Page 1
AC30 series
Variable Speed Drive
HA501718U002 Issue 7 Product Manual
aerospace
climate control
electromechanical
filtration
fluid & gas handling
hydraulics
pneumatics
process control
sealing & shielding
ENGINEERING YOUR SUCCESS.
Page 2
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS DESCRIBED HEREIN OR RELATED ITEMS
CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Parker Hannin Corporation, its subsidiaries and authorized distributors provide product or
system options for further investigation by users having technical expertise.
The user, through its own analysis and testing, is solely responsible for making the nal selection of the system and components
and assuring that all performance, endurance, maintenance, safety and warning requirements of the application are met. The user
must analyze all aspects of the application, follow applicable industry standards, and follow the information concerning the product in
the current product catalogue and in any other materials provided from Parker Hannin Corporation or its subsidiaries or authorized
distributors.
To the extent that Parker Hannin Corporation or its subsidiaries or authorized distributors provide component or system options based
upon data or specications provided by the user, the user is responsible for determining that such data and specications are suitable
and sufcient for all applications and reasonably foreseeable uses of the components or systems.
The above disclaimer is being specically brought to the user’s attention and is in addition to and not in substitution to the Exclusions
and Limitations on Liability which are set out in the terms and conditions of sale.
Page 3
AC30 series User’s Manual
Frames D, E, F, G, H, J, K including AC30P & AC30D
HA501718U002 Issue 7
Compatible with Firmware Version 1.12 onwards (AC30P & AC30D Version 2.12 onwards)
2016 © Parker Hannin Manufacturing Limited.
All rights strictly reserved. No part of this document may be stored in a retrieval system, or transmitted in any form
or by any means to persons not employed by a Parker Hannin Manufacturing Limited company without written
permission from Parker Hannin Manufacturing Ltd. Although evry efford has been taken to ensure the accuracy
of this document it may be necessary, without notice, to make amendments or corect omissions Parker Hannin
Manufacturing Limited cannot accept responsibility for damage, injury, or expenses resulting thereform.
WARRANTY
The general terms and conditions of sale of goods and/or services of Parker Hannin Europe Sàrl, Luxembourg,
Switzerland Branch, Etoy, apply to this contract unless otherwise agreed. The terms and conditions are available
on our website: www.parker.com/termsandconditons/switzerland
Parker Hannin Manufacturing Limited reserved the right to change the content and product specication without
notice.
Page 4
Contents 1
Contents ...................................................................Page No. Contents ....................................................................... Page No.
Chapter 1: Safety ............................................................. 1-1
Chapter 2: Introduction ................................................... 2-1
About this Manual ............................................................................ 2-1
Power Ratings ................................................................................... 2-3
Packaging and Lifting Details ......................................................... 2-4
Chapter 3: Product Overview .......................................... 3-1
Product Range .................................................................................. 3-1
Control Features ............................................................................... 3-2
Functional Overview ........................................................................ 3-3
Chapter 4: Installation ..................................................... 4-1
Cubicle Mount ................................................................................... 4-1
Dimensions for Cubicle Mount Installation ............................................. 4-1
Dimensions for Cubicle Mount Installation – Frame K .......................... 4-2
Mounting the Inverter................................................................................ 4-3
Ventilation .................................................................................................. 4-3
Cubicle Mounting Details ......................................................................... 4-4
Through Panel Mount Frames D to J only ..................................... 4-5
Dimensions for Through Panel Installation ............................................ 4-5
Frames D, E ............................................................................................... 4-5
Frames F, G ............................................................................................... 4-6
Frame H ...................................................................................................... 4-7
Frame J ...................................................................................................... 4-8
Mounting the INVERTER ........................................................................... 4-9
Ventilation .................................................................................................. 4-9
Through Panel Mounting Detail (frames D – J only) ............................ 4-10
Cover Removal Instructions – All Frames ............................................ 4-10
Cabling Bracket for Control & Main Cable ................................... 4-13
Cabling Bracket for AC30D System Terminals............................ 4-14
Electrical Installation ...................................................................... 4-15
Wiring Instructions.................................................................................. 4-15
AC fed power Wiring Connections ........................................................ 4-16
DC FED Power Wiring Connections (Frames D – J only) .................... 4-17
Control Module Cover Removal .................................................... 4-18
Control Module Removal ............................................................... 4-19
Control Module Terminal Cable Specification ...................................... 4-20
AC30V Control Wiring Connections ...................................................... 4-21
AC30D-P Control Wiring Connections .................................................. 4-22
System Board Control Wiring Connections – AC30D ONLY ............... 4-23
.................................................................................................................. 4-23
Wiring Diagrams ............................................................................. 4-24
The Default Application ........................................................................... 4-24
Application Description ........................................................................... 4-24
Application 0: Basic Speed Control ...................................................... 4-26
Application 1: Auto/Manual Control ...................................................... 4-28
Application 2: Raise / Lower Trim ...................................................... 4-30
Application 3: Presets Speeds .............................................................. 4-32
Application 4: PID Control ..................................................................... 4-34
Application 5: Active Front-End ............................................................ 4-36
Terminal Block Wire Range .................................................................... 4-38
Terminal Tightening Torques ................................................................. 4-39
Optional Equipment ................................................................................. 4-39
Brake Wiring ............................................................................................. 4-39
Fitting a Remote GKP ..................................................................... 4-40
Getting Started ................................................................................ 4-41
GKP Setup Wizard ................................................................................... 4-41
Ethernet Communications ...................................................................... 4-42
Firmware Update............................................................................. 4-45
Updating the inverter firmware ............................................................... 4-45
Chapter 5: Associated Equipment .................................. 5-1
Main Points ................................................................................................. 5-1
AC Motor Chokes.............................................................................. 5-4
Dynamic Braking Resistors ............................................................. 5-5
Wiring Details ............................................................................................. 5-5
Dynamic Braking Resistors ............................................................. 5-6
Resistor Selection ...................................................................................... 5-6
Circuit Breakers ................................................................................ 5-8
External EMC Filters ......................................................................... 5-8
Input Chokes ..................................................................................... 5-9
Gaskets .............................................................................................. 5-9
Cabling Bracket for Control, System Option & Power Stack ....... 5-9
Option Cards ................................................................................... 5-10
SD Cards ................................................................................................... 5-10
Installation Details ................................................................................... 5-11
Chapter 6 Safe Torque Off SIL3/PLe ............................... 6-1
General Information ......................................................................... 6-1
STO Functional Description ...................................................................... 6-2
Alignment to European Standards ................................................. 6-3
EN ISO13849-1:2008 .................................................................................. 6-3
EN61800-5-2:2007 and EN61508 ............................................................... 6-4
Safety Specification ......................................................................... 6-5
Page 5
Contents 2
Contents ...................................................................Page No. Contents ....................................................................... Page No.
EMC Specification ............................................................................ 6-6
User Connections ............................................................................. 6-7
STO Technical Specification ........................................................... 6-9
Inputs Specification .................................................................................. 6-9
Output Specification ............................................................................... 6-10
Truth Table ............................................................................................... 6-11
STO Input Timing Diagrams .......................................................... 6-12
Ideal Operation ........................................................................................ 6-12
Typical Operation .................................................................................... 6-13
Fault Operation ........................................................................................ 6-14
Pulsed Inputs ........................................................................................... 6-15
STO State Transition Diagram....................................................... 6-16
STO Trip Annunciation .................................................................. 6-17
Safety Warnings and Limitations .................................................. 6-18
Example User Wiring .............................................................................. 6-20
Applications that do not require STO function ..................................... 6-20
Minimum STO Implementation ............................................................... 6-21
STO Implementation with Safety Control Unit ...................................... 6-22
SS1 Implementation using Safety Control Unit .................................... 6-24
STO Function Checking ................................................................. 6-26
Comprehensive Check ................................................................... 6-27
The following test steps must be performed: ....................................... 6-28
Regular Check ......................................................................................... 6-32
Troubleshooting ............................................................................. 6-33
Chapter 7: The Graphical Keypad .................................. 7-1
Overview ............................................................................................ 7-2
Keypad ............................................................................................... 7-3
The Display........................................................................................ 7-4
INVERTER Status Summary ..................................................................... 7-4
Soft key action indication ......................................................................... 7-5
LEDS .................................................................................................. 7-5
The Menu System ............................................................................. 7-6
Navigating the Menu System ................................................................... 7-6
Changing a Parameter Value .................................................................... 7-6
Trips and other information displays ............................................. 7-7
Setting the display language ........................................................... 7-7
Setting the display language to Custom ................................................. 7-7
Chapter 8: Menu Organisation ........................................ 8-1
Menu Map .......................................................................................... 8-1
Menu Map Summary ................................................................................. 8-1
Menu Descriptions ........................................................................... 8-2
Control Screen ........................................................................................... 8-2
Setup ........................................................................................................... 8-2
Monitor ........................................................................................................ 8-2
Favourites ................................................................................................... 8-2
Parameters ................................................................................................. 8-2
Parameter Map .................................................................................. 8-3
Chapter 9: Setup Wizard .................................................. 9-1
GKP Setup Wizard ............................................................................ 9-1
Set Up PMAC Motor Control ............................................................ 9-9
Parker Drive Quicktool (PDQ) PC Software ................................. 9-10
Installation ................................................................................................ 9-10
Starting the Wizard .................................................................................. 9-12
Task selection .......................................................................................... 9-13
Find drive .................................................................................................. 9-14
Select Macro ............................................................................................. 9-16
Setup I/O ................................................................................................... 9-17
Select motor ............................................................................................. 9-18
Setup the Drive Control ........................................................................... 9-21
Setup Communications ........................................................................... 9-22
Commission the Drive ............................................................................. 9-23
Monitor the Drive ..................................................................................... 9-24
Chapter 10: Trips & Fault Finding ................................. 10-1
Trips and Fault Finding .................................................................. 10-1
What Happens when a Trip Occurs ........................................................ 10-1
Resetting a Trip Condition ...................................................................... 10-1
Using the Keypad to Manage Trips ........................................................ 10-2
Hexadecimal Representation of Trips .................................................... 10-7
Runtime Alerts ................................................................................ 10-8
Autotune Alerts ............................................................................. 10-10
Other Alerts ................................................................................... 10-12
Fault Finding ................................................................................. 10-14
Diagnostic LEDs ........................................................................... 10-15
Chapter 11: Routine Maintenance & Repair ................. 11-1
Routine Maintenance ..................................................................... 11-1
Preventative Maintenance ............................................................. 11-1
Fan Cassette (Frames D – J only) .......................................................... 11-1
DC Link Capacitors .................................................................................. 11-2
Repair ............................................................................................... 11-2
Saving Your Application Data ................................................................. 11-2
Returning the Unit to Parker ................................................................... 11-2
Page 6
Contents 3
Contents ...................................................................Page No. Contents ....................................................................... Page No.
Chapter 12: Ethernet...................................................... 12-1
Connecting to the Inverter ............................................................. 12-1
Recommended Cable .............................................................................. 12-1
AC30V....................................................................................................... 12-1
AC30P or AC30D ..................................................................................... 12-2
Ethernet Setup ................................................................................ 12-3
Configuration ........................................................................................... 12-3
Advanced Configuration ................................................................ ......... 12-3
Typical Wiring Configurations ............................................................... 12-6
Ethernet Parameter Summary ................................................................ 12-8
Troubleshooting the Ethernet .............................................................. 12-11
Web (HTTP) Server ....................................................................... 12-14
Web Pages ............................................................................................. 12-14
Web Server Parameter Summary ......................................................... 12-16
Troubleshooting the Web Server ......................................................... 12-17
Precision Time Protocol (PTP) .................................................... 12-18
Configuration ......................................................................................... 12-18
Advanced Configuration ................................................................ ....... 12-18
PTP Parameter Summary ..................................................................... 12-21
Peer to Peer ................................................................................... 12-24
Configuration ......................................................................................... 12-24
Peer to Peer Parameter Summary ....................................................... 12-25
Chapter 13: Fire Mode ................................................... 13-1
Configuration .................................................................................. 13-2
Functional Description ........................................................................... 13-3
Trips and Auto Restart ............................................................................ 13-4
Appendix A: Modbus TCP ................................ ............... A-1
Introduction ...................................................................................... A-1
Modbus Register Mapping Summary ...................................................... A-1
Fixed Parameter Mapping ............................................................... A-2
Fixed Parameter Mapping - Arrays .......................................................... A-2
Fixed Parameter Mapping - Strings ......................................................... A-3
User-Defined Parameter Mapping .................................................. A-5
Password Protection ....................................................................... A-6
Supported Modbus Functions ........................................................ A-7
Read Holding Registers (#3) .................................................................... A-7
Read Input Registers (#4) ......................................................................... A-7
Write Single Register (#6) ......................................................................... A-7
Write Multiple Registers (#16) .................................................................. A-7
Modbus Exception Codes ............................................................... A-8
Illegal Function (01)................................................................................... A-8
Illegal Data Address (02) .......................................................................... A-8
Illegal Data Value (03) ............................................................................... A-8
Process Active and Lost Communications Trip ........................... A-8
Process Active Flag .................................................................................. A-8
Trip ............................................................................................................. A-8
Connection Timeout ................................................................................. A-8
Parameter Summary ........................................................................ A-9
Appendix B: Sequencing Logic ..................................... B-1
Drive State Machine ........................................................................ B-1
DS402 ......................................................................................................... B-1
Sequencing State ...................................................................................... B-1
Sequencing Diagram ................................................................................ B-2
State Transitions ....................................................................................... B-3
Control Word ............................................................................................. B-5
Status Word ............................................................................................... B-6
Appendix C: Compliance ............................................. C-1
Applicable Standards ............................................................................... C-1
EUROPEAN COMPLIANCE ............................................................. C-2
CE Marking ................................................................................................ C-2
EMC Compliance....................................................................................... C-3
EMC Standards Comparison .......................................................... C-4
Radiated ..................................................................................................... C-4
Conducted Emission ................................................................................ C-5
EMC Compliance (4kHz) ........................................................................... C-6
EMC Installation Guidance ........................................................... C-11
Protective Earth (PE) Connections ........................................................ C-11
Mitigating Radiated Emissions .............................................................. C-12
Cabling Requirements ............................................................................ C-14
Harmonic Information – AC Supplied Inverters ......................... C-30
Requirements for North American and Canadian Compliance C-37
North American Compliance .................................................................. C-37
Canadian Compliance ............................................................................ C-38
North American and Canadian Compliance Information ..................... C-38
Environmental ................................................................................ C-44
Restriction, Evaluation, Authorisation and Restriction of Chemicals (REACH)
.................................................................................................................. C-44
Restriction of Hazardous Substances (RoHS) ..................................... C-44
Waste Electrical and Electronic Equipment (WEEE) ........................... C-45
Declarations ............................................................................................ C-46
Appendix D: Parameter Reference ................................ D-1
Parameter Descriptions .................................................................. D-1
Page 7
Contents 4
Contents ...................................................................Page No. Contents ....................................................................... Page No.
Active Front End (AFE) ............................................................................. D-2
App Info .................................................................................................... D-11
Auto Restart ............................................................................................. D-13
Autotune .................................................................................................. D-18
BACnet IP Option .................................................................................... D-22
BACnet MSTP Option.............................................................................. D-23
Braking ..................................................................................................... D-24
CANopen Option ..................................................................................... D-26
Clone ........................................................................................................ D-27
Communications Options ....................................................................... D-32
Configure, (Phase Control) ..................................................................... D-33
Control Mode ........................................................................................... D-36
ControlNet Option ................................................................................... D-38
Current Limit ............................................................................................ D-39
Current Loop .......................................................................................... D-41
Current Sensor Trip ................................................................................ D-42
DC Link Volts Limit ................................................................................. D-43
Device Commands .................................................................................. D-45
Device State ............................................................................................. D-46
DeviceNet Option .................................................................................... D-48
Drive info ................................................................ .................................. D-49
Encoder .................................................................................................... D-53
Encoder Slot 1 ......................................................................................... D-55
Encoder Slot 2 ......................................................................................... D-57
Energy Meter ........................................................................................... D-59
EtherCAT Option ..................................................................................... D-61
Ethernet .................................................................................................... D-62
EtherNet IP Option .................................................................................. D-63
Feedbacks ................................................................................................ D-64
Filter On Torque Dmd ............................................................................. D-68
Flash File System .................................................................................... D-71
Fluxing VHz .............................................................................................. D-72
Flycatching .............................................................................................. D-78
General Purpose IO ................................................................................. D-81
Graphical Keypad .................................................................................... D-84
Induction Motor Data .............................................................................. D-86
Inj Braking ................................................................................................ D-87
IO Configure ............................................................................................ D-89
IO Option Common ................................................................................. D-93
IO Values .................................................................................................. D-94
Local Control ........................................................................................... D-97
Minimum Speed ....................................................................................... D-98
Modbus .................................................................................................... D-99
Modbus RTU Option.............................................................................. D-100
Modbus TCP Option .............................................................................. D-101
Motor Load ............................................................................................ D-102
Motor Nameplate ................................................................................... D-105
Motor Sequencer................................................................................... D-107
MRAS ..................................................................................................... D-108
Pattern Generator ................................................................................. D-110
Peer to Peer ........................................................................................... D-112
PID .......................................................................................................... D-113
PMAC Flycatching ................................................................................ D-115
PMAC Motor Data .................................................................................. D-117
PMAC SVC ............................................................................................. D-120
Power Loss Ride Thru .......................................................................... D-128
Precision Time Protocol (PTP)............................................................. D-131
Preset Speeds ....................................................................................... D-132
Profibus DP-V1 Option ......................................................................... D-134
PROFINET IO Option ............................................................................ D-135
Raise Lower ........................................................................................... D-136
Ramp ...................................................................................................... D-138
Real Time Clock .................................................................................... D-144
Runtime Statistics ................................................................................. D-145
Scale Setpoint ....................................................................................... D-147
SD Card .................................................................................................. D-148
Sequencing ........................................................................................... D-149
Setup Wizard ......................................................................................... D-153
Skip Frequencies .................................................................................. D-154
Slew Rate ............................................................................................... D-157
Slip Compensation ............................................................................... D-159
Soft Menus ............................................................................................ D-160
Spd Direct Input .................................................................................... D-162
Spd Loop Diagnostics .......................................................................... D-163
Spd Loop Settings ................................................................................ D-164
Speed Error Trip.................................................................................... D-168
Speed Ref .............................................................................................. D-169
Stabilisation .......................................................................................... D-170
Stack Inv Time ....................................................................................... D-171
Stall Trip ................................................................................................ D-174
System Board IO ................................................................................... D-175
System Board Option ........................................................................... D-177
Torque Limit .......................................................................................... D-178
Thermistor ............................................................................................. D-181
Tr Adaptation ........................................................................................ D-182
Trips History .......................................................................................... D-184
Trips Status ........................................................................................... D-186
VDC Ripple ............................................................................................ D-193
Voltage Control ..................................................................................... D-195
Web Server ............................................................................................ D-196
Page 8
Contents 5
Contents ...................................................................Page No. Contents ....................................................................... Page No.
Parameter Table ........................................................................... D-197
Table of Parameters in Alphabetical Order ............................... D-226
Power Dependent Parameter Defaults ...................................... D-232
Appendix E: E Plan Library ............................................. E-1
E Plan Library....................................................................................E-1
Appendix F: Technical Specifications ........................... F-1
Understanding the Product Code ................................................... F-1
Model Number ........................................................................................... F-1
Environmental Details............................................................................... F-2
Earthing/Safety Details ............................................................................. F-3
Cooling Fans ............................................................................................. F-3
AC FED Electrical Ratings (400V Build Variant) ..................................... F-4
DC FED Electrical Ratings (400V Build Variant) ................................... F-10
LINE Input Fuse Ratings (Europe) ......................................................... F-15
DC Input Fuse Ratings (Europe) ............................................................ F-16
LINE Input Fuse Ratings (North America and Canada)........................ F-17
Internal Dynamic Brake Switch .............................................................. F-18
Supply Short Circuit Rating ................................................................... F-19
Analog Inputs/Outputs ............................................................................ F-20
Reference Outputs .................................................................................. F-20
Digital Inputs ........................................................................................... F-21
Digital Outputs ........................................................................................ F-21
User 24v Supply OUTPUT (X12/05) ........................................................ F-22
Auxiliary 24V Input– AC30V and Ac30P only ........................................ F-22
RelayS - AC30V ONLY............................................................................. F-22
SYSTEM Auxiliary 24V Input – AC30D ONLY ........................................ F-23
DIGITAL INPUTs – AC30D ONLY ........................................................... F-23
Encoder Power Supply Output – AC30D ONLY .................................... F-24
Encoder Inputs – AC30D ONLY ............................................................. F-25
Encoder Transmit Outputs – AC30D ONLY .......................................... F-26
Page 9
Safety 1-1
AC30 series Variable Speed Inverter
Chapter 1: Safety
Safety Information
Please read these important Safety notes before installing and operating this equipment
CAUTION
CAUTION notes in the manual warn of danger to equipment.
WARNING
NOTES IN THE MANUAL WARN OF DANGER TO PERSONEL
Requirements
Intended Users
This manual is to be made available to all persons who are required to install, configure or service equipment described herein, or any other
associated operation.
The information given is intended to highlight safety issues, and to enable the user to obtain maximum benefit from the equipment.
Complete the following table for future reference detailing how the unit is to be installed and used.
INSTALLATION DETAILS
Model Number
(see product label)
Where installed
(for your own
information)
Unit used as a:
(refer to
Certification)
Component Relevant Apparatus
Unit fitted:
Cubicle mounted
Through Panel Mounted
Application Area
The equipment described is intended for industrial motor speed control utilising AC induction motors or AC permanent magnet synchronous
machines.
Page 10
1-2 Safety
AC30 series Variable Speed Inverter
Personnel
Installation, operation and maintenance of the equipment should be carried out by competent personnel. A competent person is someone who is
technically qualified and familiar with all safety information and established safety practices; with the installation process, operation and maint enance
of this equipment; and with all the hazards involved.
DANGER
Risk of electric
shock
WARNING
Hot surfaces
Caution
Refer to documentation
Earth/Ground
Protective Conductor
Terminal
Hazards
DANGER! - Ignoring the following may result in injury
1. This equipment can endanger life by exposure to rotating
machinery and high voltages.
2. The equipment must be permanently earthed due to the high
earth leakage current, and the inverter motor must be connected
to an appropriate safety earth.
3. Ensure all incoming supplies are isolated before working on the
equipment. Be aware that there may be more than one supply
connection to the inverter.
4. There may still be dangerous voltages present at power terminals
(motor output, supply input phases, DC bus and the brake, where
fitted) when the motor is at standstill or is stopped.
5. For measurements use only a meter to IEC 61010 (CAT III or
higher). Always begin using the highest range.
CAT I and CAT II meters must not be used on this product.
6. Allow at least 5 minutes for the inverter's capacitors to discharge to
safe voltage levels (<50V). Use the specified meter capable of
measuring up to 1000V dc & ac rms to confirm that less than 50V
is present between all power terminals and between power
terminals and earth.
7. Unless otherwise stated, this product must NOT be dismantled. In
the event of a fault the inverter must be returned. Refer to "Routine
Maintenance and Repair".
Page 11
Safety 1-3
AC30 series Variable Speed Inverter
WARNING! - Ignoring the following may result in injury or damage to equipment
SAFETY
Where there is conflict between EMC and Safety requirements, personnel safety shall always take precedence.
Never perform high voltage resistance checks on the
wiring without first disconnecting the inverter from the
circuit being tested.
Whilst ensuring ventilation is sufficient, provide guarding
and /or additional safety systems to prevent injury or
damage to equipment.
When replacing an inverter in an application and before
returning to use, it is essential that all user defined
parameters for the product’s operation are correctly
installed.
All control and signal terminals are SELV, i.e. protected by double
insulation. Ensure all external wiring is rated for the highest system
voltage.
Thermal sensors contained within the motor must have at least
basic insulation.
All exposed metalwork in the Inverter is protected by basic
insulation and bonded to a safety earth.
RCDs are not recommended for use with this product but, where
their use is mandatory, only Type B RCDs should be used.
EMC
In a domestic environment this product may cause radio
interference in which case supplementary mitigation
measures may be required.
This equipment contains electrostatic discharge (ESD)
sensitive parts. Observe static control precautions when
handling, installing and servicing this product.
This is a product of the restricted sales distribution class according
to IEC 61800-3. It is designated as “professional equipment” as
defined in EN61000-3-2. Permission of the supply authority shall be
obtained before connection to the low voltage supply.
WARNING! – Control Unit Removal / Fitting
Isolate supply before plugging or unplugging control unit to the power stack.
Page 12
1-4 Safety
AC30 series Variable Speed Inverter
CAUTION!
APPLICATION RISK
The specifications, processes and circuitry described herein are for guidance only and may need to be adapted to the user’s
specific application. We can not guarantee the suitability of the equipment described in this Manual for individual applications.
RISK ASSESSMENT
Under fault conditions, power loss or unintended operating conditions, the inverter may not operate as intended. In particular:
Stored energy might not discharge to safe
levels as quickly as suggested, and can still
be present even though the inverter
appears to be switched off
The motor's direction of rotation might not be controlled
The motor speed might not be controlled
The motor might be energised
An inverter is a component within an inverter system that may influence its operation or effects under a fault condition. Consideration
must be given to:
Stored energy
Supply disconnects
Sequencing logic
Unintended operation
Page 13
Introduction 2-1
AC30 series Variable Speed Inverter
Chapter 2: Introduction
About this Manual
Motors used must be suitable for Inverter duty.
NOTE Do not attempt to control motors whose rated current is less than 25% of the inverter rated current. Poor motor control or Autotune
problems may occur if you do.
This manual is intended for use by the installer, user and programmer of the AC30 series of inverters. It assumes a reasonable level of
understanding in these three disciplines.
NOTE Please read all Safety information before proceeding with the installation and operation of this unit.
It is important that you pass this manual on to any new user of this unit.
How the Manual is Organised
This Engineering Reference manual is organised into chapters, indicated by the numbering on the edge of each page. If the manual is to be
printed it is designed so that it should be printed double-sided using the short-edge for binding.
Information for all AC30 units is included (AC30V frames D, E, F, G, H, J & K, AC30P & AC30D), which are collectively referred to as “the
Inverter” or “drive” throughout the manual.
Product coding: Any “x” within a product code indicates there are variants, see page F-1 Understanding the Product Code.
Any text placed in a highlighted area as this sample shows, only refers to the AC30P and AC30D.
Parker Hannifin Manufacturing Limited is referred to as “Parker” throughout the manual.
The manual is more detailed than the relevant QuickStart manual, and so is of use to the unfamiliar as well as the high-end user.
Initial Steps
Use the manual to help you plan the following:
Installation
Know your requirements:
certification requirements, CE/UL/CUL conformance
conformance with local installation requirements
supply and cabling requirements
AC30P
AC30D
Page 14
2-2 Introduction
AC30 series Variable Speed Inverter
Operation
Know your operator:
how is it to be operated, local and/or remote?
what level of user is going to operate the unit?
decide on the best menu level for the Keypad (where supplied)
Programming (Parker Drive Quicktool) – pc programming tool
Know your application:
Install the Parker Drive Quicktool (PDQ) after downloading it from www.parker.com/ssd/pdq
Connect your pc to your Inverter via Ethernet
Commission your Inverter with the Parker Drive Quicktool wizard
Go to Appendix D Parameter Reference for more information
PC Requirements
Minimum system requirements:
1GB RAM
1GHz Pentium
1GB free Hard Disk space
1024x768 screen resolution
Operating Systems:
Windows XP
Windows Vista (32 bit)
Windows 7 (32 & 64 bit)
Windows 8 (32 & 64 bit)
Equipment Inspection
Check for signs of transit damage
Check the product code on the rating label conforms to your requirement.
If the unit is not being installed immediately, store the unit in a well-ventilated place away from high temperatures, humidity, dust, or metal particles.
Storage and Shipping Temperatures
Storage Temperature :
-25C to +55C
Shipping Temperature :
-25C to +70C
Page 15
Introduction 2-3
AC30 series Variable Speed Inverter
Power Ratings
Order Code
Normal Duty Ratings
Heavy Duty Ratings
Frame
kW/HP
Output Current A
rms
kW/HP
Output Current A
rms
400 VAC
480 VAC
400 VAC
480 VAC
380-480 (± 10 %) VAC Supplies Three Phase
3-4D0004-B--0000
1.1/1.5
3.5
3.0
0.75/1
2.5
2.1
D
3-4D0005-B--0000
1.5/2
4.5
3.4
1.1/1.5
3.5
3.0
D
3-4D0006-B--0000
2.2/3
5.5
4.8
1.5/2
4.5
3.4
D
3-4D0008-B--0000
3/4
7.5
5.8
2.2/3
5.5
4.8
D
3-4D0010-B--0000
4/5
10
7.6
3/4
7.5
5.8
D
3-4D0012-B--0000
5.5/7.5
12
11
4/5
10
7.6
D
3-4E0016-B--0000
7.5/10
16
14
5.5/7.5
12
11
E
3-4E0023-B--0000
11/15
23
21
7.5/10
16
14
E
3-4F0032-B--0000
15/20
32
27
11/15
23
21
F
3-4F0038-B--0000
18/25
38
36
15/20
32
27
F
3-4G0045-B--0000
22/30
45
40
18/25
38
36
G
3-4G0060-B--0000
30/40
60
52
22/30
45
40
G
3-4G0073-B--0000
37/50
73
65
30/40
60
52
G
3-4H0087---0000
45/60
87
77
37/50
73
65
H
3-4H0105---0000
55/75
105
96
45/60
87
77
H
3-4H0145---0000
75/100
145
124
55/75
105
96
H
3-4J0180---0000
90/125
180
156
75/100
145
124
J
3-4J0205---0000
110/150
205
180
90/125
180
156
J
3-4J0260---0000
132/200
260
240
110/150
205
180
J
3-4K0315-B--0000
160/250
315
302
132/200
260
240
K
3-4K0380-B--0000
200/300
380
361
160/250
315
302
K
3-4K0440-B--0000
250/350
440
414
200/300
380
361
K
EMC Filter Options
No filter
N
C2 filter
F
C3 filter
E
Graphical Keypad Options
Graphical Keypad
2
Keypad Blanking Cover
1
No Keypad
0
Environmental Protection
Options
Standard Coating
Enhanced Coating
E
S
Inverter Options
Versatile
V
Advanced Inverter
P
Advanced Inverter with dual
control system option
D
Brake Option
No Brake
With Brake
B
N
Type
IP20 AC Fed
IP20 DC Fed
4
1
Page 16
2-4 Introduction
AC30 series Variable Speed Inverter
Packaging and Lifting Details
Caution
The packaging is combustible. Igniting it may lead to the generation of lethal toxic fumes.
Save the packaging in case of return. Improper packaging can result in transit damage.
Use a safe and suitable lifting procedure when moving the unit. Never lift the unit by its terminal connections.
Prepare a clear, flat surface to receive the inverter before attempting to move it. Do not damage any terminal connections
when putting the unit down.
Page 17
Product Overview 3-1
AC30 series Variable Speed Inverter
Chapter 3: Product Overview
Product Range
AC30V Frame D, E, F, G, H, J, K
AC30P & AC30D
Graphical Keypad
(GKP)
Integrated quick start
guide and multi-
language support
Figure 3-1
AC30V Illustrated
Frame E
GPIO (General Purpose I/O Options) & Encoder
A range of field fittable I/O Options.
Control Module
Cover
Removable Fan Cassette (Frames D – J only)
Can be removed for cleaning and replacement see Fan
Cassette in Chapter 11
Top Terminal Cover
Integrated Ethernet
Inverter programming, monitoring and
Modbus TCP/IP COMMS
SD Card
Inverter configuration storage and application cloning
Power Stack
Fieldbus Option
A range of field-fittable
communications and I/O options
Bottom Terminal Cover
Removable Mounting
Feet
(Frames D – J only)
Control
Module
Page 18
3-2 Product Overview
AC30 series Variable Speed Inverter
Control Features
The inverter is fully featured when controlled using the optional Keypad (or a suitable pc programming tool).
The ‘General’ control features below are not user-selectable when the unit is controlled using the analog and digital inputs and outputs.
General
Output Frequency
Limited to Switching Frequency divided by 8, with a maximum of 590Hz.
e.g. for 4kHz switching frequency it is 4000/8 = 500Hz,
for 16kHz switching frequency it is 590Hz. Refer to Parker SSD for higher output frequency.
Derating of output current may apply, refer to Appendix F Technical Specifications.
Switching Frequency
Minimum 2kHz.
Maximum 8kHz – 16kHz dependent on frame size and motor type (Induction or PMAC)
Voltage Boost for V/F
control
0-25%
Motor Control Modes
Induction motor: VHz control, Sensorless Vector Control, or Closed Loop Vector Control (with
encoder if fitted). Sensorless and Closed Loop Vector require autotune.
PMAC motor: Sensorless Vector Control
Skip Frequencies
Skip frequencies with adjustable skip band width
Preset Speeds
User selectable preset speeds
Stopping Modes
Ramp, Coast, DC Injection, Quickstop
S Ramp and Linear Ramp
Symmetric or asymmetric ramp up and down rates
Raise/Lower
Programmable MOP function
Jog
Programmable jog speed
Diagnostics
Full diagnostic and monitoring facilities
Protection
Trip Conditions
Output short line to line, and line to earth
Overcurrent > 220% HD current
Stall
Heatsink overtemperature
Motor Thermistor overtemperature (using optional GPIO)
Overvoltage and undervoltage
Current Limit
Adjustable 110% (Normal Duty) or 150% (Heavy Duty)
180% shock load limit (Heavy Duty)
Inverse Time
Dual Rating
Normal duty (110% overload for 60s)
Heavy duty (150% overload for 60s)
Inputs/
Outputs
Analog Inputs
2 configurable inputs; voltage or current
Analog Outputs
2 configurable outputs; voltage or current
Digital Inputs
3 configurable 24V dc inputs
Digital I/O
4 configurable 24V dc open collector outputs/digital inputs
Relay Outputs
2 configurable relay output
Table 3-1 Control Features
Page 19
Product Overview 3-3
AC30 series Variable Speed Inverter
Functional Overview
L1
L2
L3
PE
EMC
Filter
MOVs
Input
rectifier
LINK – customer accessible
Filter
Earth
+
DB
X6
Inverter
stage
M1/U
M2/V
M3/W
I
u
I
W
DC+ DB+
DC-
PE
DC+
DC-
SMPS
DC+
DC-
Main cooling
Fan(s) (24V)
PWM
ISOLATION
DB control
stack
temperature
POWER
CONTROL
Switched fan supply
DB
EEPROM
Precharge
Control
Control Module
LINK – customer accessible
serviceable
&
testable
These elements are omitted from the DC-fed drive variants
Block Diagram for Frames D, E, F
Page 20
3-4 Product Overview
AC30 series Variable Speed Inverter
L1
L2
L3
PE
EMC
Filter
MOVs
Input
rectifier
LINKS customer accessible
Filter
Earth
+
DB
X6
Inverter
stage
M1/U
M2/V
M3/W
I
u
I
W
DC+
DB+
DC-
PE
DC+
DC-
SMPS
DC+
DC-
Main cooling
Fan (s) (24V)
PWM
ISOLATION
DB control
stack
temperature
POWER
CONTROL
Switched fan supply
DB
EEPROM
Precharge
Control
Control Module
LINK – customer accessible
serviceable
&
testable
Unswitched fan supply
Internal cooling
fans (24V)
These elements are omitted from the DC-fed drive variants
Block Diagram for Frames G, H, J
Page 21
Product Overview 3-5
AC30 series Variable Speed Inverter
L1
L2
L3
EMC
Filter
MOVs
Input
rectifier
DBR
Inverter
stage
M1/U
M2/V
M3/W
I
u
I
W
DC+
DC-
PWM
fan TX
supply
pre-charge
control
I
V
3 x current sensor interface
+/- 15V o/l or +/- 24V c/l
EEPROM
CM Interface PCB
PE
PE
7 x gate drive
7 x Vce sense
4 way cable assy
L1 L2 L3 sense
precharge
relay control
fan supply in
switched supply out
heatsink thermistor
SELV
fan control
SMPS
accessible
disconnect
VDC supply
& VDC sense
ISOLATION
Power Control
Block Diagram for Frames K
Page 22
4-1 Installation
AC30 series Variable Speed Inverter
Chapter 4: Installation
Read Appendix C: “Compliance” before installing this unit.
Cubicle Mount
DIMENSIONS FOR CUBICLE MOUNT INSTALLATION
Figure 4-1 Mechanical Dimensions - Frame D Illustrated (All dimensions are in millimetres (inches)
Inverters
Max. Weight
H – AC30V/P
H – AC30D
H1
H2 W W1
W2
W3
D – AC30V/P
D – AC30D
Fixings
Frame D
4.5kg (10 lbs)
286.0 (11.26)
298.0 (11.73)
270.0 (10.6)
6.5 (0.25)
100.0 (3.93)
80.0 (3.15)
10.0 (0.39)
255.0 (10.0)
273.0 (10.75)
4.5mm slots &
holes, M4 fixings
Frame E
6.8kg (15 lbs)
333.0 (13.11)
333.0 (13.11)
320.0 (12.6)
6.5 (0.25)
125.0 (4.92)
100.0 (3.93)
12.5 (0.49)
255.0 (10.0)
273.0 (10.75)
Frame F
10.0kg (22 lbs)
383.0 (15.07)
383.0 (15.07)
370.0 (14.5)
6.5 (0.25)
150.0 (5.90)
125.0 (4.92)
12.5 (0.49)
255.0 (10.0)
273.0 (10.75)
Frame G
22.3kg (49.2 lbs)
480.0 (18.90)
480.0 (18.90)
465.0 (18.31)
7.25 (0.29)
220.0 (8.66)
190.0 (7.48)
13.0 (0.51)
287.0 (11.30)
305.0 (12.01)
5.5mm slots &
holes, M5 fixings
Frame H
42.8kg (94.6 lbs)
670.0 (26.38)
670.0 (26.38)
650.0 (25.59)
10.0 (0.39)
260.0(10.24)
220.0 (8.66)
20.0 (0.79)
316.0 (12.44)
334.0 (13.15)
6.8mm slots &
holes, M6 fixings
Frame J
89.0kg(196.2 lbs)
800.0 (31.50)
800.0 (31.50)
780.0 (30.71)
10.0 (0.39)
330.0(12.99)
285.0(11.22)
23.0(0.91)
142.5(5.61)
374.0(14.72)
392.0(15.43)
9.0mm slots &
holes, M8 fixings
Frame K
125kg (275.57 lbs)
See over page for dimensions and fixings
Page 23
Installation 4-2
AC30 series Variable Speed Inverter
DIMENSIONS FOR CUBICLE MOUNT INSTALLATION – FRAME K
Fixings for main cover
(15.16)
(17.99)
(50.47)
(51.57)
(2.36)
(7.87)
(15.75)
Figure 4-2 Mechanical Dimensions for Frame K
All dimensions are in millimetres (inches)
475 (18.70) for AC30D
Page 24
4-3 Installation
AC30 series Variable Speed Inverter
MOUNTING THE INVERTER
These units are not suitable for wall mounting. They must be mounted vertically inside an additional enclosure. Depending on required level of
EMC compliance refer to Appendix C "Compliance".
Note: Frame H, J & K only
These models are heavy and will require two people to lift, or the use of a fork lift to install it. The product will stand vertically on flat surfaces.
VENTILATION
The inverter gives off heat in normal operation and must therefore be mounted to allow the free flow of air through the ventilation slots and
heatsink. Maintain minimum clearances for ventilation as given in the tables below to ensure adequate cooling of the inverter, and that heat
generated by other adjacent equipment is not transmitted to the inverter. Be aware that other equipment may have its own clearance
requirements. When mounting two or more inverters together, these clearances are additive. Ensure that the mounting surface is normally cool.
Minimum Air Clearance
Cubicle-Mount Product/Application
(Europe: IP2x, USA/Canada: Open Type).
The inverter must be mounted in a suitable cubicle.
Figure 4-3 Air Clearance for a Cubicle Mount Product/Application, Frame D Illustrated.
Clearances for IP20 Product (mm)
A B C
Frames D – H
10
75
75 minimum
(excludes cabling
requirements)
Frame J
10
100
100 minimum
(excludes cabling
requirements)
Frame K
10
200
200
Heatsink
Isolated
forced
air flow
Natural air flow on Frames D – F
Fan assisted air flow on Frames G - J
Frame K: 75mm clearance from adjacent vertical surfaces
Page 25
Installation 4-4
AC30 series Variable Speed Inverter
CUBICLE MOUNTING DETAILS
Mounting Brackets
Rear view showing fixing holes for
cubicle mount
Frames D, E, F & G
The brackets can be moved
up/down by using the alternative
holes, which are set at 15mm
intervals.
Frames H, J & K
Have a single mounting plate which
cannot be moved.
For hole and fixing dimensions see
previous pages.
For top and bottom cover removal
see page 4-10.
Fixing holes
Page 26
4-5 Installation
AC30 series Variable Speed Inverter
Through Panel Mount Frames D to J only
DIMENSIONS FOR THROUGH PANEL INSTALLATION
FRAMES D, E
Through panel mounting an inverter in a cubicle allows you to use a smaller cubicle because much of the heat generated by the inverter is
dissipated outside the cubicle.
Figure 4-4 Mechanical Dimensions for Through Panel - Frames D & E Inverters
Inverters H H1
H2
H3 * W W1
W2
W3
D D1
AC30V/ AC30P
Fixings
Mounting Kits
Frame D
250 (9.8)
262 (10.3)
6 (0.2)
64 (2.51)
79 (3.1)
1.5 (0.06)
82 (3.2)
100 (3.93)
72 (2.8)
181 (7.1)
AC30D - 199 (7.83)
Use M4
fixings
LA502668
Frame E
297 (11.7)
309 (12.1)
6 (0.2)
80 (3.14)
104 (4.1)
1 (0.04)
102 (4)
125 (4.9)
72 (2.8)
181 (7.1)
AC30D - 199 (7.83)
LA502669
(* H3 only for wiring brackets) All dimensions are in millimetres (inches)
Page 27
Installation 4-6
AC30 series Variable Speed Inverter
FRAMES F, G
Through panel mounting an inverter in a cubicle allows you to use a smaller cubicle because much of the heat generated by the inverter is
dissipated outside the cubicle.
Figure 4-5 Mechanical Dimensions for Through Panel Frames F & G
Inverters
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
AC30VAC30P
W11
H1
H2
H3
H4
H5*
Fixings
Mounting
Kits
Frame F
200
(7.87)
150
(5.90)
25
(0.98)
129
(5.07)
12
(0.47)
0.1
(0.003)
20.5
(0.80)
170
(6.7)
72
(2.83)
181 (7.12)
AC30D
199 (7.83)
127
(5.0)
381
(15.0)
359
(14.13)
347
(13.66)
147.5
(5.80)
90
(3.54)
6 x 4.5mm
holes M4 fixings
LA502670
Frame G
270
(10.63)
220
(8.66)
25
(0.98)
195.8
(7.70)
12.1
(0.47)
0.4
(0.015)
22
(0.86)
240
(9.44)
95
(3.74)
192 (7.55)
AC30D
210 (8.27)
195
(7.67)
480
(18.89)
455.8
(17.94)
440
(17.32)
225.8
(8.88)
130
(5.11)
6 x 5.5mm
holes M5 fixings
LA502471
All dimensions are in millimetres (inches) (* H5 only for wiring brackets)
Page 28
4-7 Installation
AC30 series Variable Speed Inverter
FRAME H
Through panel mounting an inverter in a cubicle allows you to use a smaller cubicle because much of the heat generated by the inverter is
dissipated outside the cubicle.
Figure 4-6 Mechanical Dimensions for Through Panel Frame H
All dimensions are in millimetres (inches) - Fixings: 8 x 6.5mm holes M6 fixings, refer to panel mounting kit part number LA502472
229 (9.02) for AC30D
Page 29
Installation 4-8
AC30 series Variable Speed Inverter
FRAME J
Through panel mounting an inverter in a cubicle allows you to use a smaller cubicle because much of the heat generated by the inverter is
dissipated outside the cubicle.
Figure 4-7 Mechanical Dimensions for Through Panel Frame J - All dimensions are in millimetres (inches)
Fixings: 8 x 9.0mm holes M8 fixings, refer to panel mounting kit part number LA502793
(14.96)
(12.99)
(0.98)
(9.29)
(9.64)
(14.96)
(0.49)
(1.67)
(14.17)
(11.81)
(10.82)
(0.39)
(8.60)
263.1 (10.36) for AC30D
Page 30
4-9 Installation
AC30 series Variable Speed Inverter
MOUNTING THE INVERTER
These units are not suitable for wall mounting. They must be mounted vertically inside an additional enclosure. Depending on required level of
EMC compliance refer to Appendix C "Compliance".
Note: Frame H & J only
These models are heavy and will require two people to lift, or the use of a fork lift to install it. The product will stand vertically on flat surfaces, but
will need secondary restraining to keep upright when through panel mounting (after the panel mounting foot has been removed).
VENTILATION
The inverter gives off heat in normal operation and must therefore be mounted to allow the free flow of air through the ventilation slots and
heatsink. Maintain minimum clearances for ventilation as given in the tables below to ensure adequate cooling of the inverter, and that heat
generated by other adjacent equipment is not transmitted to the inverter. Be aware that other equipment may have its own clearance
requirements. When mounting two or more units together, these clearances are additive. Ensure that the mounting surface is normally cool.
Through-Panel Mount Product/Application (Frames D, E, F, G, H & J)
(Europe: IP2x, USA/Canada: Open Type).
The inverter can be mounted in a suitable cubicle.
Clearances for Through-Panel Mount IP20 Product
(mm)
A B C
Frames D – H
10
75
75 minimum
(excludes cabling requirements)
Frame J
10
100
100 minimum
(excludes cabling requirements)
Figure 4-8 Air Clearance for a Through-Panel
Mount Product/Application, Frame D Illustrated.
Panel
Natural air flow on Frames D - F
Fan assisted air flow on Frames G - J
Isolated forced
air flow
Heatsink
Page 31
Installation 4-10
AC30 series Variable Speed Inverter
THROUGH PANEL MOUNTING DETAIL (FRAMES D – J ONLY)
To allow mounting; first disassemble the inverter by following instructions 1 to 4 and then instructions 5 to 7 for mounting:-
1. Unscrew and remove mounting bracket(s).
2. Remove Control Module Cover (see page 4-18).
3. Remove Control Module (see page 4-19).
COVER REMOVAL INSTRUCTIONS – ALL FRAMES
4. Top & Bottom Cover Removal Instructions
Frame D
Top Cover: Squeeze together the bracket under the top cover and lift off cover.
Bottom Cover: After inserting a screwdriver into the slot slightly push to the left
to release the catch.
Page 32
4-11 Installation
AC30 series Variable Speed Inverter
Frames E, F, G, H & J
Top Cover:
To remove insert a screwdriver into the slot and
move to the right to release the catch, and then
slide off cover.
Bottom Cover:
To remove bottom cover insert a screwdriver into the
slot and move to the left to release the catch, and
then slide off cover.
Frame K
Top Cover:
To remove unscrew 4 x screws and then remove
cover.
Bottom Cover:
To remove unscrew 2 x screws and then slide off
cover.
Page 33
Installation 4-12
AC30 series Variable Speed Inverter
5. Fit gasket to the inverter so that an air-tight seal
will be made between the inverter and the
panel.
Through Panel Kits, can be purchased from
Parker using the following part numbers:
Frame D – LA502668
Frame E – LA502669
Frame F – LA502670
Frame G – LA502471
Frame H – LA502472
Frame J – LA502793
Frame K – not applicable
6. Tighten all screws in place as shown, according
to panel insert requirements.
7.
At this stage you can wire the power cables, see
page 4-16.
Upper Terminal
Cover
Cover Front
Upper
GKP
Control Unit Terminal Cover
(Cover Front Lower)
Lower Terminal
Cover
Snap out to allow entry to the
braking terminals
Gasket
Page 34
4-13 Installation
AC30 series Variable Speed Inverter
Cabling Bracket for Control & Main Cable
With the bottom cover off you can screw the cabling brackets in place, if required.
The cabling brackets are standard with C2 filtering products and can also be obtained from Parker using the following part numbers.
Frame E Illustrated
The part numbers for the cabling bracket kits are:
Wall/Panel Mount Through Panel
Mount
Frame D – LA501935U001 LA503117U001
Frame E – LA501935U002 LA503117U002
Frame F – LA501935U003 LA503117U003
Frame G – LA501935U004 LA503117U004
Frame H – LA501935U005 LA503117U005
Frame J - LA501935U006 not applicable
Control cable wiring
Main cable wiring bracket
Page 35
Installation 4-14
AC30 series Variable Speed Inverter
Cabling Bracket for AC30D System Terminals
Frame E Illustrated
The part number for the AC30D control and system
terminal cable brackets kit is: LA501935U007
Control cable wiring
Page 36
4-15 Installation
AC30 series Variable Speed Inverter
Electrical Installation
Please read the Safety Information in “Chapter :1 Safety” before proceeding.
Also refer to Appendix C: Compliance
WIRING INSTRUCTIONS
IMPORTANT: The control board 0V must be connected to protective earth outside of the product to meet EMC and safety requirements.
Power Wiring Connections
Protective Earth (PE) Connections
The unit must be permanently earthed according to EN 61800-5-1 - see below. Protect the incoming mains supply using a suitable fuse or
circuit breaker (circuit breaker types RCD, ELCB, GFCI are not recommended).
IMPORTANT: The inverter is only suitable for earth referenced supplies (TN) when fitted with an internal filter. External filters are
available for use on TN and IT (non-earth referenced) supplies.
For installations to EN 61800-5-1 in Europe:
For permanent earthing, two individual incoming protective earth conductors (<10mm² cross-section) or one conductor (>10mm²
cross-section) are required. Each earth conductor must be suitable for the fault current according to EN 60204.
Refer to Appendix C: “Compliance” - EMC Installation Options.
NOTE STO always overrides any attempt to start the inverter. If one or both STO control inputs is requesting the STO function, the inverter will
not start, even if for example, the inverter’s software malfunctions and tries to cause the motor to turn. Refer to Chapter 6 Safe Torque
Off.
Page 37
Installation 4-16
AC30 series Variable Speed Inverter
AC FED POWER WIRING CONNECTIONS
Feed the power supply and motor cables into the inverter under the cable clamps using the correct cable entries, and connect to the
power terminals. Tighten all terminals to the correct tightening torque; refer to the Terminal Tightening Torques table (page 4-39).
Earth
Earth
Earth
Stud
fuses
Circuit
Breaker
Earth
Stud
Mains in
Terminals
Motor
Terminals
Ferrite core option
To meet C2 EMC
Standard – Frames
D – J only
Cable Clamps
Frame K - no DB+ connect resistor between DC+ & DB)
Filter
(optional)
AC Motor
Chokes.
Only on long
cable runs >50m
Note: Cable clamps and earthing brackets are only
supplied with a C2 EMC Filter kit (page 4-13 for part
numbers), see page C-11 for motor termination details.
Earth
Earth
Page 38
4-17 Installation
AC30 series Variable Speed Inverter
DC FED POWER WIRING CONNECTIONS (FRAMES D – J ONLY)
Feed the power supply and motor cables into the inverter under the cable clamps using the correct cable entries, and connect to the
power terminals. Tighten all terminals to the correct tightening torque; refer to the Terminal Tightening Torques table (page 4-39).
AC Motor
Chokes.
Only on long
cable runs >50m
Earth
Earth
Earth
Stud
Cable Clamps
Earth stud
Motor Terminals
Page 39
Installation 4-18
AC30 series Variable Speed Inverter
Control Module Cover Removal
To gain access to the control wiring and for inserting the SD card first remove the control module cover as follows:
1. First remove the GKP by pulling from the top down, and remove.
2. Undo the screw and slide the control module cover down slightly,
then remove.
Page 40
4-19 Installation
AC30 series Variable Speed Inverter
Control Module Removal
WARNING Isolate supply before plugging or unplugging control unit to the power stack.
1. Unscrew captive screw.
2. Lift lower edge of assembly.
4. Lift assembly away from Power Stack
3. Slide assembly
upwards, as far as
possible, to unlatch
from unit.
Note that there are two
screws used to retain the
AC30D control module. The
communications option, if
fitted, should be temporarily
removed to access one of the
two screws.
Page 41
Installation 4-20
AC30 series Variable Speed Inverter
CONTROL MODULE TERMINAL CABLE SPECIFICATION
Solid minimum H05(07)V-U 0.2sqmm.
Solid maximum H05(07)V-U 1.5 sqmm.
Flexible minimum H05(07)V-K 0.2 sqmm.
Flexible maximum H05(07)V-K 1.5 sqmm.
W.wire end Ferrule DIN462228 Pt 1 minimum 0.25 sqmm.
W.wire end Ferrule DIN462228 Pt 1 maximum 1.5 sqmm.
W.plastic collar Ferrule DIN462228 Pt4 minimum 0. 25 sqmm (see note 1)
W.plastic collar Ferrule DIN462228 Pt4 maximum 0.75 sqmm (see note 2).
Note 1: Parker part number CI053612U001 (Davico part No. PET0505)
Note 2: Parker part number CI053612U002 (Davico part No. PET7575).
Page 42
4-21 Installation
AC30 series Variable Speed Inverter
AC30V CONTROL WIRING CONNECTIONS
Terminal ID
Function
X10/01
STO A Input
X10/02
STO Common
X10/03
STO B Input
X10/04
STO Common
X10/05
STO Status A
X10/06
STO Status B
X11/01
ANIN 01 (+10V, 0-10V, 0-20mA, 4-20mA)
X11/02
ANIN 02 (+10V, 0-10V)
X11/03
ANOUT 01 (+10V, 0-10V)
X11/04
ANOUT 02 (0-10V, 0-20mA, 4-20mA)
X11/05
+10V reference
X11/06
-10V reference
X12/01 (LH)
DIGIN 04 / DIGOUT 01
X12/02
DIGIN 05 / DIGOUT 02
X12/03
DIGIN 06 / DIGOUT 03
X12/04
DIGIN 07 / DIGOUT 04
X12/05
User +24V output
X12/06
0V
X13/01 (LH)
0V
X13/02
DIGIN 1
X13/03
DIGIN 2
X13/04
DIGIN 3
X13/05
+24V AUX input – AC30V and AC30P only
X13/06
0V AUX input – AC30V and AC30P only
X14/01 (BOT)
Relay 01 (contact A) – AC30V only
X14/02
Relay 01 (contact B) – AC30V only
X14/03
Relay 02 (contact A) – AC30V only
X14/04
Relay 02 (contact B) – AC30V only
Page 43
Installation 4-22
AC30 series Variable Speed Inverter
AC30D-P CONTROL WIRING CONNECTIONS
Terminal ID
Function
X10/01
STO A Input
X10/02
STO Common
X10/03
STO B Input
X10/04
STO Common
X10/05
STO Status A
X10/06
STO Status B
X11/01
ANIN 01 (+10V, 0-10V, 0-20mA, 4-20mA)
X11/02
ANIN 02 (+10V, 0-10V)
X11/03
ANOUT 01 (+10V, 0-10V)
X11/04
ANOUT 02 (0-10V, 0-20mA, 4-20mA)
X11/05
+10V reference
X11/06
-10V reference
X12/01 (LH)
DIGIN 04 / DIGOUT 01
X12/02
DIGIN 05 / DIGOUT 02
X12/03
DIGIN 06 / DIGOUT 03
X12/04
DIGIN 07 / DIGOUT 04
X12/05
User +24V output
X12/06
0V
X13/01 (LH)
0V
X13/02
DIGIN 1
X13/03
DIGIN 2
X13/04
DIGIN 3
X13/05
+24V AUX input – AC30V and AC30P only
X13/06
0V AUX input – AC30V and AC30P only
Ethernet Port 1 – AC30P and AC30D only
Ethernet Port 2 – AC30P and AC30D only
Page 44
4-23 Installation
AC30 series Variable Speed Inverter
SYSTEM BOARD CONTROL WIRING CONNECTIONS – AC30D ONLY
Terminal ID
Function
X30/01
DIGIN 1
X30/02
DIGIN 2
X30/03
DIGIN 3
X30/04
DIGIN 0V
X30/05
+24V System Aux. Input
X30/06
0V System Aux. Input
X31/01
Encoder 2 – A input
X31/02
Encoder 2 – /A input
X31/03
Encoder 2 – B input
X31/04
Encoder 2 – /B input
X31/05
Encoder 2 – Z input
X31/06
Encoder 2 – /Z input
X31/07
Encoder PSU Output – Positive terminal
(internally connected to X32/07)
X31/08
Encoder PSU Output – 0V terminal
(internally connected to X32/08)
X32/01
Encoder 1 – A input
X32/02
Encoder 1 – /A input
X32/03
Encoder 1 – B input
X32/04
Encoder 1 – /B input
X32/05
Encoder 1 – Z input
X32/06
Encoder 1 – /Z input
X32/07
Encoder PSU Output – Positive terminal
(internally connected to X31/07)
X32/08
Encoder PSU Output – 0V terminal
(internally connected to X31/08)
X33/01
Encoder Transmit – A output
X33/02
Encoder Transmit – /A output
X33/03
Encoder Transmit – B output
X33/04
Encoder Transmit – /B output
X33/05
Encoder Transmit – Z output
X33/06
Encoder Transmit – /Z output
Page 45
Installation 4-24
AC30 series Variable Speed Inverter
Wiring Diagrams
THE DEFAULT APPLICATION
The AC30V inverter is supplied with 5 Applications, Application 0 to Application 4. Each Application recalls a pre-programmed structure of internal
links when it is loaded.
Application 0 is the factory default application, providing for basic speed control
Application 1 supplies speed control using a manual or auto setpoint
Application 2 is a set-up providing speed control with Raise/Lower Trim
Application 3 supplies speed control using preset speeds
Application 4 PID control
The AC30P and AC30D inverters are supplied with 2 Applications, Application 0 and Application 5. Each Application recalls a pre-
programmed structure of internal links when it is loaded.
Application 0 is the factory default application, providing for basic speed control.
Application 5 supports the use of the inverter as an Active Front-End for regenerative applications.
IMPORTANT: Refer to Chapter 9: Setup Wizard – to reset the inverter to factory default values which are suitable for most applications.
APPLICATION DESCRIPTION
Control Wiring for Applications
The large Application Diagrams on the following pages show the full wiring for push-button starting. The other diagrams show the full wiring for
single wire starting.
When you load an Application, the input and output parameters shown in these diagrams default to the settings shown. For alternative usersettings refer to the Chapter 9 “Setup Wizard".
Local Control Wiring
This is the simplest installation. Every new inverter will operate in Local Control when first powered-up. The
keypad is used to start and stop the inverter.
Refer to the Connection Diagram and install the:
STO (factory fitted)
Motor cable
Supply cable
Follow the earthing/grounding and screening advice
Refer to Chapter 9 "Setup Wizard.
Page 46
4-25 Installation
AC30 series Variable Speed Inverter
Remote Control Wiring
If operating in Remote Control you will use your control panel to start and stop the inverter, via a speed potentiometer and switches or pushbuttons.
Your wiring of the control terminals will be governed by the Application you use: refer to the various Applications you can select and the
appropriate control wiring. Application 0 is the default Application.
The diagram below shows the minimum connections to operate the inverter for single-wire (switch) starting, and push-button starting. Other
control connections for your Application, can be made to suit your system.
Referring to the Connection Diagram:
Follow the instructions for Local Control Wiring, as detailed above
Install using minimum connections (suitable for Application 0 only), or refer to the appropriate control wiring for your system.
Note: You can still operate the inverter in Local mode, if necessary, with any Application selected.
This application is ideal for general purpose applications. It provides push-button or switched start/stop control. The setpoint is the sum of the
two analogue inputs AIN1 and AIN2, providing Speed Setpoint + Speed Trim capability.
Page 47
Installation 4-26
AC30 series Variable Speed Inverter
APPLICATION 0: BASIC SPEED CONTROL
ANIN 01 (X11/01)
ANIN 02 (X11/02)
FWD / REVREFERENCE SELECT
0501 Jog Setpoint
RAMP
0486 Acceleration Time
MIN /MAX SPEED
1264 Ref Min Speed Clamp
1265 Ref Max Speed Clamp
SPEED SETPOINT
SPEED TRIM
CURRENT LIMIT
V/F SHAPING
C
T
VT
V
F
PWM CONTROL
I FDBK
F
V
F
V
0484 Seq Stop Method
DIGIN 01 (X13/02)
DIGIN 02 (X13/03)
DIGIN 03 (X13/04)
DIGIN 04 (X12/01)
DIGIN 05 (X12/02)
DIGIN 06 (X12/03)
DIGIN 07 (X12/02)
SEQUENCING LOGIC
RUN FORWARD
JOG
NOT STOP
NOT COAST STOP
NOT QUICKSTOP
TRIP RESET
REVERSE
0422 Vhz Shape
0457 Base Frequency
0447 Fixed Boost
0455 Rated Motor Current
FEEDBACKS
ANOUT 01 (X11/03)
ANOUT 02 (X11/04)
SPEED DEMAND
MOTOR CURRENT
Application 0:
“Basic Speed Control”
IDEAL FOR GENERAL PURPOSE APPLICATIONS,
NORMAL DUTY AND HEAVY DUTY
Speed
0487 Deceleration Time
0504 Stop Ramp Time
0508 Quickstop Ramp Time
RUNNING
NOT
TRIPPED
RELAY 01
(X14/01)
(X14/02)
RELAY 02
(X14/03)
(X14/04)
RELAY 11
(X23/01)
(X23/02)
if AC30V
Requires IO Option
7004-01-00
RELAY 12
(X23/03)
(X23/04)
if AC30V
Requires IO Option
7004-01-00
OR
OR
Page 48
4-27 Installation
AC30 series Variable Speed Inverter
Basic Speed Control Wiring
Page 49
Installation 4-28
AC30 series Variable Speed Inverter
APPLICATION 1: AUTO/MANUAL CONTROL
ANIN 01 (X11/01)
ANIN 02 (X11/02)
RAMP
0486 Acceleration Time
MANUAL SETPOINT
AUTO SETPOINT
RUNNING
NOT
TRIPPED
CURRENT LIMIT
V/F SHAPING
C
T
VT
V
F
PWM CONTROL
I FDBK
F
V
F
V
MANUAL RUN
AUTO SELECT
REVERSE
NOT COAST STOP
NOT QUICKSTOP
TRIP RESET
AUTO RUN
0422 Vhz Shape
0457 Base Frequency
0447 Fixed Boost
0455 Rated Motor Current
FEEDBACKS
ANOUT 01 (X11/03)
ANOUT 02 (X11/04)
SPEED DEMAND
MOTOR CURRENT
Application 1:
“Auto/Manual Control”
IDEAL FOR AUTOMATIC CONTROL
APPLICATIONS WITH LIMIT SWITCHES OR
PROXIMITY TRANSDUCERS
AUTOMATIC
Pump
Auto / Manual Selector
Auto
Speed
Reference
Level
Limit
Switch
Level Sensor
LEVEL CONTROL
REF SELECT
RUN SELECT
FWD / REV
0484 Seq Stop Method
SEQUENCING LOGIC
DIGIN 01 (X13/02)
DIGIN 02 (X13/03)
DIGIN 03 (X13/04)
DIGIN 04 (X12/01)
DIGIN 05 (X12/02)
DIGIN 06 (X12/03)
DIGIN 07 (X12/02)
MIN /MAX SPEED
1264 Ref Min Speed Clamp
1265 Ref Max Speed Clamp
0487 Deceleration Time
0504 Stop Ramp Time
0508 Quickstop Ramp Time
RELAY 01
(X14/01)
(X14/02)
RELAY 02
(X14/03)
(X14/04)
RELAY 11
(X23/01)
(X23/02)
if AC30V
Requires IO Option
7004-01-00
RELAY 12
(X23/03)
(X23/04)
if AC30V
Requires IO Option
7004-01-00
OR
OR
Auto/Manual Control Application
Two Run inputs and two Setpoint inputs are provided. The Auto/Manual switch selects which pair of inputs is active.
The Application is sometimes referred to as Local/Remote.
Page 50
4-29 Installation
AC30 series Variable Speed Inverter
Auto/Manual Control Wiring
Page 51
Installation 4-30
AC30 series Variable Speed Inverter
APPLICATION 2: RAISE / LOWER TRIM
Application 2:
“Speed Raise/Lower”
IDEAL FOR APPLICATIONS REQUIRING SPEED
CONTROL FROM MULTIPLE LOCATIONS
ANIN 01 (X11/01)
ANIN 02 (X11/02)
RAMP
0486 Acceleration Time
0487 Deceleration Time
Not Used
Not Used
CURRENT LIMIT
V/F SHAPING
C
T
VT
V
F
PWM CONTROL
I FDBK
F
V
F
V
0484 Seq Stop Method
DIGIN 01 (X13/02)
DIGIN 02 (X13/03)
DIGIN 03 (X13/04)
DIGIN 04 (X12/01)
DIGIN 05 (X12/02)
DIGIN 06 (X12/03)
DIGIN 07 (X12/02)
RUN
LOWER SPEED
RAISE/LOWER RESET
NOT COAST STOP
NOT QUICKSTOP
TRIP RESET
RAISE SPEED
0422 Vhz Shape
0457 Base Frequency
0447 Fixed Boost
0455 Rated Motor Current
ANOUT 01 (X11/03)
ANOUT 02 (X11/04)
SPEED DEMAND
MOTOR CURRENT
SEQUENCING LOGIC
1901 Ramp Time
1902 Reset Value
1903 Maximum Value
1904 Minimum Value
RAISE/LOWER
MIN /MAX SPEED
1264 Ref Min Speed Clamp
1265 Ref Max Speed Clamp
0504 Stop Ramp Time
0508 Quickstop Ramp Time
FEEDBACKS
RUNNING
NOT
TRIPPED
RELAY 01
(X14/01)
(X14/02)
RELAY 02
(X14/03)
(X14/04)
RELAY 11
(X23/01)
(X23/02)
if AC30V
Requires IO Option
7004-01-00
RELAY 12
(X23/03)
(X23/04)
if AC30V
Requires IO Option
7004-01-00
OR
OR
Raise/Lower Trim Application
This Application mimics the operation of a motorised potentiometer. Digital inputs allow the setpoint to be increased and decreased between
limits. The limits and ramp rate can be set using the keypad.
The Application is sometimes referred to as Motorised Potentiometer.
Page 52
4-31 Installation
AC30 series Variable Speed Inverter
Raise/Lower Trim Wiring
Page 53
Installation 4-32
AC30 series Variable Speed Inverter
APPLICATION 3: PRESETS SPEEDS
ANIN 01 (X11/01)
ANIN 02 (X11/02)
RAMP
0486 Acceleration Time
SPEED SETPOINT
SPEED TRIM
CURRENT LIMIT
V/F SHAPING
C
T
VT
V
F
PWM CONTROL
I FDBK
F
V
F
V
0484 Seq Stop Method
DIGIN 01 (X13/02)
DIGIN 02 (X13/03)
DIGIN 03 (X13/04)
DIGIN 04 (X12/01)
DIGIN 05 (X12/02)
DIGIN 06 (X12/03)
DIGIN 07 (X12/02)
RUN
PRESET SELECT 2
PRESET SELECT 3
NOT COAST STOP
NOT QUICKSTOP
TRIP RESET
PRESET SELECT 1
0422 Vhz Shape
0457 Base Frequency
0447 Fixed Boost
0455 Rated Motor Current
ANOUT 01 (X11/03)
ANOUT 02 (X11/04)
SPEED DEMAND
MOTOR CURRENT
1916 Preset Speed 0
1917 Preset Speed 1
1918 Preset Speed 2
1919 Preset Speed 3
1920 Preset Speed 4
1921 Preset Speed 5
1922 Preset Speed 6
1923 Preset Speed 7
0V 0V 0V 0
24V 0V 0V 1
0V 24V 0V 2
24V 24V 0V 3
24V 0V 0V 4
0V 0V 24V 5
24V 24V 0V 6
24V 24V 24V 7
SEQUENCING LOGIC
Application 3:
“Speed Presets”
IDEAL FOR GENERAL PURPOSE APPLICATIONS
REQUIRING MULTIPLE DISCRETE SPEED LEVELS
Speeds
Preset
1 Setup
2 Clean
3 Operate 1
4 Operate 2
MIN /MAX SPEED
1265 Ref Max Speed Clamp
1264 Ref Min Speed Clamp
0487 Deceleration Time
0504 Stop Ramp Time
0508 Quickstop Ramp Time
FEEDBACKS
RUNNING
NOT
TRIPPED
RELAY 01
(X14/01)
(X14/02)
RELAY 02
(X14/03)
(X14/04)
RELAY 11
(X23/01)
(X23/02)
if AC30V
Requires IO Option
7004-01-00
RELAY 12
(X23/03)
(X23/04)
if AC30V
Requires IO Option
7004-01-00
OR
OR
Presets Speeds Application
This is ideal for applications requiring multiple discrete speed levels.
The setpoint is selected from either the sum of the analogue inputs, (as in Application 1 and known here as PRESET 0), or as one of up to seven
other pre-defined speed levels. These are selected using DIN2, DIN3 and DIN4, refer to the Truth Table above.
Edit parameters P1917 to P1923 on the keypad to re-define the speed levels of PRESET 1 to PRESET 7. Reverse direction is achieved by
entering a negative speed setpoint.
Page 54
4-33 Installation
AC30 series Variable Speed Inverter
Presets Speeds Wiring
Page 55
Installation 4-34
AC30 series Variable Speed Inverter
APPLICATION 4: PID CONTROL
ANIN 01 (X11/01)
ANIN 02 (X11/02)
RAMP
0486 Acceleration Time
PROCESS SETPOINT
PROCESS FEEDBACK
CURRENT LIMIT
V/F SHAPING
C
T
VT
V
F
PWM CONTROL
I FDBK
F
V
F
V
0484 Seq Stop Method
DIGIN 01 (X13/02)
DIGIN 02 (X13/03)
DIGIN 03 (X13/04)
DIGIN 04 (X12/01)
DIGIN 05 (X12/02)
DIGIN 06 (X12/03)
DIGIN 07 (X12/02)
SEQUENCING LOGIC
RUN
PID INTEGRAL DEFEAT
NOT STOP
NOT COAST STOP
NOT QUICKSTOP
TRIP RESET
PID ENABLE
0422 Vhz Shape
0457 Base Frequency
0447 Fixed Boost
0455 Rated Motor Current
ANOUT 01 (X11/03)
ANOUT 02 (X11/04)
SPEED DEMAND
MOTOR CURRENT
Application 4:
“Process PID”
EASY TUNING FOR SETPOINT/FEEDBACK
CONTROL APPLICATIONS REGULATING
VOLUME OR PRESSURE, SUCH AS AIR
HANDLING OR PUMPING
Speed
Setpoint
Pressure or Volume Feedback
Transducer
PID CONTROL
1928 Proportional Gain
1929 Integral TC
1930 Derivative TC
1931 Output Filter TC
1932 Output Pos Limit
1933 Output Neg Limit
1934 Output Scaling
MIN /MAX SPEED
1264 Ref Min Speed Clamp
1265 Ref Max Speed Clamp
0487 Deceleration Time
0504 Stop Ramp Time
0508 Quickstop Ramp Time
FEEDBACKS
RUNNING
NOT
TRIPPED
RELAY 01
(X14/01)
(X14/02)
RELAY 02
(X14/03)
(X14/04)
RELAY 11
(X23/01)
(X23/02)
if AC30V
Requires IO Option
7004-01-00
RELAY 12
if AC30V
Requires IO Option
7004-01-00
OR
OR
(X23/03)
(X23/04)
PID Control Application
A simple application using a Proportional-Integral-Derivative 3-term controller. By default the setpoint is taken from AIN1, with feedback signal
from the process on AIN2, scaling parameter 1939 swaps the routing of AIN1 & 2. The scale and offset features of the analogue input blocks may
be used to correctly scale these signals. The difference between these two signals is taken as the PID error. The output of the PID block is then
used as the inverter setpoint.
Page 56
4-35 Installation
AC30 series Variable Speed Inverter
PID Control Wiring
Page 57
Installation 4-36
AC30 series Variable Speed Inverter
APPLICATION 5: ACTIVE FRONT-END
Application 5:
“AFE”
ACTIVE FRONT END APPLICATION THAT ALLOWS THE
DRIVE TO PERFORM REGENERATION OF ENERGY BACK
INTO THE GRID, AND EXECUTES CONTROL OF
EXTERNAL PRECHARGE SWITCHES AND CONTACTORS
M
AFE Drive
Motoring Drive
Grid
Motor
AFE Control Application
A simple application that controls external precharge relays and contactors, and ensures that all pre-requisites for regenerative operation of the
drive are satisfied. If the drive is used as an active front end this application MUST be loaded and enabled. If the shown control wiring to the
control card terminals is correct no further modification to the application is needed to be able to run in AFE mode. (The line sync card needs to
be wired to the encoder option too.)
Page 58
4-37 Installation
AC30 series Variable Speed Inverter
AFE Control Wiring – Excludes 7004-04-00 Wiring
Page 59
Installation 4-38
AC30 series Variable Speed Inverter
TERMINAL BLOCK WIRE RANGE
Wire sizes for Europe should be chosen with respect to the operating conditions and your local National Electrical Safety Installation
Requirements. Local wiring regulations always take precedence. For North American UL wire sizes refer to Appendix C: “Compliance” Requirements for UL Compliance.
Product Code
Power Terminals
(minimum/maximum acceptance for aperture)
Earth Connections
Control Terminals
3xV-4D0004- ...
3xV-4D0005- ...
3xV-4D0006- ...
3xV-4D0008- ...
3xV-4D0010- …
3xV-4D0012- …
0.05 - 6 mm2
M4 ring crimp
0.229 - 2.5 mm
2
3xV-4E0016- ...
3xV-4E0023- …
0.05 – 6 mm2
M4 ring crimp
0.229 - 2.5 mm
2
3xV-4F0032- …
3xV-4F0038- …
1 - 10 mm2 (*16 mm2)
M4 ring crimp
0.229 – 2.5 mm
2
3xV-4G0045- …
3xV-4G0060- …
3xV-4G0073- …
1.3 – 25 mm2
M5 ring crimp
0.229 – 2.5 mm2
3xV-4H0087- …
3xV-4H0105- …
3xV-4H0145- …
M8 post, accepting crimps or lugs up to width 26.5mm
(minimum 25mm2 wire size)
M8 ring crimp
0.229 – 2.5 mm2
3xV-4J0180- …
3xV-4J0205- …
3xV-4J0260- …
M8 post, accepting crimps or lugs up to width 32mm
(minimum 25mm2 wire size)
M8 ring crimp
Up to width 26.5mm
0.229 – 2.5 mm2
3xV-4K0315- …
3xV-4K0380- …
3xV-4K0440- …
M12 post, accepting crimps or lugs up to width 38mm
M8 ring crimp
0.229 – 2.5 mm2
*The larger wire size can be used provided a crimp is fitted to the wire
Page 60
4-39 Installation
AC30 series Variable Speed Inverter
TERMINAL TIGHTENING TORQUES
Frame Size
Power Terminals
DC Bus Terminals
Brake Terminals
Ground Stud
Frame D
0.56-0.8Nm
(5-7 lb-in)
0.56-0.8Nm
(5-7 lb-in)
0.56-0.8Nm
(5-7 lb-in)
1.8Nm
(16 lb-in)
Frame E
0.56-0.8Nm
(5-7 lb-in)
0.56-0.8Nm
(5-7 lb-in)
0.56-0.8Nm
(5-7 lb-in)
1.8Nm
(16 lb-in)
Frame F
1.35Nm
(12 lb-in)
1.35Nm
(12 lb-in)
1.35Nm
(12 lb-in)
1.8Nm
(16 lb-in)
Frame G
* 1.35Nm or 2.0Nm
(12 lb-in or 18 lb-in)
2.0Nm
(18 lb-in)
2.0Nm
(18 lb-in)
3.6Nm
(32 lb-in)
Frame H
20Nm Max.
(177 lb-in)
20Nm Max.
(177 lb-in)
2.0Nm
(18 lb-in)
20Nm Max.
(177 lb-in)
Frame J
20Nm Max.
(177 lb-in)
20Nm Max.
(177 lb-in)
20Nm Max.
(177 lb-in)
20Nm Max.
(177 lb-in)
Frame K
38Nm Max.
(336 lb-in)
38Nm Max.
(336 lb-in)
38Nm Max.
(336 lb-in)
20Nm Max.
(177 lb-in)
* Cream power terminals 2.0Nm (18 lb-in)
Black power terminals 1.35Nm (12 lb-in)
OPTIONAL EQUIPMENT
Refer to Chapter 5 Associated Equipment.
BRAKE WIRING
Refer to Chapter 5 Associated Equipment on wiring details.
Page 61
Installation 4-40
AC30 series Variable Speed Inverter
Fitting a Remote GKP
When fitting the GKP remotely to either a cubicle or panel mount it must be fitted to a flat surface. Maximum cable length < 3 meters.
7001-00-00 – includes the GKP only
7001-00-01 - includes the GKP, 3m connection lead and screws.
If ordered and supplied with the inverter the connection lead is NOT supplied, to order the lead the part number is LA501991U300.
Cut out details:
Gasket
Reverse side of the
GKP
GKP – Reverse side
The yellow dotted line is the cutout
detail to allow remote fitting the
connection lead, also shows screw
hole details.
Use M3 x 10 self tapping screws.
Connection lead RS232/REM OP
STA with a Steward 28A2025-OAO
connector.
All measurements in millimeter.
Page 62
4-41 Installation
AC30 series Variable Speed Inverter
Getting Started
GKP SETUP WIZARD
Purpose of the Setup Wizard
The purpose of the setup wizard is to configure the inverter in a clear and concise manner.
First familiarize yourself with Chapter 7 Graphical Keypad, for the keypad functions.
Starting the Setup Wizard
The Setup Wizard is automatically invoked when the inverter is reset to factory default settings. The setup
wizard may be invoked at any other time by navigating to the Welcome Screen at the “top” of the menu
tree the pressing the key, Soft Key 1.
Running the Setup Wizard
At each point in the wizard pressing the OK key selects the displayed value and moves on to the next
step. Pressing Soft Key 1 moves back a step. Pressing the UP and DOWN keys modifies the selected
value.
Setup Wizard Stages
After selecting the required view level and language, the next option is “Set Factory Defaults”. Changing this parameter to TRUE then pressing
OK resets all parameters back to the default value determined by the inverters hardware configuration. If this choice is left FALSE the setup
wizard starts with all parameters with their previously set values. Accepting each choice without change by pressing OK will result in no change to
the inverter’s configuration.
The rest of the Setup Wizard consists of a several sections. Each section corresponds to a functional component of the inverter, for example:
Application selection
IO Option, (includes the Encoder)
Analog input and output ranges.
Motor Data
Motor Control
Fieldbus options
On-board Ethernet
Auto tune
If not required, any section may be skipped.
The default setting for all parameters depends on earlier answers and on the physical configuration of the inverter. All data entered is
automatically saved without the need for any additional commands.
Finalising Setup
Once the Setup Wizard has been run to completion the feature is automatically disabled. Re-starting the inverter will not cause the Setup Wizard
to be run again. (If it is desired to re-run the Setup Wizard, this can be achieved as detailed above in “Starting the Setup Wizard”).
For complete details go to “Chapter 9 Setup Wizards”.
OK key
Soft Key 1
Page 63
Installation 4-42
AC30 series Variable Speed Inverter
ETHERNET COMMUNICATIONS
The inverter comes with built-in Ethernet providing communications with the PC programming tools PDQ and PDD, a Modbus TCP server and a
web server. See Chapter 12 - Ethernet for recommended cable information.
Connecting the Ethernet Cable – AC30V
Disconnecting the Ethernet Cable – AC30V
To remove the cable first remove the GKP and then insert a
screwdriver to release the catch on the Ethernet clip.
Page 64
4-43 Installation
AC30 series Variable Speed Inverter
Connecting the Ethernet Cables – AC30P and AC30D
DO NOT TOUCH
DO NOT touch the board surface via the aperture shown
Page 65
Installation 4-44
AC30 series Variable Speed Inverter
Setting the IP Address
The inverter’s Ethernet requires an IP address to participate in communications. The factory default is set so that an IP address is selected
automatically depending on the network on which it is connected. It may obtain an IP address using DHCP or Auto-IP.
DHCP
If the network has a DHCP (Dynamic Host Communications Protocol) server, then the inverter will obtain an address from this.
Auto-IP
If the network has no DHCP server or if connecting the inverter directly to a PC then the IP address will be chosen randomly by the inverter from
the link-local address range 169.254.*.*. Note that when connecting the inverter directly to a PC it may take 1 – 2 minutes for the PC to obtain a
link-local address.
Manual
The IP address may be fixed if required. The DHCP and Auto-IP must both be disabled.
The current IP address of the inverter may be monitored using the following parameters 0926 IP Address, 0927 Subnet Mask, 0928 Gateway
Address, found in menu: Parameters::Base Comms::Ethernet
The state of the Ethernet may be monitored using the parameter 0919 Ethernet State and from the Ethernet icon on the GKP status bar.
More Information
For more information on customizing and troubleshooting the inverter’s Ethernet see Chapter 12 – Ethernet.
Accessing the inverter’s web page is also described in Chapter 12 and information on using the Modbus TCP server can be found in Appendix A
- Modbus TCP.
Page 66
4-45 Installation
AC30 series Variable Speed Inverter
Firmware Update
UPDATING THE INVERTER FIRMWARE
Prepare SD card
Copy the new firmware to an SD card, ensure the file is named firmware 30x for the AC30V or firmware.30P for the AC30P and AC30D.
New firmware is available at www.parker.com/ssd/pdq or can be copied from the Parker Drive Quicktool “Drive Maintenance” task.
Perform the upgrade
CAUTION: DO NOT REMOVE POWER FROM THE INVERTER DURING THE FIRMWARE UPDATE.
Insert the SD in the inverter’s SD slot. Replace the GKP if necessary. The ”Update Firmware” will now be visible in the wizard menu. This is
accessed from the top menu by pressing the key, (soft left).
To start the update, change the value from FALSE to TRUE. The inverter will restart once the process is complete.
Page 67
Associated Equipment 5-1
AC30 series Variable Speed Inverter
Chapter 5: Associated Equipment
MAIN POINTS
Connect the associated equipment to an AC Fed AC30 in the following order:
Frame E Illustrated
Earth
Stud
Earth
Earth
VDR
Note: In a different place on
Frame D, G, H, J & K
fuses
Circuit
Breaker
Filter
(optional)
AC Motor Chokes.
Only on long cable runs >50m
Note: In a different place on Frame D, G,
H, J & K
Page 68
5-2 Associated Equipment
AC30 series Variable Speed Inverter
Connect the associated equipment to a DC Fed AC30 in the following order:
A – Semiconductor fuses, rated to protect the dc supply unit and dc bus installation at maximum power.
B – Optional EMC filter.
C – AC line choke, see Note 1.
D – DC supply unit, for example 890CS, AC30 supply unit 380-x. (Refer to separate product manuals).
E – Semiconductor fuses, rated to protect the individual dc fed AC30 and its dc wiring.
NOTES:
1. The required AC line choke inductance value is determined by the total dc bus capacitance (dc bus) as:
Lac(µH) per phase = (1.05 x 106)/C
dcbus
(µF)
The dc supply unit may also have minimum inductance requirements (see table over page) to satisfy (e.g., 3% for 890CS) or may
include an internal line choke (e.g., AC30 input unit 380-x).
2. The dc supply unit may be required to precharge the dc bus at power up. If so, the precharge circuitry should be rated (in terms of
peak power and impulse energy) to charge the total dc bus capacitance, and should be rated to carry 45W to the internal power
supply of each drive, without dropping more than 40V.
Page 69
Associated Equipment 5-3
AC30 series Variable Speed Inverter
Frame Size
Product Code
Internal Capacitance
Frame Size
Product Code
Internal Capacitance
D
340x-4D0004
340 µF
G
340x-4G0045
1800 µF
340x-4D0005
340 µF
340x-4G0060
2800 µF
340x-4D0006
340 µF
340x-4G0073
2800 µF
340x-4D0008
340 µF
H
340x-4H0087
3600 µF
340x-4D0010
340 µF
340x-4H0105
4200 µF
340x-4D0012
340 µF
340x-4H0145
5600 µF
E
340x-4E0016
500 µF
J
340x-4J0180
6600 µF
340x-4E0023
700 µF
340x-4J0205
8400 µF
F
340x-4F0032
1400 µF
340x-4J0260
9900 µF
340x-4F0038
1400 µF
Page 70
5-4 Associated Equipment
AC30 series Variable Speed Inverter
AC Motor Chokes
The maximum rate of rise of Volts (dv/dt) present on the motor terminals of the inverter, can be as high as 10,000V/s. This can be
reduced by adding a motor choke in series with the motor.
Installations with long cable runs may suffer from nuisance overcurrent trips, refer to Appendix C Compliance - Cabling Requirements for
maximum cable lengths. An output choke may be fitted in the inverter output to limit parasitic capacitive current to earth. Screened cable
has a higher parasitic capacitance to earth and may cause problems in shorter runs. Contact Parker for recommended choke values.
Motor Power (kW)
Choke Inductance
RMS Current Rating
Parker Part No.
0.75
1.1
1.5
2mH
7.5A
CO055931
2.2 4.0
5.5
0.9mH
22A
CO057283
7.5
11
0.45mH
33A
CO057284
15 18
0.3mH
44A
CO057285
22
50µH
70A
CO055193
30
37
50µH
99A
CO055253
45
50µH
99A
CO055253
55
50µH
243A
CO057960
75
50µH
360A
CO387886
90
Contact Parker Hannifin Manufacturing Limited for further information
110
132
Page 71
Associated Equipment 5-5
AC30 series Variable Speed Inverter
Dynamic Braking Resistors
We can supply suitable braking resistors, found on the following pages. Alternatively, you can use the calculation on page 5-7 to help you
select alternative resistors.
We recommend using a thermal overload switch to protect the braking circuit. Refer to page 5-6.
The inverter must be fitted with external braking resistors if braking is required.
The power stack must be fitted with external braking resistors, or used with an AFE or regenerative DC supply unit, if
braking is required.
WIRING DETAILS
WARNING
Do not apply external voltage sources (mains
supply or otherwise) to either of the braking
terminals: DB+, DB. This can lead to damage to the
inverter and installation, and risk to personnel.
Figure 5.1 External Braking Resistor
Page 72
5-6 Associated Equipment
AC30 series Variable Speed Inverter
Dynamic Braking Resistors
These resistor sets are designed for stopping the system at rated power. They are rated for 10 seconds in a 100 seconds duty cycle.
See Appendix F for Minimum Brake Resistor value for each individual inverter size.
RESISTOR SELECTION
These small, metal-clad resistors should be mounted on a
heatsink (back panel) and covered to prevent injury from
burning.
There are four resistor values available.
L1
H
flying leads
L2
L3
W
a
b
a
b
D
The resistor can dissipate 10 x power rating for 5s, but the continuous rating should not be exceeded under repetitive
loading.
Flying Lead Length
L1
L2
L3 a b D W
H
500W
500
335
316
295
13
17
5.3
60
30
200W
500
165
146
125
13
17
5.3
60
30
Dimensions are in millimetres
Parker Part Number
Power Rating (W)
Resistance ()
Continuous Current Rating (A)
CZ467717
200
100
1.4
CZ463068
200
56
1.9
CZ467716
500
56
3.0
CZ388396
500
36
3.7
Page 73
Associated Equipment 5-7
AC30 series Variable Speed Inverter
Calculation
Brake resistor assemblies must be rated to absorb both peak braking power during deceleration and the average power over the
complete cycle.
Peak
braking
power P
0
0055
n
n
t
W
122
2
b
.()
(
)
pk
J
J - total inertia (kgm2)
n1 - initial speed (rpm)
Average braking power P
P
t
av
pk
c
x tb n2 - final speed (rpm)
tb - braking time (s)
tc - cycle time (s)
Obtain information on the peak power rating and the average power rating of the resistors from the resistor manufacturer. If this
information is not available, a large safety margin must be incorporated to ensure that the resistors are not overloaded.
By connecting these resistors in series and in parallel the required braking capacity can be selected for the application.
The minimum resistance of the combination and maximum dc link voltage must be as specified in Appendix F:
“Technical Specifications” - Internal Dynamic Brake Switch.
Figure 5.2 Braking Resistor Derating Graph (Metal Clad Resistors)
0
20
40
60
80
100
120
0 25 50 75 100 125 150 175 200
% of Rated Power
Ambient Temp (C)
Resistor Derating Graph
chassis mounted
free air
Page 74
5-8 Associated Equipment
AC30 series Variable Speed Inverter
Circuit Breakers
We do not recommend the use of circuit breakers (e.g. RCD, ELCB, GFCI), but where their use is mandatory, they should:
Operate correctly with dc and ac protective earth currents (i.e. type B RCDs as in Amendment 2 of IEC755).
Have adjustable trip amplitude and time characteristics to prevent nuisance tripping on switch-on.
When the ac supply is switched on, a pulse of current flows to earth to charge the internal/external ac supply EMC filter’s internal
capacitors which are connected between phase and earth. This has been minimised in Parker inverter filters, but may still trip out any
circuit breaker in the earth system. In addition, high frequency and dc components of earth leakage currents will flow under normal
operating conditions. Under certain fault conditions larger dc protective earth currents may flow. The protective function of some circuit
breakers cannot be guaranteed under such operating conditions.
WARNING
Circuit breakers used with VSDs and other similar equipment are not suitable for personnel protection.
Use another means to provide personal safety. Refer to EN50178 / VDE0160 / EN60204-1
External EMC Filters
Refer to Appendix C Compliance - Filters for complete information.
Filter Description
Filter Part Number
AC50 & Frame D & E
500V IT/TN
CO501894
Frame F
500V IT/TN
CO501895
Frame G - Please contact Parker Hannifin Manufacturing Ltd., Automation Group,
Frame H
500V IT/TN
CO502672U150
Frame J
500V IT/TN
CO502672U320
Frame K – Not applicable
Page 75
Associated Equipment 5-9
AC30 series Variable Speed Inverter
Input Chokes
For further information refer to Appendix F Technical Specifications “Supply Short Circuit Rating”.
Gaskets
Gaskets can be purchased from Parker using the following part numbers.
Frame Size
Gasket Part Number
AC50 & Frame D
BO501911U001
Frame E
BO501911U002
Frame F
BO501911U003
Frame G
Refer to Kit part number LA502471
Frame H
Refer to Kit part number LA502472
Frame J
Refer to Kit part number LA502793
Frame K
Not applicable
For installation information see Chapter 4 ‘Installation’
Cabling Bracket for Control, System Option & Power Stack
Part numbers for the cabling brackets are:
Frame Size
Control & Power Stack Cabling Bracket Kit
Part Number
Control & System Option Cabling Bracket Kit
Part Number
AC50 & Frame D
LA501935U001
LA501935U007
Frame E
LA501935U002
LA501935U007
Frame F
LA501935U003
LA501935U007
Frame G
LA501935U004
LA501935U007
Frame H
LA501935U005
LA501935U007
Frame J
LA501935U006
LA501935U007
Frame K
Not applicable
LA501935U007
For further information see Chapter 4 ‘Installation’
Page 76
5-10 Associated Equipment
AC30 series Variable Speed Inverter
Option Cards
There are a range of Option Cards that may come factory-fitted to the inverter, or are available for customer fitting.
Refer to the Technical Manual supplied with each Option Card for detailed instructions.
Product Code
Description
Part Number
7004-01-00
General Purpose I/O Option, referred to as GPIO
Digital Inputs or Outputs, Analogue Inputs, Motor Thermistor Input, Volt-free Relay
Outputs, Real-Time Clock
HA501836U001
7004-02-00
GPIO - Motor Thermistor Input
HA501836U001
7004-03-00
GPIO - Motor Thermistor plus Real-Time Clock
HA501836U001
7004-04-00
Pulse Encoder plus Thermistor input
HA502217U001
7003-PB-00
Profibus DP-V1
HA501837U001
7003-PN-00
PROFINET IO
HA501838U001
7003-DN-00
DeviceNet
HA501840U001
7003-CN-00
ControlNet
HA501936U001
7003-CB-00
CANopen
HA501841U001
7003-IP-00
EtherNet IP
HA501842U001
7003-EC-00
EtherCAT
HA501938U001
7003-BI-00
BACnet IP
HA501939U001
7003-BN-00
BACnet MSTP
HA501940U001
7003-RS-00
Modbus RTU
HA501839U001
7003-IM-00
Modbus TCP
HA501937U001
SD CARDS
The AC30 control modules have only been qualified with certain brands and types of SD memory card. Some brands do not support all
operating modes of the SD standard. We recommend that SD cards be purchased from Parker by using part number IF502785.
Page 77
Associated Equipment 5-11
AC30 series Variable Speed Inverter
Control Terminal Cover Removal
First remove the GKP by pulling from the top down and
remove.
Undo the screw and slide the control terminal cover down,
then remove
Control Terminal Cover
INSTALLATION DETAILS
HAZARDOUS VOLTAGES may be present on GPIO module motor thermistor user relays, please refer to the option technical manual or main
product manual for safety information
Page 78
5-12 Associated Equipment
AC30 series Variable Speed Inverter
Click the Option into place and tighten the retaining screw (as shown below).
Squeeze moulding
as shown to remove
All other options as
listed on page A-1
3 off General Purpose I/O (GPIO)
1 off Pulse Encoder
Page 79
Safe Torque Off 6-1
AC30 series Variable Speed Inverter
Chapter 6 Safe Torque Off SIL3/PLe
General Information
THIS EQUIPMENT IF USED INCORRECTLY IS POTENTIALLY DANGEROUS. THEREFORE UNDER NO CIRCUMSTANCES
SHOULD IT BE USED BEFORE THESE INSTRUCTIONS HAVE BEEN READ AND UNDERSTOOD BY THE END USER WHO
SHOULD BE APPROPRIATELY QUALIFIED TO OPERATE THE EQUIPMENT.
This section provides general information about Safe Torque Off (STO).
Two safety functions can be implemented with the inverter: STO and Safe Stop 1 (SS1). In order to meet all aspects of STO and SS1, an external safety
control unit should be used.
To implement Safe Stop 1 (SS1), the external safety control unit causes the drive to decelerate to rest. Once at rest, it invokes STO in the inverter.
Please refer to EN61800-5-2:2007 para 4.2.2.3 for the formal definitions.
It is the user’s responsibility to:
1) Risk assess the machine.
2) Design, implement and assess an appropriate solution for each application to meet all relevant safety requirements.
Note: STO is an electronic inhibit intended for use during normal operation of the machine. It is not intended for use during machine maintenance,
repair, replacement or other similar activities. For these activities recognised electrical power isolation devices and lock-off procedures should be used.
The inverter STO function is a factory-fitted and factory-tested feature. See the section “Safety Warnings and Limitations” on page 6-18.
Page 80
6-2 Safe Torque Off
AC30 series Variable Speed Inverter
STO FUNCTIONAL DESCRIPTION
STO is a means of preventing an inverter from delivering rotational force to its connected electric motor. Please refer to EN61800-5-2:2007 para 4.2.2.2
for the formal definition.
To ensure a high degree of safety, two independent STO control channels are implemented in hardware. The STO circuit in the inverter is designed
such that a fault in one control channel will not affect the other channel’s ability to prevent the drive from starting, i.e. the STO function of the inverter is
tolerant to any single fault. It may not be tolerant to an accumulation of faults. This is in keeping with its declared safety ratings.
STO always overrides any attempt to start the drive. If one or both STO control inputs is requesting the STO function, the drive will not start, even if for
example, the drive’s software malfunctions and tries to cause the motor to turn.
The STO function is implemented in hardware; it overrides all software activities. The only software involvement is to report STO status to the user via a
Graphical Keypad (GKP), serial communications link or user terminal as defined by the drive configuration.
WARNING
THE DECLARED SIL/PL CAPABILITY OF THIS STO PRODUCT CAN BE ACHIEVED ONLY WHEN THE TWO STO USER INPUTS ARE
DRIVEN INDEPENDENTLY. THEY MUST NOT BOTH BE DRIVEN FROM A COMMON SOURCE; OTHERWISE THE SINGLE FAULT
DETECTION WILL BE COMPLETELY INOPERATIVE.
USE OF THE PRODUCT IN THIS “COMMON SOURCE” CONDITION INVALIDATES THE STO PRODUCT SPECIFICATION AND IS
ENTIRELY AT THE USER’S OWN RISK.
Page 81
Safe Torque Off 6-3
AC30 series Variable Speed Inverter
Alignment to European Standards
EN ISO13849-1:2008
(Safety of machinery – Safety-related parts of control systems)
STO aligns internally to the following aspects of this standard:
Architecture according to Category 3:
Solid lines represent the STO control paths.
Dashed lines represent reasonably practicable fault detection.
Key: I1, I2 = user terminal
L1, L2 = logic
O1, O2 = methods of enabling or disabling output power devices
i
mxy
= interconnecting means
mx = monitoring
c = cross monitoring
Category 3 general requirements are:
A single failure, and any consequential failures, will not lead to loss of the STO safety function.
Failure of more than one component can lead to the loss of the STO safety function.
I1
L1 O1
I2
L2 O2
i
m1a im2a im1b im2b m1 m2
c
Page 82
6-4 Safe Torque Off
AC30 series Variable Speed Inverter
Most but not all single component failures will be detected. Diagnostic Coverage (DC) is required to be at least 60% (i.e. the
minimum required for ‘low’ diagnostic coverage).
Detected component failures will result in the STO function being applied without intervention from the user.
The risk associated with the loss of STO safety function caused by multiple failures must be understood and accepted by the
user.
The user must undertake a risk analysis and specify suitable components that, when connected together, meet the risk
assessment requirements.
Mean Time To Failure (dangerous) (MTTFd) of each STO channel must be ≥ 30 years.
Common Cause Failure (CCF) score must be ≥ 65 according to Annex F of the standard.
Performance Level (PL) e:
Average probability of dangerous failure per hour (PFH) must be ≤ 10
-7
EN61800-5-2:2007 AND EN61508
(Adjustable speed electrical power drive systems) and
(Functional safety of electrical/electronic/programmable electronic safety-related systems)
STO aligns to the following aspects of this standard:
Safety Integrity Level (SIL) 3
Probability of dangerous random hardware failures per hour (PFH) must be ≤ 10
-7
Subsystems type A according to EN61508-2:2001 para 7.4.3.1.2
Hardware Fault Tolerance (HFT) = 1
Safe Failure Fraction (SFF) must be ≥ 90%
Page 83
Safe Torque Off 6-5
AC30 series Variable Speed Inverter
Safety Specification
As assessed to EN ISO13849-1 and EN61800-5-2 the inverter has the following related safety values:-
Criterion
Requirement
Value achieved
SIL3
For type A subsystems, HFT = 1:
SFF ≥ 60%
SFF = 99%
SIL3
10-7 ≥ PFH ≥ 10-8
PFH = 2.3 x 10-9
SIL Capability - 3
PLe
Category 3; PFH ≤ 4,29 x 10-8
PFH = 2.3 x 10-9
PLe
30 years ≤ MTTFd < 100 years
MTTFd = 100 years1
PLe
DC = medium
DC = Medium
Mission Time
20 years
20 years
Fault Reaction Function
-
Latched STO2
Note: all values quoted in this table are valid only when the two STO user inputs are driven independently. This is as required by EN ISO
13849-1 category 3. See the Alignment to European Standards section in this chapter for the required architecture which must be used
throughout the machine design relevant to the drive under consideration.
1
EN ISO13849 limits MTTFd to 100 years.
2
A detected fault in the STO circuit causes STO to become active, and remain active until after a power cycle.
Page 84
6-6 Safe Torque Off
AC30 series Variable Speed Inverter
EMC Specification
In addition to the mandatory requirements of EN61800, the STO functionality has been subjected to testing for immunity at higher levels. In particular
the STO function (only) has been tested for radiated immunity according to EN62061:2005 Annex E up to 2.7GHz which includes frequencies used by
mobile telephones and walkie-talkies.
Page 85
Safe Torque Off 6-7
AC30 series Variable Speed Inverter
User Connections
The STO terminals are on a 6-way terminal block X10. This is mounted on the inverter control housing. Terminal designations are:
Terminal Number
Terminal Name
Description
X10/01
STO A Input
0V or not connected = drive will not run, STO is active on channel A.
24V = drive is enabled to run if X10/03 is also 24V.
This input is optically isolated from all other inverter terminals except
X10/02, X10/03 and X10/04.
X10/02
STO Common3
Signal return for STO A Input and STO B Input. Connected internally to
X10/04. This terminal or X10/04 must be connected to earth at one
common point in the drive system.
X10/03
STO B Input
0V or not connected = drive will not run, STO is active on channel B.
24V = drive is enabled to run if X10/01 is also 24V.
This input is optically isolated from all other inverter terminals except
X10/01, X10/02 and X10/04.
X10/04
STO Common
2
Signal return for STO A Input and STO B Input. Connected internally to
X10/02. This terminal or X10/02 must be connected to earth at one
common point in the drive system.
X10/05
STO Status A
Together with X10/06, this terminal forms an isolated solid-state relay
output.
This output is ON (equivalent to closed relay contacts) when the STO
circuit is in the ‘safe’ state, i.e. the drive will not cause its motor to produce
torque.
However, this output should be used primarily as an indication. In the
unlikely event of a fault in the STO circuit, this output could turn on
erroneously to give a false indication of the STO status. It must not be used
as a guarantee that the motor will not produce torque.
The solid-state relay is protected by a self-resetting fuse.
X10/06
STO Status B
Together with X10/05, this terminal forms an isolated solid-state relay
output. See the description for X10/05.
3
Do not connect both X10/02 and X10/4 to earth, otherwise an earth loop could be created.
Page 86
6-8 Safe Torque Off
AC30 series Variable Speed Inverter
Examples of wiring to X10/05 and X10/06.
Active high output:
The load is energised and X10/05 is high when
STO is in the intended safe STO state.
Active low output:
The load is energised and X10/06 is low when STO is in
the intended safe STO state.
The examples show the use of the 24V supply provided on X12/05 (+24V) and X12/06 (0V) as source of power to a load. Alternatively an external 24V
supply could be used.
Note: If a drive is powered from 24V only, i.e., 24V is applied to terminals X12/05 or X12/06 and the 3 phase power is off, the STO user output will still
reflect the status of the two STO user inputs.
24VDC
INVERTER
X10/06
X12/05
X12/06
X10/05
LOAD
24VDC
INVERTER
X10/06
X12/05
X12/06
X10/05
LOAD
Page 87
Safe Torque Off 6-9
AC30 series Variable Speed Inverter
STO Technical Specification
INPUTS SPECIFICATION
STO A Input and STO B Input comply with IEC61131-2. Note: inputs do not have hysteresis.
Recommended input voltage for low level: 0V to +5V
Recommended input voltage for high level: +21.6V to +26.4V
Typical input threshold voltage: +10.5V
Indeterminate input range: +5V to +15V. Function is undefined.
Absolute maximum input voltage: -30V to +30V
Typical input current @ 24V 9mA
Fault detection time4: 2.3sec typical;
< 1.6sec will not generate a fault
> 3.0sec will generate a fault.
Response time5 > 2ms
6ms typical
< 10ms
Conditions in which the STO inputs are operative: All, i.e. STO cannot be disabled in any condition
4
A fault is defined in this context as STO A Input and STO B Input being sensed in opposite logic states.
5
Response time is the time from the first STO input becoming active (voltage level is low) until torque production has ceased
Page 88
6-10 Safe Torque Off
AC30 series Variable Speed Inverter
OUTPUT SPECIFICATION
OFF state:
Maximum applied voltage: ±30V (X10/06 relative to X10/05)
Leakage current: Less than 0.1mA.
ON state:
Maximum output current: 150mA
Overcurrent protection: Included
Resistance between output terminals: Less than 6Ω.
WARNING
WIRED CONNECTIONS TO TERMINALS X10/01, X10/03, X10/05 AND X10/06 MUST BE LESS THAN 25 METRES IN LENGTH
AND REMAIN WITHIN THE CUBICLE OR DRIVE ENCLOSURE. PARKER IS NOT LIABLE FOR ANY CONSEQUENCES IF
EITHER CONDITION IS NOT MET.
Page 89
Safe Torque Off 6-11
AC30 series Variable Speed Inverter
TRUTH TABLE
Overview
STO Input A
X10/01
STO Input B
X10/03
Drive Function
STO Status Output
X10/05, X10/06
STO Active
0V
0V
Drive cannot start or supply power to its motor. STO trip
reported.
This is the intended safe state of the product with correct
dual-channel operation.
ON
Abnormal
one-channel
operation
detection
24V
0V
Drive cannot start or supply power to its motor. STO trip
reported. If either of these conditions persists for more than
3.0 seconds (the maximum fault detection time), the STO
function will lock into a fault state. The drive cannot start until
the fault is rectified; all power is removed and reapplied (both
mains and any auxiliary 24V dc power).
This is single channel operation and thus deemed not as
intended for category 3 / PLe / SIL3 structure
implementation.
OFF
0V
24V
STO Inactive
24V
24V
Drive is enabled to run under software control. The drive can
supply power to its motor.
OFF
Drive
unpowered
Don’t care
Don’t care
Drive cannot start or supply power to its motor.
OFF
Page 90
6-12 Safe Torque Off
AC30 series Variable Speed Inverter
STO Input Timing Diagrams
IDEAL OPERATION
In ideal operation, both inputs X10/01 and X10/03 should change state simultaneously reflecting true dual-channel operation as intended.
States:
1 Both inputs are low. Drive is tripped and STO prevents the drive from starting. User output is ON. This is the “safe torque off” state of
the drive.
2 Both inputs are high. Drive is able to run under software control. User output is OFF.
Channel A: X10/01
Channel B: X10/03
Output: X10/05, X10/06
STATE
24V
0V
24V
0V
ON
OFF
1
2
1
Page 91
Safe Torque Off 6-13
AC30 series Variable Speed Inverter
TYPICAL OPERATION
In typical operation, there can be a small time difference between changes of state on X10/01 and X10/03, due to different delays in the operation of two
sets of relay contacts.
States:
1 Both inputs are low. Drive is tripped and STO prevents the drive from starting. User output is ON. This is the “safe torque off” state of the drive.
2 Both inputs are high. Drive is able to run under software control. User output is OFF.
3 One input is high and the other input is low. Drive is tripped and cannot start due to STO action. User output is OFF. Normal operation allows this
state to persist for up to 1.6 seconds which is the minimum fault detection time required to generate a fault (3.0 seconds is the maximum). These
tolerable time differences are normally caused by switches or relays; they should be kept as short as possible.
Channel A: X10/01
Channel B: X10/03
Output: X10/05, X10/06
STATE
24V
0V
24V
0V
ON
OFF
1 2 1
3
< 1.6s 3 < 1.6s
Page 92
6-14 Safe Torque Off
AC30 series Variable Speed Inverter
FAULT OPERATION
A fault is always detected when X10/01 and X10/03 are in opposite states for more than 3.0 seconds.
States:
1 Both inputs are low. Drive is tripped and STO prevents the drive from starting. User output is ON. This is the “safe torque off” state of the drive.
3 One input is high and the other input is low. Drive is tripped and STO prevents the drive from starting. In this example, this state persists for more
than 3.0 seconds (being the maximum fault detection time), after which time the STO logic transitions to state 4 without further changes in input
state. The inverter has detected a fault or single-channel operation.
4 The fault state (one input high, the other input low) has persisted for longer than 3.0 seconds (being the maximum fault detection time). The STO
hardware logic locks into state 4. The drive is tripped and the STO function prevents the drive from starting. User output is OFF. To exit from state 4,
the drive must be powered off (all power removed including any auxiliary 24Vdc) and back on.
DANGER
OPERATION OF THE INVERTER UNIT SHOULD CEASE IMMEDIATELY AND THE UNIT SHOULD BE RETURNED TO A PARKER
AUTHORIZED REPAIR CENTRE FOR INVESTIGATION AND REPAIR.
FAILURE TO DO SO COULD RESULT IN INJURY, DEATH OR DAMAGE.
FURTHER OPERATION OF THE INVERTER WITHOUT RESOLVING THIS FAILURE IS ENTIRELY AT THE USER’S OWN RISK.
SEE SAFETY CATEGORY DEFINITIONS AND LIMITATIONS, REFER TO EN ISO 13849-1:2008.
Channel A: X10/01
Channel B: X10/03
Output: X10/05, X10/06
STATE
24V
0V
24V
0V
ON
OFF
3.0s
1 3 4
Page 93
Safe Torque Off 6-15
AC30 series Variable Speed Inverter
PULSED INPUTS
Some safety equipment, e.g. safety PLCs, regularly pulse the two STO inputs independently in order to detect a short circuit between them. This is
commonly known as OSSD (Output Signal Switch Device). The inverter STO inputs are immune to such pulses when they are less than 2ms in width.
The product will not react to such pulses and therefore will not inadvertently invoke the STO function.
States:
1 Both inputs are low. Drive is tripped and STO prevents the drive from starting. User output is ON. This is the “safe torque off” state of
the drive.
2 Both inputs are high, but regularly pulse low independently. External equipment can thus detect a short circuit between the two STO
user inputs. Each input must remain low for 6ms (typical) before the inverter reacts to it.
2 1
<2ms <2ms typ 6ms
Channel A: X10/01
Channel B: X10/03
Output: X10/05, X10/06
STATE
24V
0V
24V
0V
ON
OFF
Page 94
6-16 Safe Torque Off
AC30 series Variable Speed Inverter
STO State Transition Diagram
The flow chart below shows how the drive responds to STO inputs, start and stop commands.
Key:
* = One channel operation
** = Two channel operation
Transitional state.
User should avoid
remaining in this
state
Fault state
Normal state
Out-of-box state
Normal startup state
X10/01 low
X10/03 low
Drive cannot run **
X10/01 low
X10/03 high
Drive cannot run *
X10/03 high
X10/01 high
X10/01 low
X10/03 low
X10/01 high
X10/03 low
Drive cannot run *
X10/01 high
X10/03 high
Drive enabled but
not running
X10/03 high
X10/03 low
X10/01 high
X10/01 low
X10/01 high
X10/03 high
Drive runs
X10/03 low
X10/01 low
START command
STOP command
Fault state
Drive cannot run.
ALL Power must
be cycled
2.3 seconds (typical)
2.3 seconds (typical)
Page 95
Safe Torque Off 6-17
AC30 series Variable Speed Inverter
STO Trip Annunciation
The GKP will display a STO trip message when STO becomes active, i.e. STO prevents the drive from starting, thus:
GKP Display
This message is displayed immediately if, on starting the drive or whilst the drive is running:
One or both STO user inputs X10/01 or X10/03 is low when the user attempts to start the drive, or
One or both STO user inputs X10/01 or X10/03 goes low while the drive is running, or
The inverter has detected a fault in the STO circuit.
Note: an out-of-box inverter will report this trip if the drive, as supplied, has no connections to X10 when it is first started. Appropriate
connections must be made to X10 to prevent this trip from occurring, as described elsewhere in this chapter. The user must decide if STO is
to be permanently inactive, or to make use of the STO feature. If the STO feature is not required, see the “Applications that do not require
STO function” section on page 6-20.
STO is inserted into the trips history buffer (see Chapter 10 Trips & Fault Finding) if STO is active when the drive is commanded to start or if
STO becomes active while the drive is running, indicating an abnormal condition. The trips history buffer is not updated if STO becomes
active while the drive is not running.
Note: The normal method of operation is for STO to become active while the drive is not running and the motor is stationary.
Appropriate, application specific risk assessment is necessary when STO is activated on rotating motors, moving loads or when external
forces such as gravitation or inertial loads act on the motor.
**** TRIPPED ****
SAFE TORQUE OFF
Page 96
6-18 Safe Torque Off
AC30 series Variable Speed Inverter
Safety Warnings and Limitations
Only competent personnel are permitted to install the STO function and commission it. They must disseminate and make available all
appropriate instructions and documentation to all personnel who may come into contact with or operate the STO and provide suitable
training on the inverter to ensure it is operated in the correct manner and to avoid damage, injury or loss of life.
The inverter STO function is a factory-fitted and factory-tested feature. Repairs to the inver STO featured-product are to be carried out
only by Parker authorized repair centres. Any unauthorised attempt to repair or disassemble the product will render any warranty null and
void, and STO integrity could be impaired. PARKER WILL NOT ACCEPT ANY LIABILITY FOR FAILURE TO OBEY THESE
INSTRUCTIONS OR FOR ANY CONSEQUENTIAL INJURY, DEATH, LOSS OR DAMAGE.
It is important that the inverter product environment including all aspects of its CE conformance and IP etc., specified elsewhere in this
manual, is maintained to ensure the safety integrity of the STO function.
Should synchronous motors be operated in the field weakening range, operation of the STO function may lead to overspeed and
destructive overvoltages as well as explosions in the drive. Therefore, the STO function must NEVER be used with synchronous drives in
the field-weakening range. The user must ensure this condition is prevented.
When using synchronous permanent magnet motors, shaft movement over a small angle is possible if two faults occur simultaneously in
the power section of the drive. This depends on the number of motor poles. The maximum angle is:
Rotary motors: 360° / number of poles.
Linear motors: 180° electrically.
It is the user’s responsibility to assess, validate and safeguard as necessary against this potential hazard.
If external forces can act on the motor and/or load to cause it to move, additional measures must be taken by the user to restrain it, for
example a mechanical brake. Examples of external forces are suspended loads (effect of gravity), and other web-tensioning devices.
The inverter STO feature does not provide or guarantee any galvanic isolation in accordance with EN 60204-1:2006 A1:2009 Section 5.5.
This means that the entire system must be isolated from the mains power supply with a suitable electrical isolation device before any
drive or motor maintenance or replacement procedures are attempted. Note that even after the power has been isolated, dangerous
electrical voltages may still be present in the inverter. Safe discharge times and details are specified in Chapter 1 Safety of this manual.
The STO function must not be used for electrical isolation of the inverter and power. Whenever any personnel require to work on the
drive, associated motor or other power items, they must always use recognised and suitable electrical isolation devices.
Terminal X10/02 or X10/04 must be connected to earth at one common point in the drive system. For multi-drive systems this can be a
shared earth point.
The STO user output, serial communications or GKP messages relating to accessing or viewing any safety monitoring statuses are for
information only and should not be relied on. They are not part of the drive module safety system and its associated PL/SIL declared
ratings. Any customer use of these must be appropriately risk assessed in accordance with the relevant standards or regulations.
The STO safety function must be tested regularly. The frequency should be determined by the machinery builder. An initial minimum
frequency of once per week is suggested. Refer to page 6-26 and following pages.
When using an external safety control unit with adjustable time delay, for example when implementing an SS1 function, the time delay
must be protected to prevent unauthorized adjustment. The adjustable time delay on the safety control unit must be set to a value greater
Page 97
Safe Torque Off 6-19
AC30 series Variable Speed Inverter
than the duration of the braking ramp controlled by the inverter with maximum load inertia and from maximum speed. Any external forces
must also be considered, e.g. effects due to gravity.
When implementing a SS1 function with the inverter, the user is responsible for ensuring the drive’s configuration will allow a controlled
braking ramp to be initiated by the external safety device. This is particularly important when using serial link communications for normal
control of the drive.
During the active braking phase of SS1 or Stop category 1 (controlled stop with safely monitored time delay according to EN60204-
1:2006), faulty operation of the drive must be allowed for. If a fault in the drive system occurs during the active braking phase, the load
may coast to a stop or might even actively accelerate until expiration of the defined time delay. It is not the remit of this document to
specify these measures. This is for the user to assess.
When the inverter detects either an internal STO fault or an external single-channel user fault, the user must immediately fully resolve the
fault. The user must ensure dual-channel operation has been fully restored before attempting to use the inverter STO safety feature.
DANGER
FAILURE TO DO SO COULD RESULT IN STO NOT BEING ACHIEVABLE, AND THUS THE MOTOR MAY ROTATE UNEXPECTEDLY
AND COULD RESULT IN INJURY, DEATH OR DAMAGE. FURTHER OPERATION OF THE INVERTER WITHOUT RESOLVING THIS
FAILURE IS ENTIRELY AT THE USER’S OWN RISK. SEE SAFETY CATEGORY DEFINITIONS AND LIMITATIONS, REFER TO EN ISO
13849-1:2008.
It is the user’s responsibility to ensure that their overall control implementation recovers safely from supply loss or dips.
In all instances it is the user’s responsibility formally to perform suitable risk assessments, and invoke and fully validate the necessary risk
reduction measures after having thoroughly understood the application, the drive product and its features. Of special relevance is to assess
the risk of the two STO user inputs shorting together.
Page 98
6-20 Safe Torque Off
AC30 series Variable Speed Inverter
EXAMPLE USER WIRING
WARNING
THE WIRING EXAMPLES SHOWN IN THIS SECTION ARE FOR ILLUSTRATION ONLY. THEY ARE NOT TO BE CONSIDERED
FINAL DESIGNS, NOR AS AN ATTEMPT TO CREATE A DESIGN FOR SPECIFIC SOLUTIONS.
THE USER / INSTALLER IS RESPONSIBLE FOR DESIGNING A SUITABLE SYSTEM TO MEET ALL REQUIREMENTS OF THE
APPLICATION INCLUDING ASSESSING AND VALIDATING IT. PARKER WILL NOT ACCEPT ANY LIABILITY FOR FAILURE TO
DO THIS OR FOR ANY CONSEQUENTIAL LOSS OR DAMAGE.
APPLICATIONS THAT DO NOT REQUIRE STO FUNCTION
Here the STO inputs X10/01 and X10/03 have been set to the inactive state (tied to +24V). Drive control is performed solely through software with no
inherent safety function. The drive is controlled with its own start and stop pushbuttons.
Note: Only X10/02 or X10/4 must be earthed, i.e. they should not both be earthed otherwise it is possible to create an earth loop.
STO inputs X10/01 and X10/03 must be
connected to 24VDC with respect to
terminals X10/02 or X10/04.
STO Status output on X10/05 and X10/06
may be left disconnected.
All wiring shown is within the control cubicle.
DRIVE
START
DRIVE
STOP
24VDC
X13/02
X12/01
X10/01
X10/03
X10/06
X12/05
X12/06
X10/05
X10/04
X10/02
Page 99
Safe Torque Off 6-21
AC30 series Variable Speed Inverter
MINIMUM STO IMPLEMENTATION
This example shows the minimum connections required. To reset from STO requires that STO Request contacts are closed to permit normal drive
operation. The user must do a risk assessment to ensure that all safety requirements are met. The user must select and assess appropriate equipment.
Note: all wiring shown is within the control cubicle.
To run the drive:
Ensure the STO Request contacts are closed.
Press the DRIVE START button.
To perform operational (not STO) stop:
Press the DRIVE STOP button.
Wait for the motor to come to rest.
To invoke STO:
Press the DRIVE STOP button.
Wait for the motor to come to rest.
Open the STO Request contacts simultaneously. The
contacts must remain open for the entire duration that STO
is required: they must not be momentary action switches.
The drive will confirm via X10/05 that STO has been invoked
by the lamp being ON.
If the lamp is OFF, do not access the machine as a fault may
be present.
Note: if the STO Request contacts open while the motor is
rotating, the motor will coast to rest (unless external forces
act on it).
DRIVE
START
DRIV
E
STO
REQUEST
INVERTER STO
24VDC
X13/02 X12/01
X10/01
X10/03
X10/06
X12/05
X10/02
X10/04 X10/05
X12/06
Page 100
6-22 Safe Torque Off
AC30 series Variable Speed Inverter
STO IMPLEMENTATION WITH SAFETY CONTROL UNIT
This example improves on the previous one by showing the resetting from a STO stop. The example shows wiring and terminal numbering for a
Siemens 3TK2827, but similar products are available from other vendors. Use of this Siemens part does not imply it is suitable for the user’s application.
The user must select and assess appropriate equipment.
Note: On power-up, the safety control unit outputs are OPEN; thus the STO state is requested of the inverter. The latter responds by energising KA1 if both
channels are active and healthy. KA1 is used as a self-check for the reset cycle of the safety control unit. If a reset cannot be achieved due to KA1
being de-energised, a fault may be present and must be resolved by the user before relying on the STO function. See Fault Operation on page 6-14.
DRIVE
START
DRIVE
STOP
SAFETY
DEMAND
INVERTER STO
24VDC
SAFETY CONTROL UNIT
RESET
KA1
KA1
POWER
SUPPLY
THIS WIRING MUST BE WITHIN THE CONTROL CUBICLE.
X10/01
X10/03
X10/06
X13/02
X12/01
X12/05
X10/02
X10/04
X10/05
X12/06
A1
Y10
Y11
Y12
Y21
Y22
13
23
A2
PE
Y33
Y34
14
24
Loading...