User Guide. Part Number: Issue Number: 9. Variable Speed Drive for 3-phase induction motors 0.25kW to 0.75kW - PDF

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EF User Guide Dinverter A Part Number: Issue Number: 9 Variable Speed Drive for 3-phase induction motors 0.25kW to 0.75kW General information The manufacturer accepts no liability for any consequences
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EF User Guide Dinverter A Part Number: Issue Number: 9 Variable Speed Drive for 3-phase induction motors 0.25kW to 0.75kW General information The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional operating parameters of the equipment or from mismatching the variable speed drive (Drive) with the motor. The contents of this User Guide are believed to be correct at the time of printing. In the interests of a commitment to a policy of continuous development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or the contents of the User Guide, without notice. All rights reserved. No parts of this User Guide may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by any information-storage or retrieval system, without permission in writing from the publisher. Use within the European Union, etc The following information applies where the end use of the Drive is within the European Union, the European Economic Area, or other regions which have implemented Directives of the European Council or equivalent measures. The Drive complies with the Low Voltage Directive 73/23/EEC. The installer is responsible for ensuring that the equipment into which the Drive is incorporated complies with all relevant Directives. The complete equipment into which the Drive is incorporated must comply with the EMC Directive 89/336/EEC. If the Drive is incorporated into a machine, the manufacturer is responsible for ensuring that the machine complies with the Machinery Directive 89/392/EEC. In particular, the electrical equipment should generally comply with European Harmonised Standard EN Important... Drive software version This product is supplied with the latest version of user-interface and machine-control software. If this product is to be used with other Control Techniques variable speed drives in an existing system, there may be some differences between their software and the software in this product. These differences may cause a difference in functions. This may also apply to variable speed drives returned from a Control Techniques Service Centre. If there is any doubt, contact a Control Techniques Drive Centre. Copyright November 1999 Control Techniques Drives Ltd Author: RFD Issue Code: d2au9 Issue Date: November 1999 S/W Version: V2.01 Contents 1 Introduction 1 2 Safety information 5 3 Data 7 4 Installing the Drive EMC considerations Environmental requirements Planning the installation Installing the Drive and optional RFI filter Wiring recommendations Bench testing the Drive 54 5 Programming instructions Introduction to the display and keypad Procedures 59 6 Setting up the Drive for the application Preparation Configuring the Drive for the motor Checking operation in Terminal mode Checking operation in Keypad mode Making adjustments 72 7 Menu 0 parameters 73 8 Diagnostics Status messages Warning indications When a trip occurs Trip codes 86 9 Security Introduction to the security system Security procedures 90 Dinverter A Issue code: d2au9 Declaration of Conformity Control Techniques plc, The Gro, Newtown, Powys, UK, SY16 3BE DIN A DIN A DIN A DIN A The AC variable speed drive products listed above have been designed and manufactured in accordance with the following European harmonized, national and international standards: EN60249 IEC326-1 IEC326-5 IEC326-6 IEC664-1 EN60529 UL94 UL508C EN EN EN EN Base materials for printed circuits Printed boards: general information for the specification writer Printed boards: specification for single- and double-sided printed boards with plated-through holes Printed boards: specification for multilayer printed boards Insulation co-ordination for equipment within low-voltage systems: principles, requirements and tests Degrees of protection provided by enclosures (IP code) Flammability rating of plastic materials Standard for power conversion equipment Generic emission standard for the residential, commercial and light industrial environment Generic emission standard for the industrial environment Generic immunity standard for the industrial environment Adjustable speed electrical power drive systems Part 3: EMC product standard including specific test methods This product complies with the Low Voltage Directive 73/23/EEC, the Electromagnetic Compatibility (EMC) Directive 89/336/EEC and the CE Marking Directive 93/68/EEC. W. Drury Technical Director Newtown Date: 22nd January 1997 These electronic Drive products are intended to be used with an appropriate motor, controller, electrical protection components and other equipment to form a complete end product or system. The Drive must be installed only by a professional assembler who is familiar with requirements for safety and electromagnetic compatibility (EMC). The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used. Refer to this User Guide or the Dinverter A EMC Data Sheet for further information on EMC standards complied with by the product, and for guidelines on installation. Dinverter A Issue code: d2au9 1 Introduction 1.1 How this User Guide can help you By following this User Guide chapter-by-chapter, you will be taken in a logical sequence through the steps required for installing, performing basic programming and setting up the Dinverter for basic applications. Your and other people s safety, and the requirements of EC directives (when applicable), depend on your understanding the information and adhering to the instructions in this User Guide. 1.2 Advanced functions This User Guide covers the basic functions of the Dinverter which are intended for the majority of applications. The Dinverter also has advanced functions which are covered in the Dinverter A Technical Reference Manual. (This can be obtained from a Control Techniques distributor or Drive Centre listed at the end of this User Guide.) The advanced functions are as follows: Speed control Second analog speed reference input (20mA current loop having four options plus a low-voltage high-impedance input) 8 adjustable preset speed references Adjustable preset precision speed reference Remote selection of speed references Incremental speed control from external contacts (motorized potentiometer) Separate speed limits for forward and reverse operation 3 adjustable skip-speed bands Slip compensation Selection of PWM switching frequencies allowing output frequencies up to 960Hz Adjustable preset jog speed Torque control Torque control with maximum speed limit Ramps 8 preset acceleration ramps plus 8 preset deceleration ramps which can be split into 4 forward and 4 reverse Separate acceleration and deceleration ramps for jogging Remote selection of ramps Starting 2 auto-start modes Issue code: d2au9 1 Stopping and braking Dynamic control of braking with or without an external braking resistor Selection of 4 ways to stop the motor including by DC injection braking Digital control Selection of 5 digital control modes for remote control of start, stop, reverse and jog Control from the keypad or by remote signals, or a combination of these Programmable I/O Analog and digital I/O fully programmable for alternative functions Security Two security levels for protection against unauthorized adjustment of the software Motor protection Current limit (short-term overload) Thermal protection (long-term overload) Protection trips with a trip log Monitoring Zero speed and at speed indications Pre-warning for motor overheating Status and diagnostic information Auxiliary functions Serial communications (2-wire RS485 half-duplex) for remote control by a system controller, and/or for expansion of the I/O The Dinverter can be stopped by process-generated trips Programmable motorized potentiometer Un-dedicated programmable logic Un-dedicated programmable comparator In addition to information for the advanced functions, the Dinverter A Technical Reference Manual contains the following: Advanced data Calculating enclosure sizes and cooling Connecting a braking resistor EMC wiring variations 2 Issue code: d2au9 1.3 Bench-testing the Dinverter If this is your first encounter with a Dinverter, you may wish to understand more fully how it works by performing a bench-test before installing it. In this case, after reading Chapter 1, refer to Chapter 2 Safety information, then Bench-testing the Drive making temporary connections in Chapter 4 Installing the Drive. 1.4 Methods of control The Drive can be controlled by any of the following methods: Terminal mode Applying signals from electrical contacts, a controller or PLC to digital inputs on the Drive. Keypad mode Manual operation of the keypad on the front panel of the Drive; apart from two wire-links to be connected to a terminal block, no external signal connections are made to the Drive. Serial communications Using a system controller or PLC connected to the Drive by a 2-wire RS485 serial communications link (can be used in conjuction with Terminal mode or Keypad mode). Issue code: d2au9 3 2 Safety Information 2.1 Warnings, Cautions and Notes A Warning contains information which is essential for avoiding a safety hazard. A Caution contains information which is necessary for avoiding a risk of damage to the product or other equipment. A Note contains information which helps to ensure correct operation of the product. 2.2 Electrical safety general warning The voltages used in the Drive can cause severe electric shock and/or burns, and could be lethal. Extreme care is necessary at all times when working with or adjacent to the Drive. Specific warnings are given at the beginning of the installation instructions in this User Guide. The installation must comply with all relevant safety legislation in the country of use. 2.3 System design The Drive is intended as a component for professional incorporation into complete equipment or systems. If installed incorrectly the Drive may present a safety hazard. The Drive uses high voltages and currents, carries a high level of stored electrical energy, and is used to control mechanical equipment which can cause injury. Close attention is required to the electrical installation and the systemdesign to avoid hazards either in normal operation or in the event of equipment malfunction. System-design, installation, commissioning and maintenance must be carried out by personnel who have the necessary training and experience. They must read this safety information and this User Guide carefully. To ensure mechanical safety, additional safety devices such as electro-mechanical interlocks may be required. The Drive must not be used in a safety-critical application without additional protection. 2.4 Environmental limits The instructions in this User Guide regarding transport, storage, installation and use of Drives must be complied with, including the specified environmental limits. Drives must not be subjected to excessive physical force. 4 Issue code: d2au9 2.5 Compliance with regulations The installer is responsible for complying with all relevant regulations, such as national wiring regulations, accident prevention regulations and electromagnetic compatibility (EMC) regulations. Particular attention must be given to the cross-sectional areas of conductors, the selection of fuses or other protection, and protective earth (ground) connections. This User Guide contains instructions for achieving compliance with specific EMC standards. 2.6 Risk analysis 2.7 Motor In any application where a malfunction of the Drive could lead to damage, loss or injury, a risk analysis must be carried out, and where necessary, further measures taken to reduce the risk. This would normally be an appropriate form of independent safety back-up system using simple electro-mechanical components. Ensure the motor is installed in accordance with the manufacturer s recommendations. Ensure the motor shaft is not exposed. Standard squirrel-cage induction motors are designed for single-speed operation. If it is intended to use the capability of the Drive to run a motor at speeds above its designed maximum, it is strongly recommended that the manufacturer is consulted first. Low speeds may cause the motor to over-heat because the cooling fan becomes less effective. The motor should then be fitted with a protection thermistor. If necessary, a separate cooling fan should be used. Issue code: d2au9 5 2.8 Adjusting parameters Some parameters have a profound effect on the operation of the Drive. They must not be altered without careful consideration of the impact on the controlled system. Measures must be taken to prevent unwanted changes due to error or tampering. 2.9 Safety of personnel The Stop and Start controls or electrical inputs of the Drive should not be relied upon to ensure safety of personnel. If a safety hazard could exist from unexpected starting of the Drive, an interlock that electrically isolates the Drive from the AC supply should be installed to prevent the motor being inadvertently started. The DC bus will remain energized if a voltage is applied to the output terminals of the Drive. Under certain conditions, the Drive can suddenly discontinue control of the motor. If the load on the motor could cause the motor speed to be increased, a separate method of braking and stopping the motor should be used (eg. a mechanical brake). Before connecting the AC supply to the Drive, it is important that you understand the operating controls and their operation. If in doubt, do not adjust the Drive. Damage may occur, or lives put at risk. Carefully follow the instructions in this User Guide. Before making adjustments to the Drive, ensure all personnel in the area are warned. Make notes of all adjustments that are made. Never work on a variable speed drive on your own: ensure that a suitably qualified person is present to assist in an emergency. 6 Issue code: d2au9 3 Data 3.1 Dinverter Table 3 1 Model Number of AC supply phases Power, voltage and current ratings 150% overload output current for 60 seconds maximum Max. continuous 100% RMS output current (FLC) Max. continuous 100% RMS AC input current Continuous motor shaft power AC supply voltage V kw HP A A A DIN A ~ 240 ±10% DIN A ~ 240 ±10% DIN A ~ 240 ±10% DIN A ~ 240 ±10% Motor requirements Temperature, humidity and cooling method Ingress protection Overall dimensions Weight Number of phases: 3 Voltage: 200V to 240V ±10% (normally delta connected) Power rating: 0.25kW (0.33HP) to 0.75kW (1HP) Ambient temperature range: 10 C to 50 C (14 F to 122 F). Output current derating may apply at high ambient temperatures. Storage temperature range: 40 C to 50 C ( 40 F to 122 F) Humidity: 85% non-condensing Cooling method: Natural convection Gland plate not fitted: IP00 Gland plate fitted; cable glands not fitted: IP10 Cable-glands fitted: IP20 These dimensions exclude the mounting brackets. Height: 140mm (5 1 / 2 in) Width: 75mm (3 in) Depth: 192mm (7 1 / 2 in) Approximate weight of each model: 1.2kg (2lb 11oz) Issue code: d2au9 7 Electromagnetic compatibility (EMC) This is a summary of the EMC performance of the Drive. For full details, refer to the Dinverter A EMC Data Sheet which can be obtained from a Drive Centre or distributor listed at the end of this User Guide. Immunity Compliance with immunity standards does not depend on installation details. Single and parallel Drive modules meet EN (generic immunity standard for the industrial environment) and the following specifications from the IEC group (derived from IEC801): Part 2, Electrostatic discharge: Level 3 Part 3, Radio frequency field: Level 3 Part 4 Transient burst: Level 4 at the control terminals Level 3 at the power terminals Part 5, Surge (at the AC supply terminals) (as specified by EN informative annex): Level 4 line-to-ground Level 3 line-to-line Part 6, Conducted radio frequency: Level 3 Emission Compliance with emission standards depends on rigorous adherence to the installation guidelines, including the use of the specified RFI filter in the AC supply circuit. Compliance also depends on the PWM switching frequency used in the output stage of the Drive, and the length of the motor cable. For full details, refer to the Dinverter A EMC Data Sheet which can be obtained from a Drive Centre or distributor listed at the end of this User Guide. Conducted emission from the Drive meets the requirements of EN (generic emission standard for the industrial environment) over a wide range of conditions. In addition, the Drive meets the radiated emission requirements of this standard. The emission limits in EN are similar to CISPR11 and EN55011 Class A. Under restricted conditions, the conducted emission meets EN (generic emission standard for the residential, commercial and light industrial environment. This is similar to CISPR11 and EN55011 Class B. The optional RFI filter model number DIN 1012F must be used. 8 Issue code: d2au9 Power Drive Systems standard EN The Drive meets the immunity requirements of EN irrespective of the environment in which it is operating. The emission requirements of this standard are also met depending on the environment category, as follows: First environment: Restricted distribution only: specified RFI filter required Second environment: No RFI filter required (but RFI filter(s) are recommended where sensitive electronic systems are operating nearby); emission limits are under consideration EN defines the first environment as one that includes domestic premises. It also includes establishments directly connected without intermediate transformers to a low-voltage power supply network which supplies buildings used for domestic purposes. The second environment is one that includes all establishments other than those directly connected to a low-voltage power supply network which supplies buildings used for domestic purposes. Restricted distribution is defined as a mode of sales distribution in which the manufacturer restricts the supply of equipment to suppliers, customers or users who separately or jointly have technical competence in the EMC requirements of the application of Drives. Note Frequencies Accuracy and resolution If a Power Drive System is included as part of equipment covered by a separate EMC product standard, the EMC standard for the complete equipment applies. AC supply frequency: 50Hz to 60Hz ±2Hz PWM switching frequency: 3kHz nominal (selectable up to 12kHz) Maximum output frequency: 240Hz (up to 960Hz) For operation at PWM switching frequencies above 3kHz, refer to the Dinverter A Technical Reference Manual. The following data applies to the Drive only; it does not include the performance of the source of the control signals. Output frequency accuracy: ±0.01% Output frequency resolution: 0.001Hz up to 480Hz 0.002Hz from 480Hz to 960Hz Output voltage accuracy: depends on AC supply stability Output voltage resolution: 0.4% Tracking-accuracy of output current to changes in load: ±10% above 20Hz (with a motor matched to the Drive) Tracking-resolution of output current to changes in load: 0.1% Issue code: d2au9 9 Table 3 2 Heat dissipation and surge-current Model Maximum dissipation at... Surge-current at power-up * 3kHz 6kHz 9kHz 12kHz 50Hz 60Hz W W W W A A DIN A DIN A DIN A DIN A * Surge current at the instant the AC supply is connected to the Drive: worst-case values of half sine-wave current pulse of a quarter-cycle duration; unlimited repetition rate. 3.2 Optional RFI filter (DIN1012F) Electrical ratings Ambient temperature Weight Overall dimensions Maximum current: 12ARMS Maximum power dissipation: 8W Voltage-drop at 12A: 1V maximum Above 40 C (104 F), the current rating is reduced by 0.2A/ C (0.11A/ F). 0.65kg (1lb 6oz) These dimensions exclude the mounting brackets. Height: 140mm (5 1 / 2 in) Wid
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