Active Next Generation Operating Instruction 0.25 kW... 400 kW ANG210 / ANG 410 / ANG510 / ANG610 TABLE OF CONTENTS 1 General information about the documentation ........................................................... 11 1.1 Instruction manuals.................................................................................. 11 1.2 This document .......................................................................................... 13 1.3 Warranty and liability ............................................................................... 13 1.4 Obligation ................................................................................................. 14 1.5 Copyright .................................................................................................. 14 1.6 Storage ...................................................................................................... 14 2 General safety instructions and information on use .................................................... 15 2.1 Terminology .............................................................................................. 15 2.2 Designated use ......................................................................................... 16 2.3 Misuse ....................................................................................................... 16 2.3.1 Explosion protection ..........................................................................................16 2.4 Residual risks ............................................................................................ 16 2.5 Safety and warning signs at frequency inverter ....................................... 16 2.6 Warning information and symbols used in the Operating Instructions .. 17 2.6.1 Hazard classes ...................................................................................................17 2.6.2 Hazard symbols .................................................................................................17 2.6.3 Prohibition signs ................................................................................................17 2.6.4 Personal safety equipment .................................................................................18 2.6.5 Recycling ..........................................................................................................18 2.6.6 Grounding symbol..............................................................................................18 2.6.7 ESD symbol .......................................................................................................18 2.6.8 Information signs ..............................................................................................18 2.7 Directives and guidelines to be adhered to by the operator .................... 19 2.8 Operator's general plant documentation .................................................. 19 2.9 Operator's/operating staff's responsibilities ............................................ 19 2.9.1 Selection and qualification of staff ......................................................................19 2.9.2 General work safety ...........................................................................................19 2.9.3 Ear protectors ...................................................................................................19 2.10 Organizational measures .......................................................................... 20 2.10.1 General .............................................................................................................20 2.10.2 Use in combination with third-party products .......................................................20 2.10.3 Handling and installation ....................................................................................20 2.10.4 Electrical connections .........................................................................................20 2.10.4.1 The five safety rules .......................................................................................... 20 2.10.5 Safe operation ...................................................................................................21 2.10.6 Maintenance and service/troubleshooting ............................................................21 2.10.7 Final decommissioning .......................................................................................22 2.11 Safety Instructions on Function „Safe Torque Off“ (STO) ........................ 23 3 Storage and transport .................................................................................................. 24 3.1 Storage ...................................................................................................... 24 3.2 Special safety instructions on transport of heavy frequency inverters .... 24 3.3 Dimensions/weight .................................................................................. 24 3.4 Transfer to place of installation ................................................................ 25 3.5 Unpacking the device ................................................................................ 25 3.6 Bringing the device into installation position ........................................... 26 07/16 Operating Instructions ANG 3 3.6.1 Sizes 1 through 6 ...............................................................................................26 3.6.2 Sizes 7 and 8 .....................................................................................................26 4 Scope of Supply ............................................................................................................ 27 4.1 ANG 210 (up to 3.0 kW) and 410 (up to 4.0 kW) ..................................... 27 4.2 ANG 210 (4.0 to 9.2 kW) and 410 (5.5 to 15.0 kW) ................................. 28 4.3 ANG 410 (18.5 to 30.0 kW) ....................................................................... 29 4.4 ANG 410 (37.0 to 65.0 kW) ....................................................................... 30 4.5 ANG 410 (75.0 to 132.0 kW)..................................................................... 31 4.6 ANG 410 (160 through 400 kW) ............................................................... 32 5 Technical Data .............................................................................................................. 33 5.1 General technical data .............................................................................. 33 5.2 Technical Data – Control Electronic Equipment ....................................... 35 5.3 ANG 210 (0.25 to 1.1 kW, 230 V) ............................................................. 36 5.4 ANG 210 (1.5 to 3.0 kW, 230 V) ............................................................... 37 5.5 ANG 210 (4.0 to 9.2 kW, 230 V) ............................................................... 38 5.6 ANG 410 (0.25 to 1.5 kW, 400 V) ............................................................. 39 5.7 ANG 410 (1.85 to 4.0 kW, 400 V) ............................................................. 40 5.8 ANG 410 (5.5 to 15.0 kW, 400 V) ............................................................. 41 5.9 ANG 410 (18.5 to 30.0 kW, 400 V) ........................................................... 42 5.10 ANG 410 (37.0 to 65.0 kW, 400 V) ........................................................... 43 5.11 ANG 410 (75.0 to 132.0 kW, 400 V) ......................................................... 44 5.12 ANG 410 (160.0…400.0 kW, 400 V) ......................................................... 45 5.13 ANG 510 (160.0…400.0 kW, 525 V) ......................................................... 46 5.14 ANG 610 (160.0…400.0 kW, 690 V) ......................................................... 47 5.15 Operation diagrams .................................................................................. 48 6 Mechanical Installation ................................................................................................ 49 6.1 Air circulation ............................................................................................ 49 6.2 ANG 210 (up to 3.0 kW) and 410 (up to 4.0 KW) ..................................... 50 6.3 ANG 210 (4.0 to 9.2 kW) and 410 (5.5 to 15.0 kW) ................................. 51 6.4 ANG 410 (18.5 to 30.0 kW) ....................................................................... 52 6.5 ANG 410 (37.0 to 65.0 kW) (air cooled) ................................................... 53 6.6 ANG 410 (75.0 to 132.0 kW)..................................................................... 54 6.7 ANG 410/510/610 (160.0 to 400.0 kW) ................................................... 55 7 Electrical Installation ................................................................................................... 56 7.1 EMC Information ....................................................................................... 57 7.2 Block diagram ........................................................................................... 59 7.3 Optional Components ............................................................................... 60 7.4 Connection of Unit .................................................................................... 61 7.4.1 Dimensioning of conductor cross-section .............................................................61 7.4.1.1 Typical cross-sections ........................................................................................ 61 7.4.2 Mains Connection ..............................................................................................63 7.4.3 Motor Connection ..............................................................................................63 4 Operating Instructions ANG 07/16 7.4.3.1 Length of motor cables, without filter ................................................................. 64 7.4.3.2 Motor cable length, with output filter dU/dt ......................................................... 64 7.4.3.3 Motor cable length, with sinus filter .................................................................... 64 7.4.3.4 Group drive ....................................................................................................... 64 7.4.3.5 Speed sensor connection .................................................................................... 64 7.4.4 Connection of a Brake Resistor ...........................................................................64 7.5 Connection of types .................................................................................. 66 7.5.1 ANG 210 (up to 3.0 kW) and 410 (up to 4.0 kW) .................................................66 7.5.2 ANG 210 (4.0 to 9.2 kW) and 410 (5.5 to 15.0 kW) .............................................68 7.5.3 ANG 410 (18.5 to 30.0 kW) ................................................................................70 7.5.4 ANG 410 (37.0 to 65.0 kW) ................................................................................72 7.5.5 ANG 410 (75.0 to 132.0 kW) ..............................................................................74 7.5.6 ANG 410/510/610 (160.0 to 400.0 kW) ...............................................................76 7.6 Control Terminals ..................................................................................... 78 7.6.1 External DC 24 V power supply ...........................................................................79 7.6.2 Relay Output .....................................................................................................80 7.6.3 Motor Thermo-Contact .......................................................................................81 7.6.4 Control terminals – Connection diagrams of configurations ...................................81 7.7 Configurations overview ........................................................................... 81 7.7.1 Configuration 110 – Sensorless Control ...............................................................82 7.7.2 Configuration 111 – Sensorless Control with Technology Controller .......................82 7.7.3 Configuration 410 – Sensorless Field-Oriented Control .........................................83 7.7.4 Configuration 411 – Sensorless FOC with Technology Controller ...........................83 7.7.5 Configuration 430 – Sensorless FOC, Speed and Torque Controlled ......................84 7.7.6 Configuration 210 – FOC, Speed Controlled .........................................................85 7.7.7 Configuration 211 – FOC with Technology Controller ............................................85 7.7.8 Configuration 230 – Field-Orientated Control, Speed and Torque Controlled .........86 7.7.9 Configuration 510 – FOC of Synchronous Machine, Speed Controlled ...................87 7.7.10 Configuration 511 –FOC of a Synchronous Machine with Technology Controller ....88 7.7.11 Configuration 530 – FOC of a Synchronous Machine, Speed and Torque Controlled 89 7.7.12 Configuration 610 – Sensorless FOC of Synchronous Machine, Speed Controlled ..90 7.7.13 Configuration 611 – Sensorless FOC of a Synchronous Machine with Technology Controller 90 7.7.14 Configuration 630 – Sensorless FOC of a Synchronous Machine, Speed and Torque Controlled 91 7.8 Installation notes according to UL508c .................................................... 91 8 Control Unit KP500 ...................................................................................................... 92 8.1 Menu Structure ......................................................................................... 93 8.2 Main Menu................................................................................................. 93 8.3 Actual Value Menu (VAL) .......................................................................... 94 8.4 Parameter Menu (PARA) ........................................................................... 95 8.5 Copy Menu (CPY) ...................................................................................... 96 8.5.1 Reading the Stored Information ..........................................................................96 8.5.2 Menu Structure ..................................................................................................96 8.5.3 Selecting the Source ..........................................................................................97 8.5.4 Selecting the Destination ....................................................................................97 8.5.5 Copy Operation .................................................................................................98 8.5.6 Error Messages ..................................................................................................98 8.6 Reading Data from Control Unit ............................................................... 99 8.6.1 Activation ........................................................................................................ 100 8.6.2 Data transfer ................................................................................................... 100 8.6.3 Resetting to Normal Operation ......................................................................... 101 8.7 Control Menu (CTRL) .............................................................................. 101 8.8 Controlling the Motor via the Control Unit ............................................. 101 07/16 Operating Instructions ANG 5 9 Commissioning of the Frequency Inverter................................................................. 104 9.1 Switching on Mains Voltage .................................................................... 104 9.2 Setup Using the Control Unit .................................................................. 104 9.2.1 Configuration................................................................................................... 104 9.2.2 Data Set .......................................................................................................... 107 9.2.3 Motor Type ..................................................................................................... 107 9.2.4 Machine Data .................................................................................................. 108 9.2.5 Plausibility check ............................................................................................. 109 9.2.6 Parameter identification ................................................................................... 109 9.2.7 Status messages during commissioning (SS…)................................................... 110 9.2.8 Warnings during commissioning (SA…) ............................................................. 111 9.2.9 Error messages during commissioning (SF…) ..................................................... 112 9.2.10 Application data ............................................................................................... 113 9.2.10.1 Acceleration and deceleration ........................................................................... 113 9.2.10.2 Set points at multi-functional input ................................................................... 113 9.2.11 Quitting commissioning .................................................................................... 114 9.2.12 Selection of an actual value for display.............................................................. 114 9.3 Check direction of rotation ..................................................................... 115 9.4 Speed sensor ........................................................................................... 115 9.4.1 Speed sensor 1 ................................................................................................ 116 9.4.2 Speed sensor 2 ................................................................................................ 116 9.4.3 Speed sensor 3 ................................................................................................ 116 9.5 Set-up via the Communication Interface ............................................... 117 10 Inverter Data ............................................................................................................. 119 10.1 Serial Number ......................................................................................... 119 10.2 Optional Modules .................................................................................... 119 10.3 Inverter Software Version ...................................................................... 119 10.4 Set Password .......................................................................................... 119 10.5 Control Level ........................................................................................... 119 10.6 User Name............................................................................................... 120 10.7 Configuration .......................................................................................... 120 10.8 Language ................................................................................................ 124 10.9 Programming .......................................................................................... 124 11 Machine Data ............................................................................................................. 125 11.1 Rated Motor Parameters ......................................................................... 125 11.2 Further motor parameters ...................................................................... 125 11.2.1 Stator Resistance ............................................................................................. 126 11.2.2 Leakage Coefficient.......................................................................................... 126 11.2.3 Magnetizing Current ......................................................................................... 126 11.2.4 Rated slip correction factor ............................................................................... 127 11.2.5 Voltage constant .............................................................................................. 127 11.2.6 Stator inductance ............................................................................................ 128 11.2.7 Peak current .................................................................................................... 128 11.2.8 Change sense of rotation ................................................................................. 128 11.3 Internal values ........................................................................................ 129 11.4 Speed Sensor 1 ....................................................................................... 129 11.4.1 Operation Mode Speed Sensor 1 ....................................................................... 129 11.4.2 Division marks, speed sensor 1 ......................................................................... 131 11.4.3 Gear factor speed sensor 1............................................................................... 132 11.4.4 Filter time constant speed sensor 1 ................................................................... 132 6 Operating Instructions ANG 07/16 11.5 Sensor evaluation ................................................................................... 133 12 System Data ............................................................................................................... 134 12.1 Actual System Value ............................................................................... 134 12.2 Volume Flow and Pressure ..................................................................... 134 13 Operational Behavior ................................................................................................. 135 13.1 Starting Behavior .................................................................................... 135 13.1.1 Starting Behavior of Sensorless Control System ................................................. 135 13.1.1.1 Starting Current ............................................................................................... 136 13.1.1.2 Frequency Limit ............................................................................................... 137 13.1.1.3 Brake release time ........................................................................................... 137 13.1.2 Flux Formation ................................................................................................ 137 13.2 Stopping Behavior................................................................................... 139 13.2.1 Switch-Off Threshold ....................................................................................... 141 13.2.2 Holding Time ................................................................................................... 141 13.3 Direct current brake ................................................................................ 141 13.4 Auto Start ................................................................................................ 142 13.5 Search Run .............................................................................................. 143 13.6 Positioning .............................................................................................. 144 13.6.1 Reference Positioning....................................................................................... 145 13.6.2 Axle Positioning ............................................................................................... 147 14 Error behaviour and warning behavior ...................................................................... 150 14.1 Overload Ixt ............................................................................................ 150 14.2 Temperature ........................................................................................... 150 14.3 Controller status ..................................................................................... 151 14.4 IDC Compensation Limit ......................................................................... 151 14.5 Frequency Switch-Off Limit .................................................................... 152 14.6 Motor Temperature ................................................................................. 152 14.7 Phase Failure........................................................................................... 153 14.8 Automatic Error Acknowledgment .......................................................... 153 15 Reference Values ....................................................................................................... 154 15.1 Frequency Limits ..................................................................................... 154 15.2 Slip Frequency ........................................................................................ 154 15.3 Percentage Value Limits ......................................................................... 154 15.4 Frequency reference channel .................................................................. 154 15.4.1 Block diagram ................................................................................................. 156 15.5 Reference percentage channel ............................................................... 158 15.5.1 Block diagram ................................................................................................. 159 15.6 Fixed reference values ............................................................................ 161 15.6.1 Fixed Frequencies ............................................................................................ 161 15.6.2 JOG frequency ................................................................................................. 161 15.6.3 Fixed Percentages............................................................................................ 161 15.7 Frequency ramps .................................................................................... 162 15.8 Percentage Value Ramps ........................................................................ 164 15.9 Block Frequencies ................................................................................... 165 15.10 Motor Potentiometer .............................................................................. 165 07/16 Operating Instructions ANG 7 15.10.1 Motorpoti (MP) ................................................................................................ 166 15.10.2 Motorpoti (KP) ................................................................................................. 167 15.10.3 Controlling the Motor via the Control Unit .......................................................... 167 15.11 PWM-/repetition frequency input .......................................................... 168 16 Control Inputs and Outputs ....................................................................................... 170 16.1 Multi-Function Input MFI1 ..................................................................... 170 16.1.1 Analog input MFI1A ......................................................................................... 170 16.1.1.1 Characteristic .................................................................................................. 170 16.1.1.2 Scaling ............................................................................................................ 172 16.1.1.3 Tolerance Band and Hysteresis ......................................................................... 173 16.1.1.4 Filter Time Constant......................................................................................... 174 16.1.1.5 Error and warning behavior .............................................................................. 174 16.2 Multi-Function I/O MF2 .......................................................................... 175 16.2.1 Analog output MF2OA ...................................................................................... 175 16.2.1.1 Output Characteristic ....................................................................................... 176 16.3 Digital Outputs ........................................................................................ 177 16.3.1 Digital Signal ................................................................................................... 180 16.3.2 Setting Frequency ............................................................................................ 180 16.3.3 Reference value reached .................................................................................. 181 16.3.4 Flux Forming finished ....................................................................................... 182 16.3.5 Brake release .................................................................................................. 182 16.3.6 Current Limitation ............................................................................................ 182 16.3.7 External Fan .................................................................................................... 182 16.3.8 Warning Mask ................................................................................................. 182 16.3.9 Application warning mask ................................................................................. 186 16.4 Digital inputs........................................................................................... 187 16.4.1 Start command ................................................................................................ 192 16.4.2 3-wire control .................................................................................................. 192 16.4.3 Error Acknowledgment ..................................................................................... 193 16.4.4 Timer .............................................................................................................. 193 16.4.5 Thermo contact ............................................................................................... 193 16.4.6 n-/M Control Change-Over ............................................................................... 193 16.4.7 Data Set Change-Over ..................................................................................... 193 16.4.8 Fixed Value Change-Over ................................................................................. 194 16.4.9 Motor Potentiometer ........................................................................................ 194 16.4.10 Handshake Traverse Function ........................................................................... 194 16.4.11 User warning ................................................................................................... 194 16.4.12 External error .................................................................................................. 195 16.5 Function Modules .................................................................................... 196 16.5.1 Timer .............................................................................................................. 196 16.5.1.1 Timer – Time Constant..................................................................................... 197 16.5.2 Comparator ..................................................................................................... 199 16.5.3 Function table ................................................................................................. 200 16.5.4 Multiplexer/Demultiplexer ................................................................................. 201 17 V/f-Characteristic ...................................................................................................... 203 17.1 Dynamic Voltage Pre-Control ................................................................. 204 18 Control Functions ....................................................................................................... 205 18.1 Intelligent current limits ........................................................................ 205 18.2 Voltage controller ................................................................................... 206 18.3 Technology Controller ............................................................................. 211 18.4 Functions of Sensorless Control ............................................................. 220 18.4.1 Slip compensation ............................................................................................ 220 18.4.2 Current limit value controller ............................................................................ 221 8 Operating Instructions ANG 07/16 18.5 Functions of Field-Orientated Control .................................................... 221 18.5.1 Current Controller ............................................................................................ 222 18.5.2 Extended Current Controller ............................................................................. 223 18.5.3 Torque Controller ............................................................................................ 223 18.5.3.1 Torque Reference ............................................................................................ 224 18.5.3.2 Upper and lower limit of the frequency in Torque Control ................................... 224 18.5.3.3 Limit Value Sources ......................................................................................... 225 18.5.3.4 Switching over between speed control and torque control .................................. 225 18.5.4 Speed controller .............................................................................................. 225 18.5.4.1 Limitation of Speed Controller .......................................................................... 227 18.5.4.2 Limit Value Sources ......................................................................................... 228 18.5.4.3 Integral time speed synchronization .................................................................. 229 18.5.5 Acceleration Pre-Control ................................................................................... 229 18.5.6 Field Controller ................................................................................................ 230 18.5.6.1 Limitation of field controller .............................................................................. 231 18.5.7 Modulation Controller ....................................................................................... 231 18.5.7.1 Limitation of Modulation Controller ................................................................... 232 19 Special Functions ....................................................................................................... 233 19.1 Pulse Width Modulation .......................................................................... 233 19.2 Fan .......................................................................................................... 233 19.3 Bus controller .......................................................................................... 234 19.4 Brake Chopper and Brake Resistance ..................................................... 235 19.4.1 Dimensioning of Brake Resistor ........................................................................ 236 19.5 Motor Protection ..................................................................................... 237 19.5.1 Motor Protection Switch ................................................................................... 237 19.5.2 Motor Protection by I2t- Monitoring .................................................................. 241 19.6 V-belt Monitoring .................................................................................... 243 19.7 Functions of Field-Orientated Control .................................................... 244 19.7.1 Motor Chopper ................................................................................................ 244 19.7.2 Temperature Adjustment ................................................................................. 245 19.7.3 Speed Sensor Monitoring.................................................................................. 246 19.8 Traverse function .................................................................................... 246 20 Actual Values .............................................................................................................. 249 20.1 Actual Values of the Frequency Inverter ................................................ 249 20.1.1 STO Status ...................................................................................................... 251 20.2 Actual Values of the Machine .................................................................. 251 20.3 Actual value memory .............................................................................. 252 20.4 Actual Values of the System ................................................................... 253 20.4.1 Actual System Value ........................................................................................ 253 20.4.2 Volume Flow and Pressure ............................................................................... 254 21 Error Protocol ............................................................................................................. 255 21.1 Error List ................................................................................................. 255 21.1.1 Error Messages ................................................................................................ 255 21.2 Error Environment .................................................................................. 260 22 Operational and Error Diagnosis ................................................................................ 262 22.1 Status Display ......................................................................................... 262 22.2 Status of Digital Signals .......................................................................... 262 22.3 Controller Status ..................................................................................... 263 22.4 Warning Status and Warning Status Application ................................... 263 07/16 Operating Instructions ANG 9 23 Parameter List ............................................................................................................ 266 23.1 Actual Value Menu (VAL) ........................................................................ 266 23.2 Parameter Menu (PARA) ......................................................................... 269 Index ................................................................................................................................ 278 Functions of the control terminals (table) ....................................................................... 280 10 Operating Instructions ANG 07/16