WEG Electric CFW-11M User Guide

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Motors | Energy | Automation | Coatings

Frequency Inverter

Convertidor de Frecuencia

Inversor de Freqüência

CFW -11M

User's Guide Manual del Usuario Manual do Usuário

FREQUENCY

INVERTER

MANUAL

Series: CFW-11M

Language: English

Document: 10000069202 / 02

Models: 600...2850 A / 380...480 V

470...2232 A / 500...600 V

427...2028 A / 660...690 V

03/2009

Summary of Revisions

Revision Description Chapter

0 First edition -

1 Updating of the tables, figures, identification labels and general revision -

2 Book updating revision B, mounting rack -

Index

CHAPTER 1

Safety Instructions

1.1 Safety Warnings in the Manual .....................................................................................................1-1

1.2 Safety Warnings in the Product .....................................................................................................1-1

1.3 Preliminary Recommendations .....................................................................................................1-2

CHAPTER 2

General Instructions

2.1 About the Manual ......................................................................................................................2-1

2.2 Terms and Definitions ..................................................................................................................2-1

2.3 About the CFW-11M ..................................................................................................................2-4

2.4 Identification Label for the UC11 .................................................................................................2-9

2.5 Identification Labels for the UP11 ...............................................................................................2-10

2.6 How to Specify the CFW-11M (Smart Code) ...............................................................................2-11

2.7 Receiving and Storage ..............................................................................................................2-12

CHAPTER 3

Installation and Connection

3.1 Installation Environment ..............................................................................................................3-1

3.2 List of Components ....................................................................................................................3-1

3.3 Mechanical Installation ...............................................................................................................3-3

3.3.1 HMI Installation at the Cabinet Door or Command Panel (Remote HMI) ................................3-8

3.4 Electrical Installation ...................................................................................................................3-8

3.4.1 Input Rectifier ....................................................................................................................3-8

3.4.2 Bus Bars .........................................................................................................................3-11

3.4.3 Fuses .............................................................................................................................3-11

3.4.4 General Connection Diagram and Layout .........................................................................3-12

3.4.5 UP11 Connections ..........................................................................................................3-18

3.4.6 UC11 Connections .........................................................................................................3-22

3.4.7 Dynamic Braking .............................................................................................................3-24

3.4.7.1 Sizing the Braking Resistor ...................................................................................3-25

3.4.7.2 Motor Connections .............................................................................................3-26

3.4.8 Control Connections .......................................................................................................3-28

3.4.9 Typical Control Connections .............................................................................................3-32

3.5 Installation According to the European Directive of Electromagnetic Compatibility ..........................3-35

3.5.1 Conformal Installation .....................................................................................................3-35

3.5.2 Standard Definitions ........................................................................................................3-35

3.5.3 Emission and Immunity Levels ...........................................................................................3-36

3.5.4 External RFI Filters ...........................................................................................................3-37

Index

CHAPTER 4

Keypad and Display

4.1 Integral Keypad - HMI-CFW11 ....................................................................................................4-1

4.2 Parameters Organization .............................................................................................................4-4

CHAPTER 5

First Time Power-up and Start-up

5.1 Prepare for Start-up.....................................................................................................................5-1

5.1.1 Precautions during the Energization/Start-up ........................................................................5-1

5.2 Start-up .....................................................................................................................................5-3

5.2.1 Password Setting in P0000 .................................................................................................5-3

5.2.2 Oriented Start-Up .............................................................................................................5-4

5.2.3 Setting Basic Application Parameters ...................................................................................5-6

5.3 Setting Date and Time .................................................................................................................5-9

5.4 Blocking Parameters Modification ................................................................................................5-9

5.5 How to Conect a PC .................................................................................................................5-10

5.6 FLASH Memory Module ............................................................................................................5-10

CHAPTER 6

Troubleshooting and Maintenance

6.1 Operation of the Faults and Alarms ..............................................................................................6-1

6.2 Faults, Alarms, and Possible Causes .............................................................................................6-2

6.3 Solutions for the Most Frequent Problems ......................................................................................6-9

6.4 Information for Contacting Technical Support ..............................................................................6-10

6.5 Preventive Maintenance .............................................................................................................6-10

6.5.1 Cleaning Instructions .......................................................................................................6-12

CHAPTER 7

Option Kits and Accessories

7.1 Option Kits ................................................................................................................................7-1

7.1.1 Safety Stop According to EN 954-1 Category 3 (Pending Certification) ..................................7-1

7.2 Accessories ................................................................................................................................7-2

CHAPTER 8

Technical Specifications

8.1 Power Data ................................................................................................................................8-1

8.2 Electrical / General Specifications ................................................................................................8-4

8.2.1 Codes and Standards ........................................................................................................8-5

8.3 Mechanical Data ........................................................................................................................8-7

SAFETY INSTRUCTIONS

This manual provides information for the proper installation and operation of the CFW-11M frequency inverter.

Only trained and qualified personnel should attempt to install, start-up, and troubleshoot this type of equipment.

1.1 SAFETY WARNINGS IN THE MANUAL

The following safety warnings are used in this manual:

DANGER!

Failure to follow the recommended procedures listed in this warning may result in death, serious injury, and equipment damage.

Safety Instructions

ATTENTION!

Failure to follow the recommended procedures listed in this warning may result in equipment damage.

NOTE!

This warning provides important information for the proper understanding and operation of the equipment.

1.2 SAFETY WARNINGS IN THE PRODUCT

The following symbols are attached to the product and require special attention:

Indicates a high voltage warning.

Electrostatic discharge sensitive components. Do not touch them.

Indicates that a ground (PE) must be connected securely.

Indicates that the cable shield must be grounded.

Indicates a hot surface warning.

1-1

Safety Instructions

1.3 PRELIMINARY RECOMMENDATIONS

DANGER!

Only trained personnel, with proper qualifications, and familiar with the CFW-11M and associated machinery shall plan and implent the installation, starting, operation, and maintenance of this equipment. The personnel shall follow all the safety instructions described in this manual and/or defined by the local regulations. Failure to comply with the safety instructions may result in death, serious injury, and equipment damage.

NOTE!

For the purpose of this manual, qualified personnel are those trained and able to:

1. Install, ground, power-up, and operate the CFW-11M according to this manual and to the current legal safety procedures;

2. Use the protection equipment according to the established regulations;

3. Provide first aid.

DANGER!

Always disconnect the main power supply before touching any electrical device associated with the inverter. Several components may remain charged with high voltage and/or in movement (fans), even after the AC power supply has been disconnected or turned off. Wait at least 10 minutes to guarantee the fully discharge of capacitors. Always connect the equipment frame to the ground protection (PE).

ATTENTION!

The electronic boards contain components sensitive to electrostatic discharges. Do not touch the components and terminals directly. If needed, touch first the grounded metal frame or wear an adequate ground strap.

Do not perform a withstand voltage test on any part of the inverter!

If needed, please, consult WEG.

NOTE!

Frequency inverters may cause interference in other electronic devices. Follow the recommendations listed in Chapter 3 – Installation and Connection, to minimize these effects.

1-2

NOTE!

Fully read this manual before installing or operating the inverter.

Safety Instructions

ATTENTION!

Operation of this equipment requires detailed installation and operation instructions provided in the User's Manual, Software Manual and Manual/Guides for Kits and Accessories. Only User's Manual is provided on a printed version. The other manuals are provided on the CD supplied with the product. This CD should be retained with this equipment at all times. A hard copy of this information may be ordered through your local WEG representative.

1-3

Safety Instructions

1-4

General Instructions

GENERAL INSTRUCTIONS

2.1 ABOUT THE MANUAL

The purpose of this manual is to provide you with the basic information needed to install, start-up in the V/f control mode (scalar), and troubleshoot the most common problems of the CFW-11M (Modular Drive) frequency inverter series.

It is also possible to operate the CFW-11M in the following control modes: V V W, Sensorless Vector and Vector with Encoder. For further details on the inverter operation with other control modes, refer to the Software Manual.

For information on other functions, accessories, and communication, please refer to the following manuals:

Software Manual, with a detailed description of the parameters and advanced functions of the CFW-11M. Incremental Encoder Interface Module Manual. I/O Expansion Module Manual. RS-232/RS-485 Serial Communication Manual. CANopen Slave Communication Manual. Anybus-CC Communication Manual.

These manuals are included on the CD supplied with the inverter or can be downloaded from the WEG website at - www.weg.net.

2.2 TERMS AND DEFINITIONS

Normal Duty Cycle (ND): Inverter duty cycle that defines the maximum continuous operation current (I the overload current (110 % for 1 minute). The ND cycle is selected by setting P0298 (Application) = 0 (Normal Duty (ND)). This duty cycle shall be used for the operation of motors that are not subjected to high torque loads (with respect to the motor rated torque) during its operation, starting, acceleration, or deceleration.

: Inverter rated current for use with the normal duty (ND) cycle.

RAT-HD

Overload: 1.1 x I

Heavy Duty Cycle (HD): Inverter duty cycle that defines the maximum continuous operation current (I the overload current (150 % for 1 minute). The HD cycle is selected by setting P0298 (Application) = 1 (Heavy Duty (HD)). This duty cycle shall be used for the operation of motors that are subjected to high torque (with respect to the motor rated torque) during its operation, starting, acceleration, or deceleration.

: Inverter rated current for use with the heavy duty (HD) cycle.

RAT-HD

Overload: 1.5 x I

/ 1 minute.

RAT-ND

/ 1 minute.

RAT-HD

RAT-ND

RAT-HD

) and

2-1

General Instructions

Current Unbalance (%):

IYX - I

Unbalance at power unit X - phase Y =

YAVG

IY1 + I

Y2 + ... + IYN

Where: N = number of power units IYN = Y phase current (U, V or W) of the power unit N (P0815 to P0829) I

= Y phase average current

YAVG

x 100

Rectifier: Input circuit of inverters that transforms the AC input voltage in DC voltage. It is composed of power diodes.

Pre-charge Circuit: Charges the DC bus capacitors with limited current, which avoids higher peak currents at the inverter power-up.

DC Bus: Inverter intermediate circuit; DC voltage obtained from the rectification of the AC input voltage or from an external power supply; feeds the output inverter bridge with IGBTs.

Power Modules U, V, and W: Set of two IGBTs of the inverter output phases U, V, and W.

IGBT: Insulated Gate Bipolar Transistor; basic component of the output inverter bridge. The IGBT works as an

electronic switch in the saturated (closed switch) and cut-off (open switch) modes.

Braking IGBT: Works as a switch to activate the braking resistors. It is controlled by the DC bus voltage level.

PTC: Resistor which resistance value in ohms increases proportionally to the temperature increase; used as a temperature sensor in electrical motors.

NTC: Resistor which resistance value in ohms decreases proportionally to the temperature increase; used as a temperature sensor in power modules.

Keypad: Device that allows controlling the motor, and viewing/editing inverter parameters. The HMI presents keys for motor command, navigation keys and a graphic LCD display.

FLASH Memory: Non-volatile memory that can be electronically written and erased.

RAM Memory: Random Access Memory (volatile).

USB: Universal Serial Bus; is a serial bus standard that allows devices to be connected using the ”Plug and

Play” concept.

PE: Protective Earth.

RFI Filter: Radio-Frequency Interference Filter for interference reduction in the Radio-Frequency range.

PWM: Pulse Width Modulation; pulsed voltage that feeds the motor.

2-2

General Instructions

Switching Frequency: Frequency of the IGBTs switching in the inverter bridge, normally expressed in kHz.

General Enable: When activated, this function accelerates the motor via acceleration ramp set in the inverter.

When deactivated, this function immediately blocks the PWM pulses. The general enable function may be controlled through a digital input set to this function or via serial communication.

Start/Stop: When enabled in the inverter (start), this function accelerates the motor via acceleration ramp up to the speed reference. When disabled (stop), this function decelerates the motor via deceleration ramp up to the complete motor stop; at this point, the PWM pulses are blocked. The start/stop function may be controlled through a digital input set for this function or via serial communication. The operator keys (Start) and (Stop) of the keypad work in a similar way.

Heatsink: Metal device designed to dissipate the heat generated by the power semiconductors.

°C: Celsius degree.

°F: Fahrenheit degree.

AC: Alternated Current.

Amp, A: Ampères.

CFM: Cubic Feet per Minute; unit of flow.

cm: Centimeter.

DC: Direct Current.

ft: Foot.

hp: Horse Power = 746 Watts; unit of power, used to indicate the mechanical power of electrical motors.

Hz: Hertz.

in: Inch.

kg: Kilogram = 1000 grams.

kHz: Kilohertz = 1000 Hertz.

l/s: Liters per second.

lb: Pound.

m: Meter.

mA: Miliampère = 0.001 Ampère.

min: Minute.

mm: Millimeter.

2-3

General Instructions

ms: Millisecond = 0.001 seconds.

Nm: Newton meter; unit of torque.

rms: "Root mean square"; effective value.

rpm: Revolutions per minute; unit of speed.

s: Second.

V: Volts.

Ω: Ohms.

2.3 ABOUT THE CFW-11M

The CFW-11M frequency inverter is a high performance product designed for speed and torque control of threephaseinduction motors. The main characteristic of this product is the “Vectrue” technology, which has the following advantages:

Scalar control (V/f), V V W, or vector control programmable in the same product; The vector control may be programmed as “Sensorless” (which means standard motors without using

encoders) or as “Vector Control” with the use of an encoder; The “Sensorless” control allows high torque and fast response, even in very low speeds or at the starting; The “Vector with Encoder” control allows high speed precision for the whole speed range (even with a

standstill motor); “Optimal Braking” function for the vector control: It allows the controlled braking of the motor, avoiding the

use of the braking resistor in some applications; “Self-Tuning” feature for vector control. It allows the automatic adjustment of the regulators and control

parameters from the identification (also automatic) of the motor parameters and load.

The inverters of the CFW-11M series present a modular structure, with conFiguretions from one to five power units (UP11 - generically called books), one control unit (UC11) and interconnecting cables. There is just one control unit (UC11) that is able to control up to 5 UP11s.

The UP11 are fed directly from DC Bus (DC Link) and the UC11 is fed by means of a 24 Vdc power supply. An application example with a 6 pulse input rectifier is presented in the figure 2.1.

The control of the power units is done by the UC11 control unit. The control unit contains the CFW-11M control rack and the IPS1 board. This board sends signals to all the UP11 units (PWM, fan control, etc.) and receives signals from them (feedbacks of voltage, current, etc.).

2-4

UP11

General Instructions

Line

UP11

24 Vdc

power supply

Figure 2.1 - A conFiguretion example with 5 UP11 and a 6 pulse rectifier

UC11

UP11

Motor

The CFW-11M can be supplied as a complete drive (AFW-11M) or as a panel mounting kit.

The panel mounting kit is composed by the control set and by UP11 power units, whose number varies according to the current. The control set contains the UC11 control unit, the necessary cable sets for the connections between the IPS1 and the power units, and the flat cable that connects the IPS1 board to the CC11 control board.

2-5

General Instructions

Ext. 220V

Line

Power Section

SuperDrive G2 Software

WLP Software

Cabinet aux. power supply

Pre-

charge

Three-phase

rectifier

Control UC11

IPS1 Electronics power supplies and interface

USB

between power and control

UP11

Capacitor

DC bus

(DC Link)

UP11

bank

Power section fans

Inverter with

IGBTs transistors

Power section fans

Feedback:

- voltage

- current

Motor

Accessories

I/O Expansion

Keypad (remote)

Digital

Inputs

(DI1 to DI6)

Analog

Inputs

(AI1 and AI2)

Keypad

CC11

Control

Board with

a 32 bits

"RISC"

CPU

FLASH

Memory

Module

Figure 2.2 - Block diagram for the CFW-11M

(Slot 1 - white)

Encoder Interface

(Slot 2 - yellow)

COMM 1

(Slot 3 - green)

COMM 2

(anybus) (Slot 4 )

Analog

Outputs

(AI1 and AI2)

Digital Outputs

DO1 (RL1) to

DO3 (RL3)

NOTE!

Several additional items are necessary for mounting the complete drive, such as input rectifier, fuses in the DC supply of each power unit UP11, external pre-charge circuit and an input reactor with a minimum impedance of 3 % in case of a 6 pulse rectifier.

2-6

NOTE!

The inclusion of a current transformer (CT) in the drive for the output short-circuit to the ground protection is not necessary because each UP11 has its own internal protection.

General Instructions

Keypad

Front Cover

Control Rack

IPS1 shield

IPS1 shield base

IPS1 board - Interface between power and control

DC Bus Capacitors

PSB1 board – Switched

mode power supply

CIM1 board – Interface

with the control

Hall Effect CT

Fan

Output reactor

Figure 2.3 - UC11 main components

DC bus

IGBTs module decoupling capacitors

Set of IGBTs modules Gate resistor board Gate driver board

Figure 2.4 - UP11 main components

2-7

General Instructions

UP11

UC11

CC11

Keypad

External

Supply

(*) Tolerance: ± 10 %;

Current: 4 A.

Power Supply

Figure 2.5 - UP11: Connections between the IPS1 and the CIM1 interface boards

XC60

24 Vdc

(*)

+UD

- UD

XC60

XC9

XP XN

IPS1

VP VN WP

XC40

PSB1

XC3 XC5

N1 N2 N3 N4 N5 N6

XC40

CIM1

+ 5 V

+UD

- UD

+ 15 V

XC3

+ 20 V

XC5

CIM1

Figure 2.6 - UP11: Connections between the CIM1 interface board and the PSB1 power supply board

CIM1

XC4AB

XC4A

XC33

Ext. 220 V

XC16A

XC16B

2-8

Power Section Fans

Figure 2.7 - UP11: Connections between the CIM1 interface board and the fans

General Instructions

CIM1

558

+UD

10 11 10

TCU

11 10 11

+UD

10 11 10

TCV

+UD

TCW

(0,5 %)

UOUT

VOUT

WOUT

11 10 11

10 11 10 11 10 11

XC1U

XC14U

XC64U

XC1V

XC14V XC64V

XC1W

XC14W XC64W

-UD

GDB5

XC4

XC1 XC2

CRG9

1 2 3 4 5 8

XC14

-UD

XC1

GDB5

XC4

CRG9

XC2

XC14

GDB5

XC4

XC1

XC2

CRG9

-UD

223

XC14

Figure 2.8 - UP11: connections between the CIM1 interface board, gate driver boards,

modules and sensors for the output voltage and output current

2.4 IDENTIFICATION LABEL FOR THE UC11

The UC11 identification label is located on the control rack.

WEG part number

Manufacturing date (day/month/year)

Figure 2.9 - UC11 identification label

Identification label

UC11 model number

Serial number

Figure 2.10 - Location of the identification label

2-9

General Instructions

2.5 IDENTIFICATION LABELS FOR THE UP11

There are two identification labels, one located at the inverter front cover and another inside the UP11, close to the fans.

UP11 Model

WEG part number

Inverter net weight

Rated input data (voltage, rated currents for use with Normal Duty (ND) and Heavy Duty

(HD) cycles, frequency)

Current specifications for use with the

Normal Duty (ND) cycle

Current specifications for use with the

Heavy Duty (HD) cycle

Available certifications

Manufacturing date (day/month/year)

Serial number

Maximum surrounding air temperature

Rated output data (voltage, number of power phases, rated currents for use with Normal Duty (ND) and Heavy Duty (HD) cycles, overload currents for 1 min and 3 s, and frequency range)

Figure 2.11 - UP11 identification label

2-10

Figure 2.12 - Location of the identification labels

General Instructions

2.6 HOW TO SPECIFY THE CFW-11M MODEL (SMART CODE)

In order to specify the CFW-11M it is necessary only to fill in the desired voltage and current values in the respective fields for the nominal supply voltage and the rated output current for normal overload regime (ND) in the intelligent code according to the example of the table 2.1.

Table 2.1 - Smart code

Inverter Model Available Option Kits

Refer to chapter 8 for a list of models for the CFW-11M series and for a complete inverter's technical specification

Example EX CFW11M 0470 T 5

Field description

Market identification (defines the manual language and the factory settings)

WEG CFW-11M frequency inverter series

Rated output current for use with the Normal Duty (ND) cycle

Number of output phases

Nominal output voltage

(*)

Option kit Braking Safety stop Special

Refer to the chapter 7 for more details on the options.

S _ _ _ _ _ _ _ _ Z

hardware

Special software

Character that identifies the code end

Available options

(*) This field (voltage) represents the three-phase input voltage for the rectifier that supplies the CFW-11M with DC voltage. The rectifier is not part of the CFW-11M.

2 characters T=

threephase

4=380... 480 V 5=500... 600 V 6=660... 690 V

S=standard product O=product with option kit

Blank= standard (without internal dynamic braking) RB= regenerative braking

Blank= standard (safety stop function is not available) Y= safety stop according to EN-954-1 category 3

Blank= standard H1=special hardware #1

Blank= standard S1=special software #1

E.g.: CFW11M0470T5SZ corresponds to a modular CFW-11 470 A three-phase, with power supply voltage from 500 V to 600 V, standard. An inverter for 380-480 V would be specified as CFW11MXXXXT4SZ and for voltage of 660-690 V it would be specified as CFW11MXXXXT6SZ (where XXXX is replaced by the inverter current). The possible nominal current options for an inverter in normal overload regime (ND) are showed in the table 2.2, according to the rated input voltage.

Table 2.2 - Nominal currents at normal overload regime (ND)

380-480 V 500-600 V 660-690 V

0600 = 600 A 1140 = 1140 A 1710 = 1710 A 2280 = 2280 A 2850 = 2850 A

0470 = 470 A

0893 = 893 A 1340 = 1340 A 1786 = 1786 A 2232 = 2232 A

0427 = 427 A

0811= 811 A 1217 = 1217 A 1622 = 1622 A 2028 = 2028 A

2-11

General Instructions

2.7 RECEIVING AND STORAGE

The CFW-11M power units, as well as the control sets, are supplied packed in wooden boxes (refer to the figure 2.14).

Figure 2.13 - Power unit packing

There are identification labels outside these boxes, the same as the ones fixed on the respective products.

In order to open the box: 1- Put the control set box on a table with the help of two people; in case of the power units, put the box on

the floor. 2- Open the wood crate. 3- Remove all the packing material (the cardboard or styrofoam protection) before removing the inverter.

Check the following items once the inverter is delivered:

Verify that the product identification label corresponds to the model number on your purchase order. Inspect the product for external damage during transportation.

Report any damage immediately to the carrier that delivered your product.

If the products were note installed immediately, store them in a clean and dry place (temperature between -25 °C and 60 °C) with a cover in order to avoid the contamination with dust.

2-12

General Instructions

ATTENTION!

Capacitor reforming is required if the inverter or power units are stored for long periods of time without power. Refer to the procedures in item 6.5 - table 6.3.

Figure 2.14 - Do not tilt the power units

2-13

General Instructions

2-14

Installation and Connection

INSTALLATION AND CONNECTION

This chapter provides information on installing and wiring the CFW-11M. The instructions and guidelines listed in this manual shall be followed to guarantee personnel and equipment safety,

as well as the proper operation of the inverter.

3.1 INSTALLATION ENVIRONMENT

Avoid installing the inverter in an area with:

Direct exposure to sunlight, rain, high humidity, or sea-air; Inflammable or corrosive gases or liquids; Excessive vibration; Dust, metallic particles, and oil mist.

Environment conditions for the operation of the inverter:

Temperature:

CFW11M…T4 models with switching frequencies of 1.25 kHz or 2.5 kHz, CFW11M…T5 and CFW11M…

T6 with switching frequency of 1.25 kHz:

-10 °C to 45 °C (14 °F to 113 °F) - (measured around the inverter) nominal conditions. From 45 °C to 55 °C (113 °F to 131 °F) - 2 % current reduction for every Celsius degree (or 1.11 % each °F)

above 45 °C (113 °F).

CFW11M…T5 and CFW11M…T6 with switching frequency of 2.5 kHz:

-10 °C to 40 °C (14 °F to 104°F) - (measured around the inverter) nominal conditions. From 40 °C to 55 °C (104 °F to 131°F) - 2 % current reduction for every Celsius degree (or 1.11 % each °F)

above 40 °C (104 °F). Humidity: from 5 % to 90 % non-condensing. Altitude: up to 1000 m (3,300 ft) - standard conditions (no derating required). From 1000 m to 4000 m (3,300 ft to 13,200 ft) - 1 % of current derating for each 100 m (or 0.3 % each

100 ft) above 1000 m (3,300 ft) altitude. Pollution degree: 2 (according to EN50178 and UL508C) with non-conductive pollution. Condensation

shall not originate conduction through the accumulated residues.

3.2 LIST OF COMPONENTS

Table 3.1 - Currents and conFiguretion in 380-480 V

Nominal Current (A)

ND HD

600 515 1

1140 979 2

1710 1468 3

2280 1957 4

2850 2446 5

Number of Power Units

UP11-02

3-1

Installation and Connection

Nominal Current (A)

1340 1083 3

1786 1444 4

2232 1805 5

Nominal Current (A)

1217 969 3

1622 1292 4

2028 1615 5

Table 3.2 - Currents and conFiguretion in 500-600 V

Number of Power Units

ND HD

470 380 1

893 722 2

Table 3.3 - Currents and conFiguretion in 660-690 V

ND HD

427 340 1

811 646 2

UP11-01

Number of Power Units

UP11-01

Each cable set contains one optical fiber and one DB-25 cable. Both do the connection between the IPS1 board (control unit) and the CIM1 board (power unit).

Table 3.4 - Cable sets

Weg Part

Number

10411757 2350 (92.52) 2550 (100.39)

10509891 2800 (110.24) 3000 (118.11)

10411758 3400 (133.86) 3600 (141.73)

10411759 3900 (153.54) 4100 (161.42)

Optical Fiber Length

mm (in)

DB-25 Cable Length

mm (in)

The cable sets that come with the control sets are described in the table 3.5.

Table 3.5 - Number of cable sets

Number of Power Units Number of Cable Sets

1 1X 10411757 2 2X 10411757

2X 10411757 1X 10509891

2X 10411757 1X 10509891 1X 10411758

2X 10411757 1X 10509891 1X 10411758 1X 10411759

The other components of the drive are responsibility of the integrator. Among these components we are able to point out the input rectifier, the power bus bars, the pre-charge circuit, the panel fans, the protection fuses, input reactance, etc.

3-2

Installation and Connection

VENTILADOR DO PAINEL (QUANDO NECESSÁRIO)

SAÍDA DE AR

150

ABERTURA DE VENTILAÇÃO

NA SUPERFÍCIE FRONTAL DO

PAINEL

VENTILADOR DO PAINEL (QUANDO NECESSÁRIO)

SAÍDA DE AR

150

ABERTURA DE VENTILAÇÃO

NA SUPERFÍCIE FRONTAL DO

PAINEL

VENTILADOR DO PAINEL (QUANDO NECESSÁRIO)

SAÍDA DE AR

150

ABERTURA DE VENTILAÇÃO

NA SUPERFÍCIE FRONTAL DO

PAINEL

VENTILADOR DO PAINEL (QUANDO NECESSÁRIO)

SAÍDA DE AR

150

ABERTURA DE VENTILAÇÃO

NA SUPERFÍCIE FRONTAL DO

PAINEL

3.3 MECHANICAL INSTALLATION

The power units must be properly secured in the drive cabinet, making it possible the easy withdrawal and reinsertion in case of maintenance. The fastening must also be done so that it prevents panel transportation damage.

The “Panel Mounting Rack” accessory simplifies the mounting of the power units and allows their simple fastening and movement. Refer to the section 7.2 for more details.

Ø22.5 HOISTING EYES - WEIGHT 171 kg

Figure 3.1 - UP11: Hoisting holes

Figure 3.2 - Mounting of the UP11 side by side without lateral spacing

3-3

VENTILADOR DO PAINEL (QUANDO NECESSÁRIO)

ENTRADA DE AR

ABERTURA DE VENTILAÇÃO

NA SUPERFÍCIE FRONTAL DO

PAINEL

193

211

Installation and Connection

250

(9.84)

OUTLET AIR

SAÍDA DE AR

PANEL FAN (WHEN REQUIRED)

OUTLET AIR

SAÍDA DE AR

150

(5.91)

VENTILATION OPENINGS ON FRONTAL PANEL SURFACE

INLET AIR

Figure 3.3 - Clearance requirements for air circulation

The UP11 wheels facilitate its insertion into and withdrawal from the panel (figure 3.4).

175

584,9

221,9 221,9 85

56,5

18,9

WHEELS (BALL-BEARINGS) COVERED WITH

RODAS (ROLAMENTOS) REVESTIDAS

NYLON FOR MOVEMENT IN THE CABINET

Figure 3.4 - UP11: bottom view mm (in)

61,5

550,6

8,9

3-4

Figure 3.5 - Fixing holes of the power unit

Installation and Connection

SUPPORTS FOR

SUPORTE PARA

TOP FIXING OF THE

FIXAÇÃO SUPERIOR

DRIVE

DO DRIVE

9,2

14,5

100,5 100,5

14,5

509,8

Figure 3.6 - Supports for top fixing mm (in)

3-5

Installation and Connection

Mounting of the UC11 at the panel door: Control rack with flange mounting and IPS1 module mounted at the bottom part of the door. The control rack is secured with four M3 screws (tightening torque: 0.5 Nm).

CFW-11

INTERFACE CARD

POWER-CONTROL

Figure 3.7 - Example of the mounting of the control rack and its base

3-6

Figure 3.8 - Final mounting aspect

Installation and Connection

Ø 5.2 (4x)

(0.20)

Figure 3.9 - Control rack fixing and the necessary cuts mm (in)

283.6

(11.17)

(5.64)

143.3

286.5 (11.28)

190

(7.48)

186.5 (7.34)

7 (0.27)

R8 (4x) (0.32)

93.3

(3.67)

2 (0.08)

(0.43)

290

7 (0.27)

(11.42)

41.5

(1.63)

M6 (4x) FOR THE IPS1

Figure 3.10 - IPS1 module base fixing mm (in)

The IPS1 module base is fixed with four M6 bolts (tightening torque: 8.5 Nm).

292

(11.5)

MODULE FIXING

The total air outflow of the power unit is 1150 m3/h (320 l/s; 677 CFM). It is recommended an outflow of 1350 m3/h (375 l/s; 795 CFM) per power unit at the air exhaustion.

3-7

Installation and Connection

3.3.1 HMI Installation at the Cabinet Door or Command Panel (Remote HMI)

28.5 [1.12]

23.5 [0.93]

35.0 [1.38]

16.0 [0.63]

113.0 [4.45]

65.0 [2.56]

Figure 3.11 - Data for the HMI installation at the cabinet door or command panel – mm (in)

103.0 [4.06]

23.4 [0.92]

The keypad frame accessory can also be used to fix the HMI, as mentioned in the section 7.2.

3.4 ELECTRICAL INSTALLATION

DANGER!

The following information is merely a guide for proper installation. Comply with applicable local regulations for electrical installations.

DANGER!

Make sure the AC power supply is disconnected before starting the installation.

∅4.0 [0.16] (3X)

ATTENTION!

The CFW-11M can be connected in circuits with symmetrical short circuit capability up to 150000 Arms (480 V/690 V maximum).

ATTENTION!

Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with applicable local codes.

3.4.1 Input Rectifier

The main rectifier bridge is selected to comply with the nominal power of the drive. The heat dissipation caused by losses at the rectifier bridge should be taken into account for the sizing of the heatsink, as well as in the heating up of the panel internal air.

3-8

Installation and Connection

Table 3.6 - Sizing of the main bridge

Main Rectifier Bridge

Reverse Voltage ≥1600 V Output DC current 1.15 Drive output current

The pre-charge circuit resistors must be sized according to the following criteria:

- Maximum voltage;

- Maximum energy;

- Power overload capacity of the resistors during the pre-charge period (energy dissipation capacity).

The characteristics of the resistors must be obtained with their manufacturer.

0 0.2 0.4 0.6 0.8 1 1.2 1.4

Figure 3.12 - Current during the pre-charge

Table 3.7 - Sizing of the pre-charge

Peak current during the pre-charge (A) 0.82∙(Vline/R)

Energy stored in the capacitor bank (J)

Pre-charge duration (s)

0.4 s t 0.6 s

400 V line N∙0.016∙Vline

Other lines N∙0.073∙Vline

400 V line 0.09∙N∙R

Other lines 0.04∙N∙R

Where R is the ohmic value of the resistor used for each phase and N is the number of power units.

E.g.: At a drive composed by three power units, whose line voltage at the input of the rectifier was 380 Vrms (400 V line), the obtained values would be the following:

- Energy stored in the capacitor bank: 3∙0.016∙(380)2 = 6931 J.

- By using three 10 Ω resistors (one per phase), each resistor must withstand 2310 J.

- The resistor manufacturer is able to inform the power supported by the component.

- The peak current during the pre-charge would be 31 A and the pre-charge duration would be of 2.7 s.

3-9

Installation and Connection

Retificadora

Ponte

+UD

220 VAC

Externo

Stop

OFF

-UD

Pré-carga

K(PCR)

KA1

RT1

KA1

KA2

XC3:1

IPS

KA2

PCR

K(PCR)

KA1 K1KA2

RT1

Figure 3.13 - Pre-charge circuit example

KA2

K(PCR)

The CFW-11M input rectifier can be supplied through a contactor or a motorized circuit breaker (represented by K1), whose command must be interlocked with the pre-charge contactor K(PCR) command. The figure 3.14 presents an example of the recommended pre-charge circuit for the CFW-11M inverter, with simplified power and command diagrams. There is already a relay (XC3:1/2/3) configured with the function "Pre-charge OK" in the IPS board (refer to the table 3.21). This relay must be used to command the pre-charge contactor and the main contactor (motorized circuit breaker). Furthermore, the pre-charge length must be timed for the protection of the auxiliary circuit (resistors, rectifier bridge). This function is carried out by a timer with a normally-closed on-delay contact, represented as RT1 in the figure 3.14.

3-10

Installation and Connection

L1.a

L1.b

Figure 3.14 - 12 pulse parallel with interphase reactance (L1) conFiguretion

+UD

-UD

The 12 pulse parallel conFiguretion requires the use of an interphase reactance in order to assure the correct current division between the bridges. In the case of using this conFiguretion, consult WEG.

3.4.2 Bus Bars

The panel bus bars must be sized according to the rectifier output current and the drive output current. It is recommend the use of copper bars. In case that aluminum bars have to be used, it is necessary to clean the contacts and to apply an antioxidant compound. If the compound is not used, any copper-aluminum junction will suffer an accelerated oxidation.

3.4.3 Fuses

It is recommended the use of fuses suitable for operation with direct current at the UP11 DC supply. The maximum bus voltage at the 400 V line is 800 Vdc, at the other lines it is 1200 Vdc (IGBT overvoltage trip level). Fuses used in AC lines can be used; however, a derating in the AC voltage must be applied. Consult the fuse manufacturer in order to obtain the derating factor.

Fuse examples:

- 400 V line: 12,5URD73TTF900 (FERRAZ)

- Other lines: 12,5URD73TTF630 (FERRAZ)

Figure 3.15 - DC link fuses

3-11

Installation and Connection

3.4.4 General Connection Diagram and Layout

The figure 3.16 presents a general diagram for an inverter with five Power Units (UP11), with the connections between the Control Unit UC11 and the UP’s (XC40 DB25 connectors and optical fibers), the power connections of the UP’s (+UD, -UD, U, V, W and GND), besides the auxiliary ventilation (220 V) and UC11 (24 Vdc) supply connections. For a reduced number of UP11’s, connect them in crescent order (1, 2, 3, etc.), leaving the last positions without connections.

-UD

UC11

UH1

UL1

VH1

VL1

WH1

WL1

XC40A

UH UL

VH VL WH WL

XC40XC40XC40XC40XC40

UP11

+UD

-UD

XC33

220V Ext.

+UD

HMI

(*) Tolerance +/- 10 %

CC11

External 24 Vdc*

power supply

Current: 4 A

Pre-charge

relay

+24 Vdc DI’s

output

Braking module

DB9 connector

XC60

1-NO 2-C 3-NC 4-GND_24 5-+24V

UP11

+UD

-UD

+UD

-UD

+UD

-UD

XC33XC33XC33XC33

220V Ext.

MOTOR

UH2

UL2

VH2

VL2

WH2

WL2

XC60XC9XC3XC6

XC40BXC40CXC40DXC40E

1 2

UH3

UL3

VH3

IPS1

WH3

WL3

UH4

UL4

VH4

WH4

WL4

VL3

VL4

UH UL

VH VL WH WL

UH UL

VH VL WH WL

UH UL

VH VL WH WL

3-12

UH5

UL5

VH5

VL5

WH5

WL5

UP11

+UD

-UD

220V Ext.

UH UL

VH VL WH WL

Figure 3.16 - General Diagram

Installation and Connection

The power electrical connections of the panel must assure equal impedance at the DC bus and output connections. Refer to the example in the figure 3.17 and to the lateral section views in figures 3.18, 3.19 and 3.21. At the input (DC bus) and the motor output busbars, the dimensions identified as A, B, C and D must be approximately equal to the dimensions A’, B’, C’ and D’, respectively, as exemplified in the figure 3.17.

Figure 3.17 - Symmetry details of the panel constructive layout

A’

B´

C´

D´

The interconnection between the DC bus and each UP11 can be done with flat braided cables according to the figure 3.18 example, sized to withstand the DC bus current, according to the table 8.1. The figure 3.20 presents an example of flat braided cable used by WEG, using a fuse at +UD. Alternatively, fuses at both connections (+UD and –UD) can be used.

NOTE!

It is important that all the flat braided cables present the same length (defined by the dimension “E”) that will depend on the panel construction, and that all the fuses mounted on the DC bus are identical and mounted on the same busbar (+UD or –UD) in all the UP11’s when only one fuse per UP11 is used (in order to get more details refer to the section 3.4.3).

3-13

Installation and Connection

1 2

+UD-UD

Figure 3.18 - Lateral section view: Detail of the flat braided cables

(1.02)

(0.67)

and fuse connections

(0.67)

(1.02)

(2.36)

Figure 3.19 - Lateral section view: Detail of the DC bus

RECTIFIER

Ø 14 (3x)

(0.55)

connections

(0.98)

(1.97)

BRAIDED WIRE GAUGE: AWG-40 (0.08 mm)

Figure 3.20 - Example of flat braided cable

Besides the panel constructive form, some precautions must be taken regarding the connection of the output cables to the motor, in order to assure equal impedances among the UP’s connected in parallel. The figures

3.19 and 3.21 present details in lateral section views of the DC bus (+UD and –UD) input connections and the output to the motor (U, V, W and GND) connections.

8±1

(1.18)

(2.36)

3-14

NOTE!

The length of the cables that connect each of the Power Units to the output busbars, represented by the “F” dimension on the figure 3.21, must be the same for all the phases (U, V and W). Refer to the table 3.8 for more details on the cables.

Installation and Connection

GND

MOTOR

Figure 3.21 - Lateral section view: Detail of the output to the motor connections

The figure 3.22 presents the adequate installation layout for five Power Units.

RECTIFIER

Figure 3.22 - Example of adequate installation layout for 5 UP11’s

NOTE!

The connection of the motor cables at points different from the presented in the figure 3.22 (figures

3.23 and 3.24 present some inadequate connection forms) does not assure the impedance balance between the UP’s connected in parallel, being able to cause current imbalance among the UP’s.

3-15

Installation and Connection

Figure 3.23 - Example of inadequate installation layout for 5 UP11’s

3-16

Figure 3.24 - Example of inadequate installation layout for 5 UP11’s

Installation and Connection

The figure 3.25 presents the adequate installation layout for three Power Units.

RECTIFIER

Figure 3.25 - Example of adequate installation layout for 3 UP11’s

NOTE!

The connection of the motor cables at points different from the presented in the figure 3.25 (the figure 3.26 an inadequate connection form) does not assure the impedance balance between the UP’s connected in parallel, being able to cause current imbalance among the UP’s.

3-17

Installation and Connection

95,5

170

BARRAMENTO DE ENTRADA NEGATIVO (- UD)

BARRAMENTO DE ENTRADA POSITIVO (+ UD)

Figure 3.26 - Example of inadequate installation layout for 3 UP11’s

3.4.5 UP11 Connections

The fastening of the UP11 input connections is done with four M12 x 25 bolts (tightening torque: 60 Nm), refer to the figure 3.27.

NEGATIVE INPUT BAR (-UD)

61,3

Figure 3.27 - UP11 input bus bars: Input DC connections mm (in)

POSITIVE INPUT BAR (+UD)

3-18

Installation and Connection

9595

The output connections at the internal reactance are done by means of six M12 x 30 bolts (tightening torque: 60 Nm), 2 bolts per phase are used. The bus bars are of 40 x 10 mm and the fastening is done through M12 nuts inserted into the bar. Refer to the figure 3.28.

55,2

87,4

Ø22.5 HOISTING HOLE (0.89in)

PARA IÇAMENTO

OUTPUT BARS ''U''

BARRA DE SAÍDA "U"

OUTPUT BARS ''V''

BARRA DE SAÍDA "V"

OUTPUT BARS ''W''

BARRA DE SAÍDA "W"

22,5

OLHA

Figure 3.28 - UP11 output bus bars: Output connections to the motor mm (in)

Use two cables in parallel, with the recommended gauge indicated in the table 3.8, for connecting the UP11 output reactor to the output bus bar (motor connection).

Table 3.8 - Output cables

Current (A) Voltage (V) Regimen

600

515 HD (2X) 185

470

418 HD (2X) 120

427

340 HD (2X) 70

380-480

500-600

660-690

ND (2X) 240

ND (2X) 150

ND (2X) 120

Minimum cable cross-section

area (mm2)

The bolt used to connect the UP11 grounding cable is M12 x 30 (tightening torque: 60 Nm). Refer to the figure 3.29.

3-19

Installation and Connection

ATERRAMENTO FRONTAL

COM PARAFUSO

M12

FRONT GROUNDING

WITH AN M12 BOLT

Figure 3.29 - UP11 ground connection point

Use cables with the recommended gauge indicated in the table 3.9 for grounding the UP11 power units.

Table 3.9 - Grounding cables

Current (A) Voltage (V) Regimen Minimum cable cross-section area (mm2)

600

515 HD 185

470

418 HD 120

427

340 HD 70

380-480

500-600

660-690

ND 240

ND 150

ND 120

3-20

Connectors for Optical Fibers

CONECTOR DE ENTRADA 220V

DB25 Connectors

Installation and Connection

Figure 3.30 - Connection points for the control cables on the UP11

Keep the optic fiber bending radius bigger or equal to 35 mm. If the control is mounted on the panel door, let a curvature that causes a minimum stress on the optic fiber cables when the door is opened or closed.

Figure 3.31 - Fan supply terminals: 220 V/4 A

220 V INPUT CONNECTOR

3-21

Installation and Connection

3.4.6 UC11 Connections

The DIM1 and DIM2 digital inputs located on the IPS1 board (figure 3.35) monitor the F406, F408, F410, F412 and A010 faults/alarm. They are CLOSED during normal operation. When they OPEN faults/alarm occur.

- The DIM1 digital input is connected at XC1:4 and XC1:5 (common).

- The DIM2 digital input is connected at XC2:4 and XC2:5 (common).

XC1 Factory Default Function Specifications

1 No Function - 2 No Function - 3 DGND DGND Reference. Grounded via the IPS board shield.

4 DIM1

5 COM

XC2 Factory Default Function Specifications

1 No Function - 2 No Function - 3 DGND DGND Reference. Grounded via the IPS board shield.

4 DIM2

5 COM

Isolated digital input DIM1, programmable at P0832. Refer to the programming manual.

Common point of the IPS board digital inputs.

Isolated digital input DIM2, programmable at P0833. Refer to the programming manual.

Common point of the IPS board digital inputs.

High level ≥ 18 V. Low level ≤ 3 V.

Maximum input voltage: 30 V. Input current: 11 mA @ 24 Vdc.

High level ≥ 18 V. Low level ≤ 3 V.

Maximum input voltage: 30 V. Input current: 11 mA @ 24 Vdc.

XC3 Factory Default Function Specifications

1 PCR1 (NO)

2 PCR2 (C)

3 PCR3 (NC)

4 GND_24.

5 +24 V 24 Vdc power supply.

Figure 3.32 - Application example with high level at the DIs

Parameters

P0832/P0833

Sequential

RL digital output with pre-charge function (PCR).

0 V reference for the 24 Vdc power supply.

Table 3.10 - Functions of the digital inputs

Number

0 Not Used 1 Extern Fault F406 2 Refrigeration Fault F408 3 Braking Resistor Overtemperature F410 4 Rectifier Overtemperature F412 5 Rectifier High Temperature A010

Contact capacity: 1 A Maximum voltage: 240 Vac NO - Normally open contact; C - Common; NC - Normally closed contact.

Isolated 24 Vdc ± 8 % power supply. Capacity: 600 mA.

Note 1: This power supply may be used for feeding the IPS board digital inputs DIM1 (ISOL) and DIM2 (ISOL). Note 2: This power supply is isolated from the 24 Vdc input used to feed the IPS.

Digital Input Function

Associated

Fault/Alarm

3-22

Installation and Connection

XC60: Connection with the control rack

XC9 connector:1,3 +24 Vdc power supply

DB9 connector (XC6) for DBW-01 (380-480 V) and DBW-02 (500-690 V) Braking Modules

DIM 1 (XC1:4/5)

DIM 2 (XC2:4/5)

Connectors for Optical Fibers (connection with the UP11)

Pre-charge RL (XC3:1/2/3)

Figure 3.33 - IPS1 connection points

DB25 connectors XC40A to XC40E (connection with the UP11)

The IPS1 board mechanical installation itself makes its ground connection. This is done in several points.

Grounding point

Figure 3.34 - IPS1board grounding

The IPS1 shield securing screws must assure the electric contact between the shield and the panel for grounding purposes.

Figure 3.35 - IPS1 shield fixed on the panel

The control rack grounding must be done with a flat type braided ground strap with a minimum width of 5 mm and a minimum cross section of 3 mm2, with standard 6.35 mm FASTON terminal (e.g., TYCO 735075-0 and 180363-2) and M4 ring terminal. Refer to the figure 3.36.

3-23

Installation and Connection

Figure 3.36 - Control rack grounding

The panel door must be grounded with a braided ground strap.

Braided Ground Strap

Figure 3.37 - Panel door grounding

The IPS1 board is fed by a +24 Vdc ±10 % power supply. This supply must have a minimum capacity of 4 Adc.

3.4.7 Dynamic Braking

The braking torque that can be obtained from the frequency inverter without braking resistors varies from 10 % to 35 % of the motor rated torque.

Braking resistors shall be used to obtain higher braking torques. In this case, the energy regenerated in excess is dissipated in a resistor mounted externally to the inverter.

This type of braking is used in cases where short deceleration times are desired or when high inertia loads are driven.

The “Optimal Braking” feature may be used with the vector control mode, which eliminates in most cases the need of an external braking resistor.

NOTE!

Set P0151 and P0185 to their maximum values (400 V, 800 V or 1200 V) when using dynamic braking.

3-24

Installation and Connection

3.4.7.1 Sizing the Braking Resistor

The following application data shall be considered for the adequate sizing of the braking resistor:

- Desired deceleration time;

- Load inertia;

- Braking duty cycle.

The maximum braking current defines the minimum braking resistor value in ohms.

The DC bus voltage level for the activation of the dynamic braking function is defined by parameter P0153 (dynamic braking level).

The power of the braking resistor is a function of the deceleration time, the load inertia, and the load torque.

If the use of dynamic braking is necessary, the IPS1 board (XC6 connector – DB9) has the capability of commanding a DBW-01/DBW-02. Refer to the DBW-01/DBW-02 Installation, ConFiguretion and Operation Guide.

If necessary, accessory boards will be mounted on the standard control rack. All the CFW-11 line accessory boards are available.

DBW-01/02

Supply

Network

110 V or 220 V

Control

Supply

Contactor

Fan

DIX (CC11) No External Fault

Interconnection

cable

IPS1

R S

-UD +UD

Figure 3.38 - Connections between the DBW, the IPS1 board and the Braking Resistor

XC6

Thermal

Relay

Thermostat

XC3

Braking Resistor

3-25

Installation and Connection

3.4.7.2 Motor Connections

ATTENTION!

The inverter has an electronic motor overload protection that shall be adjusted according to the driven motor. When several motors are connected to the same inverter, install individual overload relays for each motor.

XC6

Figure 3.39 - IPS1 board - XC6 connector location

ATTENTION!

The motor overload protection available in the CFW-11 is in accordance with the IEC60947-4-2 and the UL508C standards. Important considerations for the UL508C:

Trip current equal to 1.25 times the motor nominal current (P0401) adjusted in the "Oriented

Start-up" routine.

The maximum allowed value for the parameter P0159 (Motor Thermal Class) is 3 (Class 20). The maximum allowed value for the parameter P0398 (Motor Service Factor) is 1.15.

ATTENTION!

If a disconnect switch or a contactor is installed between the inverter and the motor, never operate them with a spinning motor or with voltage at the inverter output.

The characteristics of the cable used for the inverter and motor interconnection, as well as the physical location are extremely important to avoid electromagnetic interference in other equipment and to not affect the life cycle of motor windings and motor bearings controlled by inverters.

Recommendations for the motor cables:

Unshielded Cables:

Can be used when it is not necessary to meet the European directive of electromagnetic compatibility

(89/336/EEC).

Keep motor cables away from other cables (signal cables, sensor cables, control cables, etc.), according to

table 3.11.

The emission of the cables may be reduced by installing them inside a metal conduit, which shall be grounded

at both ends.

Connect a fourth cable between the motor ground and the inverter ground.

3-26

Installation and Connection

Note:

The magnetic field created by the current circulation in these cables may induce current in close metal pieces, heat them, and cause additional electrical losses. Therefore, keep the 3 (three) cables (U, V, W) always together.

Shielded Cables:

Are mandatory when the electromagnetic compatibility directive (89/336/EEC) shall be met, as defined by

the standard EN 61800-3 “Adjustable Speed Electrical Power Drive Systems”.

These cables act mainly by reducing the irradiated emission in the radio-frequency range.

Are mandatory when RFI filters, internally or externally mounted, are installed at the inverter input. In reference to the type and details of installation, follow the recommendations of IEC 60034-25 “Guide

for Design and Performance of Cage Induction Motors Specifically Designed for Converter Supply” – refer to a summary in figure 3.40. Refer to the standard for further details and eventual modifications related to new revisions.

Keep motor cables away from other cables (signal cables, sensor cables, control cables, etc.), according to

table 3.11.

The grounding system shall be well interconnected among the several installation locations such as the

grounding points of the motor and the inverter. Voltage difference or impedance between the several points may cause the circulation of leakage currents among the equipment connected to the ground, resulting in electromagnetic interference problems.

Table 3.11 - Minimum separation distance between motor cables and all other cables

Cable length Minimum separation distance

≤ 30 m (100 ft) ≥ 10 cm (3.94 in) > 30 m (100 ft) ≥ 25 cm (9.84 in)

(a) Symmetrical shielded cables: three concentric conductors with or without a ground conductor, symmetrically manufactured, with

an external shield of copper or aluminum.

PEs

AFe

Notes: (1) SCu = copper or aluminum external shielding. (2) AFe = steel or galvanized iron. (3) PE = ground conductor. (4) Cable shielding shall be grounded at both ends (inverter and motor). Use 360º connections for a low impedance to high-frequencies. (5) For using the shield as a protective ground, it shall have at least 50 % of the power cables conductivity. Otherwise, add an external ground

conductor and use the shield as an EMC protection. (6) Shielding conductivity at high-frequencies shall be at least 10 % of the power cables conductivity.

Figure 3.40 - Motor connection cables recommended by IEC 60034-25

3-27

Installation and Connection

3.4.8 Control Connections

The control connections (analog inputs/outputs, and digital inputs/outputs) must be made at the electronic control board CC11 terminal strip XC1, at the UC11 control unit. Functions and typical connections are presented in figures 3.41 (a) and (b).

≥5 kΩ

CCW

3-28

rpm

amp

Connector XC1 Factory Default Function Specifications

1 +REF

2 AI1+

3 AI1-

4 REF-

5 AI2+

6 AI2-

7 AO1

AGND

(24 V)

9 AO2

AGND

(24 V)

11 DGND

12 COM

13 24 Vdc

14 COM

15 DI1

16 DI2

17 DI3

18 DI4

19 DI5

20 DI6

21 NC1

22 C1

23 NO1 24 NC2 25 C2 26 NO2 27 NC3

28 C3

29 NO3

Figure 3.41 (a) - Signals at connector XC1 - Digital inputs working as 'Active High'

Positive reference for potentiometer

Analog input #1: Speed reference (remote)

Negative reference for potentiometer

Analog input #2: No function

Analog output #1: Speed

Reference (0 V) for the analog outputs

Analog output #2: Motor current

Reference (0 V) for the analog outputs

Reference (0 V) for the

24 Vdc power supply Common point of the

digital inputs 24 Vdc power supply 24 Vdc power supply, ±8 %.

Common point of the digital inputs

Digital input #1: Start / Stop

Digital input #2: Direction of rotation (remote)

Digital input #3: No function

Digital input #4: No function

Digital input #5: Jog (remote)

Digital input #6: 2nf ramp

Digital output #1 DO1 (RL1): No fault

Digital output #2 DO2 (RL2):

- Speed > P0288

N > N

Digital output #3 DO3 (RL3):

- Speed reference

N* > N

> P0288

Output voltage:+5.4 V, ±5 %. Maximum output current: 2 mA

Differential Resolution: 12 bits Signal: 0 to 10 V (R Maximum voltage: ±30 V

Output voltage: -4.7 V, ±5 %. Maximum output current: 2 mA

Differential Resolution: 11 bits + signal Signal: 0 to ±10 V (R Maximum voltage: ±30 V

Galvanic Isolation Resolution: 11 bits Signal: 0 to 10 V (R Protected against short-circuit.

Connected to the ground (frame) through impedance: 940 Ω resistor

in parallel with a 22 nF capacitor. Galvanic Isolation

Resolution: 11 bits Signal: 0 to 10 V (R Protected against short-circuit.

Connected to the ground (frame) through impedance: 940 Ω resistor

in parallel with a 22 nF capacitor.

Connected to the ground (frame) through impedance: 940 Ω resistor

in parallel with a 22 nF capacitor.

Capacity: 500 mA. Note: In the models with the 24 Vdc external control power supply (CFW11MXXXXXXOW) the terminal 13 of XC1 becomes an input, i.e., the user must connect a 24 V power supply for the inverter. In all the other models this terminal is an output, i.e., the user has a 24 V power supply available there.

6 isolated digital inputs

High level ≥ 18 V Low level ≤ 3 V

Maximum input voltage = 30 V Input current: 11 mA @ 24 Vdc

Contact rating: Maximum voltage: 240 Vac Maximum current: 1 A NC - Normally closed contact; C - Common; NO - Normally open contact.

=400 kΩ) / 0 to 20 mA / 4 to 20 mA (RIN=500 Ω)

≥ 10 kΩ) / 0 to 20 mA / 4 to 20 mA (RL ≤ 500 Ω)

≥ 5 kΩ

CCW

rpm

amp

Installation and Connection

Connector XC1 Factory Default Function Specifications

1 +REF

2 AI1+

3 AI1-

4 REF-

5 AI2+

6 AI2-

7 AO1

AGND

(24 V)

9 AO2

AGND

(24 V)

11 DGND

12 COM

13 24 Vdc

14 COM

15 DI1

16 DI2

17 DI3

18 DI4

19 DI5

20 DI6

21 NC1

22 C1

23 NO1

24 NC2

25 C2

26 NO2

27 NC3

28 C3

29 NO3

Positive reference for potentiometer

Analog input #1: Speed reference (remote)

Negative reference for potentiometer

Analog input #2: No function

Analog output #1: Speed

Reference (0 V) for the analog outputs

Analog output #2: Motor current

Reference (0 V) for the analog outputs

Reference (0 V) for the

24 Vdc power supply

Common point of the digital inputs

24 Vdc power supply 24 Vdc power supply, ±8 %.

Common point of the digital inputs

Digital input #1: Start / Stop

Digital input #2: Direction of rotation (remote)

Digital input #3: No function

Digital input #4: No function

Digital input #5: Jog (remote)

Digital input #6: 2nf ramp

Digital output #1 DO1 (RL1): No fault

Digital output #2 DO2 (RL2): N > N

- Speed > P0288

Digital output #3 DO3 (RL3):

- Speed reference

N* > N

> P0288

Output voltage:+5.4 V, ±5 %. Maximum output current: 2 mA

Differential Resolution: 12 bits Signal: 0 to 10 V (R Maximum voltage: ±30 V

= 400 kΩ) / 0 to 20 mA / 4 to 20 mA (RIN= 500 Ω)

Output voltage: -4.7 V, ±5 %. Maximum output current: 2 mA

Differential Resolution: 11 bits + signal Signal: 0 to ±10 V (R Maximum voltage: ±30 V

= 400 kΩ) / 0 to 20 mA / 4 to 20 mA (RIN= 500 Ω)

Galvanic Isolation Resolution: 11 bits Signal: 0 to 10 V (R Protected against short-circuit.

≥ 10 kΩ) / 0 to 20 mA / 4 to 20 mA (RL ≤ 500 Ω)

Connected to the ground (frame) through impedance: 940 Ω resistor

in parallel with a 22 nF capacitor.

Galvanic Isolation Resolution: 11 bits Signal: 0 to 10 V (R Protected against short-circuit.

≥ 10 kΩ) / 0 to 20 mA / 4 to 20 mA (RL ≤ 500 Ω)

Connected to the ground (frame) through impedance: 940 Ω resistor

in parallel with a 22 nF capacitor.

Connected to the ground (frame) through impedance: 940 Ω resistor

in parallel with a 22 nF capacitor.

6 isolated digital inputs

High level ≥ 18 V Low level ≤ 3 V Input voltage ≤ 30 V

Input current: 11 mA @ 24 Vdc

Contact rating: Maximum voltage: 240 Vac Maximum current: 1 A NC - Normally closed contact; C - Common; NO - Normally open contact.

Figure 3.41 (b) - Signals at connector XC1 - Digital inputs working as 'Active Low'

3-29

Installation and Connection

NOTE!

Remove the jumper between XC1:11 and 12 and install it between XC1:12 and 13 to use the digital inputs as 'Active Low'.

Slot 5

Slot 1 (white)

Slot 2 (yellow)

Slot 3 (green)

Slot 4

Figure 3.42 - Connector XC1 and DIP-switches for selecting the signal type of the analog inputs and outputs

The analog inputs and outputs are factory set to operate in the range from 0 to 10 V; this setting may be changed by using DIP-switch S1.

Table 3.12 - DIP-switches conFiguretion for the selection of the signal type for the analog inputs and outputs

Signal Factory Default Function

AI1 Speed Reference (remote) S1.4

AI2 No Function S1.3

AO1 Speed S1.2

AO2 Motor Current S1.1

DIP-

switch

Selection Factory Setting

OFF: 0 to 10 V (factory setting) ON: 4 to 20 mA / 0 to 20 mA

OFF: 0 to ±10 V (factory setting) ON: 4 to 20 mA / 0 to 20 mA

OFF: 4 to 20 mA / 0 to 20 mA ON: 0 to 10 V (factory setting)

OFF

Parameters related to the analog inputs and outputs (AI1, AI2, AO1, and AO2) shall be programmed according to the DIP-switches settings and desired values.

Follow instructions below for the proper installation of the control wiring:

1) Wire gauge: 0.5 mm² (20 AWG) to 1.5 mm² (14 AWG);

2) Maximum tightening torque: 0.5 Nm (4.50 lbf.in);

3) Use shielded cables for the connections in XC1 and run the cables separated from the remaining circuits (power, 110 V / 220 Vac control, etc.), as presented in table 3.13. If control wiring must cross other cables (power cables for instance), make it cross perpendicular to the wiring and provide a minimum separation of 5 cm (1.9 in) at the crossing point.

3-30

Installation and Connection

Table 3.13 - Minimum separation distances between wiring

Inverter Rated

Output Current

≤ 24 A

≥ 28 A

Cable Length

≤ 100 m (330 ft)

> 100 m (330 ft)

≤ 30 m (100 ft)

> 30 m (100 ft)

4) The adequate connection of the cable shield is shown in figure 3.43. Figure 3.44 shows how to connect the cable shield to the ground.

Inverter side

Figure 3.43 - Shield connection

Minimum Separation

Distance

≥ 10 cm (3.94 in) ≥ 25 cm (9.84 in) ≥ 10 cm (3.94 in) ≥ 25 cm (9.84 in)

Isolate with tape

Do not ground

Figure 3.44 - Example of shield connection for the control wiring

5) Relays, contactors, solenoids or coils of electromechanical brakes installed close to the inverter may eventually create interferences in the control circuit. To eliminate this effect, RC suppressors (with AC power supply) or free-wheel diodes (with DC power supply) shall be connected in parallel to the coils of these devices.

3-31

Installation and Connection

3.4.9 Typical Control Connections

Control connection #1 - Start/Stop function controlled from the keypad (Local Mode).

With this control connection it is possible to run the inverter in local mode with the factory default settings. This operation mode is recommended for first-time users, since no additional control connections are required.

For the start-up in this operation mode, please follow instructions listed in chapter 5.

Control connection #2 - 2 - Wire Start/Stop function (Remote Mode).

This wiring example is valid only for the default factory settings and if the inverter is set to remote mode. With the factory default settings, the selection of the operation mode (local/remote) is performed through the operator key (local mode is default). Set P0220 = 3 to change the default setting of operator key to remote mode.

≥5 kΩ

Start/Stop

Direction of Rotation

Jog

Connector XC1

1 + REF

2 AI1+

3 AI1-

4 - REF

5 AI2+

6 AI2-

7 AO1

8 AGND (24 V)

9 AO2

10 AGND (24 V)

11 DGND

12 COM

13 24 Vdc

14 COM

15 DI1

16 DI2

17 DI3

18 DI4

19 DI5

20 DI6

21 NC1

22 C1

23 NO1

24 NC2

25 C2

26 NO2

27 NC3

28 C3

29 NO3

DO1

(RL1)

DO2

(RL2)

DO3

(RL3)

3-32

Figure 3.45 - XC1 wiring for Control Connection #2

Installation and Connection

Control connection #3 - 3 - Wire Start/Stop function.

Enabling the Start/Stop function with 3 Wire control. Parameters to set: Set DI3 to START P0265 = 6 Set DI4 to STOP P0266 = 7

Set P0224 = 1 (DIx) for 3 wire control in Local mode. Set P0227 = 1 (DIx) for 3 wire control in Remote mode.

Set the Direction of Rotation by using digital input #2 (DI2). Set P0223 = 4 to Local Mode or P0226 = 4 to Remote Mode. S1 and S2 are Start (NO contact) and Stop (NC contact) push-buttons respectively. The speed reference can be provided through the analog input (as in Control Connection #2), through the keypad (as in Control Connection #1) or through any other available source.

Direction of Rotation S3

(FWD/REV)

Start S1

Stop S2

Connector XC1

1 + REF

2 AI1+

3 AI1-

4 - REF

5 AI2+

6 AI2-

7 AO1

8 AGND (24 V)

9 AO2

10 AGND (24 V)

11 DGND

12 COM

13 24 Vdc

14 COM

15 DI1

16 DI2

17 DI3

18 DI4

19 DI5

20 DI6

21 NC1

22 C1

23 NO1

24 NC2

25 C2

26 NO2

27 NC3

28 C3

29 NO3

DO1 (RL1)

DO2 (RL2)

DO3 (RL3)

Figure 3.46 - XC1 wiring for Control Connection #3

3-33

Installation and Connection

Control connection #4 - Forward/Reverse.

Enabling the Forward/Reverse function. Parameters to set: Set DI3 to FORWARD P0265 = 4 Set DI4 to REVERSE P0266 = 5

When the Forward/Reverse function is set, it will be active either in Local or Remote mode. At the same time, the operator keys and will remain always inactive (even if P0224 = 0 or P0227 = 0).

The direction of rotation is determined by the forward and reverse inputs. Clockwise to forward and counter-clockwise to reverse. The speed reference can be provided by any source (as in Control Connection #3).

Stop/Forward S1

Stop/Reverse S2

Connector XC1

1 + REF

2 AI1+

3 AI1-

4 - REF

5 AI2+

6 AI2-

7 AO1

8 AGND (24 V)

9 AO2

10 AGND (24 V)

11 DGND

12 COM

13 24 Vdc

14 COM

15 DI1

16 DI2

17 DI3

18 DI4

19 DI5

20 DI6

21 NC1

22 C1

23 NO1

24 NC2

25 C2

26 NO2

27 NC3

28 C3

29 NO3

DO1 (RL1)

DO2 (RL2)

DO3 (RL3)

3-34

Figure 3.47 - XC1 wiring for Control Connection #4

Installation and Connection

3.5 INSTALLATION ACCORDING TO THE EUROPEAN DIRECTIVE OF ELECTROMAGNETIC COMPATIBILITY

The CFW-11M inverters , when properly installed, meet the requirements of the electromagnetic compatibility directive - "EMC Directive 2004 / 108 / EC".

3.5.1 Conformal Installation

For the conformal installation use:

1) CFW-11M standard inverter for emission levels in accordance with IEC/EN 61800-3 "Adjustable Speed Electrical Power Drive Systems", C4 category.

2) Additional external filters in order to comply with the conducted emission levels C2 or C3 categories.

3) Shielded output cables (motor cables) and connect the shield at both ends (motor and inverter) with a low impedance connection for high frequency. The required cable separation is presented in table 3.11.

4) Shielded control cables, keeping them separate from the other cables as described in item 3.4.8.

5) Inverter grounding according to the instructions on item 3.4.5.

3.5.2 Standard Definitions

IEC/EN 61800-3: “Adjustable Speed Electrical Power Drives Systems”

- Environment:

First Environment: includes domestic premises. It also includes establishments directly connected without

intermediate transformer to a low-voltage power supply network which supplies buildings used for domestic purposes. Example: houses, apartments, commercial installations, or offices located in residential buildings.

Second Environment: includes all establishments other than those directly connected to a low-voltage power supply network which supplies buildings used for domestic purposes. Example: industrial area, technical area of any building supplied by a dedicated transformer.

- Categories:

Category C1: inverters with a voltage rating less than 1000 V and intended for use in the First Environment.

Category C2: inverters with a voltage rating less than 1000 V, intended for use in the First Environment,

not provided with a plug connector or a movable installations, and installed and commissioned by a professional. Note: a professional is a person or organization familiar with the installation and/or commissioning of inverters, including the EMC aspects.

3-35

Installation and Connection

Category C3: inverters with a voltage rating less than 1000 V and intended for use in the Second Environment only (not designed for use in the First Environment).

Category C4: inverters with a voltage rating equal to or greater than 1000 V, or with a current rating equal to or greater than 400 Amps, or intended for use in complex systems in the Second Environment.

EN 55011: “Threshold values and measuring methods for radio interference from industrial, scientific and medical (ISM) high-frequency equipment”

Class B: equipment intended for use in the low-voltage power supply network (residential, commercial, and

light-industrial environments).

Class A1: equipment intended for use in the low-voltage power supply network. Restricted distribution. Note: must be installed and commissioned by a professional when applied in the low-voltage power supply

network.

Class A2: equipment intended for use in industrial environments.

3.5.3 Emission and Immunity Levels

Table 3.14 - Emission and immunity levels

EMC Phenomenon Basic Standard Level

Emission:

Mains Terminal Disturbance Voltage Frequency Range: 150 kHz to 30 MHz)

Electromagnetic Radiation Disturbance Frequency Range: 30 kHz to 1 GHz)

Immunity:

Electrostatic Discharge (ESD) IEC/EN61000-4-2 4 kV for contact discharge and 8 kV for air discharge.

Fast Transient-Burst IEC/EN61000-4-4

Conducted Radio-Frequency Common Mode IEC/EN61000-4-6

Surge Immunity IEC/EN61000- 4-5

Radio-Frequency Electromagnetic Field IEC/EN61000-4-3

IEC/EN61800-3

- Without external filter: C4 Category.

- With external filter: C2 or C3 Category.

2 kV/5 kHz (coupling capacitor) power input cables; 1 kV/5 kHz control cables, and remote keypad cables; 2 kV/5 kHz (coupling capacitor) motor output cables.

0.15 to 80 MHz; 10 V; 80 % AM (1 kHz). Motor cables, control cables, and remote keypad cables.

1.2/50 µs, 8/20 µs; 1 kV line-to-line coupling; 2 kV line-to-ground coupling.

80 to 1000 MHz; 10 V/m; 80 % AM (1 kHz).

3-36

Installation and Connection

3.5.4 External RFI Filters

To be used only if necessary to comply with conducted emission levels Category C2 or C3 according to IEC/ EN61800-3. The models bellow are from the manufacturer Epcos.

Table 3.15 - Filters for 380-480 V lines Table 3.16 - Filters for 500-600 V lines

Inverter

Model

Regimen Filter Model

Inverter

Model

Regimen Filter Model

600

1140

1710

2280

2850

ND B84143-B600-S20

470

HD B84143-B600-S20 HD B84143-B600-S21

ND B84143-B1600-S20

893

HD B84143-B1000-S20 HD B84143-B1000-S21

ND B84143-B2500-S20

1340

HD B84143-B1600-S20 HD B84143-B1600-S21

ND B84143-B2500-S20

1786

HD B84143-B2500-S20 HD B84143-B1600-S21

ND - - - -

2232

HD B84143-B2500-S20 HD B84143-B2500-S21

Table 3.17 - Filters for 660-690 V lines

Inverter

Model

Regimen Filter Model

ND B84143-B600-S21

ND B84143-B1000-S21

ND B84143-B1600-S21

ND B84143-B2500-S21

427

811

1217

1622

2028

ND B84143-B600-S21

HD B84143-B600-S21

ND B84143-B1000-S21

HD B84143-B1000-S21

ND B84143-B1600-S21

HD B84143-B1000-S21

ND B84143-B2500-S21

HD B84143-B1600-S21

ND B84143-B2500-S21

HD B84143-B2500-S21

3-37

Installation and Connection

Controling and Signal Wiring

Transforme

Ground Rod/Grid or Building Steel Structure

Filter

Figure 3.48 - External RFI filter connections

Rectifier

Panel or Metallic Enclosure

Protective Grounding - PE

CFW-11M

Motor

Use the listed filters only in lines with a solidly grounded neutral point. Do not use them in IT networks, lines that are not grounded or grounded via a high impedance.

Take the usual precautions for EMC filters installation: Do not cross the filter input cables with the output cables, mount the filter on a metallic plate assuring the biggest possible contact surface between the filter and the plate, connect this plate to the ground via cordage, etc.

Filter technical data:

Table 3.18 - Filter characteristics

Filter

B84143-B600-S20 600 57

B84143-B1000-S20 1000 99

B84143-B1600-S20 1600 169

B84143-B2500-S20 2500 282

B84143-B600-S21 600 57 22

B84143-B1000-S21 1000 99 28

B84143-B1600-S21 1600 169 34

B84143-B2500-S21 2500 282 105

Nominal

Current [A]

Watt Losses [W]

Weight

[kg]

105

3-38

Keypad and Display

KEYPAD AND DISPLAY

This chapter describes:

- The operator keys and their functions;

- The indications on the display;

- How parameters are organized.

4.1 INTEGRAL KEYPAD - HMI-CFW11

The integral keypad can be used to operate and program (view / edit all parameters) of the CFW-11 inverter. The inverter keypad navigation is similar to the one used in cell phones and the parameters can be accessed in numerical order or through groups (Menu).

Left soft key: press this key to select the above highlighted menu feature.

1. Press this key to advance to the next parameter or to increase a parameter value.

2. Press this key to increase the speed.

3. Press this key to select the previous group in the Parameter Groups.

Press this key to define the direction of rotation for the motor. This option is active when: P0223 = 2 or 3 in LOC and/or P0226 = 2 or 3 in REM.

Press this key to switch between LOCAL or REMOTE modes. This option is active when: P0220 = 2 or 3.

Press this key to accelerate the motor to the speed set in P0122 in the time set for the acceleration ramp. The motor speed is kept while this key is pressed. Once this key is released, the motor will stop by following the deceleration ramp. This function is active when all conditions below are satisfied:

1. Start/Stop = Stop;

2. General Enable = Active;

3. P0225 = 1 in LOC and/or P0228 = 1 in REM.

Right soft key: press this key to select the above highlighted menu feature.

1. Press this key to move back to the previous parameter or to decrease a parameter value.

2. Press this key to decrease speed.

3. Press this key to select the next group in the Parameter Groups.

Press this key to accelerate the motor in the time set for the acceleration ramp. This option is active when: P0224 = 0 in LOC or P0227 = 0 in REM.

Press this key to stop the motor in the time set for the deceleration ramp. This option is active when: P0224 = 0 in LOC or P0227 = 0 in REM.

Figure 4.1 - Operator keys

Battery:

NOTE!

The battery is necessary only to keep the internal clock operation when the inverter stays without power. If the battery is completely discharged or if it is not installed in the keypad, the displayed clock time will be invalid and an alarm condition A181 - Invalid clock time will be indicated whenever the AC power is applied to the inverter.

The battery life expectancy is of approximately 10 years. When necessary, replace the battery by another of the CR2032 type.

4-1

Keypad and Display

1 2 3

Cover

Cover for battery access

4 5 6

Press the cover and rotate it

counterclockwise

Remove the cover

Remove the battery with the

help of a screwdriver positioned

in the right side

7 8

Press the battery for its insertion

HMI without the battery

Put the cover back and rotate it clockwise

Figure 4.2 - HMI battery replacement

Install the new battery positioning it rst at

the left side

4-2

NOTE!

At the end of the battery useful life, please do not discard batteries in your waste container, but use a battery disposal site.

Keypad and Display

Installation:

The keypad can be installed or removed from the inverter with or without AC power applied to the

inverter.

The HMI supplied with the product can also be used for remote command of the inverter. In this case, use

a cable with male and female D-Sub9 (DB-9) connectors wired pin to pin (mouse extension type) or a market standard Null-Modem cable. Maximum cable length: 10 m (33 ft). It is recommended the use of the

M3 x 5.8 standoffs supplied with the product.Recommended torque: 0.5 Nm (4.50 lbf in).

When power is applied to the inverter, the display automatically enters the monitoring mode. Figure 4.3 (a) presents the monitoring screen displayed for the factory default settings. By properly setting specific inverter parameters, other variables can be displayed in the monitoring mode or the value of a parameter can be displayed using bar graphs or with larger characters as presented in figures 4.3 (b) and (c).

Indication of the control mode:

Indication of the direction of rotation of the motor.

Inverter status:

- Run

- Ready

- Config

- Self-tuning

- Last fault: FXXX

- Last alarm: AXXX

- etc.

Left soft key feature.

- LOC: local mode;

- REM: remote mode.

Run

LOC

1800 rpm

1.0 A

60.0 Hz

12:35 Menu

1800rpm

Indication of the motor speed in rpm.

Monitoring parameters:

- Motor speed in rpm;

- Motor current in Amps;

- Output frequency in Hz (default).

P0205, P0206, and P0207: selection of parameters that will be displayed in the monitoring mode.

P0208 to P0212: engineering unit for the speed indication.

Right soft key feature.

Run

rpm

Run

LOC

12:35 Menu

LOC

1800

12:35 Menu

Clock. Settings via: P0197, P0198, and P0199.

(a) Monitoring screen with the factory default settings

Monitoring parameters:

- Motor speed in rpm;

1800rpm

100%

77%

100%

(b) Example of a monitoring screen with bar ghaphs

1800rpm

rpm

- Motor current in Amps;

- Output frequency in Hz (default).

P0205, P0206, and P0207: selection of parameters that will be displayed in the monitoring mode.

P0208 to P0212: engineering unit for the speed indication.

Value of one of the parameters defined in P0205, P0206, or P0207 displayed with a larger font size. Set parameters P0205, P0206 or P0207 to 0 if it is not desirable to display them.

Figure 4.3 - Keypad monitoring modes

4-3

Keypad and Display

4.2 PARAMETERS ORGANIZATION

When the right soft key ("MENU") is pressed in the monitoring mode, the display shows the first 4 groups of parameters. An example of how the groups of parameters are organized is presented in table 4.1. The number and name of the groups may change depending on the firmware version used. For further details on the existent groups for the firmware version used, please refer to the Software Manual.

Table 4.1 - Groups of parameters

Level 0 Level 1 Level 2 Level 3

Monitoring 00 ALL PARAMETERS

01 PARAMETER GROUPS 20 Ramps

21 Speed References 22 Speed Limits 23 V/f Control 24 Adjust. V/f Curve 25 VVW C o n t r o l 26 V/f Current Limit. 27 V/f DC Volt.Limit. 28 Dynamic Braking 29

Vector Control 90 Speed Regulator

30 HMI 31 Local Command 32 Remote Command 33 3-Wire Command 34 FWD/REV Run Comm. 35 Zero Speed Logic 36 Multispeed 37 Electr. Potentiom. 38 Analog Inputs 39 Analog Outputs 40 Digital Inputs 41 Digital Outputs 42 Inverter Data 43 Motor Data 44 FlyStart/RideThru 45 Protections 46 PID Regulator 47 DC Braking 48 Skip Speed 49

50 SoftPLC 51 PLC

52 Trace Function 02 ORIENTED START-UP 03 CHANGED PARAMETERS 04 BASIC APPLICATION 05 SELF-TUNING 06 BACKUP PARAMETERS 07

I/O CONFigureTION 38 Analog Inputs

08 FAULT HISTORY 09 READ ONLY PARAMS.

39 Analog Outputs

40 Digital Inputs

41 Digital Outputs

Communication 110 Local/Rem Config.

91 Current Regulator 92 Flux Regulator 93 I/F Control 94 Self-Tuning 95 Torque Curr.Limit. 96 DC Link Regulator

111 Status/Commands 112 CANopen/DeviceNet 113 Serial RS232/485 114 Anybus 115 Profibus DP

4-4

First Time Power-Up and Start-Up

FIRST TIME POWER-UP AND START-UP

This chapter describes how to:

- Check and prepare the inverter before power-up.

- Power-up the inverter and check the result.

- Set the inverter for the operation in the V/f mode based on the power supply and motor information by using the Oriented Start-Up routine and the Basic Application group.

NOTE!

For a detailed description of the V V W or Vector control modes and for other available functions, please refer to the CFW-11 Software Manual.

5.1 PREPARE FOR START-UP

The inverter shall have been already installed according to the recommendations listed in Chapter 3 – Installation and Connection. The following recommendations are applicable even if the application design is different from the suggested control connections.

DANGER!

Always disconnect the main power supply before performing any inverter connection.

5.1.1 Precautions during the Energization/Start-up

1) Verify all the connections of the panel.

2) Search for short-circuits at the input, DC link, etc.

3) Make sure all the cables are correctly connected between the control and power units.

4) Verify the condition of all the fuses.

5) Inspect all the ground connections (panel, the door where the control is installed, etc.).

6) Remove all the material rests from the inverter or panel interior.

7) Close the inverter or panel covers.

8) Energize the control (+24 Vdc power supply).

9) The HMI must indicate undervoltage error with the control energized and the power units deenergized. The

electronics of the power units stay without power (SMPS off) and the DC link monitoring signal remains at 0 V.

10) Measure the line voltage making sure it is inside the permitted range.

5-1

First Time Power-Up and Start-Up

11) Verify if the automatic hardware identification has correctly recognized the inverter current and voltage. The inverter current must be compatible with the number of installed power units.

12) Command the drive, perform the DC link pre-charge and close the main contactor/circuit breaker.

13) Verify the proper operation of the fans. The fan control conFiguretion is done via software through the parameter P0352 (refer to the CFW-11 Software Manual). The power units do not have internal fans at the electronics, only at the heatsinks. At the factory default the fans stay on for a while during the energization and then they are switched off. They will only be switched on again if the heatsink temperature reaches

70 °C (158 ºF), and off if the temperature drops below 60 °C (140 ºF).

14) Observe the existence of faults/alarms. In case that a fault or alarm occurs, verify the possible causes and solve the problem.

15) Enable the inverter via HMI. Verify the output current of each power unit phase by programming the password 637 at the parameter P0000 (refer to the section 5.2.1), which makes the visualization of the parameters from P0815 to P0829 possible. Because the drive is with no load, the measured current is the one that circulates between the parallel power units, which must be less than 2.5 % of the nominal ND current of the power unit.

16) Disable the inverter via HMI.

17) Verify if the temperature reading parameters of the installed power units, P0800 to P0814 according to the case, indicate values close to the ambient temperature.

18) Deenergize the drive and wait until the DC link capacitors discharge completely. Then connect a motor with power close to 100 HP (75 kW) or the application motor with no load. Verify the motor connection and if its current and voltage match the inverter. If the application motor is going to be used, decouple it mechanically from the load. If the motor cannot be decoupled, make sure that the rotation in any direction (clockwise or counterclockwise) will not cause damage to the machine or accident risks.

19) Command the drive, perform the DC link pre-charge and close the main contactor/circuit breaker.

20) Enable the inverter via HMI. Verify the output current of each power unit phase: The current unbalance (P0815 to P0829) of each phase must stay below 5 %. Verify if the difference between the temperatures of the power units (P0800 to P0814) is of maximum 10 °C (50 ºF).

5-2

First Time Power-Up and Start-Up

5.2 START-UP

The start-up procedure for the V/f is described in three simple steps by using the Oriented Start-up routine and the Basic Application group.

Steps: (1) Set the password for parameter modification.

(2) Execute the Oriented Start-up routine.

(3) Set the parameters of the Basic Application group.

5.2.1 Password Setting in P0000

Step Action/Result Display indication

Monitoring Mode.

- Press“Menu”

(rigth soft key).

- Group “00 ALL PARAMETERS” is already

selected.

- Press “Select”.

- Parameter “Access to Parameters P0000: 0” is

already selected.

- Press “Select”.

- To set the password, press the Up Arrow

until number 5 is

displayed in the keypad.

- When number 5 is

displayed in the keypad, press “Save”.

Ready

LOC

0 rpm

0.0 A

0.0 Hz

15:45 Menu

00 ALL PARAMETERS

01 PARAMETER GROUPS 02 ORIENTED START-UP 03 CHANGED PARAMETERS

Return 15:45 Select

Access to Parameters P0000: 0

Speed Reference P0001: 90 rpm

Return 15:45 Select

P0000

Access to Parameters

Return 15:45 Save

P0000

Access to Parameters

Return 15:45 Save

LOC

0rpm

Step Action/Result Display indication

7 - Press ”Return”.

- The display returns to the

Monitoring Mode.

Ready

00 ALL PARAMETERS

01 PARAMETER GROUPS 02 ORIENTED START-UP 03 CHANGED PARAMETERS

Return 15:45 Select

LOC

0 rpm

0.0 A

0.0 Hz

15:45 Menu

0rpm

- If the setting has been properly performed, the keypad should display

“Access to Parameters

P0000: 5”.

- Press “Return” (left soft key).

Ready

Access to Parameters P0000: 5

Speed Reference P0001: 90 rpm

Return 15:45 Select

LOC

0rpm

Figure 5.1 - Steps for allowing parameters modification via P0000

5-3

First Time Power-Up and Start-Up

5.2.2 Oriented Start-Up

There is a group of parameters named ”Oriented Start-up” that makes the inverter settings easier. Inside this group, there is a parameter – P0317 – that shall be set to enter into the Oriented Start-up routine.

The Oriented Start-up routine allows you to quickly set up the inverter for operation with the line and motor used. This routine prompts you for the most commonly used parameters in a logic sequence.

In order to enter into the Oriented Start-up routine, follow the steps presented in figure 5.2, first modifying parameter P0317 to 1 and then, setting all remaining parameters as they are prompted in the display.

The use of the Oriented Start-up routine for setting the inverter parameters may lead to the automatic modification of other internal parameters and/or variables of the inverter.

During the Oriented Start-up routine, the message “Config” will be displayed at the left top corner of the keypad.

Step Action/Result Display indication

- Modo Monitoração.

- Pressione “Menu” (soft key direita).

- Group “00 ALL PARAMETERS” has been already selected.

- Group “01

PARAMETER GROUPS”

is selected.

- Group “02 ORIENTED START-UP” is

then selected.

- Press “Select”.

- Parameter “Oriented

Start-Up P0317: No”

has been already selected.

- Press “Select”.

- The value of

“P0317 = [000] No”

is displayed.

Ready

LOC

0 rpm

0.0 A

0.0 Hz

13:48 Menu

00 ALL PARAMETERS

01 PARAMETER GROUPS 02 ORIENTED START-UP 03 CHANGED PARAMETERS

Return 13:48 Select

00 ALL PARAMETERS

01 PARAMETER GROUPS

02 ORIENTED START-UP 03 CHANGED PARAMETERS

Return 13:48 Select

00 ALL PARAMETERS 01 PARAMETER GROUPS

02 ORIENTED START-UP

03 CHANGED PARAMETERS

Return 13:48 Select

Oriented Start-Up P0317: No

Return 13:48 Select

P0317

Oriented Start-up

[000] No

Return 13:48 Save

LOC

0rpm

Step Action/Result Display indication

- The parameter value is modified to “P0317 = [001] Yes”.

- Press “Save”.

Ready

LOC

P0317

Oriented Start-up

[001] Yes

Return 13:48 Save

- At this point the Oriented Start-up routine starts and the “Config” status is displayed at the top left corner of the keypad.

- The parameter

“Language P0201: English” is already

selected.

- If needed, change the

language by pressing “Select”. Then, press

Config

Language P0201: English

Type of Control P0202: V/F 60 HZ

Reset 13:48 Select

LOC

to scroll through the available options and press “Save” to select a different language.

- If needed, change the value of P0202 according to the type of control. To do so, press "Select".

- The settings listed here are valid only for P0202 = 0 (V/f 60 Hz) or

P0202 = 1 (V/f 50 Hz). For other options (Adjustable V/f, VVW, or Vector

Config

Language P0201: English

Type of Control P0202: V/F 60 HZ

Reset 13:48 Select

LOC

modes), please refer to the Software Manual.

0rpm

5-4

Figure 5.2 - Oriented Start-up

First Time Power-Up and Start-Up

Step Action/Result Display indication

- If needed, change the value of P0296 according to the line rated voltage. To do so, press "Select". This modification will

affect P0151, P0153, P0185, P0321, P0322, P0323, and P0400.

Config

Type of Control P0202: V/F 60 HZ

Line Rated Voltage P0296: 440 - 460 V

Reset 13:48 Select

LOC

- If needed, change the value of P0298 according to the inverter application. To do so, press "Select". This modification will affect P0156, P0157, P0158, P0401, P0404 and P0410 (this last one

only if P0202 = 0, 1, or 2 – V/f control). The time

Config

Line Rated Voltage P0296: 440 - 460 V

Application P0298: Heavy Duty

Reset 13:48 Select

LOC

and the activation level of the overload protection will be affected as well.

- If needed, change the value of P0398 according to the motor service factor. To do so, press “Select”. This modification will affect the current value

and the activation time of the motor overload

Config

Application P0298: Heavy Duty

Motor Service Factor P0398: 1.15

Reset 13:48 Select

LOC

function.

- If needed, change the value of P0400 according to the motor rated voltage. To do so, press “Select”. This

modification adjusts the output voltage by a factor x = P0400/P0296.

Config

Motor Service Factor P0398: 1.15

Motor Rated Voltage P0400: 440 V

Reset 13:48 Select

LOC

- If needed, change the value of P0401 according to the motor rated current. To do so, press “Select”. This modification will

affect P0156, P0157, P0158, and P0410.

Config

Motor Rated Voltage P0400: 440V

Motor Rated Current P0401: 13.5 A

Reset 13:48 Select

LOC

0rpm

Step Action/Result Display indication

- If needed, set P0402 according to the motor rated speed. To do so, press “Select”. This modification affects P0122 to P0131, P0133,

P0134, P0135, P0182, P0208, P0288, and

Config

Motor Rated Current P0401: 13.5 A

Motor Rated Speed P0402: 1750 rpm

Reset 13:48 Select

LOC

P0289.

- If needed, set P0403 according to the motor rated frequency. To do so, press “Select”. This

modification affects P0402.

Config

Motor Rated Speed P0402: 1750 rpm

Motor Rated Frequency P0403: 60 Hz

Reset 13:48 Select

LOC

- If needed, change the value of P0404 according to the motor rated power. To do so, press “Select”.

This modification affects P0410.

Config

Motor Rated Frequency P0403: 60 Hz

Motor Rated Power P0404: 4hp 3kW

Reset 13:48 Select

LOC

- This parameter will only be visible if the encoder board ENC1 is installed in the inverter.

- If there is an encoder connected to the motor,

set P0405 according to the encoder pulses number. To do so, press

Config

Motor Rated Power P0404: 4hp 3kW

Encoder Pulses Number P0405: 1024 ppr

Reset 13:48 Select

LOC

“Select”.

- If needed, set P0406 according to the motor ventilation. To do so, press “Select”.

- To complete the Oriented Start-Up routine, press “Reset” (left soft key) or

- After few seconds, the

display returns to the Monitoring Mode.

Config

Ready

Encoder Pulses Number P0405: 1024 ppr

Motor Ventilation P0406: Self-Vent.

Reset 13:48 Select

LOC

0 rpm

0.0 A

0.0 Hz

13:48 Menu

0rpm

Figure 5.2 (cont) - Oriented Start-up

5-5

First Time Power-Up and Start-Up

5.2.3 Setting Basic Application Parameters

After running the Oriented Start-up routine and properly setting the parameters, the inverter is ready to operate in the V/f mode.

The inverter has a number of other parameters that allow its adaptation to the most different applications. This manual presents some basic parameters that shall be set in most cases. There is a group named “Basic Application” to make this task easier. A summary of the parameters inside this group is listed in table 5.1. There is also a group of read only parameters that shows the value of the most important inverter variables such as voltage, current, etc. The main parameters comprised in this group are listed in table 5.2. For further details, please refer to the CFW-11 Software Manual.

Follow steps outlined in figure 5.3 to set the parameters of the Basic Application group.

The procedure for start-up in the V/f operation mode is finished after setting these parameters.

Step Action/Result Display indication

- Monitoring Mode.

- Press “Menu” (right soft key).

- Group “00 ALL PARAMETERS” has been already selected.

- Group “01 PARAMETER GROUPS” is then selected.

- Group “02 ORIENTED START-UP” is then selected.

- Group “03

CHANGED PARAMETERS” is

selected.

Ready

LOC

0 rpm

0.0 A

0.0 Hz

15:45 Menu

00 ALL PARAMETERS

01 PARAMETER GROUPS 02 ORIENTED START-UP 03 CHANGED PARAMETERS

Return 15:45 Select

00 ALL PARAMETERS

01 PARAMETER GROUPS

02 ORIENTED START-UP 03 CHANGED PARAMETERS

Return 15:45 Select

00 ALL PARAMETERS 01 PARAMETER GROUPS

02 ORIENTED START-UP

03 CHANGED PARAMETERS

Return 15:45 Select

00 ALL PARAMETERS 01 PARAMETER GROUPS 02 ORIENTED START-UP

03 CHANGED PARAMETERS

Return 15:45 Select

LOC

0rpm

Step Action/Result Display indication

- Group “04 BASIC APPLICATION” is

selected.

- Press “Select”.

Ready

01 PARAMETER GROUPS 02 ORIENTED START-UP 03 CHANGED PARAMETERS

04 BASIC APPLICATION

Return 15:45 Select

- Parameter “Acceleration Time P0100: 20.0 s” has

been already selected.

- If needed, set P0100 according to the desired acceleration time. To do so, press “Select”.

- Proceed similarly until all parameters of group “04

Ready

Acceleration Time P0100: 20.0s

Deceleration Time P0101: 20.0s

Return 15:45 Select

BASIC APPLICATION”

have been set. When finished, press “Return” (left soft key).

Ready

01 PARAMETER GROUPS

8 - Press “Return”.

02 ORIENTED START-UP 03 CHANGED PARAMETERS

04 BASIC APPLICATION

Return 15:45 Select

Ready

- The display returns to the

Monitoring Mode and the inverter is ready to run.

LOC

0 rpm

0.0 A

0.0 Hz

15:45 Menu

0rpm

5-6

Figure 5.3 - Setting parameters of the Basic Application group

First Time Power-Up and Start-Up

Table 5.1 - Parameters comprised in the Basic Application group

Parameter Name Description Setting Range

P0100 Acceleration

Time

P0101 Deceleration

Time

P0133 Minimum

Speed

P0134 Maximum

Speed

- Defines the time to linearly accelerate from 0 up to the maximum speed (P0134).

- If set to 0.0 s, it means no acceleration ramp.

- Defines the time to linearly decelerate from the maximum speed (P0134) up to 0.

- If set to 0.0 s, it means no deceleration ramp.

- Defines the minimum and maximum values of the speed reference when the drive is enabled.

- These values are valid for any reference source.

Reference

P0134

P0133

0.0 to 999.0 s 20.0 s

0 to 18000 rpm 90 rpm

Factory Setting

(60 Hz motor)

75 rpm

(50 Hz motor)

1800 rpm

(60 Hz motor)

1500 rpm

(50 Hz motor)

User

Setting

P0135 Max. Output

Current (V/f control mode current limitation)

0 ................................ 10 V

0 ...............................20 mA

4 mA ............................ 20 mA

10 V .................................. 0

20 mA ............................... 0

20 mA ............................ 4 mA

Alx Signal

- Avoids motor stall under torque overload condition during the acceleration or deceleration.

- The factory default setting is for “Ramp Hold”: if the motor current exceeds the value set at P0135 during the acceleration or deceleration, the motor speed will not be increased (acceleration) or decreased (deceleration) anymore. When the motor current reaches a value below the programmed in P0135, the motor speed is again increased or decreased.

- Other options for the current limitation are available. Refer to the CFW-11 Software Manual.

Motor current Motor current

P0135

Speed

Ramp acceleration (P0100)

During

acceleration

P0135

Speed

Ramp

deceleration

(P0101)

During

deceleration

TimeTime

0.2 x I 2 x I

rat-HD

1.5 x I

rat-HD

P0136 Manual Torque

Boost

- Operates in low speeds, modifying the output voltage x frequency curve to keep the torque constant.

- Compensates the voltage drop at the motor stator resistance. This function operates in low speeds increasing the inverter output voltage to keep the torque constant in the V/f mode.

- The optimal setting is the smallest value of P0136 that allows the motor to start satisfactorily. An excessive value will considerably increase the motor current in low speeds, and may result in a fault (F048, F051, F071, F072, F078 or F183) or alarm (A046, A047, A050 or A110) condition.

Output voltage

Rated

P0136 = 9

0.5x Rated

P0136 = 0

Nrat/2 Nrat

Speed

0 to 9 1

5-7

First Time Power-Up and Start-Up

Table 5.2 - Main read only parameters

Parameter Description Setting Range

P0001 Speed Reference 0 to 18000 rpm P0002 Motor Speed 0 to 18000 rpm P0003 Motor Current 0.0 to 4500.0 A P0004 DC Link Voltage (Ud) 0 to 2000 V P0005 Motor Frequency 0.0 to 300.0 Hz P0006

P0007 Motor Voltage 0 to 2000 V P0009 Motor Torque -1000.0 to 1000.0 % P0010 Output Power 0.0 to 6553.5 kW P0012 DI8 to DI1 Status 0000h to 00FFh P0013 DO5 to DO1 Status 0000h to 001Fh P0018 AI1 Value -100.00 to 100.00 % P0019 AI2 Value -100.00 to100.00 % P0020 AI3 Value -100.00 to100.00 % P0021 AI4 Value -100.00 to 100.00 % P0023 Software Version 0.00 to 655.35 P0027 Accessories Config. 1 Hexadecimal code P0028 Accessories Config. 2

P0029 Power Hardware Config. Hexadecimal code according

P0030 IGBTs Temperature U -20.0 to 150.0 °C

P0031 IGBTs Temperature V -20.0 to 150.0 °C

P0032 TIGBTs Temperature W -20.0 to 150.0 °C

P0033 Rectifier Temperature -20.0 to 150.0 °C

P0034 Temper. Ar Interno -20.0 to 150.0 °C

P0036 Fan Heatsink Speed 0 to 15000 rpm P0037 Motor Overload Status 0 to 100 % P0038 Encoder Speed 0 to 65535 rpm P0040 PID Process Variable 0.0 to 100.0 % P0041 PID Setpoint Value 0.0 to 100.0 % P0042 Time Powered 0 to 65535 h P0043 Time Enabled 0.0 to 6553.5 h P0044 kWh Output Energy 0 to 65535 kWh P0045 Fan Enabled Time 0 to 65535 h P0048 Present Alarm 0 to 999 P0049 Present Fault 0 to 999 P0050 Last Fault 0 to 999 P0051 Last Fault Day/Month 00/00 to 31/12 P0052 Last Fault Year 00 to 99 P0053 Last Fault Time 00:00 to 23:59 P0054 Second Fault 0 to 999 P0055 Second Flt. Day/Month 00/00 to 31/12 P0056 Second Fault Year 00 to 99 P0057 Second Fault Time 00:00 to 23:59 P0058 Third Fault 0 to 999 P0059 Third Fault Day/Month 00/00 to 31/12 P0060 Third Fault Year 00 to 99 P0061 Third Fault Time 00:00 to 23:59 P0062 Fourth Fault 0 to 999

5-8

VFD Status

0 = Ready 1 = Run 2 = Undervoltage 3 = Fault 4 = Self-tuning 5 = ConFiguretion 6 = DC-Braking 7 = STO

representing the identified accessories. Refer to chapter 7.

to the available models and option kits. Refer to the software manual for a complete code list.

(-4 °F to 302 °F)

Parameter Description Setting Range

P0063 Fourth Flt. Day/Month 00/00 to 31/12 P0064 Fourth Fault Year 00 to 99 P0065 Fourth Fault Time 00:00 to 23:59 P0066 Fifth Fault 0 to 999 P0067 Fifth Fault Day/Month 00/00 to 31/12 P0068 Fifth Fault Year 00 to 99 P0069 Fifth Fault Time 00:00 to 23:59 P0070 Sixth Fault 0 to 999 P0071 Sixth Fault Day/Month 00/00 to 31/12 P0072 Sixth Fault Year 00 to 99 P0073 Sixth Fault Time 00:00 to 23:59 P0074 Seventh Fault 0 to 999 P0075 Seventh Flt.Day/Month 00/00 a 31/12 P0076 Seventh Fault Year 00 to 99 P0077 Seventh Fault Time 00:00 to 23:59 P0078 Eighth Fault 0 to 999 P0079 Eighth Flt. Day/Month 00/00 to 31/12 P0080 Eighth Fault Year 00 to 99 P0081 Eighth Fault Time 00:00 to 23:59 P0082 Ninth Fault 0 to 999 P0083 Ninth Fault Day/Month 00/00 to 31/12 P0084 Ninth Fault Year 00 to 99 P0085 Ninth Fault Time 00:00 to 23:59 P0086 Tenth Fault 0 to 999 P0087 Tenth Fault Day/Month 00/00 to 31/12 P0088 Tenth Fault Year 00 to 99 P0089 Tenth Fault Time 00:00 to 23:59 P0090 Current At Last Fault 0.0 to 4000.0 A P0091 DC Link At Last Fault 0 to 2000 V P0092 Speed At Last Fault 0 to 18000 rpm P0093 Reference Last Fault 0 to 18000 rpm P0094 Frequency Last Fault 0.0 to 300.0 Hz P0095 Motor Volt.Last Fault 0 to 2000 V P0096 DIx Status Last Fault 0000h to 00FFh P0097 DOx Status Last Fault 0000h to 00F8h P0800 Phase U Book 1 Temper -20 to 150 °C (-4 °F to 302 °F) P0801 Phase V Book 1 Temper -20 to 150 °C (-4 °F to 302 °F) P0802 Phase W Book 1 Temper -20 to 150 °C (-4 °F to 302 °F) P0803 Phase U Book 2 Temper -20 to 150 °C (-4 °F to 302 °F) P0804 Phase V Book 2 Temper -20 to 150 °C (-4 °F to 302 °F) P0805 Phase W Book 2 Temper -20 to 150 °C (-4 °F to 302 °F) P0806 Phase U Book 3 Temper -20 to 150 °C (-4 °F to 302 °F) P0807 Phase V Book 3 Temper -20 to 150 °C (-4 °F to 302 °F) P0808 Phase W Book 3 Temper -20 to 150 °C (-4 °F to 302 °F) P0809 Phase U Book 4 Temper -20 to 150 °C (-4 °F to 302 °F) P0810 Phase V Book 4 Temper -20 to 150 °C (-4 °F to 302 °F) P0811 Phase W Book 4 Temper -20 to 150 °C (-4 °F to 302 °F) P0812 Phase U Book 5 Temper -20 to 150 °C (-4 °F to 302 °F) P0813 Phase V Book 5 Temper -20 to 150 °C (-4 °F to 302 °F) P0814 Phase W Book 5 Temper -20 to 150 °C (-4 °F to 302 °F) P0815 Phase U Book 1 Current -1000 to 1000 A P0816 Phase V Book 1 Current -1000 to 1000 A P0817 Phase W Book 1 Current -1000 to 1000 A P0818 Phase U Book 2 Current -1000 to 1000 A P0819 Phase V Book 2 Current -1000 to 1000 A P0820 Phase W Book 2 Current -1000 to 1000 A P0821 Phase U Book 3 Current -1000 to 1000 A P0822 Phase V Book 3 Current -1000 to 1000 A P0823 Phase W Book 3 Current -1000 to 1000 A P0824 Phase U Book 4 Current -1000 to 1000 A P0825 Phase V Book 4 Current -1000 to 1000 A P0826 Phase W Book 4 Current -1000 to 1000 A P0827 Phase U Book 5 Current -1000 to 1000 A P0828 Phase V Book 5 Current -1000 to 1000 A P0829 Phase W Book 5 Current -1000 to 1000 A

5.3 SETTING DATE AND TIME

First Time Power-Up and Start-Up

Step Action/Result Display indication

Monitoring Mode.

- Press “Menu” (right soft key).

- Group “00 ALL PARAMETERS” is already selected.

- Group “01 PARAMETER GROUPS" is

selected.

- Press “Select”

- A new list of groups is displayed and group “20 Ramps” is selected.

- Press until you reach group "30 HMI".

- Group “30 HMI” is

selected.

- Press “Select”.

Ready

LOC

0 rpm

0.0 A

0.0 Hz

16:10 Menu

00 ALL PARAMETERS

01 PARAMETER GROUPS 02 ORIENTED START-UP 03 CHANGED PARAMETERS

Return 16:10 Select

00 ALL PARAMETERS

01 PARAMETER GROUPS

02 ORIENTED START-UP 03 CHANGED PARAMETERS

Return 16:10 Select

20 Ramps

21 Speed References 22 Speed Limits 23 V/F Control

Return 16:10 Select

27 V/F DC Volt. Limit. 28 Dynamic Braking 29 Vector Control

30 HMI

Return 16:10 Select

LOC

0rpm

Step Action/Result Display indication

- Parameter “Day P0194” is already selected.

- If needed, set P0194 according to the actual day. To do so, press “Select” and then,

change P0194 value..

or to

Ready

Day P0194: 06

Month P0195: 10

Return 16:10 Select

LOC

- Follow the same steps to set parameters "Month

P0195” to “Seconds P0199”.

- Once the setting of P0199 is over, the Real Time Clock is now

updated.

- Press “Return” (left soft key).

- Press “Return”.

Ready

Minutes P0198: 11

Seconds P0199: 34

Return 18:11 Select

27 V/F DC Volt. Limit. 28 Dynamic Braking 29 Vector Control

30 HMI

Return 18:11 Select

00 ALL PARAMETERS

01 PARAMETER GROUPS

02 ORIENTED START-UP 03 CHANGED PARAMETERS

Return 18:11 Select

LOC

0rpm

- The display is back to

the Monitoring Mode.

Ready

LOC

0 rpm

0.0 A

0.0 Hz

18:11 Menu

Figure 5.4 - Setting date and time

5.4 BLOCKING PARAMETERS MODIFICATION

To prevent unauthorized or unintended parameters modification, parameter P0000 should be set to a value different from 5. Follow the same procedures described in item 5.2.1.

0rpm

5-9

First Time Power-Up and Start-Up

5.5 HOW TO CONECT A PC

NOTES!

- Always use a standard host/device shielded USB cable. Unshielded cables may lead to communication errors.

- Recommended cables: Samtec: USBC-AM-MB-B-B-S-1 (1 meter); USBC-AM-MB-B-B-S-2 (2 meters); USBC-AM-MB-B-B-S-3 (3 meters).

- The USB connection is galvanically isolated from the mains power supply and from other high voltages internal to the inverter. However, the USB connection is not isolated from the Protective Ground (PE). Use an isolated notebook for the USB connection or a desktop connected to the same Protective Ground (PE) of the inverter.

Install the SuperDrive G2 software to control motor speed, view, or edit inverter parameters through a personal

computer (PC).

Basic procedures for transferring data from the PC to the inverter:

1. Install the SuperDrive G2 software in the PC;

2. Connect the PC to the inverter through a USB cable;

3. Start SuperDrive G2;

4. Choose “Open” and the files stored in the PC will be displayed;

5. Select the file;

6. Use the command “Write Parameters to the Drive”. All parameters are now transferred to the inverter. For further information on SuperDrive G2 software, please refer SuperDrive Manual.

5.6 FLASH MEMORY MODULE

Features:

- Store a copy of the inverter parameters;

- Transfer parameters stored in the FLASH memory to the inverter;

- Transfer firmware stored in the FLASH memory to the inverter;

- Store programs created by the SoftPLC. Whenever the inverter is powered up, this program is transferred to the RAM memory located in the inverter control board and executed.

Refer to the CFW-11 Software Manual and to SoftPLC Manual for further details.

ATTENTION!

Before installing or removing the FLASH memory module, disconnect the inverter power supply and wait for the complete discharge of the capacitors.

5-10

Troubleshooting and Maintenance

TROUBLESHOOTING AND MAINTENANCE

This chapter:

- Lists all faults and alarms that may occur.

- Indicates the possible causes of each fault and alarm.

- Lists most frequent problems and corrective actions.

- Presents instructions for periodic inspections and preventive maintenance in the equipment.

6.1 OPERATION OF THE FAULTS AND ALARMS

When a fault is detected (fault (FXXX)):

The PWM pulses are blocked; The keypad displays the fault code and description; The “STATUS” LED starts flashing red; The output relay set to "NO FAULT" opens; Some control circuitry data is saved in the EEPROM memory:

- Keypad and EP (Electronic Pot) speed references, in case the function “Reference backup” is enabled in P0120;

- The fault code that occurred (shifts the last nine previous faults and alarms);

- The state of the motor overload function integrator;

- The state of the operating hours counter (P0043) and the powered-up hours counter (P0042).

Reset the inverter to return the drive to a “READY” condition in the event of a fault. The following reset options are available:

Removing the power supply and reapplying it (power-on reset); Pressing the operator key (manual reset); Through the "Reset" soft key; Automatically by setting P0206 (auto-reset); Through a digital input: DIx = 20 (P0263 to P0270).

When an alarm situation (alarm (AXXX)) is detected:

The keypad displays the alarm code and description; The “STATUS” LED changes to yellow; The PWM pulses are not blocked (the inverter is still operating).

6-1

Troubleshooting and Maintenance

6.2 FAULTS, ALARMS, AND POSSIBLE CAUSES

Table 6.1 - Faults, alarms and possible causes

Fault/Alarm Description Possible Causes

F021: DC Bus Undervoltage

F022: DC Bus Overvoltage

(*)

F030 Power Module U Fault

(*)

F034

Power Module V Fault

(*)

F038

Power Module W Fault

A046: High Load on Motor

A047: IGBT Overload Alarm

F048: IGBT Overload Fault

A050: IGBT High Temperature

F051: IGBT Overtemperature

F067: Incorrect Encoder/ Motor Wiring

(*) In the case of the modular drive, the book where the fault has occurred is not indicated on the HMI. Therefore, it is necessary to verify the indication LEDs on the IPS1 board (refer to note (2)).

DC bus undervoltage condition occurred.

DC bus overvoltage condition occurred.

U phase IGBT desaturation fault. Short-circuit between motor phases U and V or U and W.

V phase IGBT desaturation fault. Short-circuit between motor phases V and U or V and W.

W phase IGBT desaturation fault. Short-circuit between motor phases W and U or W and V.

Load is too high for the used motor.

Note:

It may be disabled by setting P0348 = 0 or 2.

An IGBT overload alarm occurred.

Note:

It may be disabled by setting P0350 = 0 or 2.

An IGBT overload fault occurred.

A high temperature alarm was detected by the NTC temperature sensors located on the IGBTs.

Note:

It may be disabled by setting P0353 = 2 or 3.

IGBT overtemperature fault [measured with the temperature sensors (NTC)].

Fault related to the phase relation of the encoder signals.

Note:

- This fault can only happen during the self-tuning routine.

- It is not possible to reset this fault.

- In this case, turn off the power supply, solve the problem, and then turn it on again.

6-2

The input voltage is too low and the DC bus voltage

dropped below the minimum permitted value (monitor the value at Parameter P0004): Ud < 223 V - For a 200-240 V input voltage (P0296 = 0); Ud < 170 V - For a 200-240 V single-phase input voltage (models CFW11MXXXXS2 or CFW11MXXXXB2) (P0296 = 0); Ud < 385 V - For a 380 V input voltage (P0296 = 1); Ud < 405 V - For a 400-415 V input voltage (P0296 = 2); Ud < 446 V - For a 440-460 V input voltage (P0296 = 3); Ud < 487 V - For a 480 V input voltage (P0296 = 4); Ud < 530 V - For a 500-525 V input voltage (P0296 = 5); Ud < 580 V - For a 550-575 V input voltage (P0296 = 6); Ud < 605 V - For a 600 V input voltage (P0296 = 7); Ud < 696 V - For a 660-690 V input voltage (P0296 = 8).

Phase loss in the input power supply. Pre-charge circuit failure. Parameter P0296 was set to a value above of the power

supply rated voltage.

The input voltage is too high and the DC bus voltage

surpassed the maximum permitted value: Ud > 400 V - For 220-230 V input models (P0296 = 0); Ud > 800 V - For 380-480 V input models (P0296 = 1, 2, 3, or 4);

Ud > 1200 V - For 500-690 V input models (P296 = 5,

6, 7 and 8).

Inertia of the driven-load is too high or deceleration time

is too short.

Wrong settings for parameters P0151, or P0153, or P0185.

Settings of P0156, P0157, and P0158 are too low for

the used motor.

Motor shaft load is excessive. Inverter output current is too high.

Inverter output current is too high.

Surrounding air temperature is too high (> 50 °C (122 °F))

and output current is too high.

Blocked heatsink fan. Inverter heatsink is completely covered with dust.

Output motor cables U, V, W are inverted.

Encoder channels A and B are inverted. Encoder was not properly mounted.

(2)

Troubleshooting and Maintenance

Table 6.1 (cont.) - Faults, alarms and possible causes

Fault/Alarm Description Possible Causes

F070: Overcurrent / Short-circuit

F071: Output Overcurrent

F072: Motor Overload

F074: Ground Fault

F076: Motor Current Imbalance

F077: DB Resistor Overload

F078: Motor Overtemperature

F079: Encoder Signal Fault

F080: CPU Watchdog

F082: Copy Function Fault

F084: Auto-diagnosis Fault

A088: Keypad Comm. Fault

A090: External Alarm

F091: External Fault

F099: Invalid Current Offset

A110: High Motor Temperature

A128: Timeout for Serial Communication

Overcurrent or short-circuit detected at the output, in the DC bus, or at the braking resistor.

The inverter output current was too high for too long. Excessive load inertia or acceleration time too short.

The motor overload protection operated.

Note:

It may be disabled by setting P0348 = 0 or 3.

A ground fault occured either in the cable between the inverter and the motor or in the motor itself.

Note:

It may be disabled by setting P0343 = 0.

Fault of motor current unbalance.

Note:

It may be disabled by setting P0342 = 0.

The dynamic braking resistor overload protection operated.

Fault related to the PTC temperature sensor installed in the motor.

Note:

- It may be disabled by setting P0351 = 0 or 3.

- It is required to set the analog input / output to the PTC function.

Lack of encoder signals.

Microcontroller watchdog fault.

Fault while copying parameters.

Auto-diagnosis fault.

Indicates a problem between the keypad and control board communication.

External alarm via digital input.

Note:

It is required to set a digital input to "No external alarm".

External fault via digital input.

Note:

It is required to set a digital input to "No external fault".

Current measurement circuit is measuring a wrong value for null current.

Alarm related to the PTC temperature sensor installed in the motor.

Note:

- It may be disabled by setting P0351 = 0 or 2.

- It is required to set the analog input / output to the PTC function.

Indicates that the inverter stopped receiving valid messages within a certain time interval.

Note:

It may be disabled by setting P0314 = 0.0 s.

Short-circuit between two motor phases. Short-circuit between the connection cables of the

dynamic braking resistor.

IGBT modules are shorted.

Settings of P0135, P0169, P0170, P0171, and P0172

are too high.

Settings of P0156, P0157, and P0158 are too low for

the used motor.

Motor shaft load is excessive. Shorted wiring in one or more of the output phases. Motor cable capacitance is too large, resulting in current

peaks at the output.

Loose connection or broken wiring between the motor

and inverter connection.

Vector control with wrong orientation. Vector control with encoder, encoder wiring or encoder

motor connection inverted.

Excessive load inertia or desacceleration time too short. Motor shaft load is excessive. Wrong setttings for parameters P0154 and P0155.

Excessive load at the motor shaft. Excessive duty cycle (too many starts / stops per minute). Surrounding air temperature too high. Loose connection or short-circuit (resistance < 100 Ω) in

the wiring connected to the motor termistor.

Motor termistor is not installed. Blocked motor shaft.

Broken wiring between motor encoder and option kit for

encoder interface.

Defective encoder. Electrical noise.

An attempt to copy the keypad parameters to an inverter

with a different firmware version.

Please contact WEG.

Loose keypad cable connection. Electrical noise in the installation.

Wiring was not connected to the digital input (DI1 to DI8)

set to “No external alarm”.

Wiring was not connected to the digital input (DI1 to DI8)

set to “No external fault”.

Defect in the inverter internal circuitry.

Excessive load at the motor shaft.

Excessive duty cycle (too many starts / stops per minute). Surrounding air temperature too high.

Loose connection or short-circuit (resistance < 100 Ω) in

the wiring connected to the motor termistor. Motor termistor is not installed. Blocked motor shaft.

Check the wiring and grounding installation. Make sure the inverter has sent a new message within the

time interval set at P0314.

(1)

6-3

Troubleshooting and Maintenance

Table 6.1 (cont.) - Faults, alarms and possible causes

Fault/Alarm Description Possible Causes

A129: Anybus is Offline

A130: Anybus Access Error

A133: CAN Not Powered

A134: Bus Off

A135: CANopen Communication Error

A136: Idle Master

A137: DNet Connection Timeout

F150: Motor Overspeed

F151: FLASH Memory Module Fault

A152: Internal Air High Temperature

F153: Internal Air Overtemperature

F156: Undertemperature

A177: Fan Replacement

A181: Invalid Clock Value

F182: Pulse Feedback Fault

F183: IGBT Overload + Temperature

A300: High temperature at IGBT U B1

F301: Overtemperature at IGBT U B1

A303: High Temperature at IGBT V B1

F304: Overtemperature at IGBT V B1

A306: High Temperature at IGBT W B1

Alarm that indicates interruption of the Anybus-CC communication.

Alarm that indicates an access error to the Anybus-CC communication module.

Alarm indicating that the power supply was not connected to the CAN controller.

Inverter CAN interface has entered into the bus-off state.

Alarm that indicates a communication error.

Network master has entered into the idle state.

I/O connection timeout - DeviceNet communication alarm.

Overspeed fault. It is activated when the real speed exceeds the value of P0134+P0132 for more than 20 ms.

FLASH Memory Module fault (MMF-01). Defective FLASH memory module.

Alarm indicating that the internal air temperature is too high.

Note:

It may be disabled by setting P0353 = 1 or 3.

Internal air overtemperature fault.

Undertemperature fault (below -30 °C (-22 °F)) in the IGBT or rectifier measured by the temperature sensors.

Fan replacement alarm (P0045 > 50000 hours).

Note:

This function may be disabled by setting P0354 = 0.

Invalid clock value alarm.

Indicates a fault on the output pulses feedback.

Overtemperature related to the IGBTs overload protection.

High temperature alarm measured with the temperature sensor (NTC) of the book 1 U phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 1 U phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 1 V phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 1 V phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 1 W phase IGBT

PLC entered into the idle state. Programming error. Master and slave set with a different

number of I/O words.

Communication with master has been lost (broken cable,

unplugged connector, etc.).

Defective, unrecognized, or improperly installed Anybus-CC

module.

Conflict with a WEG option board. Broken or loose cable.

Power supply is off.

Incorrect communication baud-rate. Two nodes configured with the same address in the network. Wrong cable connection (inverted signals).

Communication problems. Wrong master conFiguretion/settings. Incorrect conFiguretion of the communication objects.

PLC in IDLE mode. Bit of the PLC command register set to zero (0).

One or more allocated I/O connections have entered

into the timeout state.

Wrong settings of P0161 and/or P0162. Problem with the hoist-type load.

Check the connection of the FLASH memory module.

High environment temperature (> 40 °C or 45 °C

(> 104 ºF or 113 ºF) depending on the model, refer to the section 3.1) and high output current.

Blocked or defective fan. Fins of the book heatsink too dirty, impairing the air flow.

Surrounding air temperature ≤ -30 °C (-22 °F).

Maximum number of operating hours for the heatsink fan

has been reached.

It is necessary to set date and time at parameters P0194

to P0199.

Keypad battery is discharged, defective, or not installed. Defect in the inverter internal circuitry.

Surrounding air temperature too high. Operation with frequencies < 10 Hz under overload.

High environment temperature (> 40 °C or 45 °C

(> 104 °F or 113 °F) depending on the model, refer to the section 3.1) and high output current.

Blocked or defective fan. Fins of the book heatsink too dirty, impairing the air flow.

6-4

Troubleshooting and Maintenance

Table 6.1 (cont.) - Faults, alarms and possible causes

Fault/Alarm Description Possible Causes

F307: Overtemperature at IGBT W B1

A309: High Temperature at IGBT U B2

F310: Overtemperature at IGBT U B2

A312: High Temperature at IGBT V B2

F313: Overtemperature at IGBT V B2

A315: High Temperature at IGBT W B2

F316: Overtemperature at IGBT W B2

A318: High Temperature at IGBT U B3

F319: Overtemperature at IGBT U B3

A321: High Temperature at IGBT V B3

F322: Overtemperature at IGBT V B3

A324: High Temperature at IGBT W B3

F325: Overtemperature at IGBT W B3

A327: High Temperature at IGBT U B4

F328: Overtemperature at IGBT U B4

A330: High Temperature at IGBT V B4

F331: Overtemperature at IGBT V B4

A333: High Temperature at IGBT W B4

F334: Overtemperature at IGBT W B4

A336: High Temperature at IGBT U B5

F337: Overtemperature at IGBT U B5

A339: High Temperature at IGBT V B5

Overtemperature fault measured with the temperature sensor (NTC) of the book 1 W phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 2 U phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 2 U phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 2 V phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 2 V phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 2 W phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 2 W phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 3 U phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 3 U phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 3 V phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 3 V phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 3 W phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 3 W phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 4 U phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 4 U phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 4 V phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 4 V phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 4 W phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 4 W phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 5 U phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 5 U phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 5 V phase IGBT

High environment temperature (> 40 °C or 45 °C

(> 104 °F or 113 °F) depending on the model, refer to

the section 3.1) and high output current.

Blocked or defective fan. Fins of the book heatsink too dirty, impairing the air flow.

6-5

Troubleshooting and Maintenance

Table 6.1 (cont.) - Faults, alarms and possible causes

Fault/Alarm Description Possible Causes

F340: Overtemperature at IGBT V B5

A342: High Temperature at IGBT W B5

F343: Overtemperature at IGBT W B5

A345: High Load at IGBT U B1

F346: Overload at IGBT U B1

A348: High Load at IGBT V B1

F349: Overload at IGBT V B1

A351: High Load at IGBT W B1

F352: Overload at IGBT W B1

A354: High Load at IGBT U B2

F355: Overload at IGBT U B2

A357: High Load at IGBT V B2

F358: Overload at IGBT V B2

A360: High Load at IGBT W B2

F361: Overload at IGBT W B2

A363: High Load at IGBT U B3

F364: Overload at IGBT U B3

A366: High Load at IGBT V B3

F367: Overload at IGBT V B3

A369: High Load at IGBT W B3

F370: Overload at IGBT W B3

A372: High Load at IGBT U B4

F373: Overload at IGBT U B4

A375: High Load at IGBT V B4

F376: Overload at IGBT V B4

Overtemperature fault measured with the temperature sensor (NTC) of the book 5 V phase IGBT

High temperature alarm measured with the temperature sensor (NTC) of the book 5 W phase IGBT

Overtemperature fault measured with the temperature sensor (NTC) of the book 5 W phase IGBT

Overload alarm at book 1 U phase IGBT

Overload fault at book 1 U phase IGBT

Overload alarm at book 1 V phase IGBT

Overload fault at book 1 V phase IGBT

Overload alarm at book 1 W phase IGBT

Overload fault at book 1 W phase IGBT

Overload alarm at book 2 U phase IGBT

Overload fault at book 2 U phase IGBT

Overload alarm at book 2 V phase IGBT

Overload fault at book 2 V phase IGBT

Overload alarm at book 2 W phase IGBT

Overload fault at book 2 W phase IGBT

Overload alarm at book 3 U phase IGBT

Overload fault at book 3 U phase IGBT

Overload alarm at book 3 V phase IGBT

Overload fault at book 3 V phase IGBT

Overload alarm at book 3 W phase IGBT

Overload fault at book 3 W phase IGBT

Overload alarm at book 4 U phase IGBT

Overload fault at book 4 U phase IGBT

Overload alarm at book 4 V phase IGBT

Overload fault at book 4 V phase IGBT

High environment temperature (> 40 °C or 45 °C

(> 104 °F or 113 °F) depending on the model, refer to the section 3.1) and high output current.

Blocked or defective fan. Fins of the book heatsink too dirty, impairing the air flow.

High current at the inverter output (see figure 8.1).

6-6

Troubleshooting and Maintenance

Table 6.1 (cont.) - Faults, alarms and possible causes

Fault/Alarm Description Possible Causes

A378: High Load at IGBT W B4

F379: Overload at IGBT W B4

A381: High Load at IGBT U B5

F382: Overload at IGBT U B5

A384: High Load at IGBT V B5

F385: Overload at IGBT V B5

A387: High Load at IGBT W B5

F388: Overload at IGBT W B5

A390: Current Unbalance at Phase U B1

A391: Current Unbalance at Phase V B1

A392: Current Unbalance at Phase W B1

A393: Current Unbalance at Phase U B2

A394: Current Unbalance at Phase V B2

A395: Current Unbalance at Phase W B2

A396: Current Unbalance at Phase U B3

A397: Current Unbalance at Phase V B3

Overload alarm at book 4 W phase IGBT

Overload fault at book 4 W phase IGBT

Overload alarm at book 5 U phase IGBT

Overload fault at book 5 U phase IGBT

Overload alarm at book 5 V phase IGBT

Overload fault at book 5 V phase IGBT

Overload alarm at book 5 W phase IGBT

Overload fault at book 5 W phase IGBT

Phase U book 1current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase V book 1current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase W book 1current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase U book 2 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase V book 2 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase W book 2 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase U book 3 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase V book 3 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

High current at the inverter output (see figure 8.1).

Bad electric connection between the DC bus and the

power unit.

Bad electric connection between the power unit output

and the motor.

Note: In case of fast acceleration or braking, this alarm may be indicated momentarily, disappearing after a few seconds. This is not an indication of any anomaly in the inverter. If this alarm persists when the motor is operating at a constant speed, it is an indication of an anomaly in the current distribution among the power units.

6-7

Troubleshooting and Maintenance

Table 6.1 (cont.) - Faults, alarms and possible causes

Fault/Alarm Description Possible Causes

A398: Current Unbalance at Phase W B3

A399: Current Unbalance at Phase U B4

A400: Current Unbalance at Phase V B4

A401: Current Unbalance at Phase W B4

A402: Current Unbalance at Phase U B5

A403: Current Unbalance at Phase V B5

A404: Current Unbalance at Phase W B5

F406: Overtemperature at the Braking Module

F408: Failure in the Cooling System

F410: External Fault

F412: Overtemperature at the Rectifier

A010: Overtemperature at the Rectifier

Phase W book 3 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase U book 4 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase V book 4 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase W book 4 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase U book 5 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase V book 5 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

Phase W book 5 current unbalance alarm. It indicates a 20 % unbalance in the current distribution between this phase and the smallest current of the same phase in other book, only when the current in this phase is higher than 75 % of its nominal value.

These faults/alarms are associated to the conFiguretion of the parameters P0832 and P0833.

- Function of the DIM1 input.

- Function of the DIM2 input.

Bad electric connection between the DC bus and the

power unit.

Bad electric connection between the power unit output

and the motor.

Overtemperature (rectifier/braking). Failure in the connection between the digital input and

the sensor.

Failure of the corresponding sensor. Failure in the device being monitored by the sensor.

(1) Long motor cables (with more than 100 meters) will have a high leakage capacitance to the ground. The circulation of leakage currents through these capacitances may activate the ground fault protection after the inverter is enabled, and consequently, the occurrence of fault F074. Possible solution:

- Decrease the carrier frequency (P0297).

(2) In case of the faults F030 (U Arm Fault), F034 (V Arm Fault) and F038 (W Arm Fault), the indication of which book has caused the fault is done by IPS1 board LEDs. When a RESET is performed the LEDs are switched off, going on again if the fault persists.

6-8

Troubleshooting and Maintenance

Figure 6.1 - Power unit arm fault (desaturation) indication LEDs

6.3 SOLUTIONS FOR THE MOST FREQUENT PROBLEMS

Table 6.2 - Solutions for the most frequent problems

Problem

Motor does not start

Motor speed

fluctuates (oscillates)

Motor speed

too high or too low

Motor does not reach

Settings the rated speed,

or motor speed starts

oscillating around the rated

speed (Vector Control)

Point to be

Verified

Incorrect wiring connection

Analog reference

(if used)

Incorrect settings 1. Check if parameters are properly set for the application.

Fault

Motor stall 1. Decrease motor overload.

Loose connection 1. Stop the inverter, turn off the power supply, and check and tighten fluctuates

Defective reference

potentiometer

Oscillation of the external

analog reference

Incorrect settings

(vector control)

Incorrect settings

(reference limits)

Control signal from

the analog reference

(if used)

Motor nameplate

Settings 1. Decrease P0180.

1. Check all power and control connections. For instance, the digital inputs set to start/

stop, general enable, or no external error shall be connected to the 24 Vdc or to

DGND* terminals (refer to figure 3.31).

1. Check if the external signal is properly connected.

2. Check the status of the control potentiometer (if used).

1. Check if the inverter is not blocked due to a fault condition.

2. Check if terminals XC1:13 and XC1:11 are not shorted (short-circuit at the 24 Vdc

power supply).

2. Increase P0136, P0137 (V/f), or P0169/P0170 (vector control).

(oscillates) all power connections.

2. Check all internal connections of the inverter.

1. Replace potentiometer.

1. Identify the cause of the oscillation. If it is caused by electrical noise, use shielded

cables or separate from the power and control wiring.

1. Check parameters P0410, P0412, P0161, P0162, P0175, and P0176.

2. Refer to the Software Manual.

1. Check if the values of P0133 (minimum speed) and P0134 (maximum speed) are

properly set for the motor and application used.

1. Check the level of the reference control signal.

2. Check the settings (gain and offset) of parameters P0232 to P0249.

1. Check if the motor has been properly sized for the application.

2. Check P0410.

Corrective Action

6-9

Troubleshooting and Maintenance

Table 6.2 (cont.) - Solutions for the most frequent problems

Problem

Off display Keypad connections

Motor does not operate in

the field weakning region

(Vector Control)

Low motor speed and

P0009 = P0169 or P0170

(motor operating with torque

limitation), for P0202 = 4 -

vector with encoder

Point to be

Verified

1. Supply the IPS at the XC9 connector points 1 and 4 with 24 Vdc ± 10 %/4 A.

IPS1 24 Vdc power supply

voltage

Open power supply fuse(s) 1. Replace fuses.

Settings

Encoder signals are

inverted or power

connection is inverted

1. Apply a voltage of 24 Vdc ± 10 %.

1. Decrease P0180.

1. Check signals

signals are properly installed, exchange two of the output phases.

For instance U and V.

Corrective Action

- A, B - B, refer to the incremental encoder interface manual. If

6.4 INFORMATION FOR CONTACTING TECHNICAL SUPPORT

NOTE!

For technical support and servicing, it is important to have the following information in hand:

Inverter model; Serial number, manufacturing date, and hardware revision that are listed in the product nameplate

(refer to item 2.6);

Installed software version (check parameter P0023); Application data and inverter settings.

6.5 PREVENTIVE MAINTENANCE

DANGER!

Always turn off the mains power supply before touching any electrical component associated to

the inverter.

High voltage may still be present even after disconnecting the power supply. To prevent electric shock, wait at least 10 minutes after turning off the input power for the

complete discharge of the power capacitors.

Always connect the equipment frame to the protective ground (PE). Use the adequate

connection terminal in the inverter.

ATTENTION!

The electronic boards have electrostatic discharge sensitive components. Do not touch the components or connectors directly. If needed, first touch the grounded mettalic frame or wear a ground strap.

6-10

Troubleshooting and Maintenance

TRILHOS PARA DESLIZAMENTO DO VENTILADORES

SISTEMA DE TRAVA P/ TROCA RÁPIDA DOS VENTILADORES

Do not perform any withstand voltage test!

If needed, consult WEG.

The inverters require low maintenance when properly installed and operated . Table 6.3 presents main procedures and time intervals for preventive maintenance. Table 6.4 provides recommended periodic inspections to be performed every 6 months after inverter start-up.

Table 6.3 - Preventive maintenance

Maintenance Interval Instructions

Fan replacement After 50000 operating hours. Keypad battery replacement Every 10 years. Refer to chapter 4.

If the inverter is stocked (not being

Electrolytic

capacitors

(1) The inverters are factory set for automatic fan control (P0352 = 2), which means that they will be turned on only when the heatsink temperature

exceeds a reference value. Therefore, the operating hours of the fan will depend on the inverter usage conditions (motor current, output frequency, cooling air temperature, etc.). The inverter stores the number of operating hours of the fan in parameter P0045. When this parameter reaches 50000 operating hours, the keypad display will show alarm A177.

used): “Reforming”

Inverter is being used: replace

Every year from the manufacturing date printed in the inverter identification label (refer to item 2.6).

Every 10 years. Contact WEG technical support to obtain replacement procedures.

(1)

Replacement procedure shown in figures 6.2.

Supply the UP11 (at the +UD ans -UD terminal) with a voltage 250 to 350 Vdc, during 1 hour at least. Then, disconnect the power supply and wait at least 24 hours before using the inverter (reapply power).

VENTILADORES

FANS

RAILS FOR FAN SLIDING

LOCK SYSTEM FOR FAST FAN REPLACEMENT

Figure 6.2 - Fan replacement

6-11

Troubleshooting and Maintenance

Table 6.4 - Recommended periodic inspections - Every 6 months

Component Problem Corrective Action

Terminals, connectors Loose screws Tighten

Loose connectors

Fans / Cooling system Dirty fans Cleaning

Abnormal acoustic noise Replace fan. Refer to figure 6.2.

Blocked fan

Abnormal vibration

Dust in the cabinet air filter

Printed circuit boards Accumulation of dust, oil, humidity, etc. Cleaning

Odor

Power module /

Power connections

DC bus capacitors

(DC Link)

Power resistors Discoloration Replacement

Accumulation of dust, oil, humidity, etc. Cleaning

Loose connection screws Tighten

Discoloration / odor / electrolyte leakage Replacement

Expanded or broken safety valve

Frame expansion

Odor

Check the fan connection.

Cleaning or replacement

Replacement

Heatsink Dust accumulation Cleaning

Dirty

6.5.1 Cleaning Instructions

When it becomes necessary to clean the inverter, follow the instructions below:

Ventilation system:

Cut off the inverter supply and wait 10 minutes. Remove the dust accumulated at the ventilation inlets with a plastic brush or a flannel. Remove the dust accumulated on the heatsink fins and on fan blades using compressed air.

Electronic boards:

Cut off the inverter supply and wait 10 minutes. Remove the dust accumulated on the boards using an anti-static brush or ionized compressed air (E.g.:

Charges Burtes Ion Gun (non nuclear) reference A6030-6DESCO). If necessary, remove the boards from the inverter. Use always an ESD wrist strap.

6-12

Troubleshooting and Maintenance

DISSIPADORES

Inspect the heatsink fins of the power units regularly verifying if there is any dirt accumulation that could impair the inverter cooling. Therefore, remove the power unit side cover.

HEATSINKS

JANELAS PARA

HEATSINK FIN CLEANING

LIMPEZA DOS

OPENINGS

DISSIPADORES

Figure 6.3 - Covers to get access for inspection/cleaning of the heatsink fins

6-13

Troubleshooting and Maintenance

6-14

Option Kits and Accessories

OPTION KITS AND ACCESSORIES

This chapter presents:

The option kit that can be incorporated to the inverter from

the factory:

- Safety Stop according to EN 954-1 category 3. Instructions for the proper use of the option kit. The accessories that can be incorporated to the inverters.

Details for the installation, operation, and programming of the accessories are described in their own manuals and were not included in this chapter.

7.1 OPTION KITS

7.1.1 Safety Stop According to EN 954-1 Category 3 (Pending Certification)

Inverters with the following codification: CFW11MXXXXXXOY.

The inverters with this option are equipped with an additional board (SRB2) that contains 2 safety relays and an interconnection cable with the power circuit.

Figure 7.1 shows the location of the SRB2 board and the location of the connector XC25 (used for the connection of the SRB2 board signals).

The relay coils are available through the connector XC25, as presented in table 7.1.

DANGER!

The activation of the Safety Stop, i.e., disconnection of the 24 Vdc power supply from the safety relay coil (XC25:1(+) and 2(-); XC25:3(+) and 4(-)) does not guarantee the electrical safety of the motor terminals (they are not isolated from the power supply in this condition).

Operation:

1. The Safety Stop function is activated by disconnecting the 24 Vdc voltage from the safety relay coil (XC25:1(+) and 2(-); XC25:3(+) and 4(-)).

2. Upon activation of the Safety Stop, the PWM pulses at the inverter output will be blocked and the motor will coast to stop.

The inverter will not start the motor or generate a rotating magnetic field even in the event of an internal

failure (pending certification).

The keypad will display a message informing that the Safety Stop is active.

3. Apply 24 Vdc voltage to the safety relay coil (XC25:1(+) and 2(-); XC25:3(+) and 4(-)) to get back to normal operation after activation of the Safety Stop.

7-1

Option Kits and Accessories

XC25

Figure 7.1 - SRB2 board location in the control rack

Table 7.1 - XC25 connections

Connector XC25 Function Specifications

1 R1+ Terminal 1 of relay 1 coil

2 R1- Terminal 2 of relay 1 coil

3 R2+ Terminal 1 of relay 2 coil

4 R2- Terminal 2 of relay 2 coil

Rated coil voltage: 24 V, range from 20 to 30 Vdc.

Coil resistance: 960 Ω ±10 % @ 20 °C (68 °F).

Rated coil voltage: 24 V, range from 20 to 30 Vdc.

Coil resistance: 960 Ω ±10 % @ 20 °C (68 °F).

7.2 ACCESSORIES

The accessories are installed to the inverter easily and quickly using the "Plug and Play" concept. Once the accessory is connected to the slot, the control circuitry identifies the model and displays the installed accessory code in P0027 or P0028. The accessory shall be installed with the inverter power supply off.

The code and model of each availabe accessory is presented in the table 7.2. The accessories can be ordered separately and will be shippe in an individual package containing the components and the manual with detailed instructions for the product installation, operation, and programming.

ATTENTION!

Only one module can be fitted at once in each slot (1, 2, 3, 4, or 5).

7-2

Option Kits and Accessories

Table 7.2 - Accessory models

WEG Part

Number

Name Description Slot

Control accessories for installation in the Slots 1, 2 and 3

11008162 IOA-01 IOA module: 1 voltage/current analog input (14 bits); 2 digital inputs; 2

1 FD-- ----

voltage/current analog outputs (14 bits); 2 open-collector digital outputs.

11008099 IOB-01 IOB module: 2 isolated analog inputs (voltage/current); 2 digital inputs; 2

1 FA-- ----

isolated analog outputs (voltage/current) (the programming of the outputs is identical as in the standard CFW-11); 2 open-collector digital outputs.

11008100 ENC-01 5 to 12 Vdc incremental encoder module, 100 kHz, with an encoder signal

2 --C2 ----

repeater.

11008101 ENC-02 5 to 12 Vdc incremental encoder module, 100 kHz. 2 --C2 ---- 11008102 RS485-01 RS-485 serial communication module (Modbus). 3 ---- CE-- 11008103 RS232-01 RS-232C serial communication module (Modbus). 3 ---- CC-- 11008104 RS232-02 RS-232C serial communication module with DIP-switches for programming

3 ---- CC--

the microcontroller FLASH memory.

11008105 CAN/RS485-01 CAN and RS-485 interface module (CANopen / DeviceNet / Modbus). 3 ---- CA-- 11008106 CAN-01 CAN interface module (CANopen / DeviceNet). 3 ---- CD-- 11008911 PLC11-01 PLC module. 1, 2

and 3

Anybus-CC Accessories for installation in the Slot 4

11008107 PROFDP-05 ProfibusDP interface module. 4 ---- --xx 11008158 DEVICENET-05 DeviceNet interface module. 4 ---- --xx 10933688 ETHERNET IP-05 Ethernet/IP interface module. 4 ---- --xx 11008160 RS232-05 RS-232 (passive) interface module (Modbus). 4 ---- --xx 11008161 RS485-05 RS-485 (passive) interface module (Modbus). 4 ---- --xx

Flash Memory Module for installation in the slot 5 – included as a standard feature

11008912 MMF-01 FLASH memory module. 5 ---- --xx

HMI, blank cover and remote keypad frame

11008913 HMI-01 Keypad.

(4)

HMI - -

11010521 RHMIF-01 Remote keypad frame Kit (IP56). - - - 11010298 HMID-01 Blank cover for the keypad slot. HMI - -

Miscellanea

10960847 CCS-01 Kit for control cables shielding (included in the standard product). - - 10960846 CONRA-01 Control rack (containing the CC11 control board). - - 11077222 RACK 2 Rack para montagem de 2 unidades UP11 em painel 11077221 RACK 3 Rack para montagem de 3 unidades UP11 em painel

(5)

- - -

(1) Refer to the PLC Module Manual. (2) Refer to the Anybus-CC Communication Manual. (3) Refer to the Software Manual. (4) Use DB-9 pin, male-to-female, straight-through cable (serial mouse extension type) for connecting the keypad to the inverter or Null-Modem

standard cable. Maximum cable length: 10 m (33 ft). Examples:

- Mouse extension cable - 1.80 m (6 ft); Manufacturer: Clone.

- Belkin pro series DB9 serial extension cable 5 m (17 ft); Manufacturer: Belkin.

- Cables Unlimited PCM195006 cable, 6 ft DB9 m/f; Manufacturer: Cables Unlimited.

(5) Refer to the rack mounting guide.

Identification

Parameters

P0027 P0028

---- --xx

(1)(3)

(2)(3)

(3)

7-3

Option Kits and Accessories

7-4

TECHNICAL SPECIFICATIONS

This chapter describes the technical specifications (electrical and mechanical) of the CFW-11M inverter series.

8.1 POWER DATA

See table 8.1.

Technical Specifications

8-1

Technical Specifications

Table 8.1 - Technical specification for the CFW-11M series

(5)

power

[kW]

Dissipated

[Adc]

input

Rated

current

(4)

motor

[CV/kW]

Maximum

[kHz]

Carrier

frequency

(3)

[Arms]

Overload

current

773 1030 2.5 450/320 592 4

2202 2936 2.5 1200/900 1688 12

1468.5 1958 2.5 800/600 1126 8

2935.5 3914 2.5 1600/1200 2251 16

3669 4892 2.5 2000/1500 2813 20

570 760 2.5 400/315 437 5

1083 1444 2.5 800/630 830 8

1624 2166 2.5 1200/900 1245 12

2166 2888 2.5 1500/1120 1660 19

2707 3610 2.5 1900/1400 2075 24

510 680 2.5 400/315 391 5

969 1292 2.5 800/630 743 10

1453.5 1938 2.5 1250/1000 1114 15

1938 2584 2.5 1600/1280 1486 20

2422.5 3230 2.5 2000/1600 1857 25

(1)

1254 1710 2.5 900/700 1311 9.6 979

(1)

1881 2565 2.5 1400/1050 1967 14.4 1468

2508 3420 2.5 1800/1400 2622 19.2 1957

(1)

Rated

(3)

Use with Normal Duty (ND) cycle Use with Heavy Duty (HD) cycle

Overload

current

[Arms]

output

current

(5)

power

[kW]

Dissipated

[Adc]

current

Rated input

(4)

motor

[CV/kW]

Maximum

[kHz]

Carrier

frequency

[Arms]

1 min 3 s 1 min 3 s

660 900 2.5 500/370 690 4.8 515

(1)

3135 4275 2.5 2300/1750 3278 24 2446

(2)

517 705 2.5 500/400 541 6 380

(2)

982.3 1340 2.5 900/710 1027 12 722

(2)

1474 2010 2.5 1400/1120 1541 18 1083

(2)

1965 2679 2.5 1800/1500 2054 24 1444

(2)

2455 3348 2.5 2300/1850 2567 30 1805

(2)

469.7 641 2.5 500/400 491 6.2 340

(2)

892.1 1217 2.5 1000/800 933 12.4 646

(2)

1339 1826 2.5 1500/1200 1400 18.6 969

(2)

1784 2433 2.5 2000/1600 1865 24.8 1292

2232 3042 2.5 2500/2000 2332 31 1615

8-2

Rated

Power

supply

Model

output

current

[Vdc]

(1)

600

[Arms]

CFW11M 0600 T 4

CFW11M 1140 T 4 1140

(1)

436...713

CFW11M 2280 T 4 2280

CFW11M 1710 T 4 1710

(2)

470

574...891

CFW11M 0893 T 5 893

CFW11M 0470 T 5

CFW11M 1340 T 5 1340

CFW11M 2850 T 4 2850

CFW11M 1786 T 5 1786

(2)

427

758...1025

CFW11M 0811 T 6 811

CFW11M 2232 T 5 2232

CFW11M 1217 T 6 1217

CFW11M 0427 T 6

(2)

CFW11M 1622 T 6 1622

CFW11M 2028 T 6 2028

Technical Specifications

Note:

(1) Steady-state rated current in the following conditions:

- Surrounding air temperature: -10 °C to 45 °C (14 °F to 113 °F). The inverter is capable of operating with an maximum surrounding air temperature of 55 °C (131 °F) if an output current derating of 2 % is applied for each ºC (or 1.11 % each °F) above 45 °C (113 °F).

- Relative air humidity: 5 % to 90 % non-condensing.

- Altitude: 1000 m (3.300 ft). Above 1000 m (3.300 ft) up to 4000 m (13.200 ft) the output current shall be derated by 1 % for each 100 m (or 0.3 % each 100 ft) above 1000 m (3.300 ft).

- Ambient with pollution degree 2 (according to EN50178 and UL508C).

(2) Nominal current in permanent regimen at the following conditions:

- Temperature around the inverter: -10 °C to 40 °C (14 °F to 104 °F). The inverter is able to operate in environments with temperatures up to 55 °C (131 °F), if a reduction of 2 % in the output current is applied for each Celsius degree (or 1.11 % each °F) above 40 °C (104 °F).

- Relative humidity: 5 % to 90 % without condensation.

- Altitude: 1000 m (3.300 ft). Above 1000 m up to 4000 m (3.300 ft to 13.200 ft) the output current must be reduced in 2% for each 100 m (or 0.6 % each 100 ft) above 1000 m (3.300 ft).

- Environment with pollution degree 2 (according to EN50178 and UL508C).

(3) Table 8.1 presents only two points of the overload curve (activation time of 1 min and 3 s). The complete

information about the IGBTs overload for Normal and Heavy Duty Cycles is presented below.

RAT ND

2.0

1.9

1.8

1.7

1.6

1.5

1.4

1.3

1.2

1.1

1.0

0.9

0 10 20 30 40 50 60 70 80 90

(a) IGBTs overload curve for the Normal Duty (ND) cycle

RAT ND

2.0

1.9

1.8

1.7

1.6

1.5

1.4

1.3

1.2

1.1

1.0 0 10 20 30 40 50 60 70 80 90

(b) IGBTs overload curve for the Heavy Duty (HD) cycle

100 110 120

∆ t (s)

Figure 8.1 - Overload curves for the IGBTs

8-3

Technical Specifications

(4) The motor ratings are merely a guide for 440 V (400 V line), 575 V (500 V line) and 690 V (600 V line), IV

pole WEG motors. The adequate inverter sizing shall be based on the rated current of the motor used.

(5) The information provided about the inverter losses is valid for the rated operating condition, i.e., for rated

output current and rated carrier frequency.

8.2 ELECTRICAL / GENERAL SPECIFICATIONS

CONTROL METHOD

OUTPUT FREQUENCY PERFORMANCE SPEED (Vector Control) CONTROL

TORQUE

CONTROL INPUTS ANALOG (CC11 board)

OUTPUTS ANALOG (CC11 board)

DIGITAL

RELAY

Voltage source Type of control:

- V/f (Scalar);

- V V W : Voltage vector control;

- Vector control with encoder;

- Sensorless vector control (without encoder). PWM SVM (Space Vector Modulation); Full digital (software) current, flux, and speed regulators.

Execution rate:

- current regulators: 0.2 ms (5 kHz)

- flux regulator: 0.4 ms (2.5 kHz)

- speed regulator / speed measurement: 1.2 ms 0 to 3.4 x rated motor frequency (P0403). The rated frequency is programmable from 0 Hz

to 300 Hz in the scalar mode and from 30 Hz to 120 Hz in the vector mode. V/f (Scalar):

Regulation (with slip compensation): 1 % of the rated speed. Speed variation range: 1:20.

V V W:

Regulation: 1 % of the rated speed. Speed variation range: 1:30.

Sensorless:

Regulation: 0.5 % of the rated speed. Speed variation range: 1:100.

Vector with Encoder:

Regulation:

±0.01 % of the rated speed with a 14-bits analog input (IOA); ±0.01 % of the rated speed with a digital reference (Keypad, Serial, Fieldbus, Electronic Potentiometer, Multispeed); ±0.05 % of the rated speed with a 12-bits analog input (CC11).

Range: 10 to 180 %, regulation: ±5 % of the rated torque (with encoder); Range: 20 to 180 %, regulation: ±10 % of the rated torque (sensorless above 3 Hz). 2 isolated differential inputs; resolution of AI1: 12 bits, resolution of AI2: 11bits + signal,

(0 to 10) V, (0 to 20) mA or (4 to 20) mA, Impedance: 400 kΩ for (0 to 10) V, 500 Ω for

(0 to 20) mA or (4 to 20) mA, programmable functions.

6 isolated digital inputs, 24 Vdc, programmable functions. 2 isolated analog outputs, (0 to 10) V, RL ≥ 10 kΩ (maximum load), 0 to 20 mA / 4 to 20 mA

(RL ≤ 500 Ω) resolution: 11 bits, programmable functions.

3 relay outputs with NO/NC contacts, 240 Vac, 1 A, programmable functions.

8-4

8.2 ELECTRICAL / GENERAL SPECIFICATIONS (cont.)

Technical Specifications

SAFETY PROTECTION

INTEGRAL STANDARD KEYPAD KEYPAD (HMI)

ENCLOSURE IP00

PC CONNECTION USB CONNECTOR FOR INVERTER PROGRAMMING

Output overcurrent/short-circuit; Under / Overvoltage; Overtemperature; Braking resistor overload; IGBTs overload; Motor overload; External fault / alarm; CPU or memory fault; Output phase-ground short-circuit. 9 operator keys: Start/Stop, Up Arrow, Down Arrow, Direction of Rotation, Jog,

Local/Remote, Right Soft Key and Left Soft Key;

Graphical LCD display; View/edition of parameters; Indication accuracy:

- current: 5 % of the rated current;

- speed resolution: 1 rpm; Possibility of remote mounting.

USB standard Rev. 2.0 (basic speed); Type B (device) USB plug; Interconnection cable: standard host/device shielded USB cable.

8.2.1 Codes and Standards

SAFETY

STANDARDS

UL 508C - Power conversion equipment.

UL 840 - Insulation coordination including clearances and creepage distances for electrical

equipment.

EN61800-5-1 - Safety requirements electrical, thermal and energy.

EN 50178 - Electronic equipment for use in power installations.

EN 60204-1 - Safety of machinery. Electrical equipment of machines. Part 1: General

requirements.

Note: The final assembler of the machine is responsible for installing an safety stop device

and a supply disconnecting device.

EN 60146 (IEC 146) - Semiconductor converters.

EN 61800-2 - Adjustable speed electrical power drive systems - Part 2: General requirements -

Rating specifications for low voltage adjustable frequency AC power drive systems.

8-5

Technical Specifications

8.2.1 Codes and Standards (cont.)

ELECTROMAGNETIC

COMPATIBILITY (EMC)

MECHANICAL

STANDARDS

EN 61800-3 - Adjustable speed electrical power drive systems - Part 3: EMC product stan-

dard including specific test methods.

EN 55011 - Limits and methods of measurement of radio disturbance characteristics of

industrial, scientific and medical (ISM) radio-frequency equipment.

CISPR 11 - Industrial, scientific and medical (ISM) radio-frequency equipment - Electromag-

netic disturbance characteristics - Limits and methods of measurement.

EN 61000-4-2 - Electromagnetic compatibility (EMC) - Part 4: Testing and measurement

techniques - Section 2: Electrostatic discharge immunity test.

EN 61000-4-3 - Electromagnetic compatibility (EMC) - Part 4: Testing and measurement

techniques - Section 3: Radiated, radio-frequency, electromagnetic field immunity test.

EN 61000-4-4 - Electromagnetic compatibility (EMC) - Part 4: Testing and measurement

techniques - Section 4: Electrical fast transient/burst immunity test.

EN 61000-4-5 - Electromagnetic compatibility (EMC) - Part 4: Testing and measurement

techniques - Section 5: Surge immunity test.

EN 61000-4-6 - Electromagnetic compatibility (EMC) - Part 4: Testing and measurement te-

chniques - Section 6: Immunity to conducted disturbances, induced by radio-frequency fields.

EN 60529 - Degrees of protection provided by enclosures (IP code).

UL 50 - Enclosures for electrical equipment.

8-6

8.3 MECHANICAL DATA

230 (9.1)

230

Ø 22.5 (0.8)

22,5

138.9 (5.5)

578.2 (22.7)

578,2

555.8 (21.9)

555,8

138,9

Technical Specifications

58,7

58.7 (6.2)

103,9

103.9 (4.1)

62.7 (2.5)

62,7

1506,7

1506.7 (159.3)

Figure 8.2 - UP11 dimensions mm (in)

1460

1460 (57.5)

(3.10)

100.5

100,5

(3.10)

100.5

Ø 9.2 (0.3)

509.8 (20.1)

509,8

9,2

8-7

WEG Electric CFW-11M User Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Index

SAFETY INSTRUCTIONS

1.1 SAFETY WARNINGS IN THE MANUAL

1.2 SAFETY WARNINGS IN THE PRODUCT

1.3 PRELIMINARY RECOMMENDATIONS

General Instructions

2.1 ABOUT THE MANUAL

2.2 TERMS AND DEFINITIONS

2.3 ABOUT THE CFW-11M

2.4 IDENTIFICATION LABEL FOR THE UC11

2.5 IDENTIFICATION LABELS FOR THE UP11

2.6 HOW TO SPECIFY THE CFW-11M MODEL (SMART CODE)

2.7 RECEIVING AND STORAGE

Installation and Connection

3.1 INSTALLATION ENVIRONMENT

3.2 LIST OF COMPONENTS

3.3 MECHANICAL INSTALLATION

3.3.1 HMI Installation at the Cabinet Door or Command Panel (Remote HMI)

3.4 ELECTRICAL INSTALLATION

3.4.1 Input Rectifier

3.4.2 Bus Bars

3.4.3 Fuses

3.4.4 General Connection Diagram and Layout

3.4.5 UP11 Connections

3.4.6 UC11 Connections

3.4.7 Dynamic Braking

3.4.7.1 Sizing the Braking Resistor

3.4.7.2 Motor Connections

3.4.8 Control Connections

3.4.9 Typical Control Connections

3.5 INSTALLATION ACCORDING TO THE EUROPEAN DIRECTIVE OF ELECTROMAGNETIC COMPATIBILITY

3.5.1 Conformal Installation

3.5.2 Standard Definitions

3.5.3 Emission and Immunity Levels

3.5.4 External RFI Filters

Keypad and Display

4.1 INTEGRAL KEYPAD - HMI-CFW11

4.2 PARAMETERS ORGANIZATION

First Time Power-Up and Start-Up

5.1 PREPARE FOR START-UP

5.1.1 Precautions during the Energization/Start-up

5.2 START-UP

5.2.1 Password Setting in P0000

5.2.2 Oriented Start-Up

5.2.3 Setting Basic Application Parameters

5.3 SETTING DATE AND TIME

5.4 BLOCKING PARAMETERS MODIFICATION

5.5 HOW TO CONECT A PC

5.6 FLASH MEMORY MODULE

Troubleshooting and Maintenance

6.1 OPERATION OF THE FAULTS AND ALARMS

6.2 FAULTS, ALARMS, AND POSSIBLE CAUSES

6.3 SOLUTIONS FOR THE MOST FREQUENT PROBLEMS

6.4 INFORMATION FOR CONTACTING TECHNICAL SUPPORT

6.5 PREVENTIVE MAINTENANCE

6.5.1 Cleaning Instructions

Option Kits and Accessories

7.1 OPTION KITS

7.1.1 Safety Stop According to EN 954-1 Category 3 (Pending Certification)

7.2 ACCESSORIES

TECHNICAL SPECIFICATIONS

8.1 POWER DATA

8.2 ELECTRICAL / GENERAL SPECIFICATIONS

8.2.1 Codes and Standards

8.3 MECHANICAL DATA