Operating instructions ANG

284 Pages·2016·9.26 MB·English

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