Watson-Marlow Varmeca 30 User Manual

3776 en - 07.2007 / h
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VARMECA 30
Variable speed motor or geared motor
Installation and maintenance
LEROY-SOMER
INSTALLATION AND MAINTENANCE
3776 en - 07.2007 / h
VARMECA 30
Variable speed motor or geared motor
NOTE
LEROY-SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments. The information contained in this document may therefore be changed without notice.
CAUTION
For the user’s own safety, this VARMECA 30 motor must be connected to an approved earth ( terminal). If accidentally starting the installation is likely to cause a risk to p ersonnel or the machines being driven, it is essential to supply the equipment via a circuit-breaking device (power contactor) which can be controlled via an external safety system (emergency stop, detection of errors on the installation).
The VARMECA 30 motor is fitted with safety devices which, in the event of a fault, control stopping and thus stop the motor. The motor itself can become jammed for mechanical reasons. Voltage fluctuations, and in particular power cuts, may al so cause the motor to stop. The removal of the causes of the shutdown can lead to restarting, which may be dangerous for certain machines or installations. In such cases, it is essential that the user takes appropriate precautions against the motor restarting after an unscheduled stop. The variable speed drive is designed to be able to supply a motor and the driven machine above its rated speed. If the motor or the machine are not mechanically designed to withstand such speeds, the user may be exposed to serious danger resulting from their mechanical deterioration. It is important that the user checks that the installation can withstand it, before programming a high speed. The variable speed drive which is the subject of this manual is designed to be integrated in an installation or an electrical machine, and can under no circumstances be considered to be a safety device. It is therefore the responsibility of the machine manufacturer, the designer of the installation or the user to take all necessary precautions to ensure that the system complies with current standards, and to provide any devices required to ensure the safety of equipment and personnel.
LEROY-SOMER declines all responsibility in the event of th e above recommendations not being observed.
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LEROY-SOMER
INSTALLATION AND MAINTENANCE
3776 en - 07.2007 / h
VARMECA 30
Variable speed motor or geared motor
SAFETY AND OPERATING INSTRUCTIONS FOR ELECTRICAL ACTUATORS (In accordance with the low voltage directive 73/23/EEC modified by 93/68/EEC)
• Throughout the manual, this symbol warns of
consequences which may arise from inappropriate use of the VARMECA 30, since electrical risks may lead to material or physical damage as well as constituting a fire hazard.
1 - General
Depending on their degree of protection, VARMECA 30 motors may contain moving parts, as well as hot surfaces, during operation. Unjustified removal of protection devices, incorrect use, faulty installation or inappropriate operation could represent a serious risk to personnel and equipment. For further information, consult the manual. All work relating to transportation, installation, commissioning and maintenance must be performed by experienced, qualified personnel (see IEC 364 or CENELEC HD 384, or DIN VDE 0100 and national specifications for installation and accident prevention). In these basic safety instructions, qualified personnel means persons competent to install, mount, commission and operate the product and possessing the relevant qualifications.
2 - Use
VARMECA 30 motors are components designed for integration in installations or electrical machines. When integrated in a machine, commissioning must not take place until it has been verified that the machine conforms with directive 89/392/EEC (Machinery Directive). It is also necessary to comply with standard EN 60204, which stipulates in particular that electrical actuators (which include VARMECA 30) cannot be regarded as circuit-breaking devices and certainly not as isolating switches. Commissioning can take place only if the requirements of the Electromagnetic Compatibility Directive (89/336/EEC, modified by 92/31/EEC) are met. VARMECA 30 motors meet the requirements of the Low Voltage Directive 73/23/EEC, modified by 93/68/EEC. The harmonised standard of the DIN VDE 0160 series in connection with standard VDE 0660, part 500 and EN 60146/ VDE 0558 are also applicable. The technical characteristics and instructions concerning the connection conditions specified on the nameplate and in the documentation provided must be observed without fail.
4 - Installation
The installation and cooling of equipment must comply with the specifications in the manual supplied with the product. VARMECA 30 motors must be protected against excessive stress. In particular, there must be no damage to parts and/or modification of the clearance between components during transportation and handling. Avoid touching the electronic components and contact parts. VARMECA 30 motors contain parts which are sensitive to electrostatic stress and may be easily damaged if handled incorrectly. Electrical components must not be exposed to mechanical damage or destruction (risks to health!).
5 - Electrical connection
When work is performed on VARMECA 30 motors which are powered up, national accident prevention specifications must be respected. The electrical installation must comply with the relevant specifications (for example conductor cross-sections, protection via fused circuit-breaker, connection of protective conductor). More detailed information is given in the manual. Instructions for an installation which meets the requirements for electromagnetic compatibility, such as screening, earthing, presence of filters and correct insertion of cabl es and conductors, are given in the documentation supplied with the VARMECA 30. These instructions must be followed in all cases, even if the VARMECA 30 carries the CE mark. Adherence to the limits given in the EMC legisl ation is the responsibility of the manufacturer of the installation or the machine.
6 - Operation
Installations incorporating VARMECA 30 motors must be fitted with additional protection and monitoring devices as laid down in the current relevant safety regulations: law on technical equipment, accident prevention regulations, etc. Modification of VARMECA 30 motors using control software is permitted. Active parts of the device and live power connections must not be touched immediately after the VARMECA 30 is powered down, as the capacitors may still be charged. In view of this, the warnings fixed to VARMECA 30 motors must be observed. During operation, all protective covers must remain closed.
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3 - Transportation, storage
All instructions concerning transportation, storage and correct handling must be observed. The climatic conditions sp ecified in the technica l manual must be observed.
7 - Servicing and maintenance
Refer to the manufacturer’s documentation.
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LEROY-SOMER
INSTALLATION AND MAINTENANCE
VARMECA 30
Variable speed motor or geared motor
Notes
3776 en - 07.2007 / h
38
LEROY-SOMER
INSTALLATION AND MAINTENANCE
3776 en - 07.2007 / h
VARMECA 30
Variable speed motor or geared motor
CONTENTS
1 - GENERAL INFORMATION.............................................................................................................................. 40
1.1 - General operating principle............................................................................................................................. 40
1.2 - Product name................................................................................................................................................. 40
1.3 - Characteristics............................................................................................................................................... 41
1.4 - Environmental characteristics........................................................................................................................ 43
1.5 - Radio-frequency interference......................................................................................................................... 43
1.6 - Description of cables and protection devices................................................................................................. 46
1.7 - UL conformity................................................................................................................................................. 47
1.8 - Weights and dimensions................................................................................................................................ 48
2 - INSTALLATION................................................................................................................................................ 49
2.1 - General.......................................................................................................................................................... 49
3 - CONNECTIONS ............................................................................................................................................... 49
3.1 - Wiring precautions......................................................................................................................................... 49
3.2 - Control terminal blocks .................................................................................................................................. 50
3.3 - Power terminal blocks.................................................................................................................................... 52
3.4 - Terminal blocks for options............................................................................................................................ 52
3.5 - Wiring diagrams............................................................................................................................................. 53
3.6 - Power supply and control for FCR brake motors........................................................................................... 57
3.7 - Brake rectified voltage depending on the mains supply................................................................................. 58
3.8 - Example of supplying 2 motors, with or without brake, in parallel, with a single VARMECA......................... 59
3.9 - Wiring diagrams for SO VMA and VMA ESFR options.................................................................................. 60
4 - COMMISSIONING............................................................................................................................................ 62
4.1 - Starting with the power supply....................................................................................................................... 62
4.2 - Starting with remote volt-free contact ............................................................................................................ 62
4.3 - Starting with local run/stop control (BMA 31/32, BMA 33/34 or BMAVAR 31/32,
BMAVAR 33/34 OPTION) ............................................................................................................................. 62
4.4 - Setting the speed........................................................................................................................................... 62
5 - FAULTS-DIAGNOSTICS.................................................................................................................................. 63
6 - MAINTENANCE ............................................................................................................................................... 63
6.1 - Care............................................................................................................................................................... 63
6.2 - Measurements............................................................................................................................................... 63
7 - OPERATING EXTENSIONS ............................................................................................................................ 64
7.1 - Speed control knob option (B 31/32 or B 33/34)............................................................................................ 64
7.2 - Control knob with integrated run-stop control option (BMA31/32 or BMA 33/34) .......................................... 64
7.3 - Control knob with forward/reverse/stop control option (BMAVAR 31/32
or BMAVAR 33/34)........................................................................................................................................ 64
7.4 - Internal speed control option (CVI VMA 31/32 or CVI VMA 33/34) ............................................................... 64
7.5 - IP 65 braking resistor option (RF100 – RF 200 – RF 600) ............................................................................ 65
7.6 - IP 20 external braking resistor option (RF – BRR – 800 – 200)..................................................................... 65
7.7 - Electromechanical brake power supply and control option (SO VMA 31/32) ................................................ 65
7.8 - Additional I/O interface and sequential brake control option (ESFR VMA 31/32).......................................... 6
7.9 - Addit
7.10 - Fieldbus options................................ ... ... ... .... ...................................... .... ... ... ... ........................................... 65
7.11 - Encoder feedback option (COD VMA 33/34).............................................................. ... ... .... ... ... ... .............. 65
7.12 - Parameter-setting console option (PX LCD)................................................................................................ 66
7.13 - Parameter-setting software option (SOFTVMA 30) ... .... ... ... ... ..................................................................... 66
7.14 - Operator display option (PAD VMA 30) ....................................................................................................... 66
7.15 - XPress Key.................................................................................................................................................. 66
7.16 - EMC filter (FLT VMA 33/FLT VMA34) ......................................................................................................... 67
7.17 - EMC filter option (FLT VMA 31M)................................................................................................................ 67
7.18 - EMC filter option (FLT VMA 31/32).............................................................................................................. 67
ional I/O interface and sequential brake control option (ESFR VMA 33/34).......................................... 65
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LEROY-SOMER
INSTALLATION AND MAINTENANCE
3776 en - 07.2007 / h
VARMECA 30
Variable speed motor or geared motor
GENERAL INFORMATION
1 - GENERAL INFORMATION
• This manual describes the characteristics and installation of the VARMECA 31ML, 31M, 31TL, 31T, 32M, 32TL, 32T,
33TL, 33T, 34TL, 34T.
• The VARMECA 30 is designed to operate in an industrial environment. When used with an e xternal EMC filter, the VARMECA 30 complies with standards for residential environment.
• If the run command has been enabled, the motor starts as soon as it is switched on.
1.1 - General operating principle
The VARMECA 30 is the physical association of a 3-phase induction motor and an integrated variable speed drive. The motor allows all kinds of mounting arrangement (foot or flange) and can be combined with standard gearboxes from the LEROY-SOMER range. In the standard version, the drive with integrated control does not require any connection other than the power supply.
The options may be used to broaden the application range of the VARMECA 30. Thanks to the advanced technology of the IGBT power module, very high efficiency and reduced noise levels are possible.
1.2 - Product name
Single-phase power supply
115 V ±10% - 50/60 Hz
Rating
31 ML 025 0.25 31 M 025 0.25 31 TL 025 0.25 31 T 025 0.25 31 ML 037 0.37 31 M 037 0.37 31 TL 037 0.37 31 T 037 0.37
Power (kW)
Single-phase power supply
200/240 V ±10% - 50/60 Hz
Rating Power (kW) Rating Power (kW) Rating Power (kW)
31 M 055 0.55 31 TL 055 0.55 31 T 055 0.55 31 M 075 0.75 31 TL 075 0.75 31 T 075 0.75 32 M 090 0.90 32 TL 090 0.90 31 T 090 0.90 32 M 110 1.1 32 TL 110 1.1 31 T 110 1.1 32 M 150 1.5 32 TL 150 1.5 32 T 150 1.5
3-phase power supply
200/240 V ±10% - 50/60 Hz
32 TL 180 1.8 32 T 180 1.8 32 TL 220 2.2 32 T 220 2.2 33 TL 300 3 32 T 300 3 33 TL 400 4 32 T 400 4 34 TL 550 5.5 33 T 550 5.5 34 TL 750 7.5 33 T 750 7.5
3-phase power supply
400/480 V ±10% - 50/60 Hz
34 T 900 9 34 T 111 11
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LEROY-SOMER
INSTALLATION AND MAINTENANCE
3776 en - 07.2007 / h
VARMECA 30
Variable speed motor or geared motor
GENERAL INFORMATION
OPERA T ING EXTENSIONS
Designation Description
B 31/32 or B 33/34 Integrated speed control knob BMA 31/32 or BMA 33/34 Speed control knob and integrated run-stop control knob BMAVAR 31/32 or BMAVAR 33/34 Speed control knob and integrated stop forward/reverse control knob CVI VMA 31/32 or CVI VMA 33/34 Integrated speed control ESFR VMA 31/32 or ESFR VMA 33/34 Brake control RF100 – RF200 – RF600 Braking resistor Power 100, 200 and 600 W RF – BRR – 800 – 200 Braking resistor Power 800 W – External mounting PX LCD Parameter-setting console COD VMA 33/34 Encoder feedback SOFTVMA 30 Parameter-setting software PAD VMA 31/32 or PAD VMA 33/34 Local display unit PX KEY Copy key SO VMA 31/32 Fixed brake control and power supply (3-phase supply 400-480 V only) VMA COM PB 31/32 or VMA COM PB 33/34 Fieldbus: PROFIBUS DP VMA COM IS 31/32 or VMA COM IS 33/34 Fieldbus: INTERBUS S VMA COM DT 31/32 or VMA COM DT 33/34 Fieldbus: DEVICENET VMA COM CN 31/32 or VMA COM CN 33/34 Fieldbus: CAN OPEN FLT VMA 31M EMC filter for residential environment – Internal mounting (for VMA 31M) FLT VMA 31/32 EMC filter for residential environment – Internal mounting (for VMA 31TL/T 32/TL/T) FLT VMA 33 EMC filter for industrial environment – Internal mounting (for VMA 33 TL/T) FLT VMA 34 EMC filter for industrial environment – Internal mounting (for VMA 34 TL/T)
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1.3 - Characteristics
1.3.1 - Electrical data
Power supply
Phase voltage imbalance - 3% Output voltage From 0 V to input voltage From 0 V to input voltage
Power range (kW) 0.25 - 0.37* - 0.55 - 0.75 - 0.9 - 1.1 - 1.5 Maximum number of power-
ups per hour
*0.37 kW max. for 115 V supply (0,75 kW with 310M rating) **7.5 kW max. for 230 V supply
Single-phase supply 110V -10 % to 120V +10 % 50-60Hz ± 2 % 208V -10 % to 240V +10 % 50-60Hz ± 2 %
10 100
1.3.2 - Characteristics and functions
Characteristics V ARMECA 30
- 10 to 80 Hz at constant torque (factory setting can be modified with parameter-setting
Motor frequency variation range
Efficiency 97.5% motor efficiency Overload
option)
- 10 to 50 Hz for general applications (factory setting can be modified with parameter-setting option)
- 0 to Fmax depending on thermal and mechanical limits (Fmax = 400 Hz ; LEROY-SOMER to be consulted anytime the applications requires the drive to run at more than 150 Hz)
150% of In for 60 s 10 times per hour
3-phase supply 208V -10 % to 240V +10 % 50-60Hz ± 2 % 380V -10 % to 480V +10 % 50-60Hz ± 2 %
0.25 - 0.37 - 0.55 - 0.75 - 0.9 -1.1 - 1.5 - 4 -
5.5 - 7.5** - 9 - 11
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LEROY-SOMER
INSTALLATION AND MAINTENANCE
3776 en - 07.2007 / h
VARMECA 30
Variable speed motor or geared motor
GENERAL INFORMATION
Pilot control VARMECA 30
- Analogue reference (0 V or 4 mA) = Minimum speed (10 V or 20 mA) = Maximum speed
- 0 to 10 V with integrated potentiometer (B31/32 – B33/34 option)
Speed reference
Speed regulation
Run/Stop
Forward/Reverse
Stop mode
Ramps - Ramps adjustable from 0 to 600s Fieldbus - PROFIBUS DP, INTERBUS S, DEVICENET, CAN OPEN, MODBUS RTU, LS NET
- 0 to 10 V with remote potentiometer
- 4 to 20 mA with external reference
- Reference with internal potentiometer
- Digital references
- Fieldbus
- Speed regulation with encoder feedback option for VMA 33 or 34 only
- Regulation of a reference with integrated PI loop
- With power supply
- With remote volt-free contact
- With fieldbus
- With local run/stop control
- With internal connection on the terminal block
- With remote volt-free contact
- With fieldbus
- With local run/stop control
- On ramps (using volt-free contact or integrated control)
- Freewheel
- With electromechanical brake
Protection VARMECA 30
- Undervoltage (see notice 3847)
- Overvoltage (see notice 3847)
- Overloads (see notice 3847)
Power
Control - Short-circuit on 0-10 V/24 V inputs or outputs Drive reset
.thermal, drive and motor .protection against locked rotor
- Short-circuit .motor windings
- Overspeed (see notice 3847)
- By switching off the VARMECA 30 or by opening/closing the connection between the 24V and ENA (VMA 31/32) terminals or SDI 1 and SDI 2 (VMA 33/34) terminals
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LEROY-SOMER
INSTALLATION AND MAINTENANCE
VARMECA 30
Variable speed motor or geared motor
GENERAL INFORMATION
1.4 - Environmental characteristics
Characteristics Level
Index of protection IP 65 Storage temperature - 40 °C to + 70 °C Conforming to standard IEC 68-2-1. Transport temperature - 40 °C to + 70 °C Operating temperature - 20 °C to + 50 °C (with power derated by 1% per °C, above 40 °C)
< 1000 m without derating.
Altitude
Ambient humidity 95% non condensing Humidity during storage 93%, 40 °C, 4 days
Vibration
Shocks
Immunity Conforming to EN61000-6-2 Radiated and conducted
emissions UL standards Conforming to UL 508 C (E211799)
The maximum authorised altitude is 4000 m, but above 1000 m, the continuous output current should be derated by 1% per additional 100 m over 1000 m (eg: for an altitude of 3000 m, derate by 20%).
- Exposed product: 0.01 g
- Sinusoidal vibration:
• VMA 31/32 : 2-9 Hz 3,5 ms
• VMA 33/34 : 2-6 Hz 3,5 ms-2 - 6-100 Hz 5 ms in accordance with standard IEC 68-2-6.
Packaged product: 15 g, 6 ms, 500 times/direction in all 6 directions in accordance with standard IEC 68-2-29.
Conforming to EN50081-2 with internal filter
2
/Hz 1 hr in accordance with standard IEC 68-2-34.
-2
- 9-100 Hz 10 ms
-2
-2
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1.5 - Radio-frequency interference
1.5.1 - General
Variable speed drives use high-speed switches (transistors, semi-conductors) which switch high voltages (around 550VDC for 3-phase drives) at high frequencies (several kHz). This provides better efficiency and a low level of motor noise.
As a result, they generate radio-frequency signals which may disturb operation of other equipment or distort measurements taken by sensors:
- due to high-frequency leakage currents which escape to earth via the stray capacity of the drive/motor cable and that of the motor via the metal structures which support the motor
- by conduction or feedback of R.F. signals on the power supply cable: conducted emissions
- by direct radiation near to the mains supply power cabl e or the drive/motor cable: radiated emissions These phenomena are of direct interest to the user. The frequency range concerned (radio frequency) does not affect the energy distribution company.
Conformity of the drive is only assured when the mechanical and electrical installation instructions
described in this manual are adhered to.
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LEROY-SOMER
INSTALLATION AND MAINTENANCE
3776 en - 07.2007 / h
VARMECA 30
Variable speed motor or geared motor
GENERAL INFORMATION
1.5.2 - Standards (Emission)
The maximum emission level is set by the generic industrial (EN 50081-2) and residential (EN 50081-1) standards. VARMECA 30 conforms to the following standards: EN 50081-2, EN 61000-6-4 - EN 61800-3, IEC 61800-3.
Emission
Conformity conditions according to the
switching frequency
Standard Description Application
Second environment with unrestricted distribution (DENR)
Second environment with
EN 61800-3 Variable speed drive standards
EN 50081-1 Generic emission standards for EN61000-6-3
EN 50081-2 Generic emission standards for EN 61000-6-4
residential, commercial and light industrial environments
the industrial environment A.C. supply
restricted distribution (DER) First environment with
unrestricted distribution (R) First environment with restricted
distribution (I)
A.C. supply -
VMA 31/32 10kHz VMA 33/34 11kHz
VMA 31/32 10kHz VMA 33/34 11kHz
VMA 31/32 4kHz
VMA 33/34 4,5kHz
VMA 31 8kHz VMA 32 4kHz
VMA 33/34 4,5kHz
With EMC filter
Internal External
VMA 31/32 10kHz VMA 33/34 11kHz
VMA 31/32 10kHz VMA 33/34 11kHz
-
VMA 31/32 4kHz
VMA 33/34 4,5kHz
VMA 31/32 10kHz VMA 33/34 11kHz
VMA 31/32 4kHz
VMA 33/34 11kHz
VMA 31/32 10kHz VMA 33/34 11kHz
The second environment includes industrial networks supplied with low voltage but which do not serve buildings
for domestic use. Operation of a dr iv e with out an EMC filte r in this ty pe of e nvironment may resu lt in inte rference on certain electronic appliances located near the drive whose immun ity level might not be compatible with industrial conditions. If it proves impossible to filter the disturbed element, add an external EMC filter.
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LEROY-SOMER
INSTALLATION AND MAINTENANCE
3776 en - 07.2007 / h
VARMECA 30
Variable speed motor or geared motor
GENERAL INFORMATION
1.5.3 - Standards (Immunity)
The minimum immunity level is set by the generic industrial (EN 51000-6-2) and residential (EN 51000-6-1) standards. VARMECA 30 conforms to the following standards: EN 61000-4-2, IEC 61000-4-2 - EN 61000-4-3, IEC 61000-4-3 - EN 61000-4-5, IEC 61000-4-5 - EN 61000-4-6, IEC 61000-4-6 EN 61000-4-11, IEC 61000-4-11 - EN 61000-6-2, IEC 61000-6-2 - EN 61000-3, IEC 61000-3.
Immunity
Standard Description Application Conformity
IEC 61000-4-3 Immunity standards for radiated EN 61000-4-3 IEC 61000-4-6 Generic immunity standards for EN 61000-4-6 EN 50082-1 Generic immunity standards for
EN 61000-6-1 EN 50082-2
EN 61000-6-2 EN 61800-3
EN 61000-6-2 EN 61000-4-4 Bursts of fast transients Control cable Level 4 (hardened industrial)
EN 61000-4-5 Shock waves Phase-earth power supply cable Level 4
radio-frequency
conducted radio-frequency
residential, commercial and light industrial environments
Generic immunity standards for the industrial environment
Variable speed drive standards Conforms to the first and second environmentIEC 61000-6-2
shielded cables outside product
Product casing Level 3 (industrial)
Control and power cables
- ConformsIEC 61000-6-1
- ConformsIEC 61000-6-2
Power cable Level 3 (industrial)
Phase-to-phase power supply
cable
Earth signal circuits
(refer to section 1.5.5)
Level 3 (industrial)
Level 3
Level 2
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1.5.4 - Earth leakage current
Earth leakage currents may depend on the type of EMC filter used. The VARMECA 30 can be supplied with its filter integrated and wired-up. The levels of leakage current also depend on the voltage and/or the power supply frequency and the size of the motor. In all cases, for conformity with immunity standards, a voltage limiting device is connected to earth. The shunt current is negligible in normal circumstances.
1.5.4.1 - use of earth leakage detector (residual current device)
1- Type AC: which detects AC faults. Not to be used with variable speed drives. 2- Type A: which detects AC faults and pulsed DC faults (provided that the DC is cancelled out at least once per cycle). Only for use with single-phase drives. 3 - Type B: which detects AC faults, pulsed DC faults and smoothed DC faults. Only this type is suitable for use with
all variable speed drives.
Note: If an external EMC filter is being used, a delay of 50 ms should be incorporated to avoid spurious faults being taken into account.
1.5.5 - Control cable immunity
Control cable immunity can be increased outside the VARMECA 30 by one of the following 2 methods:
• Use of shielded twisted pair cable, with shielding connected to earth around its circumference within 100 mm of the VARMECA 30.
• Passing the cable through a ferrite ring at 100 mm maximum distance from the VARMECA 30.
Note: Several control cables can pass through a single ferrite.
1.5.6 - Control circuit immunity when overvoltage occurs
Immunity to overvoltages in control circuits or in long cables connected to the outside of a building. The various drive input and output circuits conform to standard EN61000-6-2 (1 kV) relating to overvoltages.
There are some exceptions, where the installation may be exposed to overvoltage peaks which exceed the levels determined by the standard. This may be the case in the event of lightning strikes or earth faults associated with long cable lengths (>30 m). To limit the risks of damage to the drive, the following precautions could be taken:
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