MSF-Vathauer ERS User Manual

Manual ERS (Energy Recovery System)

MSF-Vathauer Polska Sp. z.o.o ul. Staszica 37 PL-64-600 Oborniki
Tel: [phone] E-mail [e-mail] www.msf-technik.pl

Page 1 of 23

Manual

Energy Recovery System

Version:

23/2018 Rev. 1.5

Date: 06.06.2018

Manual ERS (Energy Recovery System)

MSF-Vathauer Polska Sp. z.o.o ul. Staszica 37 PL-64-600 Oborniki
Tel: [phone] E-mail [e-mail] www.msf-technik.pl

Page 2 of 23

Warranty

According to the current general terms of delivery and payment MSF- Vathauer

Antriebstechnik GmbH & Co. KG provides a warranty of 12 months (in single shift) after

delivery on all electronic devices covering design, material or faulty workmanship.

MSF- Vathauer Antriebstechnik reserves the right to change the contents of this operation

manual and the product specifications contained therein without prior notice.

The copyright of this documentation is reserved by

MSF-Vathauerer Antriebstechnik GmbH & Co. KG .

Attention!

Read this manual carefully and completely.

Start with the installation and commissioning only after reading.

Technical changes reserved

Manual ERS (Energy Recovery System)

MSF-Vathauer Polska Sp. z.o.o ul. Staszica 37 PL-64-600 Oborniki
Tel: [phone] E-mail [e-mail] www.msf-technik.pl

Page 3 of 23

Index

Warranty................................................................................................................................ 2

1. Safety and application notes for the ERS.......................................................................... 4

1.1. General .......................................................................................................................... 4

1.2. Intended Use.............................................................................................................. 4

1.3. Transportation and storage......................................................................................... 4

1.4. Installation.................................................................................................................. 5

1.5. Electrical connection................................................................................................... 5

1.6. Operation.................................................................................................................... 5

1.7. Maintenance and servicing......................................................................................... 5

1.8. Safety and Installation instructions.............................................................................. 6

European EMC directive.................................................................................................... 6

2. Assembly and Installation.................................................................................................. 7

2.1. Installation.................................................................................................................. 7

2.2. Cabling directives of superior controls........................................................................ 7

2.3. Measures to secure the EMC in machinery and plants............................................... 8

2.4. Grounding, earthen, potential compensation............................................................... 8

2.5. Filtering....................................................................................................................... 8

2.6. Screening signal- and control cables.......................................................................... 8

2.7. Coupling into motor cables......................................................................................... 8

3. Technical features............................................................................................................. 9

3.1. Special features.......................................................................................................... 9

3.3. Sample Application....................................................................................................10

3.4. Switching thresholds..................................................................................................11

3.5. Adjustment of the switching threshold........................................................................11

4. Connection Diagrams.......................................................................................................12

4.1. Connection diagram front side...................................................................................12

4.2. Connection diagram rear side....................................................................................12

4.3. Connection example FU with external brake chopper................................................13

4.4. Connection example FU with ERS.............................................................................13

4.5. Connection example FU interconnection with an ERS...............................................14

4.6. Connection example FU interconnecting circuit with several ERS .............................14

5. In- and Outputs.................................................................................................................15

5.1. Digital Input (DIN)......................................................................................................16

5.2. Digital Output 1 (DOUT 1)..........................................................................................16

5.3. Digital Output 2 (DOUT2)...........................................................................................16

5.4. Internal supply voltage (24Vdc)..................................................................................16

5.5. Integrated braking resistor.........................................................................................17

6. Commissioning instructions..............................................................................................18

7. Technical specifications....................................................................................................19

7.1. Electrical specifications..............................................................................................19

7.2. Measurement ERS....................................................................................................20

7.3. Front view..................................................................................................................21

7.4. Rear view ..................................................................................................................21

8. Status indications.............................................................................................................22

Notes....................................................................................................................................23

Manual ERS (Energy Recovery System)

MSF-Vathauer Polska Sp. z.o.o ul. Staszica 37 PL-64-600 Oborniki
Tel: [phone] E-mail [e-mail] www.msf-technik.pl

Page 4 of 23

1. Safety and application notes for the ERS

1.1. General

During operation the ERS can get under certain circumstances live parts and hot surfaces.
Any unauthorized removal of the required cover, inappropriate use, incorrect installation or operation
may result in death, severe injury or material damage.

All works for transportation, installation and initialization and maintenance work must be carried out by
qualified personnel (IEC 364 and CENELEC HD 384 or DIN VDE 0100 and IEC report 664 or DIN
VDE 0110 and national accident prevention regulations or VGB 4).

Qualified personnel in the context of these basic safety notes are persons familiar with installation,
assembly, commissioning and operation of the product and who possess the appropriate qualifications
(defined in IEC 364 or DIN VDE 0105).

1.2. Intended Use

The ERS is a component, which is intended for installation only in machines in commercial
installations in conjunction with a frequency inverter or a servo controller.

The commissioning of the ERS-frequency inverter or ERS-Servo controller constellation is prohibited
until it is determined that the machine in which the device is installed, complies with the provisions of
EU Directive 2006/42 / EC (Machinery Directive).

The ERS meets the protection objectives of the Low Voltage Directive 2006/95 / EC and the
harmonized standards of the EN 50178 / DIN VDE 0160 in conjunction with EN 60439-1 / DIN VDE
0660 part 500 and EN 601 146 / DIN VDE 0558.

Operation is only permitted in compliance with the EMC - law ( 2014/30/EU).
The technical data and information on the connection conditions can be obtained from the nameplate

or the documentation and must be observed.

1.3. Transportation and storage

The instructions for transportation, storage and proper handling must be observed
After delivery damages found must be reported to the transport company immediately.

Before commissioning the supplier can optionally be contacted.
Climatic conditions must be observed according to EN 50178th

Manual ERS (Energy Recovery System)

MSF-Vathauer Polska Sp. z.o.o ul. Staszica 37 PL-64-600 Oborniki
Tel: [phone] E-mail [e-mail] www.msf-technik.pl

Page 5 of 23

1.4. Installation

The installation and cooling of the device must be in accordance with the provisions of the relevant
documentation.

The ERS must be protected from excessive strain. They are to handle only in a way, so that no
components are bent and / or isolating distances altered. The contact of electronic components and
terminals must be avoided.

The ERS contain electrostatic sensitive devices. These components can be easily destroyed by
improper handling. Built-in electrical components must not be destroyed (potential health hazard).

1.5. Electrical connection

When working on live equipment and / or systems, the applicable national accident prevention
regulations (for example, VGB 4) must be observed.

The electrical installation has to be done according to the valid directives (e.g. cable diameters, fuse
protection, ground wire connection). More detailed information is to be found in the documentation.

Compliance with the limits for the plant according to the EMC juridical directive is in responsibility of
the manufacturer of the plant. Information about the EMC-compatible installation like screening,
grounding, alignment of filters and lying of cables are to be found in the documentation of the other
components.

1.6. Operation

Plants with integrated frequency inverters or servo controller with ERS must be equipped, if applicable,
with additional observation and security installations according to the concerning valid security
directives, e.g. act on technical work equipment, accident prevention regulations etc. The
documentation of the manufacturer has to be regarded.

After disconnection of the frequency inverters or the Servo controller from the supply voltage, voltage
conducting device parts and cable conductors on the ERS must not be immediately touched because
of possibly charged condensers. Please regard the according notification signs at the frequency
Inverters. During operation, all covers must keep closed.

1.7. Maintenance and servicing

The documentation of the manufacturer has to be regarded

Manual ERS (Energy Recovery System)

MSF-Vathauer Polska Sp. z.o.o ul. Staszica 37 PL-64-600 Oborniki
Tel: [phone] E-mail [e-mail] www.msf-technik.pl

Page 6 of 23

1.8. Safety and Installation instructions

The ERS is a device intended for use in industrial high-voltage plants and is operated with voltages
that can cause serious injuries or death when touching!

• Installation and other work may only be carried out by qualified specialist electricians and at a
voltage free device. The user manual must always be available to them at any time and has
to be consequently regarded.

• Local regulations for the installation of electrical systems and accident prevention regulations
must be observed.

• The device continues to carry current in the ERS, after switching off the mains at the
frequency inverter or servo controller, for up to 5 minutes dangerous voltage. Opening the
device is therefore only permitted until 5 minutes after the unit is completely free of voltage.
Before switching on the supply voltage all covers have to be reattached.

• Also at motor standstill (e.g. due to electronics lock, short circuit at the output clamps

or blocked drive) the voltage circuit clamps, motor clamps and clamps for the brake

resistance may conduct dangerous voltage. A motor standstill is not identical with

a galvanic disconnection from the mains voltage.

• Attention: The ERS may after the mains are switched on, depending on the settings,
start automatically the regenerative mode.

Attention! Danger to Life!
The power supply conducts voltage under certain circumstances for up to 5 minutes
after turning off the mains voltage. Terminals, DC lines and network terminals may be
alive!
Touching open or free terminals, cables and device parts may cause serious injuries

or death!
Attention

• Children and the public must not have access to the device!

• The device may only be used for the purpose intended by the manufacturer. Unauthorized

changes and the use of replacement parts and additional devices that are not sold or
approved by the manufacturer may cause fire, electric shocks and injuries.

• Keep the manual in reach and make it available for every user!

European EMC directive

IF a frequency inverter is installed in conjunction with an ERS as recommended by this manual, it will
meet the requirements of the EMC Directive, in accordance with the EMC product standard for motor­operated systems EN 61800-3, provided it was previously fulfilled by the frequency inverter.

Manual ERS (Energy Recovery System)

MSF-Vathauer Polska Sp. z.o.o ul. Staszica 37 PL-64-600 Oborniki
Tel: [phone] E-mail [e-mail] www.msf-technik.pl

Page 7 of 23

2. Assembly and Installation

2.1. Installation

The device requires adequate ventilation.

The hot air has to be dissipated above the ERS!

2.2. Cabling directives of superior controls

The ERS is developed for the operation in industrial environments where high values of
electromagnetic interferences are expected. In general, a professional installation ensures a risk less
and error-free operation. If limits are required that exceed the EMC directive limits, the following
directives are recommended.

1. Please make sure that all devices in the control cabinet are connected together at a shared
grounding point or rail with short cores and great diameter are properly grounded. It is
especially important that every control device connected to the frequency inverter and the
ERS (e.g. automation devices) is connected via a short core with high diameter at the same
grounding point as well as the frequency inverter and the ERS itself.

2. The PE conductor of the motor controlled by the frequency inverter should preferably directly
connected to the ground connection, connected with the heat sink together with the PE of the
power supply of the concerning inverter. The existence of a central grounding rail within the
control cabinet and the connection of alll PE conductors to this rail normally guarantee an
error-free operation.

3. As far as possible screened cables for the control should be used. The cable ends have to be
terminated carefully and ensure that the cores are not unscreened over long distances. The
screen of analogue set point cables should only be grounded at the frequency Inverter single­sided. Not used cores of the control cable should be grounded.

4. The control cables have to be laid in the most possible distance from the load cable using
separated cable trenches etc. Cable crosses should possibly get an angle of 90°.

5. Make sure that contactors and relays in the control cabinets are suppressed either by RC
connection or varistors in case of AC contactors or by „ freewheeling diodes “at DC
contactors, wherein the interference suppression bust be attached to the coils. The
suppression is especially important if the contactors are controlled by the relay in the
frequency Inverter (optional).

6. Use screened cores for the load connections and ground the screening at both ends, if
possible directly at the PE output of the Inverter.

7. If the drive should run within an environment sensible to electro-magnetic interference, the
usage of interference filters is recommended to reduce the grid-bound and radiated
interferences of the Inverter. In this case install the filter as near as possible to the inverter and
take care and be well grounded.

8. Choose the lowest possible switching frequency. This minimizes the intensity of the electro­magnetic interference created by the frequency Inverter.

During the installation of the ERS at the frequency inverter the safety regulations must not be
violated!!! Instructions of the Inverter manufacturer have to be observed!!!!