Operating Instruction - Conrad Electronic · FD 250 - 2200 FD 750/3 - 2200/3 FD KR IP54 250 - 2200...

FD 250 - 2200FD 750/3 - 2200/3

FD KR IP54 250 - 2200FD KR IP54 750/3 - 2200/3

Frequency Inverter

Future-Drive

Operating Instruction

Technik

2 Future-Drive Operating Instruction

MSF-Technik Vathauer GmbH & Co. KG Am Hessentuch 6-8 D-32758 DetmoldTel.: (05231) 66193/63415, Fax: (05231) 66856eMail: [email protected]: www.msf-technik.de


Technik

3Operating Instruction Future-Drive

Version 04/2000 Technical changes reserved

Guarrantee

According to the current general terms of delivery and paymentMSF-Technik provides a guarrantee of 6 months after delivery on all electronic devices

covering design, material, or faulty workmanship

MSF-Technik reserves the right to change the contents of this operating manual and the productspecifications contained therein without prior notice.

The copyright of this documentation is reserved by MSF-Technik Vathauer GmbH & Co Kg

Attention!

Read this manual carefully and completely.Start with the installation and commissioning only after reading.

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Table of Contents

1. General .............................................................................................................................51.1 Technical features ................................................................................................................51.2 Special features ...................................................................................................................51.3 Delivery and packaging........................................................................................................61.4 Instructions for the installation ..............................................................................................61.5 Maintenance........................................................................................................................6

2. Connection and operating conditions ...............................................................................72.1 VDE regulations ..................................................................................................................72.2 Motor cables.......................................................................................................................72.3 Analog and digital control wires ...........................................................................................7

3. Operating interface ..........................................................................................................83.1 Connection of the plain text display......................................................................................83.2 Operating values ..................................................................................................................83.3 Error messages....................................................................................................................93.4 Parameterizing by the operating interface............................................................................103.5 Parameter list ....................................................................................................................11

4. Parameterizing using the PC..........................................................................................154.1 The serial interface.............................................................................................................15

5 Outputs of the seven-segment display ..........................................................................165.1 Output at the stop..............................................................................................................165.2 Output for right hand or left hand start ................................................................................165.3 Output in case of a disturbance, a reset and communication with the PC .............................16

6. Four programmable parameter sets ..............................................................................176.1 Running-up time ................................................................................................................176.2 Running-down time............................................................................................................176.3 Maximum rotating field frequency.......................................................................................186.4 Fixed rotating field frequency.............................................................................................186.5 Minimum rotating field frequency........................................................................................186.6 Current limitation...............................................................................................................186.7 Kink frequency..................................................................................................................196.8 Static boost .......................................................................................................................206.9 Dynamic boost ..................................................................................................................216.10 Time limited boost .............................................................................................................216.11 DC brake..........................................................................................................................216.12 Duration of the DC braking................................................................................................226.13 Slip compensation .............................................................................................................226.14 Multi-function output (frequency) .......................................................................................226.15 Multi-function output (Currant)...........................................................................................226.16 Low pass ramp off/on 1=on, 0=off...................................................................................22


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7. Presettings of the independent Parameter set..............................................................237.1 Clock frequency................................................................................................................237.2 Language ..........................................................................................................................237.3 Braking chopper................................................................................................................237.4 Display/hide the menu for the programmable input terminals ................................................237.5 Show parameter sets .........................................................................................................237.6 I²t current / I²t time ............................................................................................................237.7 Temperature monitoring .....................................................................................................247.8 Temperature switch-off......................................................................................................247.9 Factory settings .................................................................................................................247.10 Copy process....................................................................................................................247.11 File name .........................................................................................................................257.12 Write protection ................................................................................................................25

8. Set value assignment ......................................................................................................268.1 Set value ...........................................................................................................................268.2 Set value - Hysteresis ........................................................................................................268.3 Set value - Offset ..............................................................................................................278.4 V/f characteristics..............................................................................................................288.5 Fade out frequency1, fade out frequency2..........................................................................28

9. Programming of the digital inputs/outputs.....................................................................299.1 Parameterization of the control inputs .................................................................................299.2 Parameterization of the control outputs...............................................................................319.3 Explanations as to the control inputs and outputs ................................................................31

10. Wiring diagram...............................................................................................................3310.1 Minimal terminal assignment ...............................................................................................3310.2 Wiring assignment for IP54 apparatus and cable................................................................. 3410.3 Wiring assignment for IP54 apparatus and plug................................................................... 34

11. Dimensions .....................................................................................................................35

12. Technical Data ................................................................................................................36

13. Application notes ............................................................................................................3713.1 Dynamic braking using a braking chopper ..........................................................................3613.2 Motor protection...............................................................................................................3813.3 Cabinet mounting...............................................................................................................3913.4 Measures to secure the EMC ............................................................................................4013.5 Warnings...........................................................................................................................41

ANNEX A: Interface protocol................................................................................................45

ANNEX B: List of errors .......................................................................................................48

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1. General

1.1 Technical features

The rotation speed of three-phase induction motors can smoothly be adjusted using the FD250-2200 digitalized frequency inverters. The inverter operates according to the principle of sine-weighted pulse width modulation. Pulse width modulation is controlled by a dual processor system.Communication is performed via a conventional plug-in terminal block. Control connections 1-19 ofthe frequency converter are floating potential-free on terminals.A protection of the power module, in case of undervoltage, overvoltage, or inadmissible convertertemperature, is guaranteed for all apparatus.

1.2 Special features

The practical design offers the following advantages:F Different installation positions optimize the installation, and minimize the space requirement in the

switch cabinetF no additional expenses for direct mounting on machines due to pre-wired power line and motor

cables as well as built-in potentiometer and mains switch according to customer requirements.F Integrated braking chopper (optional)

A plug-on type operator interface for different installation positions offers the followingadvantages:F 3-line LC-displayF plain text displayF memory for four filesF 5 operator languages (German, English, French, Italien, Dutch)F on-line parameterization

Easy parameterization via comfortable PC user surface:F RS-232 interface (standard)F 4 programmable parameter sets of 3 freely selectable set values each for positioning tasks or

multi-axis drives.F programmable input/output terminals

High operational safety due to:F aluminium cases and standard input/output filters provide high noise immunity and only slight noise

emissionsF short-circuit protection (conditional)F the new CCDS-SYSTEM (current-control dynamic scan) prevents the converter from switching-

off at short time excess current flow (e.g. dynamic acceleration)F set value input isolated from potential


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1.3 Delivery and packaging

The inverters are delivered packed in cardboard boxes.

F Please check for transportation damages.Please notify the shipping company immediately, and let them confirm the damage if you find any outsidetraces of damages.Inform the supplier of accordingly.

1.4 Instructions for the installation

The setup place of installation should be selected to allow for sufficient clean and dry airflow to cool theenclosure. The apparatus are designed for indoor use. A larger concentration of dust, a highconcentration of chemical inactive detrimental substances, fungoid growth, or the penetration of pest cancause a failure of the apparatus.For thermal reasons, the apparatus has to be mounted vertically.Special attention must be paid to sufficient cooling of the apparatus when mounting it in a controlcabinet. (re. chapter 13.3)

Note: When using the motor PTC, it is important to ensure that the motor cable is laid separatly from the PTC cable.

1.5 Servicing

In principle, the inverters are maintenance-free.Depending on the formation of dust, the air filters of cabinet appratus must be regularly checked andcleaned if required. With increased pollution, check the isolating gaps and heat sinks more frequentlyand clean where appropriate.

Cleaning of the apparatus is only permissible with halogen-free agents!

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2. Connection and operating conditions

The perfect function of a frequency inverter is only then guaranteed if the mains voltage is appliedand it does not exceed or fall short of the defined tolerance zones. The tolerance zones of thefrequency converter correspond to the guidelines defined in VDE 0160.

All conducting connections still carry voltage after shutdown of the supply voltage until theintermediate circuit condenser has been unloaded (approx. 90 sec). Only after this time, the invertercan be considered to be voltage-free.

Cabling work on the terminal block may only be carried out with a voltage-free converter.

After taking out of service, the apparatus is to be disposed as requested by applicable laws orregulations.

2.1 VDE regulations

F The VDE regulations for the installion and operation of electric equipment must beclosely observed.

2.2 Motor cables

With this inverter principle, the motor insulation is burdened in addition by the switching edges in thevoltage. Long motor cables can cause voltage increases which are not admissible in someapplications.Therefore, the maximum admissible motor cable length totals approx. 50 m. Using an external"output choke" option, the length can be further increased. The actual maximum motor cable lengthdepends essentially on the wiring of the cables (e.g.: underground, cable routing, etc.). To guaranteean EMC (electromagnetic compatibility) conforming operation, shielded cables (e.g.: LIYCY) mustbe used. (re. chapter 13.4) The screen is to be laid out as a large surface on both sides.

A contactor must never be wired between motor and converter.With a cyclic frequency pending, the frequency inverter may switch off as a result of interferencepeaks. If this should yet be required, by prior releasing supression.

2.3 Analog and digital control wires

Shielded cables must be used for all analog and digital control wires.The control wires and mains wires as well as the motor wires must be routed separately.


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3. Operating interface

3.1 Connection of the plain text display

The operator interface with a 3-line backlit display is one possibility of setting the parameters of theFutureDrive. The connection of the operator interface to the converter is shown in figure 3.1.1.The parameterization is performed quickly and simply on the basis of the clear menu structure (refer tofigure 3.4.1) and the parameters displayed in plain text.

PL1 (9-pin): connection of the operatetor interface

PL2: serial interface

PL1 PL2

Control connections

Power connections

Figure 3.1.1 Connector arrangement

The operating interface may be plugged on or taken off while the frequency inverter isrunning. When it is plugged on, a key must be operated to activate the fonts

3.2 Operating values

The "Operating values" menue item enables an operation status request with regard to the followingvisible messages:

preset value / Hz instantaneous preset value of the rotary field frequencyactual value / Hz instantaneous value of the rotary field frequencyTC active current / Amp instantaneous intermediate circuit- active currentparameters instantaneous active parameter setconv. temp. / °C instantaneous converter temperatureversion no. version number of the software used for the apparatus

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3.3 Error messages

F Voltage too highAdmissible intermediate circuit voltage exceeded.

F Voltage too lowAdmissible intermediate circuit voltage dropped below.

F Conv. temp. too high (stage 1: only as a user information)Critical operating temperature of the converter.

F Conv. temp. insufficient (stage 2: converter switches off)Operating temperature of the converter is inadmissible (results in switching the converteroff)

F Short circuitShort circuit or inadmissibly high output current

F Motor temperature to highF I²t error

Programmed current integral exceeded time limit

3.4 Parameterization with the help of the operator interface

To change a selected parmeter requires pressing the PRG key. The cursor begins to blink, and the value my be changed by the keys UP, DOWN, PRG or SH. The value must then be saved by simultaneous operation of the keys PRG and SH. If the user is in in the programming mode (cursor blinking), the value may be raised or lowered by the keys UP and DOWN. Keys PRG and SH will shift the cursor right or left.


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Figure 3.4.1 The menu structure

key

key

key

DOWN

SH

UP

param.frame1 accel.- time



param.frame4 accel.- time opperat.value

freq.s.meth. switch freq. -> 2 KHz

set value -> Poti (10k)

start-right VCC-> Kl.8

param.frame1 decel.- time

param.frame1 max. freq.

param.frame1 fix- freq.

param.frame1 min. freq.

param.frame1 max. current

param.frame1 base freq.

param.frame1 stat. boost

param.frame1 dyn. boost

param.frame1 time- boost

param.frame1 DC- break

param.frame1 time- break

param.frame1 slip comp

param.frame1 multi/freq.

param.frame1 multi/curr.

param.frame1 decel.- ramp




































param.frame4 base fre q.










opperat.value actual va lue

opperat.value act. current

opperat.value param. frame

opperat.value inv. temp.

opperat.value vers.- No.

set v. hyst. -> switch off

set v. offset -> 0 LSB

V/f-charact. -> linear

jump freq. 1 -> inactive

jump freq. 2 -> inactive

language -> English

RS232 -> 9600 Baud

brake contr. -> switch off

progr. input -> fade out

p.fr.fade in ->p. -frame1-4

II*t current -> 3,5 A

I*I*t time -> 30s

temp. control -> 60° C

temp. S. off. -> 65°C

factory set. -> copy?

copy file. -> 1x.. -> FD

file name -> xxxxx

1.xxxxx ->WRPr.ON

start-left VCC-> Kl.7

p. fr. sel.0 VCC-> Kl.6

p. fr. sel.1 -> inactive

fix. frequ. -> inactive

min. freq. VCC-> Kl.5

input reset -> inactive

Klemmenb. ->

Reaktionsz. -> 0000ms

mul.-funct. VCC-> Kl.15

mul.-funct. VCC-> Kl.16

6.2

6.1

6.4

6.7

6.8

6.6

6.5

6.9

6.10

6.11

6.12

6.13

6.14

6.16

6.15

6.3

7.2

7.1

7.4

7.7

7.8

7.6

7.5

7.9

7.10

7.11

7.12

7.13

7.14

7.3

9.1

9.1

9.1

9.1

9.1

9.1

9.1

9.1

9.2

9.2

9.1

8.2

8.5

8.5

8.4

8.3

8.1

3.2

3.2

3.2

3.2

3.2

3.2

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3.5 List of parametersThe values of all parameters memorized in the FutureDrive are shown in tables 3.5.1 and 3.5.2.These values become active after enabling the factory setting (cf., section 6.9).Tables 3.5.3 and 3.5.4 offer the possibility of entering individual parameters.Parameter set 2 is active if no further wiring is carried out (refer to 9. and 10.).

Parameter set-depending variables

Parameter set 1 2 3 4

Run.-up time 2.0 sec. 6.0 sec. 6.0 sec. 6.0 sec.

Run.-down tim 2.0 sec. 6.0 sec. 6.0 sec. 6.0 sec.

Max. frequency 120 Hz 120 Hz 120 Hz 120 Hz

Fix frequency 40 Hz 40 Hz 40 Hz 40 Hz

Min. frequency 0 Hz 0 Hz 0 Hz 0 Hz

Max. current 3.0 A 3.0 A 3.0 A 3.0 A

Corner freq. 50 Hz 50 Hz 50 Hz 50 Hz

stat. boost 4 % 4 % 8 % 8 %

dyn. boost 0 % 0 % 0 % 0 %

Time boost 0.0 s 0.0 s 0.0 s 0.0 s

Brake voltage 0 % 0 % 0 % 0 %

Brake time 0.0 s 0.0 s 0.0 s 0.0 s

Slip compens. 0.0 % 0.0 % 0.0 % 0.0 %

Multi freq. 100 Hz 100 Hz 100 Hz 100 Hz

Multi current 0.0 A 0.0 A 0.0 A 0.0 A

Ramp 1 (ON) 1 (ON) 1 (ON) 1 (ON)

Table 3.5.1Factory-set parameters


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Parameter set-independent variable

General Progr. terminals

Clock freq. 2 kHz Inputs

Language English Start cw cl. 8

RS 232 9600 baud Start ccw cl. 7

Brake chopper deactive Par selec. 0 cl. 6

Progr. cl. fade out Par selec. 1 deactivated

Display P. P.-set 1-2 Fix frequency deactivated

I*I*t (current) ∞ Min. frequen. cl. 5

I*I*t (time) ∞ Input reset deactivated

Over temp. 60ºC Terminal ass.

Deact. temp. 65ºC Reaction time 0000ms

Pass word FDxxxxxx

Preset value Outputs

Preset value Potentiom. (10k) General fault VCC --> 15

Thres. preset activate Multi-function VCC --> 16

Offset preset 0 LSB

V/f character. linear

Fade-out freq1 deactiveated

Fade-out freq2 deactiveated

Table 3.5.2Factory-set parameters

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Where have the parameters been saved and under which file name ?

Datamemory Future-Drive Operat.instr.

1st fileOperat.instr.

2nd fileOperat.instr.

3rd fileOperat.instr.

4rth file

File name

Variables dependent upon the parametersetting

Parameter set 1 2 3 4

Run.-up time sec. sec. sec. sec.

Run.-down time sec. sec. sec. sec.

Max. frequency Hz Hz Hz Hz

Min. frequency Hz Hz Hz Hz

Fixed frequency Hz Hz Hz Hz

Max. current A A A A

Kink frequency Hz Hz Hz Hz

stat. boost % % % %

dyn. boost % % % %

Time boost s s s s

Brake voltage % % % %

Brake time sec. sec. sec. sec.

Slipcompensation

% % % %

Multi frequency Hz Hz Hz Hz

Multi current A A A A

Ramp

Table 3.5.3Individually set parameters


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Table 3.5.4 Individually set parameters

Variables dependent upon the parametersetting

General Progr. terminals

Clock frequency Inputs

Language Start right

RS 232 Start left

Brake chopper Par selec. 0

Progr. cl. Par. selec. 1

Display P. Fixed frequency

I*I*t (current) Min. frequency

I*I*t (time) Input reset

Overtemperature Terminal ass.

Deact.temperatu Reaction time

Preset value Outputs

Preset value General fault

Hysteresispreset Multi-function

Offset preset

V/fcharacteristic

Fade-out freq 1

Fade-out freq2

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RXD TXDTXD RXD

(RTS) -12V(CTS)(DTR) +12V(DSR)

2

3

47

5GND GND(9- pin)

32

47

5

PC 9-pin FutureDrive

Baud rate: 9600 baud

(DTR) +12V(DSR)

RXD RXDTXD TXD

(RTS) -12V(CTS)

3

2

47

5

Figure 4.1.1 RS-232 pin assignment

GND GND(9- pin)

23

204

7

FutureDrive

Baud rate: 9600 baud

PC 25-pin

4. Parameterizing by PC

4.1 The serial interface

The serial RS-232 interface of the FutureDrive 250 -2200 is used for communication with a supervisorystation. In this so-called master/slave operation, the FutureDrive operates as a slave and is controlled orparameterized by means of a PC, a programmable controller, a microcontroller, or other facilities with anUART interface.Figure 4.1.1 shows the connections of the serial interface. Potential separation provides for an undisturbeddata transfer.For the interface protocol re Annex A.


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5 Outputs of the seven-segment display

Depending on the operating mode of the inverter (stop, cw start , ccw start, failure), importantinformation is indicated for the operator via the seven-segment display.

5.1 Output at the stopIf a stop is preset for the converter, the preset value is indicated on the seven-segment display.Example: if the set preset value is 11 Hz, -, 0, 1,1 is shown in this sequence. These values areconstantly displayed until other preset values are set or the inverter is switched into another operatingmode.

5.2 Output at cw or ccw startIf a cw or ccw start is preset for the inverter, a line circling in the determined direction is shown on thedisplay.

5.3 Output in case of a failure, a reset and communications with the PCThe instantaneous status of the inverter is indicated via the seven-segment display.

1st digit short circuit (re. 3.3)2n digit undervoltage (re. 3.3)3rd digit overvoltage (re. 3.3)4th digit converter temperature too high (re. 3.3)4th digit (flashing) converter temperature inadmissibly (refer to 3.3)5th digit motor temperature too high (refer to 3.3)6th digit not used7th digit I2 x t (the integral of the current valued across the time was exceeded, refer to 3.3)8th digit not used9th digit not usedletter C communication with the PC (refer to 4.)letter F reset active (refer to 9.3)

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6. Four programmable parameter sets

6.1 Running-up time

Time during which the motor would reach the previously set maximum frequency starting at 0 Hzusing a ramp set value. (Value range: 0,0 to 120,0 sec. provided that the 0,1 Hz /sec. to 1000 Hz/sec. limit values of the ramp slope are observed.) With 0,0 sec., the actual value directly followsthe set value without a ramp!

The running-up time always relates to the adjusted maximum frequency. The quotient: maximumfrequency/running-up time yields the so-called ramp. This designates the change of the rotating fieldfrequency change per time unit. A steep’ ramp is equivalent to a short running-up time. A’ flat’ ramp isequivalent to a long running-up time. Deficiently entered running-up times, i.e. running-up times not lyingwithin the limit values stated above are automatically corrected by the controler of the converter. Amaximum frequency of 5 Hz and a running-up time of 100 seconds (corresponding to a ramp slope of0,05 Hz/second) the controler will adjust the running-up time to 50 seconds.The set running-up times must always be application-specific, taking into account the physical realitiesresulting there from . Especially short running-up times can influence the motor stability or cause a switch-off of the converter due to an excess current. A sensible feeling is also required in the selection ofsufficiently long running-up times for large centrifugal masses.If very high currents appear during a fast running-up, the set running-up ramp is dynamically flattenedby the converter resulting in an unexpected long running-up time.

6.2 Running-down time

Time during which the motor would reach 0 Hz starting at the previously set maximumfrequency using a ramp set value of 0 V. (Value range: 0,0 to 120,0 sec. provided that the 0,1Hz /sec. to 1000 Hz /sec. limit values of the ramp slope are observed.) With 0,0 sec., the actualvalue directly follows the set value without a ramp!

As for the running up time, the running-down time always relates to the set maximum frequency.Essentially, the explanations given in the section “Running-up times” also apply here.When inappropriate short running-down ramps are selected (especially with large centrifugalmasses) overvoltages in the intermediate circuit can cause a switch-off of the converter. Since in thisstate of operation, the rotating field frequency applied to the motor is slightly less than the frequencyof the motor shaft, energy will be fed back (generator operation) resulting in an inadmissible increaseof the intermediate circuit voltage in the converter.

If the special application does not admit longer running-down times, use a braking chopper to reducethe exessive intermediate circuit voltage. (re. chapter 13.1)The braking chopper will convert the energy produced in the generator operation into heat losses.


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6.3 Maximum rotating field frequency

The maximum rotating field frequency to be set in advance which the inverter should never exceedeven if the highes possible set value (admissible range: 0 V to 10 V) is applied to the analog input. (Value range: fixed rotating field frequency - 250 Hz)

6.4 Fixed rotating field frequency

The fixed frequency the inverter assumes regardless of the analog set value.(Value ranges:minimum rotating field frequency - maximum rotating field frequencymin.frequency < fixed frequency < max. frequency)

Annotation: To activate this function, an input must be re-programmed since only a limited number of inputs are available (refer to section 9.1).

6.5 Minimum rotating field frequency

The minimum rotating field frequency to be set in advance below which the converter should notdrop even if the lowest set value is applied to the analog input.(Value range: 0 - fixed rotating field frequency)

This means that the specified value may not exceed the fixed rotating filed frequency value defined insection 6.4.

Annotationa:Only a pre-setting of a min. frequency of 1 Hz will result in a frequency of 0 Hz withan applied set value of 0 volt. With a set frequency above 1 Hz, a frequency of 0 Hz can onlybe obtained via a STOP or a RESET. frequency depends on the polarity of the applied set

6.6 Current limitation

The current to be set in advance which the inverter tries to limit by holding the rotating fieldfrequency or by lowering this frequency, respectively.(Value range: 0.4 -10.0 amps)

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6.7 Kink frequency

The rotating field frequency from which the motor is operated with the converter supplying themaximum voltage. (Value range: 30 -250 Hz)

With an increased stator frequency, the number of rotor rotations is also increased. With an increasingnumber of rotor rotations, the induction voltage also increases. To preserve a constant torque atdifferent number of rotations, however the magnetic flow must be kept constant. Hence theproportionality between rotating field frequency and voltage must be guaranteed, e. g. the output voltageincreases linearly with the rotating field frequency. This relation is guaranteed up to the kink frequency.Above the kink frequency, the converter cannot increase the voltage any more. But with an increasedfrequency, the magnetic flow cannot be held steady any longer. The motor is now operated in theso-called field weakening range. With an increased frequency, the motor torque is now reduced in aconverse proportion to the rotating field frequency. As a consequence, the motor should usually beoperated only up to the kink frequency. At a high number of rotations, the frictional losses becomeunproportionally high (e. g.: by the fan). If the torque to be achieved becomes too large, the motor ‘tips’, i.e. the torque supplied by the motor suddenly falls, and the number of shaft rotations quickly drops tolow values. A restart is only possible by drastically reducing the rotating field frequency,,or by a newstart.With the kink frequency set to low for the respective motor, the motor may be destroyed by thermaloverload. The converter might also be switched off by an excess current.The optimum setting of the kink frequency will always be the nominal motor frequency.

Figure 6.7.1 Standardized output voltage as a function of the kink frequency(linear V/f characteristics)


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Figure 6.7.2 Standardized output voltage as a function of the kink frequency(square V/f characteristics)

6.8 Static boost

Deviating from the linear V/f characteristics, this voltage increase is specified in percent of thenominal voltage to increase the starting torque at low rotating field frequencies.(Value ranges: 0 - 30%)

With low rotations, the copper resistance of the stator winding strongly influences the operatingcharacteristics of the motor. Without a voltage correction, the breakdown torque is significantly reducedtowards low rotating field frequencies. During slow starts, it could happen that the motor does not startdue a too high breakaway torque to be obtained. By using a voltage increase - the so-called BOOST- the starting torque is increased. The amount of the BOOST is specified in percentage of the nominalvoltage at 0 Hz. Starting at this value, the voltage is contiually raised with an increasing frequency and thusapproaches the normal (linear) V/f characteristic: V/f = const. A constantly available voltage increase iscalled ´static BOOST´. The range of the voltage increase extends to about a frequency of up to of 2/3of the kink frequency. To prevent a torque jump during the transition of the BOOST to the V/f=constantcharacteristics, all characteristics of the static BOOST end at the V/f characteristic.Good starting torques are achieved with a BOOST setting of 8%. Exaggerated high values result in anincreased motor temperature which may destroy in the destruction of the motor by overheat, particularlyif no separate fan is used. a high BOOST value can also cause an excessive currant, which will likewiseswitch the converter off.

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Figure 6.8.1 Standardized output voltage as a function of frequency and boost

6.9 Dynamic boost

Deviating from the linear V/f characteristics, this “time limit” voltage increase is specified inpercent of the nominal voltage for increasing the starting torque at low rotating fieldfrequencies. (Value range: 0 - 30%)

By using the dynamic BOOST the motor is exposed to a thermally limited minimal burden. The dynamicBOOST is added to a static BOOST, which may excist. The same explanations apply as for the staticBOOST.

6.10 Temporally limited boost

During the running-up-operations, the dynamic boost is activated for the set duration when the1Hz is exceeded. (Value range: 0.1 - 25.0 sec)

6.11 DC brake

The value specified in a percentage of the nominal voltage which determines the stopping torque(torque at standstill) of the motor (“DC brake”). (Value range: 0 - 20%)

Annotation: Despite a high torque generated by the motor at a rotating field frequency of 0 Hz, themotor shaft can slowly be rotated by an externally applied torque, as this is not a regulated system.


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6.12 Duration of the DC braking

The time for which the DC brake is active. (Value range: 0.1 - 25.0 sec.)

To prevent a thermal overload of the motor, the DC brake is limited to a maximum of 25 seconds, andit is activated when it reaches 0 Hz. DC braking can either be activated by applying a set value of 0 V,or by a STOP command. DC braking remains active for the entire preset time if the set value is notincreased again during the braking or a START command is given. DC braking is not activated byreversing.

6.13 Slip compensation

The compensation of the difference between the rotating field frequency and the rotor frequency.(Value range: 0.1 - 25%)

6.14 Multi-functional output (frequency)

The rotating field frequency at to be set to activate the multi-functional relay. This relay functionis activated by specifying a value which is higher than ZERO.(Value range: 2 - 250 Hz)

6.15 Multi-functional output (current)

The amount of current to be set to activate the multi-functional relay. To activate this relayfunction, the value entered for the “Multi-functional output/frequency” parameter must beZERO.(Value range: 0.1 - 20.0 Amps)

6.16 Running-down ramp off/on 1 = ON, 0 = OFF

With no signal applied to the Start/Stop input, if 1 (ONE) was specified for this parameter, the inverterreduces the rotating field frequency corresponding to the set running-down ramp. Otherwise, the inverterreleases the motor shaft immediately.

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7. Presettings independent of the Parameter-set

7.1 Clock frequency

The frequency, be which the inverter of the power circuit is clocked.The following values are possible: 2, 4, 8, and 16 kHz.Annotation: With the exception of 16 kHz, the clock frequency will be noticed as a more or less loudsecondary noise. The lower the clock frequency, the lower the switching power losses in the powercircuit, the less the inverter will warm up. The best motor characteristics are achieved from 2 kHzupwards. The clock frequency of 16 kHz should only be used in exceptional cases due to the increasedheating of the converter. If this is used a sufficient ventilation of the inverter must be guaranteed and thepower may have to be reduced.

7.2 Language

The language used for the operator prompts.The following languages may be selected: German, English, French, Italian and Dutch.

7.3 Braking chopper (optional)

This option must be activated for any apparatus using an intergrated braking chopper and an externallyconnected braking resistor. In this way, an overvoltage accumulating in the intermediate circuit during agenerating operation may be reduced by transformation into heat via the resistor (re.chaper 13.1)

7.4 Display/hide the menu for the programmable control terminals

For reasons of a clearer arrangement, the display of the programmable inputs may be suppressed in thisfunction (if no programming of the same is required).

7.5 Show parameter sets

The number of parameter sets to be displayed.

7.6 I²t current / I²t time

The I²t function is used to avoid a thermal overload of the motor, and/or to avoid a motor operationover an extended period of time in an unintended operating status (e.g. shaft blocking). For thispurpose, the current value must remain above the normal operating status. A long period of timemust be entered accordingly to avoid a shutdown of the inverter caused by short current peaks.


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FUTURE-DRIVE

Figure 7.10.11st example of acopy process

Operating interface

7.7 Temperature monitoring

The integrated temperature monitor provides for a warning signal when the set temperature isexceeded. With the help of the operating interface in the form of a flashing message "invertertemperature too high".Another possibility is to produce the warning signal via one of the programmable digital outputs(refer to 9.2)

7.8 Switching-off the temperature

When the set temperature is exceeded, the frequency inverter switches off and either signals theerror message "inverter temperature inadmissible" message or diesplays digit 4 on the seven-segmentdisplay. (r.-ü.<T.A. recommendation)

7.9 Factory settings

The factory setting is activated by selecting "à copy? Y "and causes an overwriting of everyparameter with the preset factory values (re. chapter 3.5).

7.10 Copy process

The operating interface contains a memory which can save four files. One file contains all parametersavailable in the frequency inverter (refer to figure 3.4.1). Furthermore, an individual file nameconsisting of eight freely selectable charcters may be allocated to each file.. This file name is read on-line without initiating a copy operation. Eight question marks shown instead of a file name signal amissing memory (memory area).The following examples should explain the structure and the program sequence of the possible copyoperations.

1. Band1 --> FD copies the 1st file of the operating interface named the Band1 as its file nameinto the FD.

Copy process

1.Band1 -> FD

1 st file WR PR OFF

2 nd file WR PR OFF

3 rd file WR PR OFF

4 th file WR PR OFF

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Figure 7.10.22nd example of acopy process

FUTURE-DRIVE Operating interface

Copy process

FD -> 3rd Miller

1st fileWR PR OFF

2nd fileWR PR OFF

3rd file

WR PR OFF

4th file

WR PR OFF

FD -> 3. Milling machine copies all parameters of the FD to the 3rd file of the operatinginterface with the file name Miller (precondition: write protection isinactive)

7.11 File name

A file name consisting of eight freely selectable characters can be entered for the designation of theparameters saved in the FD. While all parameters of the FD are copied into the memory of theoperating interface, the file name offers a possibility to designate the four files (refer to 7.10).

7.12 Write protection

The write protection exclusively refers to the four files of the operating interface. It is used as a safetymeasure in view of operating errors to avoid an unintented overwriting of files. With the writeprotection active, a file can only be read by the frequency inverter. Any attempt to overwrite aprotected file is prompted by an error message.


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Current input Frequency input Master reference voltage

8. Set value assignment

8.1 Set value

Presetting the set value can alternatively be achieved by specifyinga.) a master reference voltage (preset value input, refer to section 10)b.) an impressed current (preset value input, refer to section 10)c.) a frequency (preset value input, refer to section 10)d.) by using the push-buttons (UP and DOWN push-button of the operating interface) ore.) by means of a PC via the RS-232c interface (refer to section 4.1)f.) the dynamics of the set value input: Potentiometer specification -60ms, immediatly 0-10V-20msec.

Corresponding to this specification, jumpers must be set in the apparatus immedeatly behind the terminalstrip of inputs 1 - 2:Jumper settings for the different types of set value specifications

After a RESET, the rotary field frequency memorized as a as fixed preset value is provided during anactivation of the preset value assignment via push-button. The fixed preset value is memorized bysetting the desired rotary field frequency with the help of the UP/DOWN keys and the subsequentacknowledgement by the PRG, SH keys pressed simultaneously.The push-button mode is deactivated by pressing the PRG key for more than 5 seconds and byselecting any other preset value.

The preset value input of the inverter must be wired regardless of which preset valuespecification is selected!If for example, no master voltage and no potentiometer is used, the most easy possibility of wiring is abridge between terminals 2 and 3 (fmin) or a bridge between terminals 1 and 2 (fmax).

8.2 Set value - Hysteresis

Stabilization of the pre-defined rotating field frequency.

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8.3 Set value - Offset

Specification of an offset (e. g. to compensate for parasitic noise).Figures 8.3.1 and 8.3.2 show how the original characteristic is influenced by a positive or negativeoffset. 1 LSB corresponds to an input voltage of approx. 10 mV or an input current of 20 µA!

Figure 8.3.2Preset value offset at apreset assignment of0-10V, 20-0mA

0.6 fmax

2V4mA

+1 LSB

0.2 fmax

0.4 fmax

6V12mA

4V8mA

8V16mA

1 .0 fmax

0.8 fmax

Presetvalue

-1 LSB

Input voltageInput current

10V20mA

0.2 fmax

2V4mA

0.4 fmax

0.6 fmax

4V8mA

6V12mA

8V16mA

10V20mA

-1 LSB

1.0 fmax

0.8 fmax

Presetvalue

+1 LSB

Input voltageInput current

Figure 8.3.1Preset value offset at apreset assignment of0-10V, 0-20mA


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Figure 8.5.1 Rotating field frequency by use of the fade out frequencies

The actual value follows the preset value with the help of the ramp!

Fade out fr. 1

18

10

10

30

17

23 20

Fade out fr. 2

30 20 22

40 42 38

50

37 40

50

43

60

Preset value /Hz

Preset value/Hz 60

8.4 V/f characteristic

A selection can be made between the linear V/f characteristic (with the output voltage proportional to therotating field frequency) and the square characteristic (“fan characteristic" with a squared output voltageincrease in relation to the rotating field frequency). The reference point is the kink frequency.

8.5 Fade out frequency1, fade out frequency2

To suppress resonance effects in drive systems, two frequency ranges can be defined in which nostationary operation will be possible. The definition of a frequency range is made by means ofprogramming a fade-out frequency ±2 Hz. A reference value specification within this range causes anoffset of the actual value (refer to figure 8.5.1) above or below the limit frequencies.

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9. Programming of the digital inputs and outputs

The digital inputs and outputs of the FUTUREDRIVE are programmable. They can be assigned tothe inverter functions mentioned in sections 9.1 and 9.2.A special feature of the digital inputs is the programmability of a multifunctional terminal and fourlogical linking possibilities. Furthermore, the evaluation of the input signals at terminals 5, 6, 7, and 8can be programmed independently of the function parameters (refer to figure 9.1.1) by means of the"terminal assignment" parameter. A definable "reaction time" serves for the suppression of interferingnoise signals or bouncing times of switch contacts.As described in section 7.4, the menu must be displayed for the parameterization of inputs andoutputs.

9.1 Parameterization of the control inputs

The following functions can be applied to terminals 5, 6, 7, and 8. The assignment of severalfunctions to one input is possible (refer to section 9.3).

(1) cw start(2) ccw start(3) parameter set changeover 0(4) parameter set changeover 1(5) f min(6) f fix(7) input reset

The logical linking and inversion of input terminals is defined as follows:

F Kl. 5 ---> non-inverted input (high active)F INV 5 ---> inverted input (low active)F OR 5+6 ---> logical OR non-inverted inputsF INV 5+6 ---> logical OR inverted inputsF AND 5&6 ---> logical AND non-inverted inputsF INV 5&6 ---> logical AND inverted inputs

The following symbols are determined for the terminal assignment:

F ---> level-controlled input (high active)F ---> level-controlled input (low active)F ---> edge-controlled input (positive edge-triggering)F ---> edge-controlled input (negative edge-triggering)


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Figure 9.1.1 Configuration of the control inputs

Latch

Klemmenbel. sel. 5 6 7 8 ->

Latch

Reaktion active: -> 0000ms

Latch

Latch

Latch

Latch

Latch

Latch

start-right sel. -> 8

Kl.8

Kl.6

Kl.7

Kl.5

min-. freq. sel. -> 5

Reset sel. -> inactive

Kl.7

Kl.8

Kl.6

Kl.5 AND

p. fr. sel.0 sel. -> 6

p. fr. sel.1 sel. -> inactive

fix- freq. sel. ->inactive

≥ INV (OR) ≥

OR

INV (AND)

&

&

start-left sel. -> 7

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Annotation: Four parameter sets can be activated by re-programming the inputs and using theparameter set changeover 1 function (Par1).

9.2 Parameterization of the control outputs

Terminals 15 and 16 (the relay output switches together with the open collector output of terminal6). The following functions can be assigned:

(1) multi-function (8) excess temperature 2(2) PTC motor temperature (9) general failure message(3) undervoltage (10) zero monitoring(4) overvoltage 1 U1>340V DC (11) DC braking(5) overvoltage 2 U2>390V DC (12) ready for operation(6) short-circuit (13) I²t error(7) excess temperature 1 (14) digital output (only to terminal 15)

Another possibility is inverting the outputs!

9.3 Explanations to the control inputs and outputs

Minimum rotating field frequencyWith a wired input, the minimum rotating field frequency is kept independently of the set value.

Parameter set switchingThe current parameter set is displayed in the ”operating values” menu. A parameter set wanted bywiring the corresponding inputs is taken over online.

Parameter setchangeover 0

Parameter setchangeover 1

Parameter set 1 active active

Parameter set 2 inactive active

Parameter set 3 active inactive

Parameter set 4 inactive inactive Table 9.3.1


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Clockwise rotation start (cw start)If this function is activated, it will cause the motor to run up to speed at the set running-up time specifiedin the selected parameter set until the set value is reached and in the specified direction. Deactivation at aninactive Start-CCW-function will cause a rund-down at the set ramp of the selected parameter set downto a standstill. If the ramp of the corresponding parameter set is deactivated, the shaft is immediately released.

Ccounter-clockwise rotation start (ccw start)Refer to Clockwise rotation start´ in the opposite sense of rotation. If Clockwise rotation start´ is activatedin addition, this will have precedence ( reversing the procedure).

Fixed frequencyImmediate running-up/running-down to this preset value of the corresponding parameter set, independentof the instantaneously applied set value.

Annotation: The fixed frequency can be activated by re-programming the inputs and using the f-fix- function.

Input resetAn active "input reset" function de-activates all input latches (refer to figure 9.1.1) and therefore allprogrammable functions exclusively linked to edge-controlled inputs.

ResetActivating this input initializes the control and the power circuit of the inverter to make it ready to operatestate. The time of initialling is 1.8 sec.If the input is opened the inverter immediately releases the motor shaft.

PTC inputMotor protection or thermal protection as a switch

Analog outputAnalog signal (0 -10V) corresponding to the current rotating field frequency.at f max <= 127 Hz - - -> 127 Hz = 10 Vat f max <= 250 Hz - - -> 250 Hz = 10 V

Digital output (programmable function, refer to section 9.2)Digital signal corresponding to the current rotary field frequency (0-250Hz).

Programmable digital outputsRefer to section 9.2

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Figure 10.1.1

10. Connection diagram

14 external supply voltage

8 start right (cw) *

max. load 250VAC/7A

7 start left (ccw) *

17 relay output (NO contact)

15 programmable digital output 2

13 analog output

2

4

10kΩ

0V10V

820Ω

30VDC/7A

16 programmable digital output 1

*

M3 ~

braking resistor

L1L2L3

phase

phase

21 V22 W23 braking resistor

25 PE

20 U

24 braking resistor

PE

phaseL1N N

21 braking resistor22 U23 V24 W

braking resistor

M3 ~

Preset value:-potentiometer- 0-10 V- 2-10 V- 0-20 mA- 4-20 mA- 0-100 kHz

analog / digital preset value input

+15V (max 100 mA)3 GND

1 +10V reference voltage

6 parameter set changeover 0 *5 min.rotating field frequency *

9 reset

12 GND

10 reference potential digital inputs11 PTC motor temperature monitoring

19 relay output (NC contact)18 relay output (common contact)

25 PE

Control unit

Power unit

1 phase 3 phase

PEphase

protective conductormains connectionmains connection400V AC

20 braking resistor

protective conductor

factory-settings of the 4programmable inputs

Annotation: The digital inputs (terminals 5, 6, 7, 8, 9) are designed for a control voltage range of 12 Vto 30 V!The open collector outputs ( terminals 15,16 ) can be loaded by 30V/40 mA at max.!


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10.1 Min. terminal assignment

Figur 10.1.1 shows the min. required terminal assignment with the factory setting of the programmabledigital inputs.

1 +10V

3 GND2 preset value

4 +15V

10 GND 9 reset 8 cw start

23 V24 W25 PE

M3 ~

22 U

L1 L1

PE PEN N

M3 ~

20 U21 V22 W

25 PE

1 phase

3 phase

PE PEL1 L1L2 L2L3 L3Control cable

KL.no.

colour of thecable

1 violet

2 black

3 red

4 blue

5 pink

6 gray

7 yellow

8 brown

9 green

10 white

13 gray-pink

14 pink-brown

15 white-yellow

16 white-pink

17 yellow-brown

18 white-blue

19 gray-brown

The sum of the currents from10 V and 15 V must not be higherthan 100 mA.

Mains cable 1-phase

L1 black

N blue

PE green/yellow

Mains cable 3-phase

L1 black (1)

L2 black (2)

L3 black (3)

PE green/yellow

Motor cable

Pin Cable no.

U black (1)

V black (2)

W black (3)

PTC (11) black (5)

PTC (12) black (6)

PE green/yellow

10.2 Pin configuration of IP54 apparatus and cable

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* Casing with terminal compartment, progr. unit cable lockings, integrated set value potentiometer and mains switch

(for direct mounting on machines and on equipment)

bc

a

s

e

11. Dimensions

for 1 phases

for 3 phases

Mounting variant 1-mounting position A

10 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9

11 12 U W V PE BR BR N PE L1

PE L2 L1 L3

f

b

ds

Mounting variant 2-book format

18,5 mm62 mm

69,5

mm

MSF

FUTURE-DRIVE

UP DOWN PRG SH

Dimensions FD 250-750FD 250 KRIP54*- FD 750KR IP54*

FD 1100-FD 2200FD 750/3-FD2200/3

FD 1100 KRIP54- FD 2200KR IP54

a 65 mm 130 mm 65 mm 130 mm

b 220 mm 288 mm 270 mm 340 mm

c 230 mm 300 mm 280 mm 355 mm

d 70 mm 76 mm 90 mm 76 mm

e 112 mm 180 mm 112 mm 180 mm

f 50 mm 50 mm 50 mm 50 mm

s 5 mm 6 mm 5 mm 6 mm

10.3 Pin configuration of IP54 apparatus and plug


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Type FD 1100 FD 1500 FD 2200

Output Motorside

Output power ofapparatus 2,2 kVA 2,7 kVA 3,9 kVA

Max.motor power 1,1 kW 1,5 kW 2,2 kW

Rated output current 5,5 A 7,0 A 10,0 A

Max. Output Voltage 3 x 230 V 3 x 230 V 3 x 230V

Output frequency 0 - 250 Hz 0 - 250 Hz 0 - 250 Hz

Output choke internal internal internal

Inputmains side

Rated voltage 230V ±15% 230V ±15% 230V ±15%

Mains filter internal internal internal

Mains frequency 50Hz, 60Hz 50Hz, 60Hz 50Hz, 60Hz

Fusing (no motorprotection) 10 A T 12 A T 20 A T

General data

Potection class IP 20 / IP 54 IP 20 / IP 54 IP 20 / IP 54

Ambient temperature 0 - 40 ºC 0 - 40 ºC 0 - 40 ºC

Ambient humidity20 - 90%

not dewing20 - 90%

not dewing20 - 90%

not dewing

Power loss approx. 80 W approx. 100 W approx. 130 WPower reduction at 16kHz Installation height above 3000m

1% per 100m

12. Technical Data

Type FD 250 FD 370 FD 550 FD 750

OutputMotor side

Output power ofapparatus 0,6 kVA 0,88 kVA 1,3 kVA 1,6 kVA

Max.motor power 0,25 kW 0,37 kW 0,55 kW 0,75 kW

Rated output current 1,5 A 2,2 A 3,4 A 4,0 A

Max. Output Voltage 3 x 230 V 3 x 230 V 3 x 230 V 3 x 230 V

Output frequency 0 - 250 Hz 0 - 250 Hz 0 - 250 Hz 0 - 250 Hz

Output choke internal internal internal internal

Inputmains side

Rated voltage 230V ±15% 230V ±15% 230V ±15% 230V ±15%

Mains filter internal internal internal internal

Mains frequency 50Hz, 60Hz 50Hz, 60Hz 50Hz, 60Hz 50Hz, 60Hz

Fusing (no motorprotection)

3,15 A T 4 A T 6,3 A T 8 A T

General data

Potection class IP 20 / IP 54 IP 20 / IP 54 IP 20 / IP 54 IP 20 / IP 54

Ambient temperature 0 - 40 ºC 0 - 40 ºC 0 - 40 ºC 0 - 40 ºC

Ambient humidity 20 - 90% not dewing

20 - 90% not dewing

20 - 90% not dewing

20 - 90% not dewing

Power loss approx. 17 W approx. 20 W approx. 35 W approx. 45 W

Power reduction at 16kHz Installation height above 3000m 1% per 100m

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Type FD 750 / 3 FD 1100 / 3 FD 1500 / 3 FD 2200 / 3

Output Motorside

Output power ofapparatus

1,6 kVA 2,0 kVA 2,8 kVA 4,0 kVA

Max.motor power 0,75 kW 1,1 kW 1,5 kW 2,2 kW

Rated output current 2,3 A 3,5 A 4,1 A 5,8 A

Max. Output Voltage 3 x Umains 3 x Umains 3 x Umains 3 x Umains

Output frequency 0 - 250 Hz 0 - 250 Hz 0 - 250 Hz 0 - 250 Hz

Output choke internal internal internal internal

Inputmains side

Rated voltage 400-460V 400-460V 400-460V 400-460V

Mains filter internal internal internal internal

Mains frequency 50Hz, 60Hz 50Hz, 60Hz 50Hz, 60Hz 50Hz, 60Hz

Fusing (no motorprotection)

8 A T 10 A T 12 A T 20 A T

General data

Potection class IP 20 / IP 54 IP 20 / IP 54 IP 20 / IP 54 IP 20 / IP 54

Ambient temperature 0 - 40 ºC 0 - 40 ºC 0 - 40 ºC 0 - 40 ºC

Ambient humidity 20 - 90% not dewing

20 - 90% not dewing

20 - 90% not dewing

20 - 90% not dewing

Power loss approx. 43 W approx. 77 W approx. 95 W approx. 125 W

Power reduction at 16kHz Installation height above 3000m 1% per 100m

Annotation re: Mains filter + FIThe conductance currents conditioned by the mains filter may release the residual current groundingconductor.


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13. Application notes

13.1 Dynamic braking by means of a braking chopper

The built-in braking chopper equipped with an external braking resistor enables dynamic braking of largemasses and does not initiate a switch-off of the converter.

When braking a centrifugal mass at a relatively short running-down time (brake time), the mass inertiaof the entire drive works as a generatoric torque.This braking operating is equivalent to an energy feedback of the drive resulting in a temporary circuitvoltage increase up to the point where the excessive voltage switch-off is initiated.By routing this braking energy into a resistor, the switching off can be prevented.The braking chopper compares the temporary circuit voltage with a reference voltage which has a voltagelevel below the over-voltage tripping level. When the reference voltage is exceeded a power transistorconnects the braking resistor to the temporary circuit voltage. The resistor then converts the powergenerated by the motor into a heat loss.

The braking power can be calculated as a function of the activation time (ED) of the braking resistors.Thus the breaking chopper can be individually adapted to the drive.

Recommendations for the selection of brake resistors:

Table 13.1.1 Specifications of brakingresistors

The resistors used must be suited to the current andthe peak power .The electric strength of the resistors must be1000 V.

The necessary average braking power is calculated fromthe peak power and the operating-time of the chopper.

operating-time ED (s)cycle time (s)

FD Resistor Peak power I max

250 100 Ohm 1 kW 2.5 A

370 100 Ohm 1 kW 2.5 A

550 100 Ohm 1 kW 2.5 A

750 100 Ohm 1 kW 2.5 A

1100 100 Ohm 1.5 kW 3.7 A

1500 100 Ohm 1.5 kW 3.7 A

2200 100 Ohm 1.5 kW 3.7 A Nom. power (W) = X peak power (W)

The practice showed that for most applications, resistors with a nominal continuous power loss of 60Watts are sufficient.

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1

0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4

0,4

1,0

1,4

1,61,8

0,6

0,2

0,8

1,2

2,0

MMN

n2

nnN

1

cannot be achieved due to the current limitation ofconverters with normal dimensioning

n

Bild 13.2.1 Operating characteristics of a frequency-controlled asynchronousmachine

Continuous operation with forced cooling

Continuous operation with self-cooling

Motor breakdown-torque* limits theoverload capacity of the motor at highspeed

13.2 Motor protection

Despite a high-grade sine modulation,additionl losses occur in the motor in powering standard 3-phaseasynchronous motors. Even at nominal revolutions, these losses requiere a power reduction the extenton which essentially depends on the exploitation of the temperature limits of the motor.

For drives of a square counter-torque (e.g.fans) and 50 Hz as maximum rotating field frequency, theimposed power reduction is usually around 0 - 10%.

For drives of a constant counter-torque (compressors, conveyer belts, etc.), the power reduction hasto be selected accordingly larger, depending on the range of the adjustment.

To gurarantee the safe operation of a motor in the adjustment range, the stationary load torque must liebelow the continuous operating characteristic of the motor to guarantee a safe operation of a motor.During operation and starting, the drive, will momentarily be in a position to submit torques correspondingto the current limitation of the converter. The setting of the voltage increase (static Boost) essentiallydetermines the maximum torque below 10 Hz. During a continuous operation, an excessive high boostsetting for the lower rotating field frequency range (up to 15 Hz) can cause the motor to overheat.

A comprehensive thermal protection of the self-cooling motor can be achieved by means of a temperaturesensor (e.g. PTC thermistor or thermal time-delay switch) built into the motor.For revolutions above 120% of the nominal speed , the performance of the motor has to be checked.

Temporary overload capacity at the currentlimit


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50 50

100

100

Warm air outlet

Air stream(Direction of the cooling fins )

FutureDrive

Cold air intake

Mains motor wires

Mains motor wires

Control wires

Control wires

13.3 Switch mounting

Planning notes:

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13.4 Measures to secure the EMC

Grounding, earthing, potential compensationThe correct professional grounding or earthing guarantees the protection of the staff against dangeroustouch voltages (input, output and intermediate circuit voltage). Parasitic currant enductance and low-impedance potential compensation are important measures to reduce electromagnetic influences.

FilteringFilters are inserted into the lead-bound transfer way between the source of interference and theinterference supressor, which is to reduce lead-bound transmissions and to increase the noise immunity.This is why, mains-filter and output chokes have been integrated into the FD 250-2200, and have, infact,reached the EMC conformity. Additional, external filter may have a negative effect on the noise emission.

ScreeningScreening is used for decoupling fields between two spatialy separate areas, i.e. is also used to decreasethe emission of electromagnetic radiation and to increase the noise immunity. The consistent use of metalcases (FD 250-2200) is one of the most important standard measures to safeguard the EMC.

Coupling into motor cablesThe use of twisted core cables can essentially reduce inductive couplings into a circuit. Capacitive,inductive and electromagnetic interferences must be reduced by cable screens. It is important to notethat to reduce low frequency capacitive interference, it is often sufficient to place a one sided sceening,whereas inductive and high frequency electromagnetic interference can only be prevented by screeningboth sides of the cable.The screening must not be used as a protection earthing!!!


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13.5 Warnings

According to the latest state of technology, electronic power controllers are safly operating electricalequipment for use in all motive power engineering equipment.

!! Kindly observe our safety instructions !!

Caution:

Any work at the controllers, such as assembly, connection, maintenance, must only be carried out

F if the electric equipment is voltage-free,F is protected against restarting, andF all drives are at a standstill

Danger:

As long as any electrical equipment and machinery is switched on, the operator may touch voltageleading and non-isolated conductors or rotating parts when he removes the covers and the prescibedprotections, in handling the machine improperly, or during service work or improper use, and may wellcause personal injuries and material damage.

In the field of power electronics, an additional risk is involved in electrical tensions prevailing in amachine even after it has been switched off (capacitor load), a fact of which not every operator isaware. In addition to a decharging interval of approx. 90 seconds, the machine must be checked forresidual voltages prior to starting any work.

Attention:

Any electrical installations and machinery must only be

F moved,F installed,F connected,F operated for the first time,F serviced andF operated

by skilled staff who is fully aware of the respective safety regulations and assambly instuctions.

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Skilled workers are persons that

F are trained and experienced.F master the respective standards, regulations, provisions and accident prevention instructions,

valid at the given timeF have been made familiar with the functions and operating conditions of electric motion

systems.F can recognize and avoid dangers.

For the regulation applicable to skilled workers refer to VDE 0105 or IEC 364.The use

of non-qualified personnel is forbidden.

The controll unit and interlocks as well as the monitoring and protection functions (excess currentand the like) may not be put out of function neither in normal or in test operation.

The equipment may only be assembled and operated in the order documented and must only beused for the intended purpose Any other usage is not admissible!

Storage regulations:

The instructions for the storing of electric equipment must be observed.Kindly request more information if so required and refer to the specifications!

Prevent any noise to avoid personal and property damage.

The person who is responsible for the equipment must take care that that

the safety and operating instructions are avalaible observed,F the operating conditions and specifications refaining to the order are observed,F the protection facilities are used,

The operating instruction contains information for skilled workers which is required for the use ofelectrical equipment in industry. Additional information and instructions for non-qualified personnel,for the use of equipment in non-industrial installations, and about possible drive variants are notcontained in this operating manual.

The manufacturer´s guarantee is only maintained as long as the respective valid operatinginstructions are observed.


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ANNEX A:Interface Protocol

for communication betweenPC and frequency converter

(as of April 27, 1998)

A T T E N T I O N PLEASE!!As the converter is subject to permanent development, the variables and functionality of the address ranges may changein the course of time.************************************************************RS232:9600 BAUD, 8bits, no parity, 1 stop

1.) PC s e n d s p a r a m e t e r t o t h e FU* Each byte emitted by the PC is returned to the PC once for verification (to be able to detect transmission errors).* Composition of the variable’s addresses:Description of the parameter set-dependent variable —> xxxxxxxlDescription of the parameter set-independent variable —> xxxxxxx0No. of the parameter set for p.s.-dependent variables —> xxxxxPPxSignal: PC wants to write —> xxxxlxxxCoding of variables dependent on the parameter set —> VVVVxxxx* Transmission of a complete parameter:Start of transmission: * emit ‘240’

* receive ‘240’ (and verify)Transmit first byte: send address of variable

Receive (and verify) address of variableTransmit second byte: Send first byte of the parameter value

Receive (and verify) first byte of the parameter valueTransmit third byte: Send second byte of the parameter value

Receive (and verify) second byte of the parameter valueTransmit fourth byte: Send third byte of the parameter value

Receive (and verify) third byte of the parameter valueTransmit fifth byte: Send fourth byte of the parameter value

Receive (and verify) fourth byte of the parameter valueEnd of transmission: Send ‘208’

Receive ‘208’ (and verify)Annotation: Number of paramter values 1.4The defined number of the paramter values to be transmitted must be kept at all times!If the received value is <>, start from the beginning or interrupt!

2.) PC receives parameter from the FU* Each byte sent by the PC ist returned by the FU once to be verified by the PC (to be able to detect transmission errors).If the FU emits first, this context is maintained.* Composition of the variable’s addresses:Description of the parameter set - dependent variable —> xxxxxxxlDescription of the parameter set - independent variable —> xxxxxxx0No. of the parameter set for p.s.-dependent variables —> xxxxxPPxSignal: “PC want to read” —> xxxx0xxxCoding of variables dependent on the parameter set —> VVVVxxxx

Technik



* Transmission of a complete parameter:Start of transmission: emit ‘240’

receive ‘240’ (and verify)Transmit first byte: send address of variable

Receive (and verify) address of variableReceive first byte of parameter value

Trasmit second byte: Send first byte of the parameter valueReceive (and verify) first byte of the parameter valueReceive second byte of parameter value

Transmit third byte: Send second byte of the parameter valueReceive (and verify) second byte of the parameter valueReceive third byte of parameter value

Transmit fourth byte: Send third byte of the parameter valueReceive (and verify) third byte of the parameter valueReceive fourth byte of parameter value

Transmit fifth byte: Send fourth byte of the parameter valueReceive (and verify) fourth byte of the parameter value

End of transmission: Send ‘208’Receive ‘208’ (and verify)

Annotation: Number of parameter values 1.4If the received value is <>, start from the beginning or interrupt!

3.) Definition of parameter valuesAll variables depending or not depending on the parameter set are recorded under defined addresses in the FU. Eachvariable has a defined number of values (1.4.) A value generally defines one digit of the respective variable by afigure from 0 to 9. When e.g. a static boost of 13% is transmitted, the two digits 3, and then 1, are transmitted, thelowest value of the digits first).

First exampleThe PC transmits a static boost of 13% in parameter set 3 to the FU. The adress to be actually transmitted iscomposed of the following:

Composition of the variable’s addresses:(Description:Variable depending on the parameter set ->xxxxxxx1Bis already contained in the address of the variable)No. of the parameter set for variables depending on the paramter set ->xxxx10xBSignal ‘PC wants to write -> xxx1xxxBAdr stat boost(=113 decimal) ->01110001B—————The linkage supplies as an address: ->0111 1101BSequence of the transmission from the PC to the FU(01) Emit ‘240’ (start of transmission)(02) Receive ‘240’ from the FU (and verify)(03) Send address (0111 1101B)(04) Receive address (and verify)(05) Send first digit (3)(06) Receive first digit (3) from FU (and verify)(07) Send second digit (1)(08) Receive second digit (1) from FU (and verify)(09) Emit ‘208’ (end of transmission)(10) Receive ‘208’ from FU


Technik


Second exampleThe PC receives from the FU a static boost of 13% in parameter set 3. The adress to be actually transmitted iscomposed of the following:

Composition of the variable addresses:(Description:Variable depending on the parameter set ->xxxxxxx1Bis already contained in the address of the variable)No. of the parameter set for variables depending on the paramter set ->xxxxx10xBSignal ‘PC wants to read -> xxxx0xxxB !!Adr stat boost(=113 decimal) ->01110001B—————The linkage supplies as an address: ->0111 0101B !!

Sequence of the transmission from the FU to the PC(01) Emit ‘240’ (start of transmission)(02) Receive ‘240’ from the FU (and verify)(03) Send address (0111 1101B)(04) Receive address (and verify)(05) Receive first digit (3) from FU(06) Send first digit (3)(07) Receive first digit (3) from FU (and verify)(08) Receive second digit (1) from FU(09) Send second digit (1)(10) Receive second digit (1) from FU (and verify)(11) Emit ‘208’ (end of transmission)(12) Receive ‘208’ from FU

Annotation: Run-up and run-down times must be recalculated prior to the transmission.

Run-up/run-down time 0.0 - 9.9 sec, —> 0.99Run-up/run down time 10 - 210 sec. —> 100.210

If during a transmission, a parameter has been defined to have 3 digits in front, and one digit behind the decimalpoint, the digit behind the decimal point is transmitted first, and then the first and second digits in front of thedecimal point of the parameter. The digit after the decimal point is included in the number of digits.

Annotation:Any parameters written into the FU are saved permanently in the EEPROM with the respective address(‘Adr_EEProm) described by the figure ‘1’. The digit sent back is a ‘2’, and upon receipt of same the figure ‘0’ iswritten into the respective address.

Kindly contact us for the parameter addresses!

Technik



A N N E X B:

List of errors

Whenever an error occurs, it is indicated on the operator interface. If no operator interface is available,the number of the error may be taken from the seven segments display.

Errorno. Error Cause

1 Short circuit Short circuit at the exit or shorted coil

Boost value too high

DC brake set too high

Kink frequency too low

Run-up and run-down times too short

2 Undervoltage Mains voltage too low

3 Overvoltage Run-down to fast

4 Convertertemperature toohigh

Ambient temperature too high

Air circulation too low

5 Temperaturewarning Re. error 4

6 Motortemperature toohigh

Kink frequency too low

Motor speed at a high load moment too low

Boost values too high during extended times of motor operationin a low range of the rotary field frequency range

Tact operation during short run-up times

7 I*I*t error Programmed current integral has exceeded its time

Annotation: When the inverter is at a stop, the seven-segments-display shows the set value. This is not an error (re. chapter 5.1)

Date post:	23-Aug-2019
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Operating Instruction - Conrad Electronic · FD 250 - 2200 FD 750/3 - 2200/3 FD KR IP54 250 - 2200...

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