

0 – 10 V 1 mA

Analog frequency meter 0 to 10 V 1mA

t/T = variable T = 4 ms (constant)

10 V

The selection between the frequency display and display of the motor current is made under PNU C23.

Signal compensation takes place in PNU b81. The signal accuracy after compensation is g5%.

If for example, a higher level of smoothing of the FM signal is required for a motor current display, an external low-pass filter circuit is required. The accuracy is approx. g20 %.

FML

33 kO

82 kO

1 mF

–

0 – 10 V

1 mA

Figure 43: Connection of an analog frequency meter

PNU Name Adjustable in

Value Function WE

RUN mode

b81 Adjustment

j 0 to 255 The analog signal issued on the FM terminal (frequency actual value or value for analog signal on FM terminal

Figure 44: Example for a low-pass circuit

80 output current) can be adjusted here. The impulse signal (digital frequency actual value) cannot be compensated.

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Digital frequency display

The frequency of this signal (PNU C23 = 02) changes proportionally to the output frequency. The pulse duty factor remains constant at about 50 %.

Frequency display FM

FML

–

Digital frequency meter T = 1/(output frequency x factor)

10 V

Figure 45: Digital frequency meter connection

The signal frequency results from the product of the current output frequency and an adjustable factor at PNU b86.

PNU Name Adjustable in

RUN mode

b86 Frequency

j 0.1 to 99.9 The product of the value displayed under PNU d01 and this factor is

factor

Value Function WE

displayed at PNU d07. This value is also available at the FM terminal.

1.0

Programming the control signal terminals

Programmable digital inputs 1 to 5

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You can assign various functions to terminals 1 to 5. Depending on your requirements, these terminals can be configured as follows:

• clockwise start signal (FWD),

• anticlockwise start signal (REV),

• selection inputs for various fixed frequencies (FF1 to FF4),

• reset input (RST),

• etc.

The terminal function for each of the programmable digital inputs 1 to 5 occurs via PNU C01 to C05, i.e. you use PNU C01 to specify the function of digital input 1, PNU C02 to specify the function of digital input 2, etc. You cannot, however, assign the same function to two inputs.

Programmable digital inputs 1 to 5 are configured as make contacts by default. If, therefore, the function of an input terminal is to be activated, the corresponding input must be closed (i.e. the input terminal is connected to terminal P24). Conversely, to deactivate the input terminal, the input must be opened.

Caution!

If an EEPROM error occurs (fault message E08), all parameters must be checked to ensure that they are correct (particularly the RST input).

Table 10: Digital inputs 1 to 5

PNU Terminal Adjustable in

RUN mode

C01 1 – a Table 11 00 C02 2 C03 3 C04 4 C05 5

Value WE

01 02 03 18

A detailed description of the input functions can be found on the pages listed in Table 11.

Tabelle 11: Functions of the digital inputs

Value Function Description a Page

00 FWD Start/stop clockwise 55 01 REV 02 FF1 03 FF2 04 FF3 05 FF4 06 JOG 09 2CH

11 FRS

12 EXT 13 USP 15 SFT 16 AT 18 RST 19 PTC

Start/stop anticlockwise 55 First fixed frequency input 56 Second fixed frequency input Third fixed frequency input Fourth fixed frequency input Jog mode 64 Second acceleration and

deceleration time Motor shutdown and free

run stop External fault 61 Restart inhibit 62 Parameter protection 66 Setpoint input through current 58 Reset 63 PTC thermistor input

(digital input 5 only)

If required, the digital inputs can be configured as break (NC) contacts. For this purpose, under PNU C11 to C15 (corresponding to digital inputs 1 to 5), 01 is to be input. An exception exists only for inputs which you configure as RST (reset) or as PTC (PTC thermistor input). These inputs can only be operated as make (NO) contacts.

Caution!

If you reconfigure digital inputs configured as FWD or REV as break contacts (the default setting is as a make contact), the motor starts immediately. They should only be reconfigured as break contacts when it is absolutely essential.

Table 12: Configuring digital inputs as break contacts

PNU TerminalValueAdjustable in

RUN mode

C11 1 00 or 01– 00: Make C12 2 C13 3 C14 4 C15 5

Function WE

contact 01: Break contact

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Start/Stop

Clockwise rotation FWD

If you activate a digital input which has been configured as a FWD input, the motor starts to run in a clockwise direction. If you deactivate the input, the motor coasts to a stop.

If the FWD and the REV inputs are activated simultaneously, the motor coasts to a stop.

FWD

P241

Figure 46: Digital input 1 configured as FWD „Start/Stop clockwise

rotation“

Anticlockwise operation: REV

If you activate a digital input which has been configured as an REV input, the motor starts to run in an anticlockwise direction. If you deactivate the input, the motor coasts to a stop.

REV

P2413

Issue start command

By default, the start command is issued through the inputs configured as FWD or REV. If however, the start command is currently issued via the ON key on the keypad, set under PNU A02 the value 01 (start command via FWD/REV input) (a Section ”Start command”, Page 78).

X Program one of the digital inputs 1 to 5 as FWD by setting the

corresponding PNU (C01 to C05) to 00.

X Program one of the digital inputs 1 to 5 as REV by setting the

corresponding PNU (C01 to C05) to 01.

Warning!

If the supply voltage for the frequency inverter is applied when the start signal is activated, the motor will start immediately. Make sure, therefore, that the start signal is not active before the supply voltage is switched on.

Warning!

If the FWD/REV input is opened (inactive state if FWD/REV is configured as a make contact) and then it is reconfigured as a break contact, it must be noted that the motor will start immediately after the reconfiguration.

Figure 47: Digital input 2 configured as REV “Start/Stop

anticlockwise”

Programming the control signal terminals

Fixed frequency FF1 to FF4 selection

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With the digital inputs configured as FF1 to FF4 you can select up to 16 user-definable fixed frequencies (including frequency setpoints), depending on which of the inputs is active or inactive (a Table 13). It is not necessary to use all the fixed frequency selection inputs at the same time. Using only three inputs, for example, allows you to choose between eight fixed frequencies; with two fixed frequency selection inputs, four fixed frequencies are available for selection.

The fixed frequencies have a higher priority than all other setpoint values and can be accessed at any time through inputs FF1 to FF4 without needing to be enabled separately. Jog mode, to which the highest priority is assigned, is the only operation with a higher priority than the fixed frequencies.

Table 13: Fixed frequencies

Fixed frequency stage

0 = f

0 = input deactivated 1 = input activated

PNU Input

FF4 FF3 FF2 FF1

Frequency

0 0 0 0 setpoint value

a21 0 0 0 1 a22 0 0 1 0 a23 0 0 1 1 a24 0 1 0 0 a25 0 1 0 1 a26 0 1 1 0 a27 0 1 1 1 a28 1 0 0 0 a29 1 0 0 1 a30 1 0 1 0 a31 1 0 1 1 a32 1 1 0 0 a33 1 1 0 1 a34 1 1 1 0 a35 1 1 1 1

FF1

FF2

FF3

FWD

Figure 49: Function chart of “Fixed frequency“ control FF1 to FF3

X Program one or more of the digital inputs 1 to 5 as FF1 to FF4,

by entering the values 02 (FF1) to 05 (FF4) under the corresponding PNU (C01 to C05).

The fixed frequencies can be programmed in two ways:

• input of the fixed frequencies under PNU A21 to A35,

• input of the fixed frequencies under PNU F01.

With PNU F01, it is possible to modify the parameter even though the parameter protection PNU b31 is set (a Page 66).

Input of the fixed frequencies under PNU A21 to 35

X Goto PNU A21 and press the PRG key. X Use the arrow keys to enter the fixed frequency and confirm

with the ENTER key.

X Repeat these steps for PNU A22 to A35 to suit your required

frequencies.

Input of the fixed frequency under PNU F01

For frequency input under PNU F01, the value 02 must be set beforehand in PNU A01.

X To select a fixed frequency stage, activate the digital inputs as

listed in Table 13.

X Goto PNU F01.

FF4

FF3

FF2

FF1

P24123

Figure 48: Digital inputs 1 to 4 configured as FF1 to FF4

(fixed frequency)

The current frequency appears on the display.

X Use the arrow keys to enter the fixed frequency and confirm

with the ENTER key.

The entered value is saved in the parameter which you have selected with the digital inputs (a Table 13).

X Repeat these steps for your additional fixed frequencies.

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Fixed frequency FF1 to FF4 selection

Specifying frequency setpoints

The frequency setpoint value can be assigned in one of three ways, dependent on PNU A01:

• via the installed potentiometer on the keypad, PNU A01 = 00;

Table 14: Fixed frequency parameters

PNU Name

A01 Defined

frequency setpoint

A20 Frequency

setpoint value A21 Fixed A22 A23 ... A35 F01 Display/input

frequency

of frequency

value

Adjustable in RUN mode

– 00 Definition with the potentiometer on the keypad 01

j 0.5 to 360 Hz You can input a frequency setpoint value. You must input 02 under

Value Function WE

01 Definition via analog input O (0 to 10 V) or OI (4 to 20 mA) 02 Definition under PNU F01 and/or PNU A20

PNU A01 for this purpose. You can assign a frequency to each of the 15 fixed frequency parameters

from PNU A21 to A35.

Display of the current frequency setpoint value or the current fixed frequency. Modified values are saved with the ENTER key according to the selection of the digital inputs configured as FF1 to FF4. Resolution g0.1 Hz

• via analog input O (0 to 10 V) or OI (4 to 20 mA), PNU A01 = 01 (WE);

• via PNU F01 or PNU A20, PNU A01 = 02.

Selecting fixed frequencies

X The set fixed frequency values are selected by activating the

respective digital inputs (a Table 13).

0.0

If one or more of the fixed frequencies exceeds 50 Hz, you

must first increase the end frequency accordingly with PNU A (04 (a Section ”Maximum end frequency”, Page 79).

Fixed frequency stage 0 (none of the inputs FF1 to FF4 are

activated) corresponds to the frequency setpoint value. Depending on the configuration PNU A01 it is possible to implement via the integrated potentiometer, the setpoint input values O or OI, or via PNU F01 and PNU A20.

Programming the control signal terminals

Current setpoint value AT (4 to 20 mA)

When the digital input which has been configured as AT is active, the setpoint value is defined by the current flow (4 to 20 mA) on terminal OI. If however the AT input is inactive, the setpoint value is defined by the voltage present (0 to 10 V) at terminal O.

P245

Figure 50: Digital input 5 configured as AT (setpoint value via

current)

Under PNU A01, enter the type of frequency setpoint definition. With a default setting of 01, the voltage 0 to 10 V present on terminal O or the current of 4 to 20 mA flowing into terminal OI is interpreted as the setpoint value. Depending on whether the AT input is active or not. If it has not yet been correctly configured, set the parameter to 01.

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X Program one of the digital inputs 1 to 5 as AT, by inputting the

value 16 under the respective PNU (C01 to C05) to 16.

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Second time ramp 2CH

Fixed frequency FF1 to FF4 selection

If the digital input which has been configured as 2CH is active, the motor will be accelerated or braked with the second acceleration or deceleration time. If the 2CH input is again deactivated, a changeover to the first acceleration/deceleration time takes place.

2CH

FWD

P2413

Figure 51: Digital input 3 configured as the “second time ramp” 2CH

PNU Name Adjustable in

RUN mode

Value Function WE

FWD/REV

2CH

Figure 52: Function chart for 2CH (second acceleration time)

: output frequency

a First acceleration time b Second acceleration time

X Set under PNU A92 and PNU A93, the required value for the

second acceleration and delay time.

X Then set under PNU A94, the value 00 so that the changeover

to the second acceleration and delay time via the 2CH input is enabled (this is the default setting).

X Program one of the digital inputs 1 to 5 as 2CH, by setting the

value 09 under the respective PNU (C01 to C05).

A92 Second accele-

ration time

A93 Second decele-

ration time

A94 Changeover

from the first to the second time ramp

If you set PNU A94 to 01, the changeover to the second

j 0.1 to 3 000 s Setting times for the second acceleration and deceleration time

– 00 Changeover to the second time ramp if an active signal is present on a

01 Changeover to the second time ramp when the frequencies entered under

acceleration or deceleration time can take place automatically at the frequency set under PNU A95 or A96 (a Section ”Time ramps”, Page 96).

The value for the first acceleration and deceleration time

is defined in PNU F01 and F02 (a Section ”Acceleration time 1”, Page 76).

0.1 to 999.9 s; resolution: 0.1 s 1000 to 3000 s; resolution: 1 s

2CH digital input.

PNU A95 and/or A96 are achieved

Programming the control signal terminals

Controller inhibit and coasting of the motor FRS (free run stop)

If you activate the digital input configured as FRS, the motor is switched off and coasts to a stop (for example if an EmergencyStop is made). If you deactivate the FRS input, then, depending on the converter’s configuration, frequency output is either synchro- nized to the current speed of the coasting motor or restarts at 0Hz.

FWD/REV

FRS

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FRS

FWD

P2434

Figure 53: Configuration of digital input 3 as “controller inhibit” FRS

(free run stop) and 4 as FWD (start/stop clockwise rotation)

PNU Name Adjustable in

Value Function WE

RUN mode

b03 Delay time

– 0.3 to 100 s Here, set a time which is to expire before an automatic restart is initiated

until restart

b88 Motor restart

after removal of the FRS

– 00 0 Hz restart after deactivation of the FRS input 00

01 Synchronization of the motor to the current motor speed after the delay

signal

Figure 54: Function chart “control inhibit and free run stop” FRS

:motor speed

: delay time (setting under PNU b03)

a Motor coasts to a stop b Synchronization to the current motor speed c Restart from 0 Hz

X Set under PNU b88, if the motor is to restart with 0 Hz after

deactivation of the FRS input, or if a synchrinization to the current motor speed after a waiting time (PNU b03) is to occur.

X Program one of the digital inputs 1 to 5 as FRS, by inputting the

value 11 under the respective PNU (C01 to C05).

after a fault signal. This time can also be used in conjunction with the FRS function. During the delay, the following message appears on the LED display:

time entered under PNU b03.

1.0

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External fault message EXT

If the digital input configured as EXT is activated, the fault message E12 is initiated (e.g. an input used for the bimetal contacts). The fault message remains active even if the EXT input is deactivated again and must be acknowledged with a reset.

A reset can be carried out with:

• the RST input or

• the OFF key.

• Alternatively, the supply voltage can be switched off and on

again.

EXT

FWD

P2413

Fixed frequency FF1 to FF4 selection

Figure 55: Digital input 1 configured as FWD “start/stop clockwise

rotation” and digital input 3 as EXT “external fault”

FWD/REV

EXT

RST

K14

Figure 56: Function chart for EXT (external fault message)

: motor speed

K14: signalling relay contact K14 a Motor coasts to a stop

X Program one of the digital inputs 1 to 5 as EXT, by inputting the

value 12 under the respective PNU (C01 to C05).

Warning!

After a reset, the motor restarts immediately if a start command (FWD or REV) is present.

Programming the control signal terminals

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Restart inhibit USP

If the digital input configured as USP is activated, the restart inhibit is also activated. This prevents restart of the motor, when the voltage recovers after a mains fault if a simultaneous start command (active signal on FWD or REV) is present. Fault message E13 is issued. By pressing the OFF key or by an active signal on the RST input, E13 is erased. Alternatively, the start command can be revoked.

USP

FWD

P2413

Figure 57: Digital input 1 configured as FWD (start/stop clockwise

rotation) and digital input 3 as USP (restart inhibit).

FWD/REV

X Program one of the digital inputs 1 to 5 as USP, by inputting the

value 13 under the respective PNU (C01 to C05).

Warning!

If the restart inhibit has activated (fault message E13) and this fault message is acknowledged with a reset command when the start command (input FWD or REV active) is still active, it is important to note that the motor will start to run immediately.

If you issue a start signal within three seconds of reestab-

lishing the power supply and the restart inhibit is active, the restart inhibit is also triggered and issues fault message E13. When the restart inhibit is used, you should therefore wait for at least 3 seconds before issuing a start command to the frequency inverter.

The restart inhibit can still be executed, after an undervol-

tage fault message (E09) when a reset command is issued via the RST input.

USP

K14

E13

Figure 58: Function chart for USP (restart inhibit)

:supply voltage

K14: signalling relay contact K14

: output frequency

a Revoke start command (alarm no longer present) b Start command

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Reset: RST

A fault message can be acknowledged by activating and subsequently deactivating (i.e. resetting) the digital input configured as RST.

RST

P244

Figure 59: Digital input 4 configured as RST (reset)

f 12 ms

RST

K14

~ 30 ms

Figure 60: Function chart for RST (reset) K14: signalling relay contact K14

Fixed frequency FF1 to FF4 selection

Warning!

If a malfunction is responded to by a reset, the motor will start immediately if a start signal is applied simultaneously. To avoid the risk of serious or fatal injury to personnel, you must ensure that the start signal is not present before acknowledging an error message with a reset.

When a fault condition has occurred, the OFF key on the

keypad acts as a RESET key, and can be used instead of the RST input to reset the fault.

If the RST input is active for more than 4 seconds, it can

cause a false trip.

The RST input is always a make (NO) contact and cannot

be programmed as a break contact (NC).

Alternatively, you can acknowledge a fault message by

briefly switching the supply voltage off and on again.

If a reset is initiated during operation, the motor will coast

to a stop.

X Program one of the digital inputs 1 to 5 as RST, by inputting the

value 18 under the respective PNU (C01 to C05).

Programming the control signal terminals

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Jog mode (JOG)

When the digital input configured as JOG is activated, the motor can be operated in jog mode. This mode is used, e.g. for manual setting actions on machinery by issuing a start command on the FWD or REV input with a relatively low frequency without applying an acceleration ramp to the motor.

JOG

FWD

P2413

Figure 61: Digital input 1 configured as FWD (start/stop clockwise

rotation) and 3 as JOG (jog mode).

JOG

FWD/REV

X Input under PNU A38 the frequency which is to be applied to

the motor when jog mode is active.

Make sure that the frequency is not too high, as it is applied directly to the motor without an acceleration ramp. This could cause a fault message to occur. Set a frequency below about 5 Hz.

X As the start command in jog mode is to be set via the FWD or

REV input, set under PNU A02 the value 01.

X Under PNU A39, you determine how the motor is to be braked. X Program one of the digital inputs 1 to 5 as JOG, set the value

06 under the respective PNU (C01 to C05).

Caution!

Make sure that the motor has stopped before using jog mode.

Figure 62: Function chart for JOG (jog mode)

:motor speed

a Depending on the setting of PNU A39

00: free run (coast) 01: deceleration ramp 02: DC braking

PNU Name Adjustable in

RUN mode

A02 Start command – 01 The start command for starting the motor is issued by the digital inputs

A38 Frequency in

jog mode

A39 Type of motor

stop in jog mode

Jog mode cannot be applied if the value set for the jog

j 0.5 to 9.99 Hz The frequency to be applied to the motor in jog mode. 1.0

– 00 Stop command on: the motor coasts to halt 00

Value Function WE

configured as FWD or REV.

02 The start command for starting the motor is issued by the ON key on the

keypad.

01 Stop command on: the motor is braked to standstill using a deceleration

ramp

02 Stop command on: the motor is braked to standstill using DC braking

mode frequency under PNU A38 is less than the start frequency set under PNU b82 (a Section ”RUN operational”, Page 70)

Jog mode can only be activated when the frequency

inverter is in the Stop state.

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PTC thermistor input: PTC

If programmable digital input 5 is configured as PTC, the motor temperature can be monitored with a thermistor with a positive temperature coefficient (PTC) connected to terminals 5 and L. If the resistance of the thermistor rises above 3000 O (g10 %), the motor is stopped and fault message E35 is displayed.

PTC

Figure 63: Digital input 5 configured as PTC (thermistor input)

X Program digital input 5 as PTC by setting PNU C05 to 19.

Fixed frequency FF1 to FF4 selection

The PTC thermistor can be connected only to digital input

5, not to digital inputs 1 to 4 .

If digital input 5 is configured as PTC, but no thermistor is

connected, fault message E35 is displayed.

The PTC input is always a make contact; it cannot be

configured as a break contact.

Programming the control signal terminals

Software protection SFT

If you activate the digital input configured as SFT, the configured parameters cannot be overwritten unintentionally.

SFT

FWD

P2413

Figure 64: Digital input 3 configured as “Software protection” SFT

X First of all set under PNU b31 if the software protection should

also apply for the frequency setting under PNU F01.

X Then, program one or more of the digital inputs 1 to 5 as SFT,

set the value 15 under PNU (C01 to C05).

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PNU Name Adjustable in

RUN mode

b31 Software

dependent parameter protection

There is however, an alternative method of software

– 00 Software protection through SFT input; all functions inhibited 01

Value Function WE

01 Software protection through SFT input; input via PNU F01 possible 02 Software protection without SFT input; all functions inhibited 03 Software protection without SFT input; input via PNU F01 possible

protection available which does not require an SFT input. For this purpose, set under PNU b31 the value 02 or 03, depending on whether or not the software protection should also apply for the frequency setting made with PNU F01.

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Programmable digital outputs 11 and 12

The programmable digital outputs 11 and 12 are open collector transistor outputs (a Fig. 65), to which e.g. relays can be connected. These outputs can both be utilized for various functions, for example to signal when a determined frequency setpoint is reached or when a fault occurs.

11, 12

– +

CM2

24 V

F 27 V H, 50 mA

Figure 65: Digital output Transistor output: maximum 27 V H, 50 mA

The terminal function for each of the programmable digital inputs 11 and 12 is implemented via PNU C21 and C22, i.e. with PNU C21 the function for digital output 11 is determined and with PNU C22 the function for digital output 12 is determined.

Table 15: Digital outputs 11 and 12

PNU Terminal

Adjustable in RUN mode

Value WE

Programmable digital inputs 11 and 12 are by default configured as break (NC) contacts. If, therefore, you activate the function of an output terminal, the corresponding input opens; if you deactivate it, the output closes.

If required, the digital inputs can be configured as make (NO) contacts. To do this, enter 00 under PNU C31 and C32 (corresponding to digital output 11 and 12) for this purpose.

Table 17: Configuration of digital outputs as make contacts

PNU TerminalValueAdjustable in

RUN mode

C31 11 00 or 01– 00: Make C32 12

Function WE

01 contact 01: Break contact

C21 11 – a Table 16 01 C22 12

A detailed description of the output functions can be found on the pages listed in Table 16.

Table 16: Functions of the digital outputs

Value Function

00 RUN Signal during operation of the

01 FA1 02 FA2 03 OL 04 OD

05 AL

Description a Page

motor Frequency setpoint reached 68 Frequency exceeded Overload 71 PID control deviation

exceeded Fault 73

Programming the control signal terminals

Frequency value messages FA1/FA2

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The digital output configured as FA1 will be activated as soon as the setpoint frequency is achieved.

The digital output configured as FA2 is activated as long as the frequencies set under PNU C42 and C43 are exceeded.

To ensure a certain level of hysterysis, the FA1 and FA2 signals are activated 0.5 Hz before the frequency setpoint value or the frequency value set under PNU C42 is achieved and deactivated

1.5 Hz after the frequency setpoint value or the frequency value set under PNU C43 is achieved.

0.5 Hz

FA1

PNU F01

60 ms

Figure 66: Function chart for FA1 (frequency achieved)

: output frequency

F01: setpoint value As the digital outputs 11 and 12 are configured as break contacts, FA1

is active with “0”.

0.5 Hz

1.5 Hz

PNU F01

60 ms

1.5 Hz

PNU C42

PNU C43

FA2

0.5 Hz

60 ms

1.5 Hz

Figure 68: Function chart for FA2 “frequency exceeded”

: output frequency

As the digital outputs 11 and 12 are configured as break contacts, FA2 is active with “0”.

X If you want to configure a programmable output as FA2, you

must set the frequency under PNU C42, at which the FA2 signal is to be generated in the acceleration phase.

X With PNU C43, you set the respective frequency which is to

remain active until the FA2 signal is deactivated during deceleration.

X Program one of the digital outputs 11 or 12 as an FA1 or FA2

output by setting under PNU C21 or C22, the value 01 for FA1 or 02 for FA2.

The transition of an FA1 or FA2 signal from the inactive to

the active state takes place with a delay of about 60 ms.

FA1/FA2

1112CM2

24 V 50 mA

Figure 67: Digital output 11 configured as FA1/FA2 (frequency

achieved/exceeded)

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Frequency value messages FA1/FA2

PNU Name Adjustable in

RUN mode

C42 Frequency from

– 0 to 360 Hz The digital output (11 or 12) which FA2 becomes active during acceleration

C43 Frequency at

which FA2 becomes inactive during deceleration

Value Function WE

PNU C42

PNU C43

configured as FA2 becomes active when the frequency

0.0

entered here is exceeded during acceleration.

FA2

The digital output (11 or 12) configured as FA2 remains active as long as the actual frequency remains higher than the frequency entered during deceleration (a also the illustration for PNU C42).

Programming the control signal terminals

RUN operational

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The digital output configured as RUN remains activated as long as a frequency not equal to 0 Hz is present, i.e. as long as the motor is driven in a clockwise or anticlockwise direction.

RUN

1112CM2

24 V 50 mA

Figure 69: Digital output 11 configured as RUN “operational”

PNU Name Adjustable in

RUN mode

b82 Increased start

– 0.5 to 9.9 Hz An increase in the start frequency leads to a corresponding reduction in

frequency

Value Function WE

the acceleration and deceleration times (for example to overcome high frictional resistance). If the frequencies are too high, fault message E02 may be issued. With the set start frequency, the motor starts without a ramp function.

FWD/REV

RUN

Figure 70: Function chart for RUN “operational”

: output frequency

a At PNU b82 set start frequency As the digital outputs 11 and 12 are configured as break contacts, RUN

is active with “0”.

X Program one of the digital inputs 11 or 12 as a RUN output by

setting the value 00 under PNU C21 or C22.

0.5

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Overload message OL

The digital output configured as OL is activated when a freely selectable motor current is exceeded. The OL output is active as long as the motor current is higher than this threshold.

1112CM2

24 V 50 mA

Frequency value messages FA1/FA2

PNU C41

Figure 71: Digital output 11 configured as an OL “overload

message”

PNU Name Adjustable in

Value Function WE

RUN mode

C41 Overload alarm

– 0 to 2 x I

threshold

1) Frequency inverter’s rated current

Figure 72: Function chart for OL “Overload message” As the digital outputs 11 and 12 are configured as break contacts, OL

is active with “0”.

X If you want to configure a programmable digital output as OL,

you must set the current under PNU C41, at which the OL signal activates when it has been exceeded.

X Then, program one or more of the digital outputs 11 or 12 as

the OL output, by setting the value 03 under PNU C21 or C22.

The current value entered here determines when the OL overload signal should be activated.

Programming the control signal terminals

PID controller deviation message OD

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The digital output configured as OD is activated when a user definable PID deviation (actual value versus setpoint value) is exceeded. The OD output remains active as long as this differential is exceeded.

1112CM2

24 V 50 mA

Figure 73: Digital output 11 configured as OD “PID deviation”

Figure 74: Function chart for OD “PID deviation”

a Setpoint b Actual value

As the digital outputs 11 and 12 are configured as break contacts, OD is active with “0”.

X If you want to configure a programmable output as OD, you

PNU C44

must set the threshold under PNU C44 at which the OD signal should be activated.

X Then, program one or more of the digital outputs 11 or 12 as

the OD output, by setting the value 04 under PNU C21 or C22 .

PNU Name Adjustable in

RUN mode

C44 PID regulator

deviation

– 0 to 100% If the deviation between the setpoint and actual value exceeds the

Value Function WE

3.0 value entered here when the PID controller is active, the OD signal activates.

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Error message AL

The digital output configured as AL activates when a fault has occurred.

1112CM2

24 V 50 mA

Figure 75: Digital output 11 configured as AL (fault occurrence)

X Program one of the digital inputs 11 or 12 as the AL output, by

setting the value 05 under PNU C21 or C22.

When the AL output is configured as a break contact (default setting), remember that there is a delay from the time the supply voltage is switched on until the AL output is closed, and a fault message relating to the AL output therefore appears for a short time after the supply is switched on.

Frequency value messages FA1/FA2

Please note that the programmable digital outputs (including the one configured as AL) are open collector types and therefore have different electrical characteristics than the signalling relay outputs (terminals K11, K12 and K14). In particular, the maximum voltage and current carrying capacity ratings are significantly lower than those of the relay outputs.

After the frequency inverter supply voltage has been switched off, the AL output remains active until the DC bus voltage has dropped below a certain level. This time depends, among other factors, on the load applied to the inverter.

The delay from the time a fault occurs until the AL output is activated is about 300 ms.

Programming the control signal terminals

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Signalling relay terminals K11, K12, K14

If a fault occurs, the signalling relay (changeover) is triggered. The switching conditions can be programmed as required.

Table 18: Default setting of the signalling relay

Default setting of the signalling relay Reconfigured signalling relay terminals (PNU C33 = 00) Fault or DF5 switched off Operating message Fault message Operating message or DF5

switched off

K12K11 K14

K12K11 K14 K12K11 K14

K12K11 K14

Voltage Operating

status

On Normal Open Closed On Normal Closed Open On Fault Closed Open On Fault Open Closed Off – Closed Open Off – Closed Open

X Use the above table to configure contacts K11–K12 or K11–K14

K11–K12 K11–K14 Voltage Operating

status

K11–K12 K11–K14

as make or break contacts under PNU C33.

PNU Name Adjustable in

RUN mode

C33 Signalling relay

output

– 00 K11-K14 close with a fault message 01

After a fault has occurred, the associated fault message is retained even after the voltage supply is switched off. The fault message can be displayed again after the voltage has been switched back on. However, the inverter is reset when the device is switched off, i.e. the fault message will not be signalled on the terminals of the

Value Function WE

01 K11-K14 close when the supply voltage is applied

When the signalling relay output is configured as a break contact (default setting), it is important to remember that there is a delay from the time the supply voltage is switched on until the AL output is closed, and that a fault message for the AL output therefore appears for a short time after the supply is switched on.

signalling relay after the inverter is switched back on.

If however, the fault signalling is to be retained even after

the inverter is switched back on, a latching (self maintaining) relay should be used.

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6 Setting Parameters

The parameters listed in this section can be set using the keypad. The adjustment and setting possibilities listed below are themati-

cally arranged according to their function. This provides a clear overview of all parameters assigned to a particular functional area (e.g. Section ”DC braking (DC-Break)”, PNU A51 to A55).

Setting the display parameters

In this section, you will see which parameters can be set using the display on the keypad.

PNU Name Function

d01 Output frequency in Hz Output frequency display from 0.5 to 360 Hz. The “Hz” lamp on the keypad lights up. d02 d03

d04

d05

d06

d07

d08

d09 Older fault messages (fault

Motor current in A Display of the output current from 0.01 to 999.9 A. The “A” lamp on the keypad lights up. Direction of rotation Display:

F for clockwise rotation (forward),

•

r for anticlockwise rotation (reverse),

•

0 for stop

•

Actual value x factor Only with active PID closed loop control. The factor is set under PNU A75 and can have a value from

0.01 to 99.99; the default setting is 1.0.

Status of digital inputs 1 to 5 Example: Digital inputs 1, 3 and 5 are activated. The digital inputs 2 and 4 are

deactivated.

54321

Digital outputs 11 and 12 and fault message output

K14 12 11

Output frequency x factor The display of the product of the factor (PNU b86) and the output frequency in the range 0.01 to

99990. Examples:

• Display

•

Last alarm indication Display of the most recent fault message and (after the PRG key is pressed) the output frequency,

motor current and DC bus voltage at the time the fault occurred. If a fault message is not available, the display shows

Display of the second from last and (after the PRG key is pressed) third from last fault message. If

message register)

neither the second last or third last fault message has been stored, the display shows

11.11 corresponds to 11.11,

111.1 corresponds to 111.1,

1111. corresponds to 1111, 1111 corresponds to 11110.

Example: The digital output 11 and the signal output K14 are activated. Digital output 12 is deactivated.

---

Setting Parameters

Basic functions

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Input/display frequency value

PNU F01 displays the current frequency setpoint value or the current fixed frequency. You can change the frequencies with the arrow keys and save the settings in accordance with the setting of PNU A01 and the fixed frequency stages FF1 to FF4 (digital inputs) (a Section “Fixed frequency FF1 to FF4 selection”, Page 56).

With PNU F01, you can change parameters even when the parameter protection PNU b31 has been set (a Page 66).

Display/input frequency setpoint value

If you have not activated any fixed frequencies, PNU F01 displays the frequency setpoint value.

The frequency setpoint value can be assigned in one of three ways, depending on PNU A01:

• via the installed potentiometer on the keypad, PNU A01 = 00;

PNU Name Adjustable in

RUN mode

F01 Input/indication

of frequency setpoint value

j 0.5 to 360 Hz Resolution g0.1 Hz

Value Function WE

• via analog input O (0 to 10 V) or OI (4 to 20 mA), PNU A01 = 01 (default setting);

• via PNU F01 or PNU A20, PNU A01 = 02.

If you specify the frequency setpoint value with PNU A20 (a Page 78), you can enter a new value under PNU F01. This is automatically saved under PNU A20:

X Change the current value with the arrow keys. X Save the modified value with the ENTER key.

The saved value is automatically written to PNU A20.

Displaying/entering fixed frequencies

If you have activated the fixed frequencies via the functions FF1 to FF4 of the digital inputs, PNU F01 displays the selected fixed frequencies.

For information about changing the fixed frequencies, see Section“Input of the fixed frequency under PNU F01”, Page 56.

0.0

The setpoint can be defined using various methods:

• With PNU F01 or A20: Enter the value 02 under PNU A01.

• With the potentiometer on the keypad: Enter the value 00 under PNU A01.

• With a 0 to 10 V voltage signal or a 4 to 20 mA current signal at input terminals O or OI: Enter the value 01 under PNU A01.

• With the digital inputs configured as FF1 to FF4. After selection of the required fixed frequency stage using FF1 to FF4, the frequency for the respective stage can be entered.

The display of the setpoint value is independent of which method was used to set the setpoint value.

Acceleration time 1

Acceleration time 1 defines the time in which the motor reaches its end frequency after a start command is issued.

PNU Name Adjustable in

RUN mode

F02 Acceleration

time 1

j 0.1 to 3 000 s Resolution of 0.1 s at an input of 0.1 to 999.9

Value Function WE

10.0

Resolution of 1 s at an input of 1000 to 3000

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Deceleration time 1

Deceleration time 1 defines the time in which the motor brakes to 0 Hz after a stop command.

Basic functions

PNU Name Adjustable in

RUN mode

F03 Deceleration

time 1

j 0.1 to 3 000 s Resolution of 0.1 s at an input of 0.1 to 999.9

Value Function WE

Direction of rotation

The direction of rotation defines the direction in which the motor turns after a start command is issued.

PNU Name Adjustable in

RUN mode

F04 Direction of

rotation

– 00 The motor runs in a clockwise direction. 00

Value Function WE

01 The motor runs in an anticlockwise direction.

10.0

Resolution of 1 s at an input of 1000 to 3000

Setting Parameters

Setting the frequency and start command parameters

This section describes the methods for adjusting and setting the start command and basic frequency-related parameters.

Definition of frequency setpoint value

With PNU A01, you set how the frequency setpoint value is to be defined:

• Via the potentiometer on the keypad

• Via analog input O (0 to 10 V) or OI (4 to 20 mA)

• Definition under PNU F01 and/or PNU A20

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PNU Name Adjustable in

RUN mode

A01 Defined

frequency setpoint

A20 Frequency

setpoint value

F01 Display/input

of frequency value

– 00 Definition with the potentiometer on the keypad 01

j 0.5 to 360 Hz You can input a frequency setpoint value. You must assign 02 under

j Display of the current frequency setpoint value or the current fixed

Value Function WE

01 Definition via analog input O (0 to 10 V) or OI (4 to 20 mA) 02 Definition under PNU F01 and/or PNU A20

PNU A01 for this purpose.

frequency. Modified values are saved with the ENTER key according to the selection of the digital inputs configured as FF1 to FF4 (a Section ”Fixed frequency FF1 to FF4 selection”, Page 56). Resolution g0.1 Hz

Start command

With PNU A02, you define whether the start command is issued using the ON key of the keypad or through the digital inputs configured as FWD and REV.

PNU Name Adjustable in

RUN mode

Value Function WE

0.0

A02 Start command – 01 The start command for starting the motor is issued by the digital inputs

configured as FWD or REV.

02 The start command for starting the motor is issued by the ON key on the

keypad.

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Base frequency

The base frequency is the frequency at which the output voltage has its maximum value.

Setting the frequency and start command parameters

PNU Name Adjustable in

Value WE

RUN mode

A03 Base frequency – 50 to 360 Hz 50

Maximum end frequency

If you want to set another frequency range with a constant voltage that lies beyond the base frequency set under PNU A03, this frequency is set with PNU A04. The maximum end frequency may not be smaller than the base frequency.

100

[%]

[Hz]

Figure 76: Maximum end frequency

: base frequency

: maximum end frequency

PNU Name

Adjustable in RUN mode

A04 Maximum end

– 50 to 360 Hz 50

frequency

Value WE

Setting Parameters

Analog setpoint value matching

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The external setpoint signal can be specifically matched with parameters PNU A11 to A16, which are described below. A configurable voltage or current setpoint range can be assigned to a configurable frequency range.

Furthermore, analog setpoint signal filtering can be adjusted using PNU A16.

PNU Name Adjustable in

RUN mode

A11 Frequency with

– 0 to 360 Hz Here, the frequency that corresponds to the minimum voltage setpoint minimum setpoint value

A12 Frequency with

maximum setpoint value

A13 Minimum

setpoint value

A14 Maximum

setpoint value

A15 Conditions for

start frequency

A16 Analog input

filter time constant

Value Function WE

0 to 360 Hz Here, the frequency that corresponds to the maximum voltage setpoint

0 to 100 % The minimum setpoint value entered here relates to the maximum

0 to 100 % The maximum setpoint value entered here relates to the maximum

Determines the behaviour at setpoint values below the minimum setpoint value. 01 00 The frequency defined under PNU A11 is applied to the motor. 01 A frequency of 0 Hz is applied to the motor. To reduce the inverter’s response time to setpoint changes at the O or OI terminal, and

thereby determine the degree to which analog signal harmonics are filtered, you can enter a value between 1 and 8 here.

1 Minimal filtering effect/fast response to setpoint value changes

....

8 Maximum filtering effect/slow response to setpoint value changes

[Hz]

PNU A12

PNU A15 = 00

PNU A11

PNU A13 PNU A14

0 V

4 mA 20 mA

PNU A15 = 01

Figure 77: Setpoint value matching x: Voltage or current setpoint signal on analog input O or OI

value under PNU A13 is set.

value under PNU A14 is set.

possible voltage or current setpoint (10 V or 20 mA).

10 V

0.0

100

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Voltage/frequency characteristics and boost

The boost with the V/f characteristic has the effect of boosting the voltage (and consequently boosting the torque) in the lower frequency range. The manual boost raises the voltage in the frequency range from the start frequency (standard setting 0.5 Hz) to half the base frequency (25 Hz with the standard setting of 50 Hz) in every operating stage (acceleration, normal operation, deceleration), independently of the motor load. With automatic boost, in contrast, the voltage is boosted according to the motor load. A voltage boost may cause a fault message and trip due to the higher currents involved.

PNU Name Adjustable in

RUN mode

Value Function WE

[%]

100

PNU A42 = 50

5.0

PNU A43 = 10 %

Figure 78: Boost characteristics Parameter settings:

A41 = 00 A42 = 50 A43 = 10.0 A44 = 00 A45 = 100

25.0

50.0

[Hz]

A41 Boost characteristics – 00 Manual boost 00

01 Automatic boost

A42 Manual boost

j 0 to 99 % Setting the voltage boost level with manual boost. 11

percentage

A43 Maximum boost at 1 %

of the base frequency

A44 Voltage/frequency

characteristic

j 0 to 50 % Setting the frequency with the highest voltage boost as a percen-

tage of the base frequency.

– You can select a quadratic or a V/f

[%]

100

characteristic for accelerating or decelerating the motor.

10.0

a Linear b Quadratic

00 Linear V/f characteristic (constant torque). 01 Quadratic V/f characteristic (reduced torque)

A45 Output voltage

j 50 to 100 %

of the input voltage

[%]

100

The output voltage can be set to 50 to 100 % of the input voltage.

100

Setting Parameters

DC braking (DC-Break)

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To activate DC braking, apply a stop signal (PNU A51 to A55). By applying a pulsed DC voltage to the motor stator, a braking torque is induced in the rotor and acts against the rotation of the motor. With DC braking, a high level of stopping and positioning accuracy can be achieved.

PNU Name Adjustable in

RUN mode

A51 DC braking active/

inactive

A52 DC braking starting

frequency

A53 DC braking waiting

time

A54 DC braking torque A55 DC braking duration

– 00 DC braking is not used (is inactive) 00

Value Function WE

01 DC braking is used (is active)

0.5 to 10 Hz DC braking is active if the frequency is less than the frequency

0.0 to 5 s When the frequency set with PNU A52 is reached, the motor

0 to 100 % Adjustment range for the level of braking torque. 0

0.0 to 60 s The time during which DC braking is active. 0.0

Caution!

DC braking results in additional heating of the motor. You should therefore configure the braking torque (PNU A54) as low and the braking duration (PNU A55) as short as possible.

0.5

entered here.

0.0 coasts for the time duration entered here before DC braking is activated.

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Operating frequency range

The frequency range which is determined by the values configured under PNU b82 (start frequency) and PNU A04 (end frequency) can be limited by PNU A61 and A62 (a Fig. 79). As soon as the frequency inverter receives a start command, it applies the frequency set under PNU A62.

[Hz]

PNU A04

PNU A61

PNU A62

PNU b82

Figure 79: Upper frequency limit (PNU A61) and lower frequency

limit (PNU A62)

[V]

To avoid resonance within the drive system, it is possible to program three frequency jumps under PNU A63 to A68. In the example (a Fig. 80 ), the first frequency jump (PNU A63) is defined as 15 Hz, the second (PNU A65) as 25 Hz and the third (PNU A67) as 35 Hz. In the example, the frequency jump widths (adjustable under PNU A64, A66 and A68) are set to 1 Hz.

[Hz]

15 Hz

0.5 Hz

PNU A64

PNU Name Adjustable in

RUN mode

A61 Maximum operating

– 0.5 to 360 Hz This function can be deactivated by entering 0.0 0.0

frequency

A62 Minimum operating

frequency A63 First frequency jump A64 First jump width A65 Second frequency jump A66 Second jump width A67 Third frequency jump A68 Third jump width

Figure 80: Frequency jumps

Value Function WE

0.5 to 360 Hz 0.0

0.1 to 360 Hz 0.0

0.1 to 10 Hz 0.5

0.1 to 360 Hz 0.0

0.1 to 10 Hz 0.5

0.1 to 360 Hz 0.0

0.1 to 10 Hz 0.5

Setting Parameters

PID controller

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The DF5 series frequency inverter is a PID controller. This can be used, for example, for flow and throughput controllers with fans and pumps. PID control has the following features:

• The setpoint value can be issued via the frequency inverter keypad or via an external digital signal (fixed frequencies). Sixteen different setpoint values are possible. In addition, the setpoint can be defined with an analog input signal (0 to 10 V or 4 to 20 mA).

• With the DF5, you can implement the actual value signal feedback through an analog input voltage (of up to 10 V) or an analog input current (up to 20 mA).

• The permissible range for the actual value signal feedback can be specifically matched (e.g. 0 to 5 V, 4 to 20 mA, or other ranges).

–

• With the aid of a scale adjustment, you can match the setpoint signal and/or the actual value signal to the actual physical quantities (such as air or water flow, temperature, etc.) and represent them on the display.

The PID closed-loop control

“P” stands for Proportional, “I” stands for Integral and “D” stands for Differential. In control engineering, the combination of these three terms is termed PID closed-loop control, PID regulation or PID control. PID closed-loop control is used in numerous types of application, e.g. for controlling air and water flow or for controlling pressure and temperature. The output frequency of the inverter is controlled by a PID control algorithm to ensure that the deviation between the setpoint and actual value is as small as possible. The following figure shows a block diagram representation of a PID closed loop control:

Figure 81: PID closed-loop control block diagram G1:frequency inverter DF5

w: Setpoint value x: Actual value P1: Controlled variable B1: Measured value converter

PID closed loop control is only possible after the type of

setpoint value and actual value used have been defined.

a System deviation b Converter c Fans, pumps or similar devices d Frequency setpoint value

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PID controller

The example in the following figure shows a fan control:

0... +10 V H ; 4 – 20 mA

Figure 82: Example of a fan control G1:DF5 series frequency inverters

w: Setpoint value x: Actual value P1: Controlled variable B1: Measured value converter a Fan

P: Proportional component

This component ensures that the output frequency and the system deviation are subject to a proportional relationship. Using PNU A72, the so-called proportional gain (K

), expressed in %,

can be defined. The following figure illustrates the relationship between system

deviation and output frequency. A large value for K

results in a

quick reaction to a change of the system deviation. If, however, K is too large, the system becomes unstable.

[%]

100

Kp = 2

Kp = 1

Kp = 0.75

Kp = 0.5

I: Integral component

This component results in a correction of the output frequency by integration of the system deviation. In the case of purely proportional control, a large system deviation causes a large change in the output frequency. It follows, then, that if the system deviation is very small, the change in the output frequency is also very small. The problem is that the system deviation cannot be completely eliminated. Hence the need for an integral component.

The integral component causes a continuous adding up of the system deviation so that the deviation can be reduced to zero. The reciprocal value of the integration gain is the integration time

=1/Ki.

With the DF5 series frequency inverters, set the integration time (T

). The value may be between 0.5 s and 150 s. To disable the

integral component, enter 0.0.

D: Differential component

This component causes a differentiation of the system deviation. As pure proportional control uses the current value of the system deviation and pure integral control values from previous actions, a certain delay in the control process always occurs. The D component compensates for this behaviour.

Differential control corrects the output frequency using the rate of change of the system deviation. The output frequency can therefore be compensated very quickly.

can be set between 0 and 100 s.

The PID controller

A PID controller combines the P, I and D components described in the previous sections. In order to achieve the optimum control characteristics, each of the three PID parameters must be set.

frequency is guaranteed by the proportional component; the inte-

Uniform control behaviour without large steps in the output

gral component minimizes the existing system deviation the steady-state and the differential component ensures a quick response to a rapidly changing actual value signal.

As differential control is based on a differentiation of the system deviation, it is very sensitive and also responds to unwanted signals, such as interference, which can result in system instability. Differential control is normally not required for flow, pressure and temperature control.

Figure 83: Proportional gain K x: System deviation

Kp = 0.25

0.2 F Kp F 0.5

10050 75250

x [%]

The maximum output frequency in the above figure is defined as 100 %. K

can be set between 0.2 and 5.0 under PNU A72.

Setting Parameters

Setting the PID parameters

Values for the PID parameters must be chosen depending on the application. and the system’s control characteristics. To ensure correct PID closed loop control, the following points should be observed:

• Stable steady-state behaviour,

• Fast reaction

• Small system deviation in the steady state.

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Parameters K range. As a general rule, increasing one of the parameters K (= reduction of T

, Ti and Kd must be set within the stable operating

, Ki

) and Kd results in a system with a faster

response. A very large increase however, causes system instability, as the returned actual value increases and decreases continuously as if subject to oscillation. In the worst case, divergent behaviour will be the result (a Fig. 84 to Fig. 87):

Figure 84: Divergent behaviour w: Setpoint value

a Output signal

Figure 85: Oscillation, dampened w: Setpoint value

a Output signal

Figure 86: Good regulation behaviour w: Setpoint value

a Output signal

Figure 87: Slow regulation, large static system deviation w: Setpoint value

a Output signal

The following table provides guidelines for setting each parameter.

Table 19: Setting the controller regulation times

Setpoint change

Setpoint and actual value

After increase of K

Causes a slow reaction: Increase proportional

component (K

Causes a fast but unstable reaction

Differ greatly: Reduce integral

Approach each other after oscillation:

The reaction is still slow: Increase D component

The reaction is still unstable:

Set a lower P component

component (T Set a higher I

component

)

Set a lower D component

)

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PID controller

Structure and parameters of the PID controller PID controller active/inactive

DF5 frequency inverters can operate in one of the following two control modes:

• Frequency control active (i.e. PID closed loop control inactive)

• PID closed loop control active

PNU Name Adjustable in

RUN mode

A71 PID control active/inac-

– 00 PID closed loop control is not used (inactive) 00

tive

Value Function WE

01 PID closed loop control is used (active)

Frequency control is the standard method of control used by many frequency inverters. A setpoint value is defined by a control unit (keypad) as an analog voltage or current signal, or via a 4 bit wide digital command applied to the control signal terminals.

With PID closed loop control, the inverter’s output frequency is controlled by a control algorithm to ensure that the deviation between the setpoint and actual value is kept at zero.

You can switch between both modes with PNU A71 (PID control active/inactive).

Parameter

The following figure illustrates which parameters are effective in different areas of the PID block diagram. The stated parameters (e.g. PNU A72) correspond to those on the integrated frequency inverter keypad:

PNU A75

PNU F01

(PNU A76)

Figure 88: PID closed loop control parameters w: Setpoint value

x: Actual value

: output frequency

PNU A75

PNU A12

PNU A11

PNU A01

-1

PNU A13

PNU A14

P: PNU A72

I: PNU A73

–

D: PNU A74

PNU A75 PNU d04

a Frequency definition with keypad, fixed frequency b Analog definition with potentiometer, analog inputs, current or

voltage

Setting Parameters

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PNU Function Adjustable in

RUN mode

A01 Defined

frequency setpoint

A11 Frequency with

minimum setpoint value

A12 Frequency with

maximum setpoint value

A13 Minimum

setpoint value

A14 Maximum

setpoint value

d04 Actual value x

factor

F01 Input/display

frequency value

A72 P component of

the PID controller

A73 I component of

the PID controller

A74 D component of

the PID controller

A75 Setpoint factor of

the PID controller

A76 Input actual

value signal for PID controller

– 00 Definition with the potentiometer on the keypad 01

– 0 to 360 Hz Here, the frequency that corresponds to the minimum voltage setpoint

– 0 to 360 Hz Here, the frequency that corresponds to the maximum voltage setpoint

– 0 to 100 % The minimum setpoint value entered here relates to the maximum

– 0 to 100 % The maximum setpoint value entered here relates to the maximum

j – Only with active PID closed loop control. The factor is set under

j 0.5 to 360 Hz Resolution g0.1 Hz

j 0.2 to 5.0 Adjustment range of the proportional component of the PID closed loop

j 0.0 to 150 s Adjustment time Ti of the integral component of the PID closed loop

j 0.0 to 100 s Adjustment time Td of the differential component of the PID closed loop

– 0.01 to 99.99 The display of the frequency setpoint or actual value can be multiplied

– 00 Actual value signal present on analog input OI (4 to 20 mA) 00

Value Function WE

01 Definition via analog input O (0 to 10 V) or OI (4 to 20 mA) 02 Definition under PNU F01 and/or PNU A20

0.0

value under PNU A13 is set.

0.0

value under PNU A14 is set.

possible voltage or current setpoint (10 V or 20 mA).

100

possible voltage or current setpoint (10 V or 20 mA).

–

PNU A75, from 0.01 to 99.99; default setting = 1.0.

0.0

The setpoint can be defined using various methods:

• With PNU F01 or A20: Enter the value 02 under PNU A01.

• With the potentiometer on the keypad: Enter the value 00 under

PNU A01.

• With a 0 to 10 V voltage signal or a 4 to 20 mA current signal at input terminals O or OI: Enter the value 01 under PNU A01.

• With the digital inputs configured as FF1 to FF4. After selection of the required fixed frequency stage using FF1 to FF4, the frequency for the respective stage can be entered.

The display of the setpoint value is independent of which method was used to set the setpoint value.

1.0

control

1.0

control

0.0

control

1.00 by a factor, so that process related quantities (e.g. flow or similar) can be displayed instead of the frequency.

01 Actual value signal present on analog input O (0 to 10 V)

Internal regulator-based calculations

All calculations within the PID algorithm are carried out in percentages, so that different physical units can be used, such as

• Pressure (N/m

• Flow rate (m

/min),

• Temperature (°C), etc.

The setpoint and returned actual values can, for example, also be compared as percentages.

A useful scaling function (PNU A75) is also available. When these parameters are used, you can define the setpoint directly as the required physical quantity and/or display setpoint and actual values as physical quantities suitable for the process.

Additionally, analog signal matching (PNU A11 to A14) is available, with which a range based on the actual value feedback can be defined. The following graphs illustrate the mode of operation of this function.

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PID controller

Setpoint definition

There are three ways of entering the setpoints:

• Keypad

• Digital control signal terminal input (4 bit)

• Analog input (terminals O-L or OI-L)

If the digital setpoints are defined through the control signal terminals, define the required setpoint value in PNU A21 to A35. The setting procedure is similar to the one which is used in frequency regulation mode (i.e. with a deactivated PID controller) for setting the respective fixed frequencies (a Section ”Fixed frequency FF1 to FF4 selection”, Page 56).

100

[%]

PNU A13 = 20 % PNU A14 = 100 %

10 V2 V

20 mA4 mA

100 %20 %

100

[%]

PNU A13 = 0 % PNU A14 = 50 %

Actual value feedback and actual value signal matching

You can specify the actual value signal as follows:

• With an analog voltage on control signal terminal O (maximum 10 V)

• With an analog current on control signal terminal OI (maximum 20 mA)

One of the two methods mentioned is selected via PNU A76. To adapt the operation of the PID controller to the respective appli-

cation, the actual value feedback signal can also be matched as shown in Figure 89:

100

[%]

10 V5 V

20 mA10 mA

100 %50 %

PNU A13 = 25 % PNU A14 = 75 %

7.5 V

15 mA

75 %

10 V2.5 V

20 mA5 mA 100 %25 %

100

[%]

PNU A13 = 20 % PNU A14 = 100 % PNU A11 = 25 % PNU A12 = 100 %

10 V2 V

20 mA4 mA

100 %20 %

100

[%]

PNU A13 = 0 % PNU A14 = 50 % PNU A11 = 0 % PNU A12 = 75 %

Figure 89: Analog actual value signal matching

As evident from the graphs, the setpoint value must be within the valid range on the vertical axis if you have set functions PNU A11 and A12 to a value not equal to 0. Because there is no feedback signal, stable control cannot otherwise be guaranteed. This means that the frequency inverter will either

• output the maximum frequency,

• go to stop mode,

• or output a lower limit frequency.

100

[%]

10 V5 V

20 mA10 mA

100 %50 %

7.5 V

15 mA

75 %

10 V2.5 V

20 mA5 mA

100 %25 %

PNU A13 = 25 % PNU A14 = 75 % PNU A11 = 25 % PNU A12 = 75 %

Setting Parameters

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Scaling adjustment

Scaling adjustment and scaling allow the setpoint and actual value to be displayed and the setpoint value to be entered directly in the correct physical unit. For this purpose, 100 % of the returned actual value is taken as a basis. By default, inputs and displays are based on 0 to 100 %.

Example: In the first diagram in Figure 89, 20 mA of the feedback signal correspond to 100 % of the PID internal factor. If for example the current flow is 60 m 20 mA, the parameter is set to 0.6 with PNU A75 (= 60/100). With PNU d04, the process corrected value can be displayed and the setpoint value can be entered directly as a process corrected quantity.

w [%]

PNU F01 0 – 60m

w [%]

PNU F01 = 0 – 100 %

Factory default setting PNU A75 = 0.6

4 – 20 mA PNU d01 = 0 – 100 %

Figure 90: Example for scaling adjustment w: Setpoint value

x: Returned actual value a Fan

/min

/min with a feedback signal of

4 – 20 mA

PNU d01

/min

0 – 60m

Summary of the relevant parameters

With the DF5 series frequency inverters, the same parameters are used for both the frequency control mode and the PID mode. The designations of the respective parameter only relate to the

frequency control mode, however, as this mode is used in most cases. When the PID mode is used, some of the parameters have other designations.

The following table contains an explanation of these parameters in conjunction with the frequency control mode as well as the PID mode:

PNU Meaning of the parameters when used in

Frequency control mode PID mode

d04 – Display of the returned actual value F01 A01 A11

A12

A13

A14

A21 to A35

Displays of the output frequency Display of the setpoint value Defined frequency setpoint Defined setpoint Frequency with minimum setpoint value (Units: Hz) Feedback percentage actual value for lower acceptance

threshold (units: %)

Frequency with maximum setpoint value (Units: Hz) Feedback percentage actual value for upper acceptance

threshold (Units: %)

Minimum setpoint value (Units: Hz) Lower acceptance threshold for the voltage or current on the

actual value input (Units: %)

Maximum setpoint value (Units: Hz) Upper acceptance threshold for the voltage or current at the

actual value input (Unit: %)

Fixed frequencies 1 to 15 Digital adjustable setpoint values 1 to 15

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PID controller

PNU

A71 – PID control active/inactive A72 A73 A74 A75 A76

Settings in the frequency control mode

Before you use the PID mode, you must configure the parameters in frequency control mode. Observe the following two points:

Acceleration and deceleration ramp

The output frequency calculated by the PID algorithm is not immediately available on the frequency inverter output, as the output frequency is affected by the set acceleration and deceleration times. Even when, for example, a large D component is defined, the current output frequency is significantly influenced by the acceleration and deceleration time, and this causes unstable regulation.

To achieve stable behaviour in each PID closed loop control range,

Meaning of the parameters when used in Frequency control mode PID mode

P component of the PID controller I component of the PID controller D component of the PID controller Setpoint factor of the PID controller Input actual value signal for PID controller

After every acceleration and deceleration ramp parameter change, parameters PNU A72, A73 and A74 must be rematched.

Frequency jumps/range

Frequency jumps must be defined to meet the following requirement: A change to the feedback actual value signal must not occur during execution of a frequency jump. If a stable operating point exists within a frequency jump range, operation between both end values of this range occurs.

Configuration of setpoint value and actual value

In PID mode, you must first of all specify how the setpoint is to be defined and where the actual value is to be supplied. The following

table provides the required settings: the acceleration and deceleration times should be set as low as possible.

Actual value input Setpoint value definition

Integrated keypad Digital via control

terminals (fixed frequencies)

Analog voltage (O-L: 0 to 10 V)

Analog current (OI–L: 4 to 20 mA)

PNU A01 = 02 PNU A76 = 01

PNU A01 = 02 PNU A76 = 00

PNU A01 = 02 PNU A76 = 01

PNU A01 = 02 PNU A76 = 00

It is not impossible to enter the setpoint value and the actual value through the same analog input terminal.

Please note that the frequency inverter brakes and stops according to the set deceleration ramp as soon as a stop command is issued during PID operation.

Scaling

Please set the scaling to the process-corrected physical quantity as required by your application, i.e. to flow, pressure, temperature, etc. For a detailed description, see Section ”Scaling adjustment”, Page 90.

Setpoint adjustment via digital inputs

The following points must be observed when setting the setpoint via digital inputs (4 bit):

Integrated potentiometer

PNU A01 = 00 PNU A76 = 01

PNU A01 = 00 PNU A76 = 00

Analog voltage on O-L

– PNU A01 = 01

PNU A01 = 01 PNU A76 = 00

Analog current on OI-L

PNU A76 = 01

–

Assignment of the digital inputs

The DF5 series have five programmable digital inputs. Assign the

functions FF1 to FF4 to four of the inputs. Use PNU C01 to C05 for

this purpose, corresponding to the inputs 1 to 5 of the frequency

inverter.

Adjustment of the setpoint values

First of all, select the required number of different setpoints (up to

16) from the following table. Under PNU A21 (corresponds to the

first setpoint) to A35 (corresponds to 15th setpoint), enter the

required setpoint. PNU A20 and F01 correspond to setpoint 0.

If the setpoints are to be scaled, note that the setpoints

must be entered as process-corrected quantity values in accordance with this scaling.

Setting Parameters

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No. FF4 FF3 FF2 FF1 Setpoint number (PNU)

1 0 0 0 0 Setpoint value 0

(PNU A20 or F 01)

0 0 0 1 Setpoint value 1 (PNU A21)

0 0 1 0 Setpoint value 2 (PNU A22)

0 0 1 1 Setpoint value 3 (PNU A23)

4 5

0 1 0 0 Setpoint value 4 (PNU A24) 0 1 0 1 Setpoint value 5 (PNU A25)

0 1 1 0 Setpoint value 6 (PNU A26)

7 8

0 1 1 1 Setpoint value 7 (PNU A27) 1 0 0 0 Setpoint value 8 (PNU A28)

1 0 0 1 Setpoint value 9 (PNU A29)

1 0 1 0 Setpoint value 10 (PNU A30)

1 0 1 1 Setpoint value 11 (PNU A31)

1 1 0 0 Setpoint value 12 (PNU A32)

1 1 0 1 Setpoint value 13 (PNU A33)

14 15

1 1 1 0 Setpoint value 14 (PNU A34) 1 1 1 1 Setpoint value 15 (PNU A35)

16 1: On

0: Off

If, for example, you only require up to four different setpoint values, only FF1 and FF2 need to be used; for five to eight different setpoint values, only FF1 to FF3 are required.

Activating PID mode

X Set PNU A71 to 01.

You can make this setting at the very start, before making all other settings.

Example for setting K

and Ti

As for the parameter changes, check the output frequency or the feedback actual value signal with an oscilloscope (a Fig. 84 to Fig. 87, Page 86).

Use two different setpoint values and switch between them using the digital control signal terminals.

The output should then always exhibit a stable behaviour.

Adjustment of the P component

Begin by setting only the P component, but not the I component and the D component.

X First of all, set a small P component via PNU A72 and check the

result.

X If necessary, slowly increase this value until an acceptable

output behaviour has been achieved.

Alternatively, set a very large P component and observe the behaviour of the output signal. If the behaviour is unstable, set a lower value and observe the result. Repeat this process.

If the behaviour is unstable, reduce the P component. The P component is correct when the system deviation reaches a

static state within acceptable limits.

Setting the integral component and matching K

First of all, define a very small integral component in PNU A73.

X X Set the P component a little lower.

If the system deviation does not decrease, reduce the integral component a little. If the performance becomes unstable as a result, reduce the P component.

X Repeat this process until you have found the correct parameter

settings.

Note about the automatic voltage regulation (AVR) function

If you have set the AVR function (PNU A81) to 02, whereby the automatic voltage regulation function with an active PID closed loop control is deactivated only during deceleration of the motor, the motor may, depending on the application, start to “knock”. In such cases, the motor accelerates and decelerates repeatedly and smooth running of the motor is not guaranteed. In this case, set the AVR function to 01 (OFF).

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PID controller

Application examples

This section contains some setting examples for practical applications.

4 – 20 mA

Figure 91: Examples for flow control w: Setpoint value, 4 Bit digital

x: feedback actual value (500 m

/min at 20 mA) B1: Measured value converter P1: Flow sensor a Pump

Flow control

The example shown in the figure below has the setpoint values

/min and 300 m3/min:

150 m

500 m3/min

100

/min

300 m

150 m

/min

5.8 mA

29 %

10.6 mA

53 %

20 mA 100 %

4 mA0

20 %

PNU

Meaning in PID control mode Value Notes

F01 Setpoint 150 Direct input of “150 m3/min”, as the scaling

factor has been set A01 A11

Frequency setpoint definition 02 Keypad Feedback percentage actual value for lower acceptance threshold

0 0%

(Units: %)

A12

Feedback percentage actual value for upper acceptance threshold

100 100 %

(Units: %)

A13

Lower acceptance threshold for voltage or current on the actual value

20 20 %

input (in %)

A14

Upper acceptance threshold for voltage or current on the actual value

100 100 %

input (in %) A21 A71 A72 A73 A74 A75 A76

Digitally adjustable setpoint value 1 300 300 m3/min

PID control active/inactive 01 PID mode active

P component of the PID controller – Application dependent

I component of the PID controller –

D component of the PID controller –

Setpoint factor of the PID controller 5.0 100 % at 500 m3/min

Input actual value signal for PID controller 00 Feedback from OI–L terminal

Setting Parameters

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Temperature control

With the flow control in the previous example, the frequency inverter’s output frequency increases if the feedback signal is less than the setpoint and falls if the feedback signal is greater than the setpoint. With temperature control, the opposite behaviour must

0... +10 V H

Figure 92: Example for temperature control w: Setpoint value, 4 Bit digital

x: Feedback actual value (50 °C at 10 V) B1: Measured value converter P1: Temperature sensor a Fan

be implemented: if the temperature is above the setpoint, the inverter must increase its output frequency to increase the speed of the connected fan.

The following figure contains an example for temperature control with the two setpoints 20 and 30 °C:

50 °C

100%

60%

30 °C

40%

20 °C

4 V

40 %

6 V

60 %

10 V

100 %

PNU

Meaning in PID control mode Value Notes

F01 Setpoint 20 Direct input of “20 °C”, as the scaling

factor has been set A01 A11

Frequency setpoint definition 02 Keypad Feedback percentage actual value for lower acceptance threshold

100 100 %

(Units: %)

A12

Feedback percentage actual value for upper acceptance threshold

0 0%

(Units: %)

A13

Lower acceptance threshold for voltage or current on the actual value

0 0%

input (in %)

A14

Upper acceptance threshold for voltage or current on the actual value

100 100 %

input (in %) A21 A71 A72 A73 A74 A75 A76

Digitally adjustable setpoint value 1 30 30 °C

PID control active/inactive 01 PID mode active

P component of the PID controller – Application dependent

I component of the PID controller –

D component of the PID controller –

Setpoint factor of the PID controller 0.5 100 % at 50 °C

Input actual value signal for PID controller 01 Feedback from O-L terminal

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Automatic voltage regulation (AVR)

The AVR function stabilizes the motor voltage if there are fluctuations on the DC bus voltage. These deviations result from, for example:

• Unstable mains supplies or

• DC bus voltage dips or peaks caused by short acceleration and

deceleration times.

A stable motor voltage provides a high level of torque, particularly during acceleration.

PNU Name Adjustable in

RUN mode

A81 Characteristic of the

AVR function

A82 Motor voltage for AVR

function

– 00 AVR function active during entire operation. 02

– 200, 220, 230,

Value Function WE

01 AVR function is not active. 02 AVR function active during operation except for deceleration

240, 380, 400, 415, 440, 460

If the mains voltage is higher than the rated motor voltage, enter the mains voltage under PNU A82 and reduce the output voltage in PNU A45 to the rated motor voltage.

Regenerative motor operation (without AVR function) results in a rise in the DC bus voltage in the deceleration phase (particularly with very short deceleration times), which also leads to a corresponding rise in the motor voltage. The increase in the motor voltage causes an increase in the braking torque. For this reason, you can deactivate the AVR function for deceleration under PNU A81.

The settings depend on the device series used:

• 200 V series: 200, 220, 230, 240 V

• 400 V series: 380, 400, 415, 440, 460 V

230/ 400

Example: With 440 V mains voltage and 400 V rated motor voltage, enter 440 under PNU A82 and 91 % (= 400/440 x 100 %) under PNU A45.

Setting Parameters

Time ramps

09/01 AWB8230-1412GB

During operation, you can switch over from the time ramps configured under PNU F02 and F03 to those configured under PNU A92 and A93. This can be done either by applying an external signal to input 2CH at any time or when the frequencies configured under PNU A95 and A96 are reached.

PNU Name Adjustable in

RUN mode

A92 Second accelera-

j 0.1 to 3 000 s Setting times for the second acceleration and deceleration time

tion time

A93 Second decelera-

tion time

A94 Changeover from

– 00 Changeover to the second time ramp if an active signal is present on the first to the second time ramp

A95 Acceleration time

– 0.0 to 360.0 Hz Here, set a frequency at which the changeover from the first to the changeover frequency

A96 Deceleration time

– 0.0 to 360.0 Hz Here, set a frequency at which the changeover from the first to the changeover frequency

A97 Acceleration

– Here, you can set a linear or an S-curve acceleration characteristic for motor acceleration characteristic

Value Function WE

01 Changeover to the second time ramp when the frequencies entered

(first and second time ramp):

PNU A95

Figure 93: Time ramps

: acceleration time 1

: acceleration time 2

0.1 to 999.9 s; resolution: 0.1 s 1000 to 3000 s; resolution: 1 s

a 2CH digital input.

under PNU A95 and/or A96 are achieved

second acceleration time is to occur.

second deceleration time is to occur.

2CH/PNU A95

0.0

A98 Deceleration

characteristic

00 Linear acceleration of the motor from the first to the second time

ramp

01 S-curve characteristic for acceleration of the motor from the first to

the second time ramp

– 00 Linear deceleration of the motor from the second to the first time

ramp

01 S-curve characteristic for deceleration of the motor from the second

to the first time ramp

09/01 AWB8230-1412GB

Automatic restart after a fault

With the default settings, each malfunction triggers a fault message. An automatic restart is possible after the following fault

Warning!

When a fault has occurred, this function initiates an automatic restart of the frequency inverter if a start command is present after the set waiting time has expired. Ensure an automatic restart does not present a danger for personnel.

messages have occurred:

• Overcurrent (PNU E01 to E04, up to four restart attempts within 10 minutes before a fault message is issued)

• Overvoltage (PNU E07 and E15, up to three restart attempts within 10 minutes before a fault message is issued)

• Undervoltage (PNU E09, up to 16 restart attempts within 10 minutes, then a fault message is issued)

PNU Name Adjustable in

RUN mode

b01 Restart mode – 00 The above fault messages are displayed when the associated fault occurs

b02 Permissible

power failure duration

b03 Delay time

until restart

– 0.3 to 25 s Here, you set a time duration during which the undervoltage condition is

– 0.3 to 100 s Here, set a time which is to expire before an automatic restart is initiated

Value Function WE

(restart is not activated).

01 A restart at the start frequency after the time set under PNU b03 has

elapsed.

02 After the time set under PNU b03 has elapsed, the inverter synchronizes

to the current motor rotation speed and the motor accelerates for the set acceleration time.

03 After the time set under PNU b03 has elapsed, the inverter synchronizes

to the current motor rotation speed and the motor brakes for the set deceleration time. A fault message is then displayed.

met without the corresponding fault message in PNU E09 being initiated.

after a fault signal. This time can be used in conjunction with the FRS function. During the delay, the following message appears on the LED display:

1.0

Moeller DF5 Hardware And Engineering

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety instructions

Contents

About this Manual

Abbreviations and symbols

1 About DF5 series frequency inverters

System overview

Type code

Inspecting the items supplied

Layout of the DF5

Selection criteria

Intended use

Service and guarantee

2 Engineering

Features of the DF5

Connection to the mains

Electrical grid types

Mains voltage, Mains frequency

Interaction with compensation devices

Fuses and cable cross-sections

Mains contactor

Current peaks

Mains choke

Line filter, Radio interference filter

EMC guidelines

EMC interference class

Noise immunity

Emitted interference and radio interference suppression

3 Installation

DF5 Installation

Mounting position

Installation dimensions

DF5 attachment

EMC compliance

EMC compliant installation

Radio interference filter usage

EMC measures in the control panel

Grounding

Screening

Electrical connection

Connecting the power section

Open the front cover and the front of the enclosure

X Flap open the front cover and remove the terminal shroud. Power terminal arrangement

Power terminal connection Laying the cables

Tightening torques and conductor cross-sections

Connecting the supply voltage

Connecting the motor cable

Parallel connection of motors on a frequency inverter

Motor cable

Bypass operation

Connecting the signalling relay

Connecting the control signal terminals

Function of the control signal terminals

Control signal terminal wiring

4 DF5 Operation

Initial startup

LCD keypad

Operation with LCD keypad

Menu overview

Changing display and basic parameters

Changing the parameters of the extended parameter groups

Display after the supply voltage is applied

Operational warning message

5 Programming the control signal terminals

Overview

Frequency display FM

Analog frequency display

Digital frequency display

Start/Stop

Clockwise rotation FWD

Anticlockwise operation: REV

Issue start command

Fixed frequency FF1 to FF4 selection

Specifying frequency setpoints

Selecting fixed frequencies

Second time ramp 2CH

External fault message EXT