Siemens CM750-3, CM550-3, CM150-3, CM400-3, CM300-3 User Manual

...

STÖBER CombiDrive

SIEMENS Micromaster integrated

Installation and Commissiong instructions

It ist essential to read and comply with these instructions prior to installation and commissioning!

01/2001

Safety precautions................................................................................................ ..1

1. OVERVIEW ..................................................................................................... ..2

2. INSTALLATION............................................................................................... ..3

3.OPERATING INFORMATION ........................................................................... 10

4. CLEAR TEXT DISPLAY MODULE & SYSTEM PARAMETERS............................. 15

5. FAULT CODES ............................................................................................... 30

6. SPECIFICATIONS............................................................................................ 31

7. SUPPLEMENTARY INFORMATION................................................................ 34

8. ACCESSOIRES................................................................................................ 37

Safety Precautions

Before installing and putting this equipment into operation, please read these safety precautions and warnings carefully and all the warning signs attached to the equipment. Make su re that the warning signs are kept in a legible condition and replace missing or damaged signs.

WARNING

This equipment contains hazardous voltages an controls hazardous rotati ng mec hanical part s. Los of life, severe personal i njury or property damag can result if the instructions contained in thi manual are not followed.

Only suitable qualified personnel should work o this equipment, and only after becoming familia with all safety notices, installation, operation an maintenance procedures contai ned in this manual. The successful and safe operation of thi equipment is dependent upon its proper handling, installation, operation and m ai nt enance.

• The CombiDrive

• ALWAYS isolate the equipment from the powe

supply before starting any work on it.

• The dc-link capacitor remains charged t dangerous voltages even when the power i removed. For this reason it is not perm issibl to open the equipment until one minute afte the power has been turned off. When handlin the open equipment it should be noted that liv parts are exposed. Do not touch these liv parts.

• The equipment must not be connected to supply via an ELCB (Earth Leakage Circui Breaker - see DIN VDE 0160, section 6.5).

• The following terminals can carry dangerou voltages even if the inverter is inoperative:

-the power supply terminals L1, L2, L3.

-the motor terminals U, V, W.

• Ensure that the inverter’s cover has been fi tte correctly before applying mains power to th CombiDrive®. If a Braking Unit has bee supplied, ensure that the term inal connection fitted to the underside of the cover mat correctly with those on the inverter whe refitting the cover.

• Only qualified personnel may connect, st art t h system up and repair faults. These personne must be thoroughly acquainted with all th warnings and operating procedures containe in this manual.

• Certain parameter settings may cause th motor to restart automatically after an inpu power failure.

• This equipment must not be used as a ‘emergency stop’ mechani sm (see EN 60204

9.2.5.4).

operates at high voltages.

CAUTION

• Children and the general public must b prevented from accessing or approaching t h equipment!

• This equipment may only be used for th purpose specified by the manufacturer. Unauthorised modifications and the use o spare parts and accessori es that are not sold or recommended by the manufacturer of th equipment can cause fires, electric shock and injuries.

• Keep these operating instruc tions within eas reach and give them to all users!

European Low Voltage & EMC Directives

The CombiDrive® product complies with the requirements of the Low Voltage Directive 73/23/EEC and the EMC Directive 89/336/EEC.

The units are certified for compliance with the followi ng standards: EN 60204-1 Safety of machinery - E l ectrical equipment of

machines

EN 60146-1-1 Semiconductor convert ers - General

requirements and line commutated converters

BS EN50081-2: 1995 Generic Emission St andard - Industrial

Environment

BS EN50082-2: 1995 Generic Immunity St andard - Industrial

Environment

Proviso: The CombiDrive

an OPm2 is connected.

European Machinery Directive

The CombiDrive® product (combined inverter and motor ass embly) is suitable for incorporation into machinery.

The CombiDrive which it is incorporated has been certified to be in c ompliance with the provisions of the European Directive 89/392/EEC.

Note: Only valid for machinery to be operated in the European

must not be put into serv ice until the machi nery i nto

Community.

European EMC Directive

When installed according to the recommendations described in this manual, the Co mb iD ri ve defined by the EMC Product Standard for Power Drive Systems EN61800-3.

does not meet CE requirements when

fulfills all requirements of the EMC directive as

05.02.01

English 2. Installation

1. OVERVIEW

The CombiDrive® is an integrated motor/inverter for variable speed applications. The inverter is microproc ess or -c ontr olled and us es s tate of the ar t IG BT tec hnology for r eliability and flex ibility.

A special pulse-width modulation method with ultrasonic pulse frequency permits extremely quiet motor operation. Inverter and motor protection is provided by comprehensive protective functions.

Features:

• Easy to install and commission.

• Closed loop control using a Proportional, Integral (PI) control loop function.

• High starting torque with programmable starting boost.

• Remote control capability via RS485 serial link using the USS protocol.

• Ability to control up to 31 CombiDrive

• Optional remote control capability via RS485 serial link using PROFIBUS-DP.

• Factory default parameter settings pre-programmed for European and North American requirements.

• Output frequency (and hence motor speed) can be controlled by one of four methods:

(1) Built-in potentiometer.

via the USS protocol.

(2) High resolution analogue setpoint (voltage or current input). (3) Fixed frequencies via binary inputs. (4) Serial interface.

• Built-in dc injection braking.

• Acceleration/deceleration times with programmable smoothing.

• Single signal relay output incorporated.

• External connection for optional Clear Text Display (OPm2) or for use as external RS485 interface.

• Fast Current Limit (FCL) for reliable trip-free operation.

• Optional factory-fitted resistive braking unit (also available as a separate post-sale option).

• Optional motor brake and interface.

• Integral class A or class B filter options.

05.02.01

2. Installation English

2. INSTALLATION

WARNING

To guarantee the safe operation of the equipment it must be installed and commissioned b qualified personnel only.

Take particular note of the general and regional installation and safety regulations regarding work on high voltage installations (e.g. VDE), as well as the relevant regulations r egarding th correct use of tools and personal protective gear.

Use the lifting eyes provided if the motor has to be lifted. Do not lift machine s ets (e.g. built- on gearboxes, fan units) by suspending the individual machines!

If the PROFIBUS option has been fitted, remove the PROFIBUS module before attaching cables or chains to the lifting eyes.

Always check the capacity of the hoist before lifting any equipment.

2.1 Wiring Guidelines to Minimise the Effects of EMI

The CombiDrive® are designed to operate in an industrial environment where a high level of Electro Magnetic Interference (EMI) can be expected. Usually, good installation practices will ensure safe and trouble free operation. However, if problems are encountered, the following guidelines may prove useful. In particular, grounding of the system 0V at the inverter, as described below, may prove effective.

(1) Ensure that all equipment is well earthed using short, thick earthing c able connec ted to a c ommon s tar

point or busbar. It is particularly important that any control equipment that is connected to the inverter (such as a PLC) is connected to the s ame earth or st ar point as the inv erter via a s hort, thick link. Flat conductors (e.g. metal brackets) are preferred as they have lower impedance at high frequencies.

(2) Wherever possible, use screened leads for connections to the contr ol circuitry. Terminate the ends of

the cable neatly, ensuring that long strands of unscreened wire are not left visible.

(3) Separate the control cables from the power connections as much as possible, using separate trunking,

etc. If control and power cables cross, arrange the cables so that they cross at 90°.

(4) Ensure that contactors in the cubicle are suppressed, either with R-C s uppressors for AC contactors

or ‘flywheel’ diodes for DC contactors, fitted to the coils. Varistor suppressor s are als o effectiv e. This is particularly important if the contactors are controlled from the relay connection on the CombiDrive

(5) Use screened or armoured cables for the power c onnections and ground the screen at both ends v ia

the cable glands.

On no account must safety regulations be compromised when installing the

CombiDrive

05.02.01

English 2. Installation

2.2 Mechanical Installation

Figures 1 and 2 show dimensional information for all CombiDrive® variants.

Note: ‘Case size’ refers to the type of inverter box mounted on the motor. ‘Motor frame’ refers to the motor

frame size only.

Remove or tighten down screw-in lifting eyes prior to using the CombiDrive Stable foundations or mounting conditions, exact alignment of the motors and a well-balanced tr ansmission

element are essential for quiet, vibration-free running. If necessary, insert shims under the motor's feet to prevent strain, or balance the whole rotor and transmission element.

Always use the correct tools for fitting and removing transmission elements (coupling halv es, pulleys, pinions, etc.).

The rotors are dynamically balanced with the full featherkey inserted as standard. Since 1991 the type of balance has been marked on the drive end of the shaft (shaft end face). F denotes balanced with full featherkey; H denotes balanced with half featherkey. Bear in mind the type of balance used when fitting the transmission element.

Poor running characteristics can arise in cases where the trans mission elements have a length ratio of hub length to length of shaft end < 0.8 and they run at speeds of > 1500 rpm. In such cases r ebalancing may be necessary, e.g. by reducing the dis tance by whic h the featherk ey protr udes fr om the tr ansmis s ion element and the shaft surface.

WARNING

Take suitable precautions to prevent transmission elements from being touched. If th

CombiDrive

secured in position to prevent it from flying off while the shaft is rotating.

Please check the following prior to commissioning:

• The rotor turns freely without rubbing.

• The motor is assembled and aligned properly.

• The transmission elements are adjusted correctly (e.g. belt tension) and the transmission element is

suitable for the given operating conditions.

• All electrical connections, mounting screws and connecting elements are tightened and fitted correctly.

• All protective conductors are installed properly.

• Any auxiliary equipment that might be fitted (e.g. brakes) is in working order.

• Protection guards are installed around all moving and live parts.

• The maximum speed (see rating plate) is not exceeded. Note that the maximum speed is the highest

operating speed permitted for short periods. Remember that motor noise and vibration are wors e at this speed and bearing life is reduced.

The above list is not meant to be exhaustive - additional checks may also be required.

is started up without a transmission element attached, the featherkey must b

05.02.01

2. Installation English

CombiDrive® – Dimension (Only dimensions of the motor, total dimensions of the gear motor see

MGS-catalog, Impr.-No. 440 637)

qx = Max. dimension; Given either through the inverter or through the fan cowl.

single-phase

three-phase

Motor-type

71 K 0,25 kW PM 25/1 122 182 237 71 L 0,37 kW PM 37/1 122 182 237 80 K 0,55 kW PM 55/1 122 193 259,5 80 L 0,75 kW PM 75/1 122 193 259,5

Motor-type

71 L 0,37 kW PM 37/3 122 182 237 80 K 0,55 kW PM 55/3 122 193 259,5 80 L 0,75 kW PM 75/3 122 193 259,5 90 K 1,1 kW PM 110/3 171 201 296

90 L 1,5 kW PM 150/3 171 201 296 100 K 2,2 kW PM 220/3 171 234 328,5 100 L 3,0 kW PM 300/3 171 234 328,5 112 K 4,0 kW PM 400/3 171 248,5 353 132 K 5,5 kW PM 550/3 171 264,5 372,5 132 L 7,5 kW PM 750/3 171 264,5 372,5

Motor

output rating

Motor

output rating

Inverter type Width (b)

Dimension

w´

Dimension

w´

Dimension in mm

Installation notes

The position of the inverter related to the gearbox, see MGS-catalog (Impr.-No. 440 637). The rotation of the terminal box is not possible.

05.02.01

English 2. Installation

2.3 Electrical Installation

Remove the four M5 cross-head screws on the inverter's cover to access the electrical terminals (see Figure 3 and Figure 4).

Notes: (1) Refer to the electrical data table for cable sizes (see section 6).

(2) We recommend introducing a `drip loop' when connecting the mains and c ontrol c ables (see

Figure 5).

CAUTION

The printed circuit boards contain CMOS components that are particularly sensitive to stati electricity. For this reason, avoid touc hing the boards or components with your hands or meta objects.

Mains Connector *

L1 L2 L3

Jumpers for

PI Input Type

Default = V

Control Cable Connector

(PL800)

112

Jumpers for

Analogue Input Type

Default = V

JP303

JP302

LED

(Green)

1 4

OPm2 Connector

(SK200)

JP303

JP301

JP300

LED

(Yellow)

Contr ol

Potentiometer

(R314)

IMPORTANT

Ensure that the following tightening torques are used:

Electrical terminal screws: 1.1 Nm Access cover retaining screws: 4.0 Nm Gland hole covers: 1.0 Nm

Jumper in ‘V’ positi on = voltage input (default)

Not e:

Jumper in ‘I’ position = current input

Figure 1: Electrical Connection Diagram

05.02.01

Check that the supply voltage is correct for t he

COMBIMASTER used by referring to the voltage code part of t he or der number (see section 6).

2. Installation English

2.3.1 Mains Cable Connections

Ensure that the power source supplies the correct voltage and is designed for the necessary current. Ens ure that the appropriate circuit-breakers with the s pecified current rating are connected between the power supply and CombiDrive

(see section 6).

Use Class 1 60/75oC copper wire only. Use a 4-core screened cable (for cross-section of each c ore see section 6). If crimp terminals are used then

they must be insulated. If crimps are not used, the strip length must not exceed 5 mm. Feed the power cable into the inverter via the gland hole nearest to the motor shaft (see Figure 3). Connect the

power leads to terminals L1, L2, L3 and the separate earth. Use a 4 - 5 mm cross-tip screwdriver to tighten the terminal screws.

2.3.2 Control Cable Connections

CAUTION

The control and power supply cables must be laid separately. They must not be fed throug the same cable conduit/trunking.

Use screened cable for the control lead. Feed the control cable into the inverter via the appropriate gland hole (s ee Figure 3). Unplug connector block

PL800 from the PCB and connect the control wires in acc ordance with the inform ation given in F igures 4a and 4b (also see Figure 3).

IMPORTANT: A wire link must be fitted between control terminals 5 (DIN1) and 8 (P15+) otherwise the

CombiDrive

will not operate when control potentiometer R314 is used. The wire link must be

removed when operation via a run/stop switch is required.

Plug the connector block back into the PCB, refit the cover and tighten the four securing screws.

Rel ay

(24 V dc, 1 A max.)

P10+0VAIN+AIN-DI N1DIN2

123456

Power Supply

for

Analogue Input

1234

N (- )

For USS Protocol

(250 mA max.)

P (+)

RL1B

RL1C

(COM)

(0 - 10 V or 0 - 20 mA)

(NO)

PI +ve Input

P15+PI-PI+

9101112

Power Supply

(+15 V, max. 50 mA)

DIN3

Dig it al Inputs

(7.5 - 33 V, max. 5 mA)

Analogue

Input

(0/2 - 10 V or

0/4 - 20 mA)

(+10 V, max. 10 mA)

PL800

Control Terminals

Figure 4a: Control Terminal Connections

SK200

Telephone Socket

(FCC 68 Type 4/4)

05.02.01

English 2. Installation

1. 8 mm ma x.

Figure 4b: Connecting Control Wires to PL800

Figure 2: Cable Connections with Drip Loop

05.02.01

2. Installation English

, V,

)

ype

2.3.3 Block Diagram

PE 3 AC 380 - 500 V

Power supply for PI feedback transducer or other load

PI -ve Inpu

PI +ve Input

: 0 - 10

2 - 10

I: 0 - 20 m

4 - 20 m

24 V

Relay Connections

Connections for Serial Link or OPm2

PL800

AIN

AIN-

DIN1

DIN2

DIN

RL1B

RL1C

SK200

5V 0V

N (-

P (+

1 2 3 4

5 6 7

9 10

11 12

1 2 3 4

+10V (10 mA max.

A/D

+15

A/D

RS485 PE

CPU

JP302 JP303

JP300 JP301

PI Input T

Analogue Input Type

3 ~

L1, L2, L3

3 ~

AD CPU GR M RS485 SI WR ZK

Analogue to Digital Converter Microprocessor Rect if ier Mot or Serial Interface Mai ns Fuse Inverter DC Link Capacitor

Figure 3: Block Diagram

05.02.01

English 3. Operating Information

3. OPERATING INFORMATION

WARNING

The equipment must not be switched on until after its cover has been fitted and the cove screws have been tightened to the correct torque.

After the power has been turned off, you must always wait one minute so that the dc-lin capacitors can discharge. Do not remove the cover until this time has elapsed.

All settings must only be entered by qualified personnel, paying particular attention to th safety precautions and warnings.

3.1 General

(1) The CombiDrive® does not have a main power switch and is therefore live when the mains supply is

connected.

(2) When delivered, the inverter has a frequency setpoint range of between 0 Hz and 50 Hz. Regar dless

of its initial position, internal potentiometer R314 must be turned fully counter-clockwise before the

CombiDrive R314 can be accessed by removing the right-hand gland hole cover (see Figure 3). (3) Parameter settings can only be changed by using either the serial interface (SK200) or an optional

Clear Text Display (OPm2). Refer to the parameter list in section 4 for a full description of each

available parameter. Connecting a serial link or the OPm2 to the serial interface is made simple by removing the appropriate gland

hole cover (see Figure 3) and plugging a suitably terminated interface cable into the telephone soc ket

(SK200). (4) Analogue input type selection is determined by jumpers JP300 and JP301. JP300 closed selects

current input, JP301 closed (default) selec ts voltage input. T hese jumpers can only be ac cess ed while

the cover is removed (see Figure 3). (5) If the CombiDrive

change P077 from 0 to 1 (requires OPm2).

can be started.

is run unloaded (e.g. for test purposes) and vibration or trip conditions occur,

3.2 Basic Operation

There are two basic modes of operation for the CombiDrive®. Neither mode requires the use of an OPm2 or serial link connection:

(1) Using the internal potentiometer only:

(a) For forward rotation, ensure that a link is fitted between DIN1 (pin 5) and P15+ (pin 8) on PL800 (see

Figure 4a). For reverse rotation, connect the link to DIN2 (pin 6) instead of DIN1.

(b) Apply mains power. The green and yellow LEDs will illuminate to show that power is applied. Turn

potentiometer R314 fully counter-clockwise, otherwise the CombiDrive

applied to the motor. Continue turning clockwise to increase the speed of the motor.

(d) Turn the potentiometer counter-clockwise to reduce the speed of the motor . Turning the potentiometer

fully counter-clockwise causes the motor to slow to a complete stop. Check that both LEDs are illuminated (STANDBY mode).

05.02.01

cannot be started.

+ 28 hidden pages

Siemens CM750-3, CM550-3, CM150-3, CM400-3, CM300-3 User Manual

Contents

Safety Precautions