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
Contents |
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Safety precautions................................................................................................ |
..1 |
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1. |
OVERVIEW ..................................................................................................... |
..2 |
2. |
INSTALLATION ............................................................................................... |
..3 |
3.OPERATING INFORMATION ........................................................................... |
10 |
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4. CLEAR TEXT DISPLAY MODULE & SYSTEM PARAMETERS............................. |
15 |
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5. |
FAULT CODES ............................................................................................... |
30 |
6. SPECIFICATIONS............................................................................................ |
31 |
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7. SUPPLEMENTARY INFORMATION................................................................ |
34 |
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8. ACCESSOIRES................................................................................................ |
37 |
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 sure that the warning signs are kept in a legible condition and replace missing or damaged signs.
WARNING |
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CAUTION |
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This equipment contains hazardous voltages and |
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Children and the general public must be |
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controls hazardous rotating mechanical parts. Loss |
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prevented from accessing or approaching the |
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of life, severe personal injury or property damage |
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equipment! |
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can result if the instructions |
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this |
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• |
This equipment may only be used for the |
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manual are not followed. |
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purpose specified by the manufacturer. |
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Only suitable qualified personnel should work on |
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Unauthorised modifications and the use of |
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this equipment, and only after becoming familiar |
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spare parts and accessories that are not sold |
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with all safety notices, installation, operation and |
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or recommended by the manufacturer of the |
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maintenance procedures contained in this manual. |
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equipment can cause fires, electric shocks |
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The successful and safe operation of this |
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and injuries. |
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equipment is dependent upon its proper handling, |
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• Keep these operating instructions within easy |
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installation, operation and maintenance. |
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reach and give them to all users! |
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• The CombiDrive® operates at high voltages. |
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• ALWAYS isolate the equipment from the power |
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supply before starting any work on it. |
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• The dc-link capacitor remains charged to |
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dangerous voltages even when the power is |
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removed. For this reason it is not permissible |
European Low Voltage & EMC Directives |
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to open the equipment until one minute after |
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the power has been turned off. When handling |
The CombiDrive® product complies with the requirements of the Low |
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the open equipment it should be noted that live |
Voltage Directive 73/23/EEC and the EMC Directive 89/336/EEC. |
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parts are exposed. Do not |
touch |
these live |
The units are certified for compliance with the following standards: |
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parts. |
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• The equipment must not be connected to a |
EN 60204-1 |
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Safety of machinery - Electrical equipment of |
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supply via an ELCB (Earth Leakage Circuit |
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machines |
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Breaker - see DIN VDE 0160, section 6.5). |
EN 60146-1-1 |
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Semiconductor converters - General |
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• The following terminals can carry dangerous |
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requirements and line commutated converters |
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voltages even if the inverter is inoperative: |
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BS EN50081-2: 1995 |
Generic Emission Standard - Industrial |
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-the power supply terminals L1, L2, L3. |
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Environment |
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- the motor terminals U, V, W. |
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BS EN50082-2: 1995 |
Generic Immunity Standard - Industrial |
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• Ensure that the inverter’s cover has been fitted |
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Environment |
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correctly before applying mains power to the |
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CombiDrive® . If a Braking |
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been |
Proviso: The CombiDrive does not meet CE requirements when |
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supplied, ensure that the terminal connections |
an OPm2 is connected. |
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fitted to the underside of the cover mate |
European Machinery Directive |
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correctly with those on the inverter when |
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refitting the cover. |
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The CombiDrive® |
product (combined inverter and motor assembly) is |
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• Only qualified personnel may connect, start the |
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suitable for incorporation into machinery. |
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system up and repair faults. These personnel |
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must be thoroughly acquainted with all the |
The CombiDrive® |
must not be put into service until the machinery into |
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warnings and operating procedures contained |
which it is incorporated has been certified to be in compliance with the |
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in this manual. |
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provisions of the European Directive 89/392/EEC. |
•Certain parameter settings may cause the Note: Only valid for machinery to be operated in the European
motor to restart automatically after an input |
Community. |
power failure. |
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• This equipment must not be used as an |
European EMC Directive |
‘emergency stop’ mechanism (see EN 60204, |
When installed according to the recommendations described in this |
9.2.5.4). |
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manual, the CombiDrive® fulfills all requirements of the EMC directive as |
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defined by the EMC Product Standard for Power Drive Systems |
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EN61800-3. |
© STÖBER plc 1998
05.02.01
English |
2. Installation |
The CombiDrive® is an integrated motor/inverter for variable speed applications.
The inverter is microprocessor-controlled and uses state of the art IGBT technology for reliability and flexibility. 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® via the USS protocol.
•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.
(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.
© STÖBER plc 1998
05.02.01 |
2 |
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2. Installation |
English |
2. INSTALLATION
WARNING
To guarantee the safe operation of the equipment it must be installed and commissioned by 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 regarding the correct use of tools and personal protective gear.
Use the lifting eyes provided if the motor has to be lifted. Do not lift machine sets (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.
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 cable connected to a common star 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 same earth or star point as the inverter via a short, 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 control 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 suppressors for AC contactors or ‘flywheel’ diodes for DC contactors, fitted to the coils. Varistor suppressors are also effective. 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 connections and ground the screen at both ends via the cable glands.
On no account must safety regulations be compromised when installing the CombiDrive® !
© STÖBER plc 1997
3 |
05.02.01 |
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English |
2. 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 transmission 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 halves, 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 transmission 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 rebalancing may be necessary, e.g. by reducing the distance by which the featherkey protrudes from the transmission element and the shaft surface.
WARNING
Take suitable precautions to prevent transmission elements from being touched. If the CombiDrive® is started up without a transmission element attached, the featherkey must be
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 worse at this speed and bearing life is reduced.
The above list is not meant to be exhaustive - additional checks may also be required.
© STÖBER plc 1998
05.02.01 |
4 |
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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.
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Motor-type |
Motor |
Inverter type |
Width (b) |
Dimension |
qx |
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phase |
output rating |
w´ |
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71 K |
0,25 kW |
PM 25/1 |
122 |
182 |
237 |
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single- |
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71 L |
0,37 kW |
PM 37/1 |
122 |
182 |
237 |
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80 K |
0,55 kW |
PM 55/1 |
122 |
193 |
259,5 |
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80 L |
0,75 kW |
PM 75/1 |
122 |
193 |
259,5 |
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Motor-type |
Motor |
Inverter type |
Width (b) |
Dimension |
qx |
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output rating |
w´ |
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71 L |
0,37 kW |
PM 37/3 |
122 |
182 |
237 |
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80 K |
0,55 kW |
PM 55/3 |
122 |
193 |
259,5 |
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phase |
80 L |
0,75 kW |
PM 75/3 |
122 |
193 |
259,5 |
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90 K |
1,1 kW |
PM 110/3 |
171 |
201 |
296 |
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three- |
90 L |
1,5 kW |
PM 150/3 |
171 |
201 |
296 |
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100 K |
2,2 kW |
PM 220/3 |
171 |
234 |
328,5 |
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100 L |
3,0 kW |
PM 300/3 |
171 |
234 |
328,5 |
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112 K |
4,0 kW |
PM 400/3 |
171 |
248,5 |
353 |
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132 K |
5,5 kW |
PM 550/3 |
171 |
264,5 |
372,5 |
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132 L |
7,5 kW |
PM 750/3 |
171 |
264,5 |
372,5 |
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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.
© STÖBER plc 1997
5 |
05.02.01 |
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English |
2. 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 control cables(see Figure 5).
CAUTION
The printed circuit boards contain CMOS components that are particularly sensitive to static electricity. For this reason, avoid touching the boards or components with your hands or metal objects.
Mains Connector * |
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L1 L2 L3 |
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(Yellow) |
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Control Cable Connector |
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(PL800) |
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12 |
1 |
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4 |
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OPm2 Connector |
Control |
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(SK200) |
Potentiometer |
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(R314) |
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Jumpers for |
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PI Input Type |
Analogue Input Type |
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Default = V |
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Default = V |
V |
JP303 |
V |
JP301 |
I |
JP302 |
I |
JP300 |
Note: Jumper in ‘V’ position = voltage input (default) Jumper in ‘I’ position = current input
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 |
*Check that the supply voltage is correct for the COMBIMASTERused by referring to the voltage code part of the order number (see section 6).
Figure 1: Electrical Connection Diagram
© STÖBER plc 1998
05.02.01 |
6 |
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2. Installation |
English |
Ensure that the power source supplies the correct voltage and is designed for the necessary current. Ensure that the appropriate circuit-breakers with the specified 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 core 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.
CAUTION
The control and power supply cables must be laid separately. They must not be fed through the same cable conduit/trunking.
Use screened cable for the control lead.
Feed the control cable into the inverter via the appropriate gland hole (see Figure 3). Unplug connector block PL800 from the PCB and connect the control wires in accordance with the information given in Figures 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.
Relay
(24 Vdc, 1 Amax.)
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PI+ |
PI- |
P15+ |
DIN3 |
DIN2 |
DIN1 |
AIN- |
AIN+ |
0V |
P10+ |
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12 |
11 |
10 |
9 |
8 |
7 |
6 |
5 |
4 |
3 |
2 |
1 |
1 |
2 |
3 |
4 |
RL1C |
RL1B |
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OR |
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(COM) |
(NO) |
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5V |
0V |
N(-) |
P(+) |
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(250 mAmax.) |
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Power Supply |
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Analogue |
Power Supply |
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For USS |
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PI +ve Input |
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(+15 V, max. 50 mA) |
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Input |
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for |
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Protocol |
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(0/2 - 10 Vor |
Analogue Input |
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(0 - 10 Vor 0 - 20 mA) |
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Digital |
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0/4 - 20 mA) |
(+10 V, max. 10 mA) |
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Inputs |
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(7.5 - 33 V, max. 5 mA) |
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PL800 |
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SK200 |
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Telephone Socket |
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Control Terminals |
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(FCC 68 Type 4/4) |
Figure 4a: Control Terminal Connections
© STÖBER plc 1997
7 |
05.02.01 |
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English |
2. Installation |
3
1.8 mm max.
1
2
OR
1
3
2
Figure 4b: Connecting Control Wires to PL800
Figure 2: Cable Connections with Drip Loop
© STÖBER plc 1998
05.02.01 |
8 |
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2. Installation |
English |
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PE |
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3 AC 380 - 500 V |
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SI |
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PL800 |
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+10V(10mAmax.) |
PE |
L1, L2, L3 |
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1 |
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V: 0- 10 V |
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2 |
0V |
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AIN+ |
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2- 10 V OR |
3 |
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AIN- |
A/D |
~ |
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4 |
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I: 0- 20 mA |
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4- 20 mA |
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GR |
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- |
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24V |
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+ |
DIN1 |
5 |
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DIN2 |
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6 |
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DIN3 |
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7 |
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Power supply for |
OR |
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PI feedback |
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+15V |
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transducer or |
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8 |
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other load |
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CPU |
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OR |
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PI -ve Input |
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9 |
A/D |
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PI +ve Input |
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10 |
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ZK |
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Relay |
RL1B |
11 |
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Connections |
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RL1C |
12 |
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WR |
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SK200 |
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3 ~ |
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5V |
1 |
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Connections for |
0V |
2 |
RS485 |
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Serial Link or OPm2 |
PE |
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N (-) |
3 |
PE |
U, V, W |
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I |
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P (+) |
4 |
V |
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PI Input Type |
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JP302 JP303 |
M |
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Analogue Input Type |
3 ~ |
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JP300 JP301 |
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AD |
Analogue to Digital Converter |
CPU |
Microprocessor |
GR |
Rectifier |
M |
Motor |
RS485 |
Serial Interface |
SI |
Mains Fuse |
WR |
Inverter |
ZK |
DCLink Capacitor |
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Figure 3: Block Diagram
© STÖBER plc 1997
9 |
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 cover 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-link 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 the safety precautions and warnings.
(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. Regardless of its initial position, internal potentiometer R314 must be turned fully counter-clockwise before the CombiDrive® can be started.
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 socket (SK200).
(4)Analogue input type selection is determined by jumpers JP300 and JP301. JP300 closed selects current input, JP301 closed (default) selects voltage input. These jumpers can only be accessed while the cover is removed (see Figure 3).
(5)If the CombiDrive® is run unloaded (e.g. for test purposes) and vibration or trip conditions occur, change P077 from 0 to 1 (requires OPm2).
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® cannot be started.
(c)Turn the potentiometer clockwise until the yellow LED extinguishes. This indicates that power is now 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).
© STÖBER plc 1998
05.02.01 |
10 |
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