TCF SeriesInstallation and Operation Manual

Table of Contents1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 .1 PRODUCTSCOVEREDINTHISMANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 .2 PRODUCTCHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 .3 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 .4 RECEIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 .5 SAFETYINFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 .6 CUSTOMERMODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 TCFDIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 TCFMODELDESIGNATIONCODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 TCFSPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 TCFRATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 .1 INSTALLATIONAFTERALONGPERIODOFSTORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 .2 EXPLOSIONPROOFAPPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7 INPUTACPOWERREQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 .1 INPUTVOLTAGERATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 .2 INPUTFUSING&DISCONNECTREQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 .3 INPUTWIRESIZEREQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 .4 INSTALLATIONACCORDINGTOEMCREQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

8 POWERWIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 .1 WIRINGFORSINGLEPHASEORTHREEPHASEINPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

9 TCFPOWERWIRINGDIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1510 CONTROLWIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

10 .1 CONTROLWIRINGVS .POWERWIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1610 .2 TB-2ANDTB-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1610 .3 SURGESUPPRESSIONONRELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1610 .4 START/STOPCONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1610 .5 SPEED/TORQUEREFERENCESIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1710 .6 SPEEDREFERENCESELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1710 .7 ANALOGOUTPUTSIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1910 .8 DRIVESTATUSDIGITALOUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

11 TCFCONTROLWIRINGDIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2011 .1 TCFTERMINALSTRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2011 .2 TWO-WIRESTART/STOPCONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2111 .3 ALTERNATETWO-WIRESTART/STOPCONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2211 .4 THREE-WIRESTART/STOPCONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2311 .5 SPEEDPOTANDPRESETSPEEDCONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2411 .6 BIPOLARSPEEDCONTROL(-10to+10VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

12 INITIALPOWERUPANDMOTORROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2613 PROGRAMMINGTHETCFDRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

13 .1 ELECTRONICPROGRAMMINGMODULE(EPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2913 .2 TCFDRIVEPERSONALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

14 PARAMETERMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3215 DESCRIPTIONOFPARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3616 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5717 TCFDISPLAYMESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

17 .1 SPEED/TORQUEDISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5917 .2 CHANGINGTHESPEEDREFERENCESOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6017 .3 STATUSANDWARNINGMESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

A APPENDIX-VECTORMODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62B APPENDIX-INPUTASSERTIONLEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

TCF Sub-Micro DriveINPUTPOWERTERMINALS

OUTPUT(MOTOR)

TERMINALS

CONTROLTERMINAL

STRIP

3-DIGITLEDDISPLAY

ELECTRONICPROGRAMMINGMODULE(EPM)

PROGRAMMINGBUTTONS

DCBUSTERMINALS

Safety InformationAllsafetyinformationgivenintheseOperatingInstructionhavethesamelayout:

Signal Word!(Characterizestheseverityofthedanger)Note(describesthedangerandinformsonhowtoproceed)

Icon Signal WordsWarningofhazardouselectricalvoltage

DANGER! Warnsofimpending danger .Consequencesifdisregarded:Deathorsevereinjuries .

Warningofageneraldanger

WARNING! Warnsofpotential, very hazardous situations .Consequencesifdisregarded:Deathorsevereinjuries .

Warningofdamagetoequipment

STOP! Warnsofpotential damage to material and equipment .Consequencesifdisregarded:Damagetothecontroller/driveoritsenvironment .

Information Note Designatesageneral,usefulnote .Ifyouobserveit,handlingthecontroller/drivesystemismadeeasier .

1 GENERAL

1 .1 PRODUCTSCOVEREDINTHISMANUALThismanualcoverstheLenzeACTechTCFSeriesVariableFrequencyDrive .

1 .2 PRODUCTCHANGESLenzeACTechCorporationreservestherighttodiscontinueormakemodificationstothedesignofitsproductswithoutpriornotice,andholdsnoobligationtomakemodificationstoproductssoldpreviously .LenzeACTechalsoholdsnoliabilityforlossesofanykindwhichmayresultfromthisaction .Instructionmanualswiththemostup-to-dateinformationareavailablefordownloadfromtheLenzeACTechwebsite(www .lenzeamericas .com) .1 .3 WARRANTYLenzeACTechCorporationwarrantstheTCFSeriesACmotorcontroltobefreeofdefectsinmaterialandworkmanshipforaperiodof24monthsfromthedateofshipmentfromLenzeACTech'sfactory .IfaTCFmotorcontrol,undernormaluse,becomesdefectivewithinthestatedwarrantytimeperiod,contactLenzeACTech'sServiceDepartmentforinstructionsonobtainingawarranty replacementunit .LenzeACTechreserves theright tomake thefinal determination as to the validity of awarranty claim, and sole obligation is to repairorreplaceonlycomponentswhichhavebeenrendereddefectiveduetofaultymaterialorworkmanship .Nowarrantyclaimwillbeacceptedforcomponentswhichhavebeendamagedduetomishandling,improperinstallation,unauthorizedrepairand/oralterationoftheproduct,operationinexcessofdesignspecificationsorothermisuse,orimpropermaintenance .LenzeACTechmakesnowarrantythatitsproductsarecompatiblewithanyotherequipment,ortoanyspecificapplication,towhichtheymaybeappliedandshallnotbeheldliableforanyotherconsequentialdamageorinjuryarisingfromtheuseofitsproducts .Thiswarrantyisinlieuofallotherwarranties,expressedorimplied .Nootherperson,firmorcorporationisauthorizedtoassume,forLenzeACTech,anyotherliabilityinconnectionwiththedemonstrationorsaleofitsproducts .

1 .4 RECEIVINGInspectallcartonsfordamagewhichmayhaveoccurredduringshipping .Carefullyunpackequipmentandinspectthoroughlyfordamageorshortage .Reportanydamagetocarrierand/orshortagestosupplier .Allmajorcomponentsandconnectionsshouldbeexaminedfordamageandtightness,withspecialattentiongiventoPCboards,plugs,knobsandswitches .

1 .5 SAFETYINFORMATIONGENERALSomepartsofLenzeACTechcontrollerscanbeelectricallyliveandsomesurfacescanbehot .Non-authorizedremovaloftherequiredcover,inappropriateuse,andincorrectinstallationoroperationcreatestheriskofsevereinjurytopersonnelordamagetoequipment .Alloperationsconcerningtransport,installation,andcommissioningaswellasmaintenancemust be carried out by qualified, skilled personnelwhoare familiarwith the installation,assembly,commissioning,andoperationofvariablefrequencydrivesandtheapplicationforwhichitisbeingused .

1

INSTALLATIONEnsureproperhandlingandavoidexcessivemechanicalstress .Donotbendanycomponentsand do not change any insulation distances during transport, handling, installation ormaintenance .Do not touch any electronic components or contacts . This drive containselectrostatically sensitive components,which can easily be damaged by inappropriatehandling .Staticcontrolprecautionsmustbeadheredtoduringinstallation,testing,servicingandrepairingofthisdriveandassociatedoptions .Componentdamagemayresultifproperproceduresarenotfollowed .ThisdrivehasbeentestedbyUnderwritersLaboratory(UL)andisanapprovedcomponentincompliancewithUL508SafetyStandard .

Warnings!

SuitableforuseonacircuitasdescribedinSection7 .0ofthismanual .Useminimum75Ccopperwireonly .Shallbeinstalledinapollutiondegree2macro-environment .

Thisdrivemustbeinstalledandconfiguredinaccordancewithbothnationalandinternationalstandards .LocalcodesandregulationstakeprecedenceoverrecommendationsprovidedinthisandotherLenzeACTechdocumentation .TheTCFdriveisconsideredacomponentforintegrationintoamachineorprocess .Itisneitheramachinenoradevice ready foruse inaccordancewithEuropeandirectives (referencemachinerydirectiveandelectromagneticcompatibilitydirective) .Itistheresponsibilityoftheendusertoensurethatthemachinemeetstheapplicablestandards .ELECTRICALCONNECTIONWhenworkingonlivedrivecontrollers,applicablenationalsafetyregulationsmustbeobserved .Theelectricalinstallationmustbecarriedoutaccordingtotheappropriateregulations(e .g .cablecross-sections,fuses,protectiveearth[PE]connection) .Whilethisdocumentdoesmakerecommendationsinregardstotheseitems,nationalandlocalcodesmustbeadheredto .ThedocumentationcontainsinformationaboutinstallationincompliancewithEMC(shielding,grounding,filtersandcables) .ThesenotesmustalsobeobservedforCE-markedcontrollers .ThemanufacturerofthesystemormachineisresponsibleforcompliancewiththerequiredlimitvaluesdemandedbyEMClegislation .APPLICATIONThedrivemustnotbeusedasasafetydeviceformachineswherethereisariskofpersonalinjuryormaterialdamage .EmergencyStops,over-speedprotection,accelerationanddecelerationlimits,etcmustbemadebyotherdevicestoensureoperationunderallconditions .Thedrive does featuremanyprotectiondeviceswhichare aimedat protecting thedriveandthedrivenequipmentbygeneratingafaultandshuttingthedriveandmotordownbyremovingpower .Mainspowervariancescanalsoresultinshutdownofthedrive .Whenthefaultconditiondisappearsoriscleared,thedrivecanbeconfiguredtoautomaticallyrestart,it is theresponsibilityof theuserand/orOEMand/or integrator toensurethat thedrive isconfiguredforsafeoperation .

1 .6 CUSTOMERMODIFICATIONLenzeACTech,itssalesrepresentativesanddistributors,welcometheopportunitytoassistourcustomersinapplyingourproducts .Manycustomizingoptionsareavailabletoaidinthisfunction .LenzeACTechcannotassumeresponsibilityforanymodificationsnotauthorizedbyitsengineeringdepartment .

2

2 TCF DIMENSIONS

MountingTabDetail

IfR