USER'S GUIDE for the CD75- 750 VARIABLE SPEED | DRIVES for STANDARD | AC INDUCTION MOTORS "~0,75KW to 7.5kW |Safety at Work The voltages present in standard drive modul and may be lethal drive and the way in which itis operated and maint spable of inlcting a severe electric shock, Itis the responsibilty of the ownef or user to ensure that the instalation of the ined compli with the requirements of the Health & Safety at Work Act in the United Kingdom and applicable lagislation and regulations and codes of practice in the UK or elsewher Only qualified personne! should install this equipme| information in this Guice, The oub! should be referred to the supplier of the equipm Operational Safety Warning The drive software incorporates optional auto-start an take all necessary precautions, # operating the drive , after first reading and understanding the installation instructiqns should be adhered to. Any question or restart features. Users and operators must this mode, to prevent damage to equipment and especially to prover: the risk of injury to personnel working on or near the motor and the driven sqvipment. The drive stop and start inputs should not be relied ta safety hazard could arise from the unexpect ‘mechanism should be provided to prevent the motor ft The manufacturer accepts no lability for any conse: + incorrect installation or adjustment of the optional trom mismatching ofthe drive to the motor, ‘Tho contents of this Gude are believed to be corre ‘commitment to a policy of continuous development ‘he right to change the specification of the product ot Guide without notice. Al rights reserved. No part of this book may be repr ‘means, electronic or mechanical including photoco pvt oF retrieval systom without permission from the publi Copyright © 1998 Control Te Part No. 0412-0008 (CD75.750 Issue 3 September 1898 ‘SOFTWARE VERSION alone to ensure the safety of personnel starting of the drive, a further interlock ‘unning except when its sate to do so. Nees resulting from inappropriate, negligent ‘Operating parameters of the equipment, or atthe time of printing. In the interests of a id improvement, the manufacturer reserves Is performance or the contents of the User's Jucad or transmitted in any form or by any 19, Tacording, or by any information storage in wen. niques Drives LidUSER'S GUIDE for the CD75-750 Variable Speed Drives for STANDARD AC INDUCTION MOTORS 0175 to 7.5kWBisa ioes ate ema | contTROLFECHMIO WorLpwine CONTROL TECHNIQUES DRIVES LTD 79 MOCHDRE INDUSTRIAL ESTATE NEWTOWN, POWYS SY16 4LE DECLARATION OF CONFORMITY Dinverter | Power range 0.37kW Commander CD2 Power range 0.75kW-7.5kW. Commander CD Power range 11kW-75kW Commander CDV Power range 11kW-90kW Commander CDEPower range [TKW-90kW | Vector Power range 1kW-75W The above listed A variable speed drive ploducts, have been designed and manufactured in accordance with the following European harmonised, national and international standards: EN60249 Base materials for printed circults 1EC326-1 Printed boards: General information for the specification writer 1EC326-5 Printed boards: Specification for single and double sided printed boards with plated through holes 1EC326-6 Printed boards: Specification for multilayer printed boards 1EC664-1 Insulation eo-ordination for equipment within low-voltage systems: Principles, requirements and tests | EN60529 Degrees of protection provided by enclosures (IP code) UL9a Flanmability rating of plastic materials ULSO8 Staxdard for Industrial Control Equipment These products comply with the Low Voltage Directive 73/23/EEC and the CE Marking Directive 9B/68/EEC W. Drury Newtown Technical Director Date: 26th September 1996 Nowe ‘This electronic drive product is intended to be ised with an appropriate motor, controller, electrical protection components and other equipment to fijrm a complete end product or system. It must only be installed by a professional assembler who is fanfiliar with requirements for safety and electromagnetic compatibility ("EMC"). The assembler is responsible for ensuring that the end product or system ‘complies with all the relevant laws in the country where itis to be used. Refer to the product manual or EMC data sheet for further information on EMC standards complied with by the product, and uidelines for installation, kK WWong Revd 16/9°96 Issue AAddendum 6 Part No. of addendum: 0512-0000 Issue code: C2NU2 Issue No: 2 Date of issue: February 1995, Software version: v3-3-x Eemc Connections Power supply requirements ‘An additional transient voltage suppressor {variston is fitted between power terminals Eerc and PE as shown in Figure 1. The varistor connection permits the use of power supply configurations where the maximum line-to-ground (earth) voltage exceeds 320Vac. For example, this is possibie in a 480V {grounded-detta supply (Figure 2) where one phase is grounded, and the line-to-ground voltage is equal to the line voltage. The maximum line-to-grdund voltage must net exceed 528VAc (480V +10%). the line-to-ground voltage is less than 320VAc for example in a grounded star (Y) configuration (Figure 3), the varistor between Eare and RE may be removed and replaced by a jumper. This brings into circuit the integral RFI fiter. It is recommended that the filter is used in most applications because it provides an effective reduction in RFI emigsions into the Ac power supply. Figure 1 Power terminals with vatistor connected between Eeuc and PE Mo <828VAC Figure 2 Drive connected to a grounded-delta AC supply na oer smFigure 3 _ Drive connected to a groundet The following guidelines must be observed ‘The PE connection must always be connectet ‘The Ese Connection must be connected to Pl d-star AC supply 1d 10 ground (power earth) E only when it is known that the line-to-ground voltage is. less than 320VAc (in a grounded-star configuration, for example) if there is any doubt over the type of ac supply configuration, do not remove the varistor. The drive is protected from line-to-ground voltage transiet I an application requires the integral RFI fit ‘grounded-star, an :solation transformer with The alternative to using an isolation transforr} RFI filter rated for the line and line-to-ground| Motor thermistor protecti ‘The drive has been supplied with link PLS in a nrigre Te, page #0), Aaja nk oy of the drive nts by this component. to be used, and the power supply configuration is not ‘grounded-star secondary is required. er for grounded-delta Ac supplies is to use an external lvottages. ion isabled position (not in the enabled position as shown n'a motor thermistor is connected to control terminal 9 Since short-circuit thermistor protection is now disabled, the drive will not trip if a short-circuit appears etween OV and control terminal 9. Auto reset There is no auto reset when an Et fault trip occ#rs. Serial communications Hroadcast When a number of drives are linked to a serial broadcast facility allows all drives to respond to| mmunications network, the serial communications ne command simultaneously. This parameter operates regardless of the comipunication address set in parameter Pr9 of the drive. To invoke the broadcast mode, specify address} Note ‘Since user address 0 is used to invoke broadca| the controlling station. The use of address 0 st t mode, a drive having Pr 9 = 0 will not transmit data to Juld be reserved for broadcast mode only.New parameters ‘The following new parameters reside in the Pr d menu, b21, b23 — Preset ramp selector Using a combination of settings for bit parameters b21 and b23, the following can be achieved ‘The drive can use its own preset speed acceleration and deceleration ramps. Terminals A10, A11 and A12 can be configured as ramp select inputs. ° Default settings: b21 = 0, b2: Presel speeds use the acceleration and deceleration ramps of Pr 2 and Pr 3. b2t=1 b23=0 Preset speeds use their own acceleration and deceleration ramps. Pr 20 preset uses acceleration ramp Pr30 and deceleration ramp Pré0. Pr21 preset uses acceleration ramp Pr31 and deceleration ramp Prd ete. Terminals A10, 11 and A12 can be configured as digital inputs to select pre-programmed ramp times. ‘The following table shows the terminals that correspond with the parameters. b20=0 3 preset speeds and jog an] _Aw Ramps. ° | 0 P23 Enon aE Parad ° Paupar zB alain Paap Note Jog input A12! operates as normal ds at an a10 Ramps ° ° ° Praprs | o = 1 Pro0Pr a) eo | 4 ° Pr Strat ot, 4 1 Prazir a2 1 | ° ravers | 1 ° 1 erawpres 1 1 ° PSST a5 1 ee Prowpras | Note When a combination of terminals are grounded, the associated ramp time become active Immediately, even wnile 2 ramp is in progress. These ramps will also apply to all analogue inputs and serial communications. 3 A asc ANG ha eabaa) : Piece! speeds ute thei own ramp times (same as b21 = 1, b23 = 0) b24 — Load output Default setting 24 = 0 b24=0 Terminal 18 is a standard load output 24 1 Terminal 19 becomes 2 digital output in the form of a load-reached output, where the output changes state trom OV to +10V. when the drive load is equal to or greater than the value set in Pro. b25 Default setting’ p25 = 0 This parameter is currently not used b26 — Mains ride-through and phase-loss disable Default setting: b26 = 0 b26= 0 [ACUU mains nde-thrsugh and phase-loss capability work as normal b26=4 ACUU mains ride-through and phase-loss capability are disabled. The dynamic braking voltage is now set to a fixed value of 735VDC. b27 - Normal-running ramp selector 627 selects the braking mode ramp during normal running when the input speed reference is reduced. Default setting: b27 = 0 bar =0 Uses the standard ramp braking mode when the input speed reference is reduced when either coast-to- halt or DC injection braking are selected. ba7=4 Uses the high-(evel ramp braking mode when the input speed reference is reduced for all stopping modes, Related parameters: b2, b7, Pr 8 ear Ramp mode soncard ‘Standard “wanders high eve gneve Tigh eve gh eve igh levelb28 - PI control selector 28 is used to select PI contro! when the feedback from a transducer, etc, is used to control the speed of the motor. Default setting: 928 = 0 b2s=0 Pl mode disabled bas =4 P| mode enabled Serial mnemonic: Pl Related parameters: Pr 20, Pr 21, bt1 When PI mode \s enabled, Pr 20 and Pr 21 are used as the P and | gain parameters instead of preset speeds. Pr20 — Proportional gain factor P 120 = P gain (Kp) Default setting: 0 Range: 0 to 24.0 ‘The Proportional gain factor Kp is a multiplication factor applied to the speed error signal in order to produce the correction term Kp factor (Pr 20/Pr 1) x 75] x error (H2)} in Hz Increasing the value of Kp increases the system damping and the transient speed response. If the value is made too high for a given load, the system will become unstable, The optimum setting is the highest value possible before instability starts to occur. Optimum performance is achieved by setting the best combination of P and | gains, Pr21 — Integral gain factor Prat gain (Kk) Default setting: ( Range: 0 to 25.5 The Integral gain factor Kp is a multiplication factor applied to the speed error signal in order to produce the correction term Ki factor = {{(Pr21/Prt) x 2.25] x error (Hz)} in Hz/second. The Ki term ensures zero speed error during steady-state load conditions. Increasing the value increases the rate of recovery after a disturbance. if the value of Ki is made too high, speed tends to oscillate instead of settling quickly. The optimum setting is the highest value before oscillation starts to ‘occur. Optimum performance is achieved by setting the best combination of P and gains. Transducer feedback ‘The feedback from the transducer is applied to the remote-speed current input, terminal 8, The form of the input can be configured by bitPI control using serial communications to enable PI control using serial communications for drive 15 for example, send the following message GONTROL [ADORESS [conTRoL _[MNEM [DATA [CONTROL _/8CC cor vss | sx pr | so | Ex (smo | Ley cure 4 BCC eaiulated [ ‘To disable PI control using serial communications for drive 15 for example, send the following message TonTROL | ADDRESS | conTROL | MNEM| DATA CONTROL | BCC e0T 1155; Tx er | 700) em 3 (cr-D) [ots cue Reading data using serial communications To read the status of tne Pl control parameter using serial communications, send the following message. ‘CONTROL ‘ADDRESS: i MNEM ‘CONTROL eoT T 1155 Pr ENG. co) l (one) When Pi control is enabled, the drive will respond as follows: CONTROL TNE pata [commmor | 606 srk D — ex cue | gre | [ BCC calculated When PI control is disabled, the drive will respond as follows: CONTROL vem [pata | contr | 8ce ‘STX | Pr 00 | em $ one [cue [ [ 36 casedPl control ‘To select the Pl control software, set b28 at 1. Also connect terminal 16 to OV to select remote control ‘The Pl software can be used to regulate the speed of a motor in applications where a constant pressure or air flow, etc, needs to be maintained Set the drive frequency by applying a Local speed input signal to terminal 5. ‘Apply the feedback from the transducer to the remote speed input, terminal 8, The transducer output ‘must be in one of the following current-loop formats: 440 20mA, 20 to 4ma Oto 20m Set b11 for the appropriate format (A voltage signe! from a transducer must be converted and scaled into the appropriate current-loop signal ) Setting up PI control ‘To achieve optimum performance from the PI contol, the following set up procedure should be followed + Connect an uscilloscope to the feedback input, terminal 8 2 Set the drive frequency at a value which gives the nominal pressure or air flow etc, from the system 3. Increase the value of Pr20. At the same time, monitor the trace on the oscilloscope. When the trace becomes unstable, decrease the value of Pr 20 slightly, 4 Increase the value of Pr21. At the same time, monitor the trace on the oscilloscope. When the trace becomes unstable, decrease the value of Pr 20 slightly 5 Stop the drive. Monitor the trace on the oscilloscope and re-start the drive. When optimum performance is achieved, the trace should be as shown in Figure 4 6 Achieve optimum performance by setting the best combination of P and I gains. Figure 4 Ideal response curve under PI controlb55 — AC power loss ramps 1356 can be used to select the acceleration and deceleration ramps which are followed by the drive during ‘oss and restoration of Ac power Default setting: b55 = 0 85 = nen ac power is ost, the ramp times are controlled by Pr2 and Prd or, if selected, the required preset acceleration or deceleration rates. bss Wen ac power s 1st, the deceleration ramp is controlled by Pr46, When Ac power is restored, the acceleration ramp is controlled by Pr36, b56 — Ramp selector for non-important trips 556 is used to Ramp to halt when a non-important trip occurs, Default setting: D56 = 0 bs6 = 0 Non-important tips are treated 8s normal trips. ps6 1 Ramp to halt for non important trips. The non-important trips are as follows Et eL On th “These trips cause the drive to ramp to @ halt with a deceleration rate that is determined by the drive setup When the drive is operated under terminal control, the display shows a steady (not flashing) tip code wii the drive reacties OHz. The IGBT output stage is disabled and the display flashes the tnp code, san a “he status relay immediately de-energises when the drive receives the trip and starts to arp 10 ae The tip can be feset at any time. If it occurs during the ramp stage, the drive will ramp back t0 the set frequency When the drive is uperated under keypad control, the display indicates the trip condition during he am1P age by allerating between the set speed value and the rip code. Ifthe trip is reset, he dive will not soe ey to the set speed. It will continue to ramp down to OH2.. The cisplay will show rd¥ alternating with the set speed value.Serial control of new parameters Serial contro! of new bit parameters b23 to b27, b5S and bS6 is possible. The bits are resident in the C1 Configuration word. The order of the bits is as follows: Sedcharacter__ | ___ Default ba 2 ba ° bas 2 7 B25 L ° ‘ath character Defaut Bs o ba 0 bss onemEee | 26 2 Control Keypad The removable control keypad can now be unclipped from the front ofthe drive, allowing access to the jumpers. Drives from serial number 370000 have this addition, Enhanced frequency resolution using high resolution ASIC ‘The CD drive allows the motor speed to be controlled using either an analog reference, the keypad or the serial conununications link (SP command). This gives the following drive frequency resolutions: ‘Output frequency ] Resolution ULF, He He He rd on 120 O10 241 oz 20 O10 Oa 80 010 96 08, 60 Drives fitted with the new high resolution ASIC (from serial number 355000). allow the output frequency to be set to a higher resolution using the serial communications link. The new command to allow the control is HR and permits 0.001Hz frequency resolution, The resolution depends on the set value of ULF. ‘Output reaueney Resolution ULF He He He O12 0.008 120 O10 240 ‘008 20 010.48 0.002 0 rr 0.004 360 ‘The HR command appears between RC and TO in the mnemonic sequence. The serial protocol for HR increases the rumberiof data characters to eight. All other commands used in the drive remain at six characters, we " 7The following are the protocol formats for the new command, Sending da ta Send the following string, ZonTROL | ADDRESS | CONTROL [wnEW] DATA | conTROL | Ecc cn _| one cure 30 cae Reading data Send the following string CONTROL ADDRESS mew |__e0NTROL EoT rr HR leerenc eno out Response string ‘CONTROL | MNEM DATA CONTROL Bcc, xR “per 001 em 3 one coe [ BGG coated Long-cable driving capability For cable sizes refer to Fuse and Cable Data on page 4-6 of the User Guide Dive Water abe ~ ‘Standard 4 core ‘Armoured Maxima tng rete) axirur ent metres) cocov | winoutchoke | with choke | Without choke | _ with choke 75 & 110 = 70 io A 170 © io | 150 125 220 110 180 0. 180 310 160 0 <0 ao 0 130 zo Die cate i ‘Armoured Maxima egy etre) asimurtength retres) witout ene cocov | Cablesize ‘Cable size, Cable size Zen 28mm oem ‘aawe ‘anne feawe = 250 15 720 760 155 16 ze ome Motor able Siandard 4 core "mowed Maximum length et Maximum ong (et) cocov | Without choke ‘With choke ‘Without choke ‘with choke 7 15 0 15 0 710 260 555 195, 360 70 10 7 20 500 ze a0 75 Es eo [eeetaca] 7018 1310 500, L772 10Drive | ‘Motor cable Standard 4 core ‘armoured Aaximurn length eet) ‘Maximum length (fet) L without choke without choke corcov Cabiesize | Cablesize | Cablesue | Cablesize 25 0m ‘0mm 25mm ‘40mm Ee 7s | 880 750 505 7 5] 720 Important Notes Cable lengths are based on a drive overload (torque) capability of 125% for CD and 120% for CDV. Cable lengths given in the tables are typical. Operating beyond these lengths may cause the drive to trip on overcurrent (Ol), or fold-back in frequency, ‘Motor line-chokes will allow longer cables to be driven by CD75-400. Use 2mH per phase, connected at the drive end, Select the lowest PWM switching frequency to minimise heat dissipation in the choke and reduce radio frequency emissions. ‘The effect of cable voltage-drop becomes increasingly significant for drives above CD40. The use of ‘chokes is not normally necessary Use a drive of higher rating if longer cables or a greater overload capability is needed. Driving very long cables (as a guide: greater than 200 metres armoured, greater than 360 metres standard 4 core) and tusing motor line chokes may cause the DC bus voltage to increase slightly at low output frequencies. ‘This may be overcome by connecting a small capacitor between DC-VE and drive power earth, Consult the supplier of the drive for guidance. 1CD75-750 CONTENTS Features of CD75-750 Drives 1 Theory of Inverter Drives 2 Specification & Data Currant & Volage Ratings Specifications Encoder Specification Electromagnetic Compatibility Drive Module Weights 3. Installation —- Mechanical Drive Mourting — General Requirements Front- and Through-Panel Mounting, Control Pos Mounting Cooling & Ventilation 4 Installation — Electrical Installation Safety Power Connections. Control Connections Other Contiguration Detaits Connecting Serial Communications 5 Operating Procedures Safety Setting Up to Run Keypad & Display Modes of Operation 6 Drive Configuration Parameters Parameters & their Functions Operating Parameters Bit Parameters Parameter Quick Reference & Setting Record 7 Diagnostics & Fautt Finding Fault Finding 72 Control Pod Trip Codes 73 Healthy Indications 14 8 Serial Communications at Introduction rey Fundamentals 23 ‘Components of Messages. 86 Structure of Messages a6 Configuring the Drive through Serial Communications. 810 9 Braking Unt (Optional) ot Introduction 33 Principles of Operation 93 Braking Usit Spactication a4 Extemal Braking Resistor Sizing 26 Electrical installation 98 ‘Mechanical installation att Operating Procedures 941 Diagnostics — Problem Solving 942 10 Electromagnetic Compatibility (EMC) 104 Introduction 103 Immunity . 103 The Nature of Drive Emissions 103 Immunity of Senstve Circuits 105 Precautions lor Drive Installations 106 ‘Additional Precautions of Sensitive Circuts 106 Optional RFI Fiter 10-10 Installing the Optional RFI Fier 10-10 Earth Leakage Current to Control Techniques Worldwide MWpasa avin Se i a CD75-750 ILLUSTRATIONS Page 1 Locations of principal components o2 2 Schematic block diagram of the power system 03 3 deal voltagortrequency ratio 13 ‘4 Typical luvfrequency relationship 13 5 Volage boost to increase low-speed torque 13 6 Locations of principal components 32 7 Overall and mounting dimensions. ae 8 Procedure for removing the rear case 36 8 Procedure for removing the control pod 36 10 Dimensions for remote mounting of the control pod 37 11. Minimum clearances for ventilation ofthe drive 38 12 Typical enclosure, cooling surfaces 39 43 Locations of principal components 44 14 Power terminals, standard connections 45 15 Control terminals and typical external circuits 48 416 Locations of components on pb INSO 410 17 Mutidrop links, FS485, and typical serial addresses 412 18 Serial ink connections, RS485 and RS422 412 19 Serial link connections, RS232 412 20 Power terminals, standard connections 53 21. Minimum external control connections 54 22 Control Pod 56 23 Display features 58 24 Structure of Prd menus, and access procedure 5:10 25 Roceleration time Pr2 6s 28 Deceleration time Pr3 6s 27 Overcurrent protection 67 28 xt characteristics, selected by Pr5 67 29 Voltage (torque) boost Pré 68 30 Slip compensation PrT 69 31 Injection braking Pre 6-10 32 VA profile and Pre 612 33 Skip frequency control, Pri0 - 15 613 34 Application of presat speeds, Pr20 - 26, Pr30 - 36, Pr40 - 46, 615 35 Fixed and dynamic Vf, 54 6-26 36 Multidrop links, RS485, and typical serial addresses, a2 37 Serial link connections, RS485 and RS422 a2 38 Serial ink connections, RS232 82 38 Optional braking unit, dimensions 97 40° Braking system, schematic diagram 98 ‘41 Braking system, connection for internal resistor a9 42._Braking system, connection for external resistor 9-10 43. RF currant paths, no special precautions 10-4 44 Wiring and layout, non-sensitive systems 107 45. Wiring and layout, sensitive systems 107 46 Current paths with supply fiter and screened motor cable 109 47 Procedute for installing the RFI fier internally 10-12, -13, 14 Logie Diagrams 5.41 Speed referonce 514 542 Torque reference 515 S43 Reversing 518, 5.44 ' Starting S16 545 Stopping 516 548 Reset 517 say Trip 518 54.8 Speed loop 519 5.49 Acceleration 5-20 5.410 Deceleration 5-20 5.411 Voltage loop 821 5.A12 DC link voltage contro! 822 5.413 Digital outputs 522 5.4.14 Serial Communications 522on pigseant i i tem sense aii sc vow open wnedlataaalaaaiaas CD75-750 Features of CD75-750 onCD75-750 FEATURES of the CD75-750 Drives 1. Locations of principal components,| CD75-750 + Full digtal control. + Complete digital adjustment of drive parameters. + 150% (industrial) and 120% (HVAC) trating torque. + Insulated gate bipolar transistor (IGBT) output * OC injection braking bridge for high speed switching and low power Removable control pod for addtional secur consumption. + Fully-isolated RS485 serial communications + Motor speed digtally-contralled from OH to 960Hz intertace. * Choice of up to four switching frequencies in the + ltegral RFfiter as standard range 24H to 11.7KH2. + Supply-phase. loss protection and mains + Fixed and atematively variable VA characteristic. siscontnuty ride-through + Internal monitoring and protection includes Ixt_ * Programmable preseting of speeds and jog. curr k current limit, + Programmable skip frequencies. instantaneous overcurrent and individual GBT + Selectable avto-restar aftr tip. Protec bet ana + Mountings for frontof-pane o through-hole + Complete isolation between control and power. Aumrioeuing of faut events fctronie circuite, Impedance isolation for ac, Aut2-9Ging of fauk events deta, Efficient thermal management, derating not required. ‘+ Slip compensation. supply and dc ink voltage feedback + Ability to start the drive when the motor ie spinning, in ether dtecton, without large vansiant torques. ‘Control Pod CONTROL PCB INSO Ssaennsiamsesreomceeesanatin _prcenansceansoemnnnsnenisa f [ PowER pcs || INS2— C75, cot10 “| INS3— C400 || INS4 — C560 - C0750 Integral RFI iter} (Bult In) DC Link Choke E \ cca eanescnsooara st Neem 2. Schematic block diagram of the power system. al og075-750 Base speed Dc tink Defaut Hvac MVF GLOSSARY of TERMS The shaft speed of an PLC induction motor when supplied at rated vokage and frequency. (DC bus’) The de voltage ‘source connecting the input ‘rectifier to the output inverter. Power factor A single pre-determined value to which a parameter is set during manutacture. Reduce the nominal rating of | PWM apparatus because of departure from specified ‘operating condtions. ‘The cosine of the phase angle between fundamental voltage ULF and fundamertal current Full oad current. Full lad torque. Heating, ventilating and air- conditioning. Maximum Voltage Frequency (@f a CO drive): the frequency selected to be delivered to motor when the output vokage is equal to the rated input voltage (= Pre}. Programmable logic controller. Equipment designed to manipulate and transmit data for controlling ‘other equipment. (apparent power is rms voltage x me currant). Pulse width modulation. A technique for synthesizing a ‘waveform by making individual pulses in a pulse train diferent widths. Upper limit frequency. The highest motor ouput frequency of the drive, (Actual maximum frequency can be lower than this as set by Pr).CD75-750 1 Theory of Inverter DrivesCD75-750 42 Theory of Inverter Drives Induction Motor Characteristics Standard industrial squirrel cage induction motors are wound to match the supply votage and ‘requancy which prevails in the country where they will be used or are manutactured. When itis desired to operate an induction motor at variable speeds, it is necessary to consider the effect of voltage and frequency on fx and torque. ‘An induction motor depends for its operation on the rotating field created by the balanced three-phase currants in the stator (field) winding. The magnitude of the field is controlled not by the stength of the current, but by the voltage impressed on the field windings by the supply. This is because resistance of the field windings resus in only a small voltage drop, even at full load current, and therefore the supply voltage must be balanced by the emf induced by the rotating field. This emt sdopends on the product of three factors: the total fx per pole, the total number of turns per phase of the field winding, and the rate of field rotation. ‘The emf can be expressed as E = kgNf a whore E is the induced emt, 9s the total flux per pole, Nis the number of tuns per pole, {is the frequency, and kis @constant. I the applied voltage is increased, the emf must increase to balance, and if the frequency is held ‘constant the flux per pole must increase also, since the number of turns per pole is fixed. For economy of material, the magnetic circuits of standard motors are designed to operate every close to saturation at rated voltage and frequency. This is the optimum condition for the production of maximum torque. At rated frequency, any further increase of voltage cannot increase torque but will ‘cause current, and consequently losses, to rise. For optimum acceleration, of rapid response to an increase in load torque, @ should be maximum to ‘maximise the torque, as the designer intended. Equation (1) can be restated as — 1, ) ww * 4 ‘This shows that, since Nis fixed and k is constant, a near relationship must be maintained between ‘mt (and consequent the applied voltage) and frequency, if ux isto remain constant at diferent speeds. This linear relationship is known as ‘constant Vit (or Viz). Drives possessing this essential feature are usually called ‘variable voltage variable frequency’ (vwvf) drives. The speed of a motor at {ull rated voltage and normal VA ratio is called its ‘base speed’, expressed in Hz or rpm as convenient. [Although constant Vi control is an important underying principle, departures from i enable the speed range to be extended both above and below the base speed. Operation of the motor at speeds above its base speed is achieved by increasing the output frequency of the inverter above the rated frequency while the applied vohage remains at maximum value. ‘The VA characteristic is typically as shown in Fig.3, which also shows the change above base speed. Since V is constant above base speed, the flux falls as the frequency increases, Fig. 4, in directORNS 2: ALN ek RE RNE NS. es ‘Typical mains ‘Base aol speed pical mains Ppl frequency) 3. Variable motor sf voltage to-froquency (VA or Vitiz) characteristic. Constant ° ‘power —e Base speed’ —1 502 typical 4 ariable motor speed — pial faxto- equency rian F Sore f 5 \otage boost to increase torque at low ftequencias. (Nott teas)” Equipoed with suitable control tunctir from zero to input line voltage, over a PWMIGET quency range from zero to some practical maximum mesos amesni CD75-750 proportion to the VA ratio. The ability of the ‘motor to produce torque is correspondingly teduced, and in fact the power output remains constant. The second operating condition where departure from a constant VA ratio is beneficial is at low spoeds, where the voltage drop arising from stator resistance becomes significantly large. This voltage drop is at the expense of the flux. As the applied frequency approaches zero, the optimum voltage becomes equal to th stator IR drop. To maintain a constant flux in the motor at low speeds the voltage must be increased to compensate for the stator- resistance effect. Compensation for stator resistance is called ‘voltage boost’, Fig. 5, and most drives offer some form of adjustment so ‘that the degree of boost can be matched to the winding resistance. Wis also normal to taper the bboost to zero as the frequency increases. A refinement is to increase the degree of voltage boost fer loads that impose a high starting torque, since the IR drop will be greater because of the increased current. Automatic toad-depandent control of the voltage boost in this manner has practical advantages for many ‘applications. Drive Configuration To operate an induction motor successfully in all varieties of industrial applications a drive must at least be capable of varying both voage and frequency, for which it is necessary to separate the input from the output. This is most Conveniently done by rectitying the supply and inverting the de output. Variable output votage ccan be obtained by varying the de link vokage ‘and maintaining the gain of the inverter constant + The gain is the ratio of ac output to de input. Alternatively, the de link voltage can be Uncontrolled and the gain varied. This latter method is usually achieved by pulse-width ‘modulation (PWM) control of the inverter. ‘The use of a mathematically-advanced PWM switching strategy to control the latest high power high speed semiconductor switching devices — insulated gate bipolar transistors (IGBT) — in the power output bridge enables the output waveform to be closely approximated ‘to a pure sine wave, The de input vokage can then be derived from a simple diode bridge rectifier which, besides being highly reliable, also has the advantage of reducing the amplitude of harmonics seen on the input of the inverter. ter is capable of providing any voltage Considerably above the rated frequency of standard squire cage motors. The contol function is also capable of enabiing the voltage to be raised at low frequencies to increase torque at low speeds, and t is relatively simple to arrange that the phase sequence of the output can be changed to enable the 13075-750 ‘motor to reverse. These functions are the basic minimum and they can, with a suitable control system, ‘be considerably extended. Digital control logic is essential to gain the full advantage of a PWM switching strategy applied to the 1GBT output bridge. The speed and adaptabilty of digital logic makes it feasible to extend the scope of the control functions in two important directions. One is to equip the dive to monitor and protect ltsell and the motor; the other is to enable the performance of the drive and motor to be refined to take ‘account of the widest possible variety of applications. ‘A Iurther advantage of digital control isthe precision with which operating parameters can be adjusted, and maintained without driting from set values. A standard interface ‘extemal analogue signals into the control scheme, and also to provide analogue signal outputs. Finally, digital control makes communication with other digital devices simple to implement and ‘operate through industrial standard serial communication links, MMsti estes | 075-750 SPECIFICATIONS 2 Specifications & Data 2.1 Current & Voltage Ratings 2.2. Specifications 2.3. Encoder Specification 2.4 Electromagnetic Compatibility (EMC) 2.5 Drive Module Weights 24SPECIFICATIONS CD75-750 2 Specifications and Data 2.1 Current and Voltage Ratings “The CD75-750 (0.75.7 5KW) range is rated for Curent outpt, thus fora fixed maximum current oupes the power ouput is dependent on the value ofthe supply voltage inthe range SEDV 400V. Power Supply Input supply Voltage range, and Frequency — 380V to 480V ac #10% 6OHz #2Hz ‘380V to 440V ac #10% SOH2 422 Minimum supply source impedance — Zoro Ohms. ‘Maximum supply imbalance — ‘2% nagative phase sequence (equivalent to 3% phase voltage imbalance) CD75-750 (0.75 -7-5kW) Industrial Inverter, 380V Supply DRIVE ourpuT ‘MOTOR INPUT ‘MODULE RATINGS ox | 160m 100% 00% us | rus rus FUNDAMENTAL ‘CURRENT | CURRENT] | cunRENr ‘CURRENT o @ | A A_|ewonp| aA wa | A ew, cos 21 | 32 [ov 19 | sa 36 | 18) 12 como 28 | 42 | 11 15] 59 38 | 24 16] epso 638 | 57 | 15 20| ss as | a3 22 cozo sé | a4 | 22 30) 71 47 | 49 32 coo 95 | 143 | 40 53/ 95 63 | a3 55 cosso 6120 | 180 | ss 73| 1397 90 | 104 69 corso 160 | 260 | 75 100] 163 107 | 199 92 NOTES (1) RMS curent required by a3-phase, 6-pole motor to produce rated ouput shaft power. 100% FMS current is available at all switching frequencies without derating, up to a maximum ambient temperature of 50°C, @) Maximum inverter RMS curent. 22hati. CD75-750 SPECIFICATIONS (CD75-750 (0.75 -7.5kW) HVAC Inverter, 380V Supply - pave_| output | MOTOR INPUT MODULE |_ RATINGS tome | 1am | 00% 10% pws | As mus FUNDAMENTAL EURRENT | CURRENT ccunrent ‘CURRENT (rong A ate on] awa | a kw eovs | 21 | 25 jo 10| 54 36 | 18 12 covito | 28 | 34 | 11 18 | 59 38 | 24 16 coviso| ae | 46 1s 20] ss a5 | a3 22 covezo | s6 | 67 |22 30] 71 47 | 49 92 covaoo | 95 | 114 | 40 53] 95 63 | 83 55 covsso | 120 | 4 | 55 73] 197 90 | 04 69 covrso | 160 | 192 | 75 100] 163 107 | 139 92 Losses DRIVE. | FREQUENCY | POWER ‘CONTROL ToTaL | MODULE | Hz w w w | cps | 2fkHr 2 30 72 corto Sox 52 30 eofaaaa | 8.8kHz 62 30 92 | 11.72 R 30 102 co1s0 2.9kHz 82 35 417 | + ope20 5.9kHz 97 35 we | 8.8kHz n2 35 | 17ie 127 35 162 4 2.9kHz 135 35, 170 Some | 180 oe ee ie B.8kHz 185 35, 220 17a 218 38 250 cos50 2ortz | 251 35 286 *¢D750 S.9kHz an 35 348 8.8kHz 368 3 aot [riz 421 3 | as * C220 to ©0750 are fan cooled 28SPECIFICATIONS CD75-750 2.2 Specifications Accuracy Frequency — Accuracy + 0.01%, fll scale, NOTE — This figure implies — (Crystal-controlied intemal reference Attitude : Faated up to 1000m above sea level. In excess of 1000m above sea level derate FLC by 1%/100m to ‘a maximum atttude of 400m above sea level. RELEVANT SPECIFICATION — IEG 146-2, Section 3.1.2. Ambient Temperature and Humidity Fated ambient temperature -10°C to +50°C Maximum storage ambient temperature: -40°C to +50°C for one year maximum, Humidity — Non condensing at any temperature. Environmental Protection Ingress protection IP10, Materials, Al plastics have flammability rating UL84 VO. Starts Per Hour Drive limited to 10 starts per hour if started by switching the supply. lf the motor is started only by ‘lactronic control ofthe drive, the number of starts per hour is unlimited by the drive. PWM Switching Frequencies Constant switching frequencies selectable from four values — 29k, 5.9kHz, 8.8kHz oF 11.7kHz. Vibration Tested to a level of 1g (rms) in the frequency range SHz to 150H2 in accordance with IEC 68-2-34. Inverter Output The three phase balanced output can be adjusted to either 120H2, 240Hz, 480Hz or 960H2 maximum frequency. NOTE (1) With a switching frequency = 2.9kH2, ULF = 120/240Hz only are possi (2) 960H2 ULF is only available with a switching frequency of 11.7KH2. Maximum output voltage is normally equal to the input vokage. Current maximum = 150% of drive FClindustrial CD drives) and 120% for drive FLC ((HVAC CDV drives). Resolution When parameters are set from the keypad or serial communications link, resolution is 0.1 unit excopt forthe following - Value > 100 units: + 1.0 unit, keypad mode ‘Acceleration & deceleration rates: resolution becomes coarser towards 600 seconds, PrO, Pri, Pr7: 0.2H2 for ULF = 240H2. 0.4H2 for ULF = 480Hz. Pri0, Pr20, Pr20-Pr27:_0.8Hz for ULF = 960HZ. Pre: 0.4% Display resolution 0.1Hz. a4CD75-750 SPECIFICATIONS Serial Communications interface Fis4as, S422 and RSZ32 Protocol ANSI x3.28-2.5-A4 operation — S485 Multidrop, equipment can be connected along the length of the cable (22 ‘transmitters and receivers). S422 One transmitter can drive ten receivers atthe end of the cable. S232 One transmitter can drive one receiver. 2.3. Encoder Specification PULSE RATE: 15 pulses per revolution per motor pole — jo 90 pulses per rev for ‘8 2:pole machine; 60 pulses per rev. for a 4-pole machine. ENCODER OUTPUT: Rectangular square wave, Quadrature or complement signals are ‘not required. ‘Amplitude nominally equal to the supply. ‘Mark : space ratio from 40 : 60 to 60 : 40. Rise-and-fallimes not o exceed 50us. ‘SUPPLY REQUIREMENTS: CD drives will accept either — -24V signal (current sink) ( +SV signal (souree and sink) “The drive will supply +24V at 100mA. 24 Electromagnetic Compatibility Refer also to Chapter 10 Immunity tn accordance with IECE01 without significant disturbance to operation atthe folowing levels: Part2 (ESD) Levels Part3 (Radiatod AF field) Level Part 4 (Transient Burst) Level 3 (Level 4a control and serial nk terminals) Par 5 (Surge) (Draft 1990) Level 4 ‘Surge immunity in accordance with IEEES@7-1980 2.5 Drive Module Weights DRIVE MODULE WEIGHT ko * CD75, D110 ery * ©0150, D220, CD400 5.65 * CBS50, CD750 64 Control Ped 02s Blank Pod on (Optional RFI Fiter 10 Rear Case 275 ‘Weight includes Rear Case and Control Pod. if drive is supplied with a blank pod, reduce these values by 0.15kg. 25©D75-750 MECHANICAL INSTALLATION 3 Installation — Mechanical 3.1. Drive Mounting — General Requirements 3.2. Front- and Through-panel Mounting 3.3 Control Pod, Remote Mounting 3.4 Cooling and Ventilation atWS SSE: A 075-750 MECHANICAL INSTALLATION 6 Locations of principal components,CD75-750 MECHANICAL INSTALLATION 3 Installation — Mechanical 3.1 Drive Mounting — General Requirements Location ‘The installation should be located in a place free from dust, corrosive vapours, gases and all iquids. Care ‘must also be taken to avoid condensation of vaporised liquids, including atmospheric moisture Ht the drive is to be located where condensation is likely to occur when the drive is not in use, a sultable ‘anticondensation heater must be installed, The heater must be switched OFF when the drive is ‘energised. An automatic changeover switching arrangement is recommended. P Rating “The drive enclosure contorms to international enclosure specification 1P10 itis therefore necessary to consider the location of the module in the light of local safety regulations applicable to the type of installation. Hazardous Areas ‘The application of vatiable speed drives and soft starters of all types may invalidate the hazardous area corthication (Apparatus Group and/or Temperature Ciass) of Ex-protected squire cage induction motors. ‘Approval and certification should be obtained for the complete installation of motor and drive, CD drives are not to be installed in classified hazardous areas unless correctly mounted in an approved fenclosure and certified (Refer to "Hazardous Areas" Chapter 4 Installation - Electrical". 3.2. Front- and Through-panel Mounting Front-of Panel Mounting Overall cimensions and dling dimensions are shown in Fig. 7. When mounting a drive in a cubicle, tie important to provide adequate air-circulation space for cooling. Refer to Section 3.4. ‘Through-Panel Mounting “The essential dimensions are shown in Fig. 7. To mount the drive with the heatsinks projecting through the mounting pane! i is necessary to remove the Rear Case of the drive. Instructions for this are shown in Fig. 8 Note that I it is intended also to mount the Control Pod remotely, the Pad can convenierty be removed from the drive during this same procedure.MECHANICAL INSTALLATION (CD75-750 FRONT.OF-PANEL MOUNTING ‘THROUGH PANEL MOUNTING 2 —-— 194 —4 ey 7 Ik | | ! | & abt L sntir bets 7 Overall and mounting dimensions.(CD75-750 MECHANICAL INSTALLATION a 1 Remove the control terminals cover — pull down and lit away. 2 Remove the 2 scraws, M4 x 10, ther side of the power temninals, Wwhich secure the Top Cover. wares tS watt Bina ay \ supponr Lit the lower edge of the Tor over una the Mating Lugs af the age arotroe from he Babe Wouing. = ¢* 79 im Bike Base hcadng. { t '5 Remove the INSO peb complete. Ray 6 Remove the four sorews, MA x {sone at each corner which secure the Base Moulding to the Roar Case. Lit the Baso T install the Base Moulding out of Moulding ro the panel and secure With four M4 x 16 - Fives Ping ence aeons. TOCEMPLETE, vere OME T Rn 8 Procedure for removing the Rear Case. 35 Sn HeMECHANICAL INSTALLATION CD75-750 1 Remove the control terminals cover — pull own and lit away. a ef \ ‘sueroar re items caeeiae auuraats treo Bee Mouling. songs aamSeaon om 5 Sa the Top Cover aside, and iave the INGO poo inthe base. ey & ENGAGE PCB INSO 6 Turn the Top Cover on its face and remove the four screws securing the Control Pod. 7 Engage he po NEO iro the ver, and re-engage the Ninos 2 (of Steps 3, 2 and 1. 9 Procedure for removing the Control Pod {rom the module for ram 36CD75-750 MECHANICAL INSTALLATION 33. Control Pod Mounting “The Contre Ped can be removed ftom Tocation on the front panel tthe cive and mounted anywhere eo ec catance permitad by maximum cable lang of 100m tom the drive othe Pod. To Remove the Control Pod from the Drive 1 Disconnect and SAFELY ISOLATE the power supply from the drive. 00 NOT REMOVE ANY ‘COVER MOULDING FOR AT LEAST FIVE MINUTES, to allow ample time for internal caoastanoss to discharge oa eae votage. 2. Fallow the instructions shown ia Fig. 9 Remote Mounting of the Control Pod “To provide aocess for the the control cabling to the rear of the pod, @ remote mounting requires @ ‘small qut-out in the mounting panel. Drill the fixing holes and the cut-out as shown in Fig. 10. Extension cable must be screened data cable. A standard 9-pin D-type plug is required at the deve end, and socket at the pod end. Full details of control cables and screening are to be found INSTALLATION — ELECTRICAL. 10 Remote-mounting for the Control Pod. Driling and cut-out dimensions. a7MECHANICAL INSTALLATION 075-750 3.4 Cooling and Ventilation Enclosure minimum dimensions Care must be taken that the enclosure in which the drive is sited is of adequate size to dissipate the heat ‘Generated by the drive. A minimum clearance of 100mm all around the drive is essential, Fig. 11. All ‘equipment in the enclosure must be taken into account in calculating the internal temperature so as not to raise the internal temperature of the cubicle above the maximum allowable forthe drive. 11 Aminimum distance of 100mm trom the. enclosure boundaries. or from adjacent “comtaciors, relays, and Other. types of heat-producing ‘equipment is essential to allow Citeulation of cooking at. Effective heat-conducting area ‘The required surface area Ag for an enclosure containing equipment which generates heat is calculated ‘rom the following equation Pe a KOj-Tamb) whew Ag = Effective hoat-conducting area, in m2, oqualto the um ol he areas ofthe furfaces which aro notin contac wih anyother auface. PL = Powor loss of all hat-producing equipment in Watts. Ti = Maximum permissible operating temperature ofthe drive module in °C. inc, Tamp = Maximum external ambient temperature lamb k = Heat transmission costfcient ofthe material trom which the onclosure is made. EXAMPLE To caloulate the size ofan IP54 cubicle for @ CD750 (7.5KW) drive. ‘Tho worst case'is taken as the basis fr the example, so the folowing conditions are assumed “The drive sto be operated at 2.9kH2 PWM switching frequency (b14 = 2.9). + The instalation isto conform to IP54, which means thatthe dive module and its heat srk are to be mounted wholly within the cubicle, and thatthe cubicle is vitually sealed and without any ventilation of the air inside, Heat can escape only by conduction through the skin of the cubicle, which is cooled by radiation to the external airCD75-750 MECHANICAL INSTALLATION 12 Enclosure with typical Biotitaows undBe lsperse heat «The cubicle is to stand on the floor and against a wal, Fig.12, so that ts base and back surfaces cannot be considered to play any part in the cooling process. The effective heat- conducting area, ‘es provided by the top, front, and two sides onl. + The cubicie is to be made of 2mm sheet steel, painted. +The maximum ambiert temperature is 25°C. To Find the Effective Heat-conducting Area “The values ofthe variables appropriate to the above specification are — = 286W (trom the table of Losses, CD 750 module operating at 2.9KHz PWM switching frequency, Section 2.1, page 2-3) = 80°C (forall CD75-750 and CDV7S-750 drives) = 25°C k= 55 (typical value for 2mm sheet steel, painted) 28 55 (60-25) = 2.08m2 NOTE this essential to include any other heat-generating equipment in the value for P. To Find the Dimensions of the Enclosure — fa cubicle is to be fabricated to suit the installation, there is a free choice of dimensions. Akernaively, ¢ may be decided to choose a cubicle from a range of standard products Either way, its important to take into account the dimensions of the drive module, Fig. 7, and the ‘minimum clearance of 100mm round the module, Fig. 11 “The procedure isto estimate two of the dimensions — the height and depth, for example — then calculate ird, and finally check that it allows adequate internal clearance. 39MECHANICAL INSTALLATION CD75-750 “The effective het-conductng area oa cubis located onthe foor and against one wall as shown in Fg. 125 — Ag" 2AB + AC + BC ‘Suppose the cubicle height Ais 1.0m to aw adequate clearance above and below, and the deoth B is (0.5m, a8 a frst estimate. The actual figures chosen in practice wil be guided by available space, perhaps, or standard enclosure sizes. Since Ag, A, and B are known, the dimension to be calculated is C. The ‘equation needs tobe rearranged to enable Cto be found, thus — Ag-2AB=C (A+B) ° cw Ae2A8 Aw ce 28 2.08 ce 28 C= 0.78, or 780mm approx. Clearance on either side of the inverter module must be checkad. The width of the module is 170mm, Fig.7. 100mm clearance is required all round, s0 the minimum internal width of the enclosure must be 370mm or 0,37m. This figure is within the calculated width at the selected height, and therefore ‘acceptable. However, although the figure allows additional space, any additional equipment must be ‘considered as a factor in the total power losses P,, and may demand that the calculation is reworked. 0, recalculate Ag, modify the value of C it necessary to allow for other equipment, and re-cakculate either ‘of the other two dimensions A and B. 1 a catalogue stock enclosure is to be used the corresponding surface area should be not less than the figure calculated for Ag. this important that heat-producing equipment should not be located below the drive. ‘As a general rule, it is better to locate heat-generating equipment low in an enciosure to encourage internal convection and distribute the heat. If # is unavoidable to place such equipment near the top, ‘consideration should be given to increasing the width and depth dimensions at the expense of the height. Enclosure Ventilation Wa high IP rating is not a critical factor, or if a ventilating fan can be used to exchange air betwoen tho inside and the outside of the enclosure, the enciosure can be smaller. To calculate the volume cf ventilating air, V, the following formula is used — 34 PL Tam vos where Vo =Required airflow in m3 ht ‘To Find the Ventilation Required for a CD750 Drive — = RW J, = 50°C (lor all CD75-750 & CDV7S-750 drives) Tamb = 25°C (or example) Thon 1x 288 8 Vo = 95.46 m8 het or, say 36m$ ht as a practical minimum. 310(CD75-750 ELECTRICAL INSTALLATION 4 Installation — Electrical a 4.1 Installation Safety 4.2 Power Connections 4.3. Control Connections 4.4 Other Configuration Details 4.5. Connecting Serial Communications anCD75-750 ELECTRICAL INSTALLATION 4 Installation — Electrical 4.1 Installation Safety Safety ‘The voltages present in the supply cables, the output cables and terminals, the control power supply wiring and in certain internal parts of the drive are capable of causing severe electric ‘shock and may be lethal. ELECTRIC SHOCK RISK! Whenever the drive has been energised, it MUST be ISOLATED betore work may continue. A period Oi seven minutes MUST elapse atter isolation to allow the internal capacitors to discharge fully. Unti the discharge period has passed, dangerous voltages may be present within the module. Persons supervising and performing electrical instalation or maintenance must be suitably-qualfied ‘and competent in these duties, and should be given the opportunity to study, and to discuss if necessary, this User's Guide before work is started. Hazardous Areas ‘The application of variable speed drives and soft starters of all types may invafidate the hazardous area certification (Apparatus Group andiot Temperature Class) of Ex-protected motors. Approval and Centfisation should be obtained for the complete instalation of motor and drive, (Refer to Chapter 3 “INSTALLATION MECHANICAL”) Earthing ‘The drive must be connected to the system earth at the power earth (PE) terminal provided on the power terminal block. This terminal, marked with the standard ‘earth’ symbol, Fig. 14, is to be distinguished from the terminal marked Ezuc. Earth impedance must conform to the requirements of local industrial safety regulations and should be inspected and tested at appropriate and rogula itarvats. “The Eexc terminal must be linked to the earth (PE) terminal to bring the Integral RFI Fite into use. Wis Tcommended that this iter is used as in most situations it provides an etfective reduction of AFI ‘Omissions into the mains supply. it does, however, introduce 2 small leakage current. ¥ this leakage Current is not acceptable, the Eguc terminal should be left unconnected. Refer to Chapter 10, Section 410.9 for information on leakage current levels. In order to ensure the electrical safety of equipment incorporating the drive, tis important that a fixed ‘tarth connection Is provided, e the safety earth Is not connected solely through a flexible cable or Connector which might become accidentally disconnected or open-circulted. If additional fitering is required, an optional RFI iter is available. Refer to Chapter 10. Grounded Detta Supplies “The drive is designed for use with conventional three-phase supplies which are symmetrical with respect to earth, Surge suppression devices ate included to protect the drive trom lightning-induced overvotages between lings and earth. For this reason the drive must not be used directly with supplies where one phase is grounded, ie the voliage between the other phases and ground is equal to the line votage (the Grrangernent sometimes referred to as "Grounded Delta” in the USA). In such cases an isolation transformer must be used to provide a supply balanced with respect to earth. 43 eopeaey che cy samtCD75-750 ELECTRICAL INSTALLATION 13 Locations ot principal components.CD75-750 ELECTRICAL INSTALLATION Motor Speed Standard squirrel-cage ac induction motors are designed as single speed machines. If it Is intended to use the capability of the drive to run the motor at speeds above Its designed maximum, it ls strongly recommended that the motor manufacturer Is consulted first. ‘The principal risks due to overspeeding are the destruction of the rotor by centrfugal force, or of the ‘bearings by vibration or heat. Low speed is liable to result in overheating of the motor because the effectiveness of the internal cooking fan reduces in proportion to the square of the reduction of speed. Motors should be equipped with thermistor protection, and if full benefit of the use of low speeds is to be gained from a variable speed ceive it may be necessary to arrange additional cooling for the motor. 42 Power Connections FRter to Fig 14 Terminals ‘Access to the power connections is gained by removing the Terminal Cover, Fig. 13. Mf internal RFI ‘itering is required, link the power earth and the Eguc terminals by a 2.5mm? wire link, Fig. 14. Li Line 1(R) *U" Motor Phase -U "47 DC Link Positive 12 Line 218) “Vt Motor Phase - V “DC Link Negative 13 Line 3(T) "W Motor Phase - W Eye Intergral RFI tor Power earth ‘The layout of the power terminals and connections is shown in Fig. 14. PERMANENTLY ‘CONNECTED ‘TOE BUS. MAINS SUPPLY 7 |CONNECTS INTEGRAL | SAFETY EARTH MUST ‘BE CONNECTED RRIFILTER 14 Power terminals and standard connections for the drive. 45 aba ie Hiss he aanELECTRICAL INSTALLATION CD75-750 Fuses and Cables: Dike | “Raconmonaed | Topas Bie, | “Aecrmaen | eee a seo A net cos $ i con) i coun a 5 ooze c is coe ‘e 2 come | 20 2s + The use of slow fuses is recommended because a current surge may appear at power on. As an attemative to fuses, mebs or mocbs may be used i equipped with adjustable thermal and magnetic ‘tip devices of a suitable rating. f The cable sizes are for 3-core and 4-core pvc-insulated armoured cable rated at 6OOV ac (1000V de) ‘and laid in accordance with the maker's defined conditions. Power Cabling ‘The cabling o the drive must be rated for 600V ac of 1000V de. Cable sizes speciied are for PVC/SWA cables laid under defined conditions, and are general recommendations only. Cabling should conform to local codes of practice and regulations. Connect the 3 phase mains supply to the large terminals, L1-L2-L3. The mains supply should be fed via an isolator, contactor, mcb or mecb, with {uses or thermal current protection. Discard the labal ‘WARNING — FIT FUSES". This is @ reminder to ensure thatthe mains supply ia adequately protected. Connect the motor terminals to the U, V, W terminals ofthe ve, The dive MUST BE EARTHED. “The power connections from the drive output to the motor may be switched, for isolation purposes, but not {or control purposes, 2s the drive may trip. Installations prone to mains vokage disturbances may need special consideration; $0, consult the supplier of the drive. Installations with long cable runs, to the motor, may need the addition of motor line chokes, to prevent fuisance tripping of the drive (PrA = Ol) caused by capacitatve loakage effects. Refer to the table on tho following page. Electrical Interference ‘Some attention is needed to the arrangement of the power and earth connections to the drive to avoid interference with nearby sensitive equipment. The cable to the motor caries rapidly-switched voltages ‘and should be routed well away from sensitive equipment. ‘The earth core of the mator cable should be connected directly 10 the drive earth terminal, a8 shown i Fig. 14. It should not be connected to the drive indirectly, for example through a cubicie-earth busbar; this will cause hightrequency current to circulate in the earth system of the cubicle. At the motor end, the ‘earth core should be connected to the motor earth terminal inthe normal manner. Screened or armoured cable may be used to prevent emissions from the motor cable. The screen or armour should be connected in the same way as for standard cable, that is, to both the motor earth terminal and the drive earth terminal. ‘The drive input power safety earth conductor should follow the same route as the input power conductors. It should be a dedicated earth wire, not ‘dalsy-chained’ from any other equipment in the cubicle.CD75-750 ELECTRICAL INSTALLATION Langt of able sbove which motor the chokes may be rqued (pa ee | Module cD75 | cD110 | CD150 | CD220 @0400 | Coss Choke | oS | Vive an [eee [aortas [eases [ores [oat [osm | imi Length (m) | oo_180 | 125-250 | 145-290 | 165-330 | 200-400 | 300-600 | 2mH cage [sme | om | | om | | mA her usc ine dake hte pat abo Bis eamended a te 22 PWM pichingrequecy eeenlminc tne Wo ken creerELECTRICAL INSTALLATION CD75-750 TERMINAL ———————__———, REFERENCES i cosnecton "| JogPPreset Speed input | A12 REFEREM JS Preset Spoed2 input | AIT PRESETS S preset Speed input | Ato f}———__-} so8, even | wa (OV Common A = ‘Statue Out DRIVE RUNNING AT : a MINIMUM SPEED ‘solated Commsov | C1 A} 23 reweur ate At 2 recente << a 19 Load Ouput SERIAL COMMUNICATIONS. uNK BVI S|P RRR L|Bjpsys Ria! 8 Frequency Output 7 is Forward/Reverse Input Localemote Input Fun input ‘Stop Input Reeat input Exemal Trp Input -——} 11 OV Common, 10 Encoder Input Motor Thermistor Input ‘Carag Spod Fates tion ‘Torque Referance Input “s1OV Reterence Speed Fate (Local) Input oa ov Common t Status Relay NC fT Stane Relay NO |t status Retay Common 1 ‘NOTES + 1 Betore connecting motor thermistor, refer to text page 4-9, terminal 9. | 2A'Stati lay cin be programed as an rel . 5 SLPS inves the play ofthe eterno. Factor Sting i compatble wih 4 Riclay can be connected directly betwoen Ay and A, for ‘ive running at minimum speed. 15. Control terminals and typical extemal control circuits. 48©D75-750 ELECTRICAL INSTALLATION 43 Control Connections Refer o Fig. 15. For control connections use cable of 0.5mm? screened. Connect screen to earth AT THE DRIVE ONLY. “Aiways segregate control and power cabling. Connections to termina are shown in Fig. 15 and should be made to earth at the sending end i long cables are used (i.e. greater than Sm). ‘Auaillary Supplies and References 424V 4 10% 100mA 4 Seey ser een )) san creuitprotte ov OV Analogue OV Digital ‘0V Serial Communications (isolated) Logic Inversion By atering the postion of link PLS (Fig. 16) the logic of the cigtal inputs and outputs is inverted, eo that the "on’ state corresponds to +24V (positive logic) instead of the standard OV (negative logic, as Golivered). This allows the use of certain types of programmable controller in which positive logic is ‘standard. ‘Specifications of Control Inputs and Outputs ANALOGUE INPUTS Local speed reterence: unipolar 0 to +10V, 110K input impedance for bipolar -10 to +10V, 110K input impedance Remote speed reference: ‘40 20mA, 100 ohms input impedance (of © -20to4mA, 100 ohms input impedance ‘of 010 20mA, 100 ohms input impedance Torque reterence: (010 +10V, 27K input impedance Motor thermistor: Motor thermistor terminal voltage < 2.5V, capable of protecting from 1 to 6 standard 250R machine thermistors connected in series. ‘Trip resistance 3k: 15%, reset 1k8 215%. ‘Short circuit protection will nt trip above 100R. DIGITAL INPUTS Digital inputs (1-8), can be configured for either postive or negative logic via hardware inks, which should ‘only be adjusted at commissioning. Negative logic (lactoryfited option), active low, 5k input impedance. Positive logic, active high, Sk input impedance NOTE High = +24V de, low = ze10 volts — applies to nogative and positive logic. Input Functions for Negative Logic External Trip: low = no trip, momentary high = trip (NIC contact) Run: momentary low = start (N/O contact) Stop: low = not stop, momentary high = stop (NC contact) Reset: momentary ow = reset faut (NO contact) LocalRemote: + low = select romote reference igh = salet local reference ForwardMeverse: low = select raverse direction high = select forward direction Proset Speed 1 (Two binary preset inputs select preset speeds, Preset Speed 2: when both high normal speed contro is selected) Sogn tow = jogfnch NOTE Momentary = hold state for 216 ms. NOTE The Jogiinch input can be software selectable to give a third preset speed input and thus a total of sevenpreset speeds. “9ELECTRICAL INSTALLATION ©D75-750 DIGITAL OUTPUTS Drive Status or At-Spoed Relay Drive Running or Minimum Spaod ANALOGUE OUTPUTS Frequency (Speed): Load (Torque: De-energised at power of, crive tripped at speed operational. Volt free contact, ‘7Aresistive, Changeover type relay. Software programmable assignation. Open collactor or PLC type 24Vde output, 025A sink capabilty and 0.05A source capabilty. Software programmable assignation. 10 10Vde, SmA capability; OV = , 10V = . Accuracy + 2%. “ADV to +10Vde, SmA capability; OV = no load, -10V = 150% regenerating, #10V = 150% motoring Accuracy # 10% above 15H2 with matched motor. 410 Enabletdigable link PLE for motor Logie selector ink PLS, Postions 1 & 2 for negative loge. Location for Serial Control Pod ‘connector. thermistor. 16 Top Cover removed to show location of ‘components on peb INSO. ibisCD75-750 ELECTRICAL INSTALLATION Functions of Control Terminals Torminat Number D/A Description NOTE D = Distal Az Analogue 1 D StausorArSpeedray common Votttrae change-over contact, 240V AC 7A | resistive oad 2 (0 Status or At-Speed relay | Relay energised when drive heathy/at speed: normally open | do-energised when drive of, tipped, or not at | speed. Contigured by parameter b50. 3 D Stas or ArSpeed relay | rormally closed J 4 A Zerovoks common _—ntarnally connected to terminals 11, At. 5 A Local set speed 410k potentiometer or voltage signal OV to +10V or -10V 10 +10V potentiometer input (BIPOLAR) 110k input impedance. Configured by parameter b4. 6 A SOV 2% reference SmA maximum loading (short-circuit proot to zero vos) votage 7 ‘A Torque reterence 10k potentiometer, or votage signal, OV to +10V, 27K input impedance (always acive, independent of pararnator 0}. 8 A Remote set speed 4220mA of 20/4mA or 020mA, 100R input impedance. current input Configured by parameter B11. ° A Motor thermal peo- Vout <2.5V. Trp resistance 3k 15%, reset 1.8k = 15% tection (thermistor) ‘Short reut protection will nat tip above 100R. input NOTE f no motor thermistor isto be used, a link on the INSO pcb must be repositioned to disable the Input. Refer to Fig. 18 for location ofthe link, FRoter also to the paragraph Logic Inversion on page 4-9. 10 D Encoder input OV to +5V at 16mA open collector. ‘Square wave, mark:space 60:40 or 40:60, up to 24V, 15 pulses per motor pole per revolution (enabled by parameter BS) " A oVcommeon {eternally connected to terminals 4, A1. 12D Extemaltrip tow = no tip momentary high « tip (NIC contact to zero volts) 19D RReset momentary low = rest faut (NO contacto ro voks) 14D St» low = not stop, momentary high = stop (NC contact to 2210 vots) 15D Run(star) momentary low = star (tun) (N/O contact o zero vot) 16 —_D_LocalRemote tow « select remote reference high « select local reference 7 D fwdiev input low = select reverse direction high = select forward directionELECTRICALINSTALLATION 075.750 17 Basic RS485 Serial Communications arrangement ‘and serial address. Unique entity code for up to 32 fives per communications port atthe host. Receive Transmit OV (pret.) or Differential GND from host twisted-pair cable transmitier 18 S495 oF S422 serial communicatrions 19 _RS232__serial communicattions nk ink connections. Cable must be screened. connections. Cable must be scroonsd: 412(CD75-750 ELECTRICAL INSTALLATION Terminal Number D/A Description 18 ‘A Frequency output V10+10V, 5mA. Accuracy +2% signal OV at Pro, 10V at Pri 19 A Load output signal OV 10 +10V, 5mA OV =no bad +1OV = 150%FLT monitoring (120% “10V = 150%FLT regenerating HVAC) Accuracy 10% above 15Hz with matched motor 20 D Serial link receive A or B - ‘Two lines for diferential receive a D— Satia ink receive A Dire apt: 90 SV, ng impedence 35k V(A-A) > +0.2V = Logic high atthe microprocessor. V(&-A) <-0.2V = Logic low at the microprocessor. 2 D Serial link transmit A or B _ Twines for differential transmit 23 D Seria ink transmit A Diterenial Outpt: Output is to SV, curent cxpabity + 6OmA Logic high at the microprocessor A = SV, A= OV. Logic low at the microprocessor A = OV, A = SV. [Not transmitting (intornal buttar is tr-stated) ‘A, 10k pull up to SV; A, 10k pull down to OV. Rater also to Section 4.5 below, and Figs. 16. e ‘A Serial ink OV common Isolated from zero volt terminals 4, 11. Serial link is aways active, parameter b6 allows control. NOTE Refer to Chapter 8 “SERIAL COMMUNICATIONS" for further details. 40 al ato ant a2 D Drive running Zero volts common +24V supply, 100mA Preset speed 1 Preset speed 2 Jogyinch Programmable open collector output source, 30mA from or ‘minimum speed +24V sink, 250mA to OV. +24V extemal relay de- ‘energised if rive not running or not at minimum speed. Configured by parameter b53 Intemaly connected to terminals 4, 11 General purpose (10%). Short-crcut protected from OV. ‘Two binary preset speed inputs salect 3 proset speeds. When both are high, normal speed control is salected. (NO contact to ze10 votts) Low = Jog/inch (N/O contact to zero volts) ‘This input can be software soloctable to give a third preset spood Input and thus 2 total of 7 preset speeds. Configured by parameter 820) 413ELECTRICAL INSTALLATION ©D75-750 4.4 Other Configuration Details The outline of the control PCB is shown in Fig. 16. The only remaining customer useable selections are — PLS To select positive or negative (standard) contol logic. 125 ‘Serial communications terminating resistor. Refer to Fig. 17. PLE Link to enable/diable motor thermistor input 45 Connecting Serial Communications : ‘SERIAL COMMUNICATIONS VO ‘The standard connection is RS485/RS422, refer to Fig. 18. Always use screened, twisted-pair cables for RS485 serial, Alternatively the single ended communications system, RS232 can be used, Fig. xx. ‘Serlal communications cabling — IS485 cable type, braid screened, 120 Ohm characteristics impedance dual twisted pair. Termination: Cable terminated at each end by 120 Ohm resistor. Maximum cable length: 120 m. S422 cable type: braid screened, 100 Ohm charactetstics impedance dual twisted pair. ‘Termination: Cable terminated at receiver end by 100 Ohm resistor. ‘Maximum cabie length: 120 m. S232 cable type: braid screened, 3 core. ‘Termination: None. Maximum cable length 15 m. 414CD75-750 ELECTRICAL INSTALLATION 5 Operating Procedures ‘sone nono essen 5.1 Safety 5.2. Setting Up to Run 5.3 Keypad and Display 5.4 Modes of OperationCD75-750 OPERATING PROCEDURES 5 Operating Procedures 51 Safety Safety procedures must be properly observed It Is advisable particularly to take care to check the Girection of rotation of the motor Ensure that... * the person in charge ofthe tral un is fully competent to perform or supervise the mechanical and the electrical instalation. + the motor rating is compatible withthe inverter rating, the motor fs securely boted down, + the invertors firmly attached in an upright postion and is property ventilated. Pretiminary For access to the power and contro! terminals, remove the Terminal Cover — the lower portion of the lid, Figs. 6 and 13. Make power connections as shown in Fig. 20. + Electrical supply connections must be earthed in accordance with local industrial safety regulations, Protective hre fuses or a circuit breaker of the correct rating must be installed in the supply, rotor te Chapter 4, Section 42, page 4-5. MOTOR EARTH MAINS SUPPLY SAFETY EARTH MUST BE CONNECTED. ICONNECTS INTEGRAL RFIFILTER 20 Power terminals and standard connections forthe drive.OPERATING PROCEDURES 075-750 { OV common (intemally connected) 21 Spustra control components and connections to enable the dive 1o ‘operate under Procedure A. Procedure 2h and noe Snel coral wiring ta start anda op swich, wih a potertiomeer a8 shown Sagara tan strain of parame athe heypa Sang end enero Shs, mode is a8 simple as with a conventional tater sro ‘motor is immediately under manual speed Procedure A External contro, not using keypad, ‘At Install the contol wiring connections to terminal boar, ‘shown in Fig. 21, as follows — Terminals 4, 5,6, so at Potentometer. Ensure thatthe potentiometer is sot atthe er0 volts point. Termina's 9, 14 T.a.motor thermistor is avaiable, connect betwoen terminals 9 and ", ‘efer to Chapter 4 Section 4.3, page 4. Mec te thermistor i 1 be used, a link on the INSO pcb must be ‘epostioned to disable the input. Fer to Fig. 16 fr lcatbonoy aie Terminals 11, 12, Unk together to bypass the external trp, 54(CD75-750 OPERATING PROCEDURES Terminals 11, 14, 15. Install two control switches — RUN switch, normally-open contacts, torminals 11 and 15, and a STOP switch, normally. closed contacts, terminals 11 and 14. A2 Set speed pot to minimum speed. Tum on the 3 phase input. Close the RUN contro! contact. ‘Observe that the Inverter Active’ LED and the FWD’ LED illuminate. The keypad display indicates. (0. The motor remains at rest, but is energised at zero Hz. 3 Turn the potentiometer a small amount to start the motor at low speed. Observe that the keypad display indicates the motor speed. The value shown is the frequency supplied to the motor. NOTE tis not advisable to run the motor at low speed for any length of time, especialy iit is loaded, unless the motor has a thermistor for over-tamperature protection and this is connected 1 the drive as shown in Fig. 15, page 4-8, or arrangements have been made for additional cooling. Ad Use the potentiometer to increase and reduce speed. The motor is at full speed when the display shows 50.0 and the potentiometer is at the +10V end. ‘A5 Operate the STOP switch. ‘Observe that — the motor ramps to rest, ‘eypad display value reduces to zero, the keypad display changes to rd¥. ‘The display indicates that the motor is now stopped. The output bridge is not energised, as indicated by the ‘inverter Output Active’ LED being extinguished when rd appears. [At this stage adjustments can be made to some parameters for practice and to observe the effects. The drive can be powered-off at any stage of the procedure. Press the RUN switch at any time to restart the drive. Observe that — the motor ramps to the potentiometer set speed, and the keypad display changes from Fd¥ to @ numerical display of the set speed expressed as a frequency. Procedure B Keypad control, without using external control cuts. FIRST DISCONNECT THE POWER SUPPLY B1 the motor has a thermistor, and this is to be used for protection, connect it between terminals 9 ‘and 11. ithe thermistor input is not being used itis necassary to disable the internal circutt Link PLE must be removed, Reter to Fig. 16, page 4-10, for the location o lnk PLE. 82 __Turmon3 phase input and observe that the keypad display becomes active and shows rdY. 83 Make control parameter adjustments to put the motor under Keypad Control, as follows ‘SELECT KEYPAD CONTROL b9 = 0 NOTE When using the keypad, i there is a pause of 8 soconds between successive keystrokes, the display will overt to a non-active state. Press MODE to resume wherever keying paused. Press the MODE key to enable a parameter to be selected. Observe that the PAR LED illuminates. The display will show PrO, aerating with 0. Press either the UP or the DOWN kay. One key-stroke always changes the display to the noxt parameter. Choose parameter b9. The display alternates betwoon b9 and its present valve, which wil be 1. This is the as-dalivered value, and means that the motor is in TERMINAL control mode. (If 8 seconds elapses between keystrokes the display reverts to rd and the PAR LED will go off. To resume adjustment, press the MODE key again.) ened ssOPERATING PROCEDURES 075-750 Prass the MODE key to hold the display value 1, then press the UP or the DOWN key once to change the value to 0. Press the MODE key to ext the parameter adjustment. Control is now in KEYPAD mode and the display will akernate betwsen b9 and its now value, 0. Ater és the display wll change to rd and alternate wth the sat speed value inital zero) RUN AND STOP THE MOTOR Press the RUN key. The motor will start and run up to the sot speed displayed. Presb and hold the UP key to increase the set speed. Press the STOP key. The motor will ramp to a stop, and will display rdY, aternating with the set speed, when the speed reaches zero, When tha display is not showing a parameter, o is not being used to change a parameter, the set speed ‘can be adjusted by using the UP and DOWN keys. lavertor output active Serial comms active Dynamic brake active (Current iit active Remote control of drive 22 The Control Pod. fight, the four-panel digital dis with ‘NEG’ LED ‘ahes Leer et, ro (Ss nee aan is play wis NEG Le LED uminates vnan the daplay fs showing a parammoter sucbar fhe CWS when the drive is conrlld o Tur forward 56CD75-750 OPERATING PROCEDURES 53 Keypad and Display Control Pod, Fig. 22. Display Features, Fig. 23. ‘The Control Pod combines keypad and display functions. All operational functions of the drive and motor ‘can be controlled and all parameter values can be changed from the keypad. Parameters and their values ‘are adjusted by the three upper keys. The three lower keys control motor RUN (stan), STOP/ RESET and FORWARD/REVERSE when in keypad mode (b9 = 0). ‘The upper row of three keys controls the parameters in two modes — selecting a parameter number and ‘changing a parameter value. Parametar numbers or values, as appropriate, are shown in the four-window display, with an LED to indicate when values are negative. When parameters are being read or changed, the display defauts to the Present indication (see Display Description, below) after 8 saconds without a keystroke, Operational status is shown by the group of five LEDs on the Iett of the keypad and also by the Forward/Reverse LED above the FWD/REV key. ‘A feature of the control pod is that it can be demounted from the module. This enables the drive module to ‘be located in a secure enclosure and the control pod to be located in an accessible posttion. The Procedure for removing the Pod is described in Chapter 3, Section 3.3, page 3-7. When demounted, the pod is connected to the module by standard 9-way control cable (preferably screened) connected one-for-one to standard 8-pin D-type terminations, one male, one female. Maximum length of cable is 100m. Leads can be obtained from the supplier of the diva. ‘The faciity to demount the control pod can also be used to provide secuty, as the pod can be removed ‘completely. Removal of the pod in terminal mode — even while the drive is active — has no effect on the ‘operation of the drive. Removal of the pod in keypad moda, i the drive is running, will ause it to stop. Display Description When parameters are not being read or adjusted, the display shows either drive status or running performance, thus — DRIVE CONDITION DISPLAY Healthy and stopped ‘ether — rd (Terminal Mode, b9 =1) or— rd ahtomating with SET SPEED (Keypad Mode, b9 = 0) Heatthy and running be =t ‘either — output tirequency (b8 = 0) or— oad in % of output FLC (68 = 1) Note that whichever value is displayed, the other can be viewed by pressing both UP and DOWN keys simuttaneously. b9 = 0 set frequency Tripped Trip Code Reter to page 5-1 When the drive trips, Trip Code flashes. When the drive i in the process of boing resat, Tip Cod (0ot ashing). When the drive completes the reset, ‘ther — the display shows rd (Manual Start mode) and the drive waits fora star signal or— the drive automatically starts (Auto Stan mode) steady 57OPERATING PROCEDURES CD75-750 11 Hardware taut at power-on cir |= I | ul or CO} ri rer Riba 2. Parameter number and its value. Ie] = Ao = MODE key pressed once. Parameter Number Parameter value 3 Adjusting a parameter value. , a MODE key pressed twice. 4 4 Drive TRIPPED LE = ip Ce 5 Drive TRIPPED and RESET. {Only for 1s) a 6 Drive STOPPING 1 Ramp mode Co 2 Coast to rest (nih > ive nhied 3 Injection brake cS 3 baking moe 7 ve STOPPING 1 Keypasmode [T— d/i]}== a * rive ready wart 2 Terminal mode bent = 8 Drive STARTING Sgieting ‘spinning motor a 9 Drive RUNNING 1 Koypaa mode Co 2 Terminal mode a UP and DOWN keys. Pressed simultaneously 3 Terminal mode Co bent 1, 2ce, Prony of display soa ora 1 2a Priority of display RED og oy preaueney SB Display shemating ‘oe oF anbing. BW PAF LED itsminated PAR LED of 23 Display features, 58(CD75-750 OPERATING PROCEDURES Display Flashing ‘The display flashes when one ofthe following conditions is present — + The drive has tripped and display is showing a Trip Code, + Apparameter value has been adjusted to one ofits limits + Allunused decimal points flash to indicate when the drive output has entered the Ix t region Display Value ‘Selected by parameter b8, During normal operation, and when the drive is not in Keypad mode (b8 = 1), the keypad display can show either the motor speed or the load. Load is displayed as a percentage of full toad current. ‘Speed in Hz b8 = 0— Actual frequency delivered to the motor, not the set speed frequency Load%FLC B= 1 ‘A quick way of changing the displayed value from speed to load or from load to speed is to press both the UP and DOWN kays simultaneously. 1b = 0, the Set Speed is displayed rogardless of bS. Operational Status Five red LEDs 1 the left of the keypad, and the LED above the FWD/REV key indicate the status ofthe drive. INVERTER OUTPUT ACTIVE indicates that the output power bridge is active (even if output frequency is zero H2). SERIAL COMMS ACTIVE indicates the serial link is actively sending or receiving information DYNAMIC BRAKE ACTIVE indicates the dynamic braking threshold has been exceeded, due to regeneration — that is, the dc link voltage has exceeded a given level above the ac supply voltage. CURRENT LIMIT ACTIVE indicates the drive is in current (torque) limit which means one of the following — + the load exceeds either the full load of the motor as set by Pr4, of — + the torque limit as set at torminal 7. + the output current transiently excoeds the 150% (HVAC 120%) drive output. REMOTE CONTROL OF DRIVE i an indication that the control mode is Remote, as determined by terminal 16, This means that the drive speed reference is either 4-20mA current controlled or ‘serial comms controled. ‘The LED above the FWO/REV key indicates the direction of rotation demanded. The actual ireetion of motor rotation at any instant may or may not correspond. LED illuminated means FWD ‘demand. LED not illuminated means REV demand. Manipulating the Parameters via the Keypad To Select a Parameter ‘The MODE key enables a parameter number to be selected. When the MODE key is pressed the green LED (PAR) above the MODE key is Huminated, a parameter number is displayed, and atemates with the parameters value. Ordinarily, the PAR LED is extinguished. With the PAR LED illuminated, press the UP or the DOWN key once to select the NEXT parameter. To ‘scroll through parameter numbers press UP or DOWN repeatedly. there is a delay of more than 8s in pressing another key, the display will default to the Present Indication (see above) of the output of the drive. Pressing MODE again returns to the parameter selected. ‘To Read a Parameter ‘Select a parameter (when the PAR LED is extinguished) by pressing the MODE key once. The LED will iluminate, and the display will show the Pr or b number, alternating with the value, of whichever 59OPERATING PROCEDURES 075-750 ‘Structure of Prd menus and access procedure. 5-10CD75-750 OPERATING PROCEDURES parameter was last read or adjusted. The display will atemate between the parameter number and its Value for a potied of 8s, afiar which It will defauh to the Prosent indication. if a different parameter is required, select as explained above. The new parameter will aternate with ts valve in the display for 8s. ‘To Change a Parameter ‘STOP FOR BIT PARAMETERS! Bit parameter values can be changed only when the drive is stopped and the display is showing rd, or the drive has tripped, then the Trip Code wil flash in the display. In both cases, the Inverter Output Active LED is not iluminated. press the STOP/RESET key i the drive is in Keypad control mode (b=0), or open the ‘eontrol mode (b9=1). Wait unl the display shows rd. ‘SEGURITY CODE! Wf a Security Code (s00 below) has boon assigned it is not possible to change any parameter value Unt! the correct code has been entered. Any parameter can be read without need for the Security Code, with the exception of Pr d menu 10 to 50. Select the required parameter. When the PAR LED is illuminated, press MODE once. The display will hold the parameter value steady. If a further keystroke is not made within @s, the displayed valve will dofauk to the Present Indication. ‘The values of all Pr parameters can be adjusted whether the motor is running or not. ‘Change the parameter value by pressing the UP or the DOWN key. A single keystroke changes the value by 2070 of 40.1, depending on display resoktion. Press and hold either Key) to increase or decrease the ‘parameter value to the maximum or minimum avaliable. The parameter change acts immediately on the internal setting. I the drive is operating the motor, the motor responds to the change as iis being made. The last parameter value set is stored it the power supply is disconnected, and is restored when the drive is next energised. DECIMAL VALUES! ‘The display operates an automatic floating decimal point. According to the range of values of the parameter, the display inserts a decimal point appropriately. For example, the range of Pr2 is 0.2 to 600s. The display will therefore show all values between 0.2 and 1600, The range of Pr6 is 010 25.5%. The values displayed will therefore be 0 to 25. NEGATIVE VALUES! ‘A negative value is indicated by the negative LED beside the display becoming illuminated. Parameters Pr20 to pr28 are the only ones which can have negative values. The priorty is set by the FWDMREV key. ‘Access to Parameters, Fig. 24 shows the configuration and manipulation of drive parameter menus. eaOPERATING PROCEDURES CD75-750 Security Code Selected by parameter Pr. Prevents unauthorised alteration of any parameters. To assign a security code, the drive must be energised. Using the Control Pod, the code can be sat to any three-digit number from 100 to 255, or 0. Press MODE to onter, Using Serial Communications, the code can be set to any number from 0 10 255. When a securty code has beon assigned, each time the drive is energised the code must be used to allow adjustment of parameters. To gain access, select Prb, set tho code number and press MODE. Parameters remain alterable without further use of the security code until the power supply ‘disconnected trom the drive. It the wrong code is entered, parameters will not be availabe for adjustment. Return to Prb, and enter the correct code. ‘As delivered, Prb = 0, that is, the Security Code is not operational. I desired, the code can be left a this ‘0 that access is available without a code. itis convenient o do this during commissioning, and to assign 8 security code after the operating parameter settings are satistactory. 512©D75-750 OPERATING PROCEDURES 5.4 Modes of Operation — Logic Diagrams 541 SA2 543 54.10 5411 S412 5413 SANS ‘Speed Reference Torque Reference Reversing Starting Stopping Reset Trip ‘Speed Loop ‘Acceleration Deceleration Voltage Loop DC Link Voltage Controt Digital outputs Serial Communications Page 514 515 515 516 516 517 5-18 519 5-20 5-21 5:22 5-22 5-22OPERATING PROCEDURES CD75-750 COS PRESETS Ee Ca eet rp Vota bal -r0¥] ov [-10v 7 ats O[-Prt]2Pr0 | «Pri SET SPEED UF hay raises SP bynctment: Bown coy Socroses nput Curent bi oma [amazon [a20lct wp] Pre] Prt] [20.4] Pri| Pro] t= Ter] Bat Booed ———— REVERSE ‘rout Stone SPEED SE} Pon Gules (thou drecton) ) Input 9 Contel Loops idinament SP ®ve PS | >——__—— ‘Ato A — cele, 77 Parameter must =1 to have affect At [D>—Communications input ! Intemal egic function “parameter must =0 to have oflect w | 12] a11 | Ato] ps" oO 0 o | 00 o}fo 1} oO 0 1 0 | 02 oO i 1 03. [+o [| 04 1 0 1} 05 1 [1 To [6 afi [ito] 7 P7, 0 = eternal contact open clu Tettenalcomatebea oy ||| 2 | Ps Nore “In the configuration, p ‘The dive is assumed to be running. forthe the eve wuss ony PRESET speed reference inputs shown above apan source of. speed ma ‘SPEEDS ftom JopPreset;forthese the drive must be felerence thar e 3 cumently vad. = = | 5. SPEED REFERENCE -wfeve| fd¥] PRESETS $14CD75-750 OPERATING PROCEDURES CURRENT thar Pra CURRENT TORQUE ‘LIMITS SET POINT TORQUE ‘rout o Moemonic TP 010 +10V only”! in Stat con Tap Out input aR a Contra Loops) sow | ee Word TP NOTE 10 i input is open-circuit. FWDREV ‘osed FWOREY key pressed ‘2 Keypae LE eWDor REV recta /ERSE ‘NeGaTv ca Wor SF fhe BaD) ‘ ve ramps” negATVE down to zero and Upto reverse set and back zantin FWD in FWD) So CEB ‘at Control Pod is exinguished Preset Spaod negaTVE + ACCELERATION Pr2 oF Pr30-87 If using a Preset/Jog cee eae 515OPERATING PROCEDURES External select ‘Jog’ (closed) External RUN [contactor closea| momentanly Word CW bit 0 = 0 momentarily RON rected ioypad Drive RESET ‘and rue prot to TAP 230 ER ‘spplied ‘S.44— STARTING DISCONNECT Mains ‘Supply External STOP ‘contact open ‘momentary Word CW bit <0. momentarily res a Keypad 075-750 RuwsTanT| ‘and NOT ‘tipped ‘STOP MODES [Standard ramp |Coast to rest Inject de braking High level ramp =e-eGCD75-750 OPERATING PROCEDURES (O— control terminal 4 Communications input ~~ Parameter must =1 to have effect tena or Remote parameter ‘must =0 to have effect 517 ‘Heep eRerER RM: He agp ec sntee we PD ngsOPERATING PROCEDURES 075-750 ‘Trip cannot be reset. Drive hardware] Power off and on tory to reset. >CEE] power-on Inverse time (integrating b = See] — oper Dive heat eaten >{LoH TIP Instantaneous es > ge om k re provtoe anna ly DC bus indepen pd ae ‘overvolage Lio RESET acon Drive frst ramps down to zero speed, Pe displaying ACUU, before tripping sat >F Powtaut See gto i, [eineesaeeaseP EE DC link Drive frst ramps down to zero speed, Ac nga | sesins A006 See as ts = > Ue 5.47 — TRIP 518D75-750 SPEED SET POINT (without direction) (Diagram 5.4.1) I OPERATING PROCEDURES 'O—Contro! terminal 9 ® LED on Control Pod Parameter must =1 to have etfect twat jor Remote —Rsunmaton Point Diagrams 5.4.9/10. ‘Accel. Decl, SKIP FREQUENCY FUNCTION, "Current Limit ‘ative’ Jonas ‘compensation Pr? (SU) ‘Max contin. ccurent Ps (TH) ENCODER input shen bo (witout drecton) Load.) signal | FREQUENCY is ELECTRICAL FREQUENCY (with direction) (ac) 519 B00 4 i remap emgCD75-750 OPERATING PROCEDURES DECELERATION i & 3 Bl llltles a alels/e ul 3 eto 7 E cece z 5.4.10 — DECELERATION 5:20CD75-750 OPERATING PROCEDURES 9 ©—Control terminal 77 Parameter must =1 to have atfect Imeral logic Function — sumtin Point "Boca 18 boost taper proven vohage exceeding 8.1% at z0r0 fegulncy ACTUAL ELECTRICAL FREQUENCY (with direction) (ac) {ibd or torque signal} peSrom debus OUTPUT, VOLTAGE ;________—»| when overtiow/ IxtTRIPOPERATING PROCEDURES CD75-750 9 O— Controlterminal ——-—_-"_Parametor must =1 to have elect LED on Control Pod —Q)semaon point | Postve error | ‘eater than set level i DC Bus 1 Vohage Measured 01 Ramp down to }->)2000 speed then Teen Ramp down to 12010 speed then TRIP ACUU (5.4.12 — DC BUS VOLTAGE CONTROL’ ACTUAL, ELECTRICAL FREQUENCY (with direction) (acy terminals 28 “Oi message format Paty bit set (610) Baud rate set (612) ve lo ‘Serial Address correct = only £85 set in Pr9 (Word SE) nerropation FS. BD conn {|p om me biO=1 Terminal 16= Dive wil —_—____ 2 REMOTE m7 eta ‘5.4.14 — SERIAL COMMUNICATIONS 522CD75-750 PARAMETERS 6 Drive Configuration Parameters AAT TTT 61 6.2 6.3 6.4 Parameters and their Functions Operating Parameters Bit Parameters Parameter Quick Reference and Setting Record orCD75-750 PARAMETERS 6 Drive Configuration Parameters 6.1 Parameters and their Functions Paramoters are the means by which the operating characteristics of a system are controlled and ‘monitored. The two principal kinds of parameter of a digtal drive are the operating parameters and the bit parameters. Operating parameters have a real-value range, for example from 0 to 150%, and take the place of variable potentiometer setings Bit parameters take the place of the links as used in analogue drives for selecting different contro ‘configurations and are ‘sither-or functions. ‘The response of the drive and the motor depends fundamentally on the set up of the drive parameters: (designated by the intials Pr). These values are accessible through the keypad, and addtionally by signals through the serial communications link from a host computer, a terminal, a programmable logic controller or ther communicating device, ‘The operator can read the value or state of any parameter, so all parameters are ‘reac! parameters. Those \which the operator can change are called ‘write’ parameters. Some parameters are therefore known as ‘read-write’. The rest are ‘read only’. Read-write parameters can be adjusted in any sequence and ‘changed as desired. Operating parameters can be adjusted while the motor is running. Bt parameter adjustment requires the ‘motor to be stopped and the display to show rd, oF to be tripped, whan the display will flash the Trip ‘Code indicating the condition, ‘No parameter can be adjusted to a value outside the operating range of the drive, and all are limited to safe levels of inverter operation, Al parameters can be allowed to remain at their default values, or as sot atthe factory during final test, or ‘can be adjusted in any sequence to suit specific applications. Default values are settings to which all ‘parameters can be caused to return at wil. 63PARAMETERS CD75-750 64 6.2 Operating Parameters Parameters are listed in the sequence which they appear In the keypad lisplay when the UP key is Used following one press of the MODE key. Parameter: Pro Minimum frequency: The lower limit of inverter output frequency, determining the ‘minimum speed of the motor. Oz < Pro.< Prt oz MN Prt, pr20- 26, Pri0- 12, b14 NOTE Adjusting PrO may alter the Preset Speeds and the Skip Frequencies — Preset Speeds — Pro < Pr20- 26 < Prt ‘Skip Frequencies —PrO s Pri0- 12 Pri ‘The © 10 +10V range of the extemal vottage reference Viq (terminal 5) operates on the difference between Pr0 and Pri. For example, if PrO = 10, the inverter output is 10Hz when the minimum speed reterence is OV. 1 Prt = 50, say, then when the speed reference is SV the output frequency is — v Pri-Pro) x Me} + Pro te »* aay) (50-10) x (S +10) = 30H Pararneters PrO and Pr1 apply to both forward and reverse operation. Parameter: Pri ‘Maximum frequency: The value of speed in Hz above which the motor is not 1o operate. Range: Pr0.< Pri < ULF (Refer to b14 for information about ULF) Detault value: SoH Sorial mnemonic: MX Rolated parameters: Pri, pr20- 26, Pri0- 12, b14 NOTE Adjusting Prt may alter the Preset Speeds and the Skip Frequencies — Preset Speeds — Pr0 s Pr20 - 26 < Pri ‘Skip Frequencies —Pr0 < Pri0- 12< PriCD75-750 PARAMETERS CHANGE-OF SPEED RAMPS Provision for controling acceleration and deceleration has three objectives — to serve the many applications where abrupt changes of speed are not acceptable, to limit current demand during any upward speed change, and to limit DC link voltage during a downward speed change. Deceleration time is set by parameter Pr3 which has a range from 0.2s to 600.0s, Fig. 26. The etfect of deceleration time is, however, not exactly analogous to acceleration time, even though the two characteristics shown in Figs. 25 and 26 apparently have much in commen. ‘When the frequency of the supply to an induction motor is reduced while its rotating, slip takes a negative value, In effect, the motor becomes a generator and retums power tothe inverter. To some extent, this power can be absorbed by the DC ink capacitor and by losses within the system, but the DC votage cannot be ‘alowed to rise without risk of damage to drive components. The DG link protection logic is not adjustable. 11s found that a chosen deceleration time causes the inverter to trip and indicate a DG link overvokago, ‘ther the deceleration time must be increased or, if this is not possible due to the needs of the driven system, the optional dynamic braking unit will have to be utilised to absorb the excess energy. This ‘altamative is discussed further in Chapter 9 “OPTIONAL BRAKING UNIT”. Parameter: Pr2 ‘Acceleration time: The time to accelerate from OHz tothe selected value of ULF: determines the slope of the acceleration ramp. (Refer to b14 for information about ULF) Range: 0.25 10 6008 Defaut value: 50s. Serial mnemonic: AL Rotated parameters: Pr3, b14 Acceleration time is set by parameter Pr2 which has a range from 0.2s to 600.08. The actual time to ‘accelerate from any speed to any other is then a linear proportion of Pr2, Fig. 25. Acceleration limits are imposed by the maximum and minimum available values of Pr2 and by the chosen valve of ULF (14) Parameter: Pr3 Deceleration time: The time to decelerate from the ssolacted value of ULF to 0} determines the slope of the deceleration ramp. 0.2s to 6008 10.08 Pr, bia ue cea ' 1. ' Range of P2———" Range of Pr3———=. 25 Acceleration Time Pr2.The time t to 26 Deceleration Time Pr3. The time t to ‘accelerate from 11 to 12 depends on the decelerate from 11 to £2 depends on the aloe selectod forthe ULF as wal! as for abe solctd ortho ULF as wel a or 6sPARAMETERS 66 CURRENT & PROTECTION ‘An inverter is usually selected with a maximum continuous current rating to match that of the motor. To prevent overheating at ful load the motor full load current (FLC) rating must not be exceeded. The ‘continuous current limit is parameter PrS and its value isthe ratio of the motor rated FLC to the inverter FLC, expressed as a percentage — Pr5 = (motor FLC /inverter FLC) x 100 PrS is the lower threshold of the inverse time-current protection of the motor and its cabling. Any current value in excess of PrS when integrating in the Ix t region is signalled at the keypad display by flashing of the unused decimal points in the display and will, if sustained, result in tripping of the inverter. Curves are shown in Fig. 28. ‘Trip time = kx PrS / (actual % current - Pr8) in seconds, where k= 25.7 for Industrial or HVAC drives ‘A short acceleration time combined with a high inertia load may demand a current higher than the ‘maximum continuous current PrS and the current is likely to enter the 1 x t inverse time protection zone. Only i the drive were grossly under-rated relative to load inertia or if the current limit (Pr4) were set low ‘would there be a likelihood of an overload trip during acceleration, ‘The drive logic recognises threa levels of high transient curent above the current limit Pr4, such as might be caused by severe shock loading, or by short circut or earth faut in the motor or cabling. The logic responds to transients protecting the motor, the cabling and the drive by shutting down the inverter IGBT bridge. The speed of electronic fault detection is greatly superior to the performance of hre fuses. Note thatthe intemal current imit fs scaled by the torque reference inout (terminal 7) such that — Ve Internal current limit = (Pra x —©) + 10% iov Parameter: Pré ‘Timed current limit: | Maximum level of inverse time-current overload. Range: PS < Prd < 1S0%FLC for Industrial rating drives PrS § Prd < 120%FLC for HVAC rating drives Default values: 150% FLC for Industrial rating drives 120% FLG for HVAC rating drives Serial mnemonic: = TR Related parameters: Pr8, Terminal 7 Parameter: PrS Max continuous Percentage of FLC at which current can be supplied continuously; currant: threshold level of timed current limit Range: 10% to 105%FLC, and not greater than Pr Detautt value: 100%FLC. Serial mnemonic: = TH Related parameters: Pra ©D75-750(CD75-750 PARAMETERS DEVICE LMT INSTANTANEOUS. TRIP REGION ‘Continuous current Prs t(sec) 27 Overeurrent protection by internal electronic monitoring. Protection curves according 10 setting of PrS (%4FLC of drive) 150% FLC 120% of rated} FLC of drive = fee 100% of rated titel a FLC of drive 1 30 180 ‘{sec) 28 I xt characteristics (not to scale 67PARAMETERS CD75-750 TORQUE (VOLTAGE) BOOST Parameter: Pr Voltage (torque) Maximum level of voltage boost boost at 2010 frequency. Range: 0 to 25.5% of main supply voltage Detauk value: 51% 0 Serial mnemonic: 80 Related parameters: b3 When the boost value (Pr6) is sot high, the profile below a frequency of one-sixteenth of Pro assumes the gradient of constant Vf provided thatthe line wil intersect the OHz axis ata value of 5.1% of mains supply voltage or loss. Otherwise, the intercopt is made at 5.1%. Ifthe chosen value of boost is ow, the gradient of boost values is constant (refer to Fig. 29b). It le best to choose the lowest effective degree of boost as too high a value may, when starting the ‘motor, result in stalling. For this reason It Is recommended that Pré should be increased in small ‘steps from a low vaiue until the motor starts Smoothly and with minimal hesttation. ‘When AUTO boost (b3 = 0) is selected, the inverter logic applies a boost increase proportional to the load demand as a percentage of the chosen value of maximum continuous current PrS. The applied voltage boost is therefore given by — neo I, for example — the selocted value of Pré is 10% the selected value of PrS is 100% FLO. land the actual oad demand is 47% FLC then the applied voltage boost is — tox fF 47% ‘This is tapered trom 4.7% boost at zero frequency to 50% of MVF (ie at 0.5 x Pre). iz 2 ae Normal Varatio 16 2 2 (torque) boost (eh {vel of boost, tapering to 5.1% at OHz. Note that 1G maintained st high level above a frequency of ‘one sixteenth of Prc. {@) Low level of boost — tapers avenly from boost setting ‘when boost is <5.1% of rated voltage. 68CD75-750 PARAMETERS SLIP COMPENSATION Slip compensation compensates for speed varied by increasing load due to the slip characteristic of ‘squiral cage induction motors. Wis applied by parameter Pr7, Fig. 30. In open loop mode (65 = 1) Pr7- increases the output frequency of the inverter to a value above the frequency demanded by the speed reference. In closed loop mode, (b5 = 0), Pr7 has no etfect. The available values of sip compensation ee ULF | Available Range Maximum He of rT Compensation 720 Oto SHz 7.8Hz 240 Oto toHz 15.2H2 420 0t0 20H 30.3Hz 960 00 25Hz eo.sHz ‘Tne amount of compensation applied is dependent on the folowing factors — + The valuo of ULF solected +The value of Pr7 selected from the available range for the ULF +The actual oad as a proportion ofthe selected value of maximum continuous current PrS. For example, if the ULF is 120Hz and Pr is sat to SHz, then when tho motor is drawing current equal to the selected value of PrS the compensation will be 5.0H2. If a lower setting of Pr7 had been selected, th ‘compansation would be proportionally lass atthe same load current. In any case, at loads below the value ‘et in PrS the compensation i proportionally lass. For good compensation, PrS should be set tothe value of the moto fll load current, and Pr7 adjustod to the slip frequency of the motor. Slip compensation apples in both forward and reverse oparation and gives near-constant speed holding with fluctusting speed and load. Compensation in Hz = Pr7 x 4238 Paramater: Pr? Slip compensation: Increases inverter output frequency as load increases; scaled by the ratio of ‘actual curent the selected vaive of Pr5, up tothe frequency increase selected. Range: Oto SHz — ULF 120Hz Oto 10H2 — ULF 240 Hz, Oto 20H2 — ULF 480Hz Oto 25Hz — ULF 960Hz Osfauit value: oH Serial mnemonic: SL Rolated parameters: BS, b14 Js0 Sip Compensation Pr7 increases reguency ‘cording to ‘Compensation may be selected within the’ 69PARAMETERS INJECTION BRAKING Parameter: Pro Injection braking: Maximum level injection braking curre percentage of rated FLC. Range: 40% to 150%FLC (Industrial) or 120% FLC (HVAC) Dofaut valu 150%FLC for Industrial Drives: 120% FLC for HVAC Rated Drives Serial mnemonic: BR Rolated Parameters: 62, b7 NOTE — Injection braking is operational only when the drive is stopping and when b2 = 1 and b7 = 0 6-10 Value of Pre Minimum — Maximum 40% of FLC 180% of FLE fp a Il : : kK aie tegom jon braki 31 Injecters tinea relationship of the assigned value of Pr8 tothe braking 9 ape NEG} “The effect of a STOP command, which cai ‘1 Buced ineary to ero at ful requencyYolowed by: {G) injection of braking current at tow frequency for @ period which is {a ghdent on the inersa ofthe load: yine Raking trgue ime, 16 G2 eMalue of the os holng torque (8) s a proportion of Pr. The braking current level (4) is determined by the the voltage to be lve of Pre.CD75-750 PARAMETERS SERIAL ADDRESS Parameter: Pro Sorlal address: Identifies the inverter to enable ‘serial davice to address a solected ‘rive in & mutiple drive system, Range: 01099 n SE 6, b10, biz FAILURE MODE (MEMORY) Parameter: Pra SERIAL MNEMONICS Failure Mode Contains the last 10 tp Pr-O = TO Parameter: codes saen by the drive Prat oT ‘Does not hold UU it the PrA2=T2 dive was in a tripped PrA3 = 13 ‘tate during power down. Prag = T4 Holds the last 10 trip PrAS = T5 ‘codes even when power PrAS=T6 disconnected. PAT = 17 PrAS=T8 Range: PrA-O last trip to PrA-9 previous PrA-D = T9 tenth trip Detaut: PrA-0 to PrA-8 Blank Data Logging ‘The drive can be interrogated for the history of faut tips for logging and for system analysis. The software saves the most-recent ten trips. Data is read-only, and is not lost when power is disconnected from the drive, The procedure at the keypad is as follows — Find PrA in the main menu, Press the MODE key to go into parameter adjustment mode. The display will then show the code of the most racent trip in the windows to the right-hand side of the display. The left-hand window will show 0, the log sequence number. To view the codes of sarier tips, press DOWN to view in sequence, 0 to 8, or UP to view in reverse sequence, 9 to 0. After power-up, the starting point wil always be 0. (NOTE The minus LED also illuminates for log sequence fumbers 1 through 10 9.) I no keystroke is made, the display reverts to the main menu after 8 seconds. SECURITY CODE Parameter: Prb ‘Security code Permits choice of the selector: ‘security code for each individual inverter. Prb = 0 ‘corresponds to no security . ‘code. In keypad adjustment mode, values of 100 to 255 and zero can bbe sot. in serial comms control ‘mode, values of 0 to 255 can be set Range: 010.255, Detauk value: 9 Serial mnemonic: SC (Once the Security Code has been correctly entered, all paramters can be adjusted. The code needs to be entered only ones to allow access to all parameters after power-on, until the drive is powered ot. enPARAMETERS (CD75-750 VOLTAGE/FREQUENCY PROFILE ‘The vottage-io-frequency ratio (VA) dalivered by an inverter is normally held constant up to the maximum, (rated) voltage and frequency of the motor — the base speed. Up to this point the motor torque is, in principle, constant. Above base speed, where the voltage can no longer increase, further increase of frequency output produces a constant-power characteristic. The value of the frequency to be assigned at the rated voltage of the motor is called the maximum. voltage frequency (MVF) and is adjusted by parameter Pre. The MVF is defined by relating Pre to the selected value of the upper mit of frequency (ULF), parameter b14. The maximum value of the MVF is: ‘equal to the ULF (Pre = b14). The minimum valve is one-sixteenth of the ULF. and when ULF = 960Hz tha maimum value of MVF is 60H2. Datines the lowest frequency at which the invertor Pri speed bi = 204 20mA =» PrO speed 4mA = Prt speed bi = 020 OmA => PrO speed 20mA => Pri speed vu uu Baud Rate Selector Parameter: b12 Baud rate selector: 4.8 = 4900 baud 9.6 = 9600 baud Detaut valve: 43 Serial mnemonic: 05 (locaton Qin the 2-bye hex word) RRolated parameters: Pr8, 6, b10 622CD75-750 PARAMETERS Reset Defaults Parameter: b13 Reset parameters to default values: 0 inactive 1 = sot defaut values Default value: ° Setting b13 = 1 affects ALL parameters. Define Vatues of PWM and ULF Parameters: b14 Define PWM switching frequency and ULF First entry — PWM switching frequency - 2.9 = 2.9KH2. 59= ‘kHz ‘8kHz ANT = A-Tkz ‘Second entry (press MODE once) — Upper limit of frequency (ULF) 120 = 120H2, 240 = 240Hz, 1480 = 480Hz 1960 = 96042 Press MODE a second time to exit. Defaut values: -PWM 2.9kH2 LF 120Hz Sotial mnemonic: Fa NOTES (When a switching frequency of 2.9kHz is selected only 120Hz and 240Hz ULF are availabe. ULF of 960H2 is available ony with 11.7kHz. (i) Atoring 614 can affect Pr0, Pri, Pr7, Pre, Pri0— 12, Pr20— 25, FREQUENCY RELATIONSHIP ‘The ULF, the maximum frequency Prt, and the minimum frequency PrO are related as foliows — OlHz ¢ Pro < Pri < ULF FREQUENCY RESOLUTION Ot 120Hz = oLtHz ULE = 120Hz Ot 240Hz = O2Hz ULF = 24oHz Oto480Hz OAH ULF = 480Hz Ot960Hz Oz ULF = 960H2 PWM SWITCHING FREQUENCY Selected by parametor b14 (fist entry) — alternative values are displayed by repeated operation of the UP or the DOWN key. In makag a choice of PWM switching frequency, the factors to be considered are the effect on the motor performance, and the relationship to the upper limit of inverter output frequency (ULF, see below). Lower PWM switching frequencies improve motor torque al low speed, keep heat losses to a minimum, and ‘would be preferred for applications involving high-inenia loads, repeated acceleration, of frequent start- ‘Sop duty. The higher switching frequencies reduce torque ripple and acoustic noise, but increase losses ‘due to inverter heating. Parameter b14 also enables the ULF to be adjusted as a second entry, see below. To leave PWM ‘switching frequency, without altering the ULF value after adjusting the PWM value, press MODE twice instead ol once. canine. 623PARAMETERS CD75-750 UPPER LIMIT OF FREQUENCY (ULF) Selected by parameter b14 (second entry) — integer values of 120Hz, 240Hz, 490H2 or 960HZ are displayed successively by repeated operation of the UP or the DOWN key. ‘The ULF is the highest frequency of the inverter AC output sinewave. As the behaviour of other control functions is dependent on the ULF value chosen, it is convenient to sclect @ value at an early stage. The ‘main reason for choosing one ULF value rather than ancther wil be, primary, the required value of Pri and Pre. ULF ig adjusted by bit parameter b14 as a second entry after setting the PWM switching frequency. iis necessary to press the MODE key once again, after it has bean pressed to set the PWM switching frequency, and then to enter the ULF vaiue, finally pressing MODE once more to exit b14 adjustment. To set the ULF without entering a value for PWM first, press MODE twice after adjusting the parameter code to b14, ‘Special Function Parameters Prd=20 > Function Sorial Mnemonic Detaut 20 Select jog and 3 preset a 0 =/og and 3 presets. ‘speeds or 7 preset speeds (location 8) 21 Standard or selected a 0 standard preset, acceldecel rates (location 9) 22 Preset speed, reverse co = terminal source, keypadnerminal (ocation 7) BIT-PARAMETERS b20, b21 and b22, Related parameters Pr20— 27, Pr30— 37, Pr40— 47 Preset Speeds ara further controlled by two bit parameters, b20 and b21, in the menu Prd = 20, as folows — 1. Bit parameter b20 = 0 (default) enables only terminals A10 and A11 for Preset Spoods. In this mode, Prasat Speeds 1, 2 and 3 are available, with Jog (otherwise called ‘inch’, meaning that the motor is under momentary on-off contro). The Jog facilty is controled by applying OV at terminal ‘A12 so that terminal A12 becomes a Jog control Only from rd¥ will the drive run at the set Jog frequency (Pr27) for as long as terminal A12 is connected to OV. The acceleration and deceleration rates of the Jog operation are always controlled by Pr37 and Pré7. 2 Bit parameter b20 = 1 enables terminals A10, A11, A12 to control seven possible Proset ‘Speeds. Thare is no Jog facilty in his mode. 3. Bit parameter b21 = 0 (dafaut) puts Pr2 and Pr3 in control of acceleration and deceleration, for presets Pr20— 26. 4 Bit parameter b21 = 1 enables the individual profiing accelerations and decelerations available in menu Prd «30... and = 40. Pr20 uses acceleration Pr30 and decoleration Pra Pr2t uses acceleration Pr31 and deceleration Prt at. ‘5 Bit parameter b22 = 0 (defaut) enables reversing of preset speeds to be controled from terminal 117 while the motor is running. The polarity of Pr20— 26 is ignored, 6 Bitparametor b22 = 1. The direction of rotation of preset speeds is preset by parameters Pr20 0 Pr26. 6-24075-750 PARAMETERS Prd = 50 b Function Serial Mnemonic, Detaut 50 Drive healthy/t speed relay 1 0 = Drive heathy ralay (location 10) 51 Disable or enable fwdrov ce = Dieabie kay on control pod (ecation 11) 52 Disable or enable catch co = Disable spinning motor software (location 12) 53. Runvminimum speed o (= Drive running status output (cation 13) 54 Fixed or dynamic vf ratio 1 0 fixed vit ratio (location 14) NOTE (On all COV drives the following detauits wil ator. Drive Healthy = not tripped and notin Err condition after power on, ‘AtSpeed «indicated speed equal to set speed. 1852 spinning motor = 1 enabled 6 dynamic vf = 1 dynamic wf enabled BIT PARAMETERS bS0 to B54 50-0 Status relay indicates (detaut) Drive Healthy when energised (terminals 1,2, 3) b50=1 Status relay indicates A-Speed when energised (terminals 1,2, 3) bS1=0 DISABLE keypad FWD/REV key (default) ) Relevant only in keypad bSt=1 ENABLE keypad FWO/REV key mode, b8 = 0 NOTE When bS1 = 1, terminal 17 controls motor drection when b9 = 0 b52.=2.0 —Notcatch spinning motor detaut) b52=1 Catch spinning motor Enables the drive to be energised onto a motor whose shaft is rotating, without causing a trip. On receiving a RUN signal, the drive scans the motor frequency and synchronises at the values. The drive ‘scans from Prt to zero in the last direction of rotation, then from Pri to zero in the opposite direction. ‘Once the drive synchronises at the motor speed, it then ramps to the set speed. During the scanning period the keypad displays SCAN. On systems where thera is no mechanical load on the motor when it is over-running, a change of speed may be observed during the scanning ‘operation. Dependent on the systam and the dynamic conditions, there may be a delay of up to § seconds. bolore the drive resumes normal operation. 253-0 Open-collector output = (default) Drive Running | Terminal AO 53-1 Open-collector output = minimum speed Extemal relay energised NOTE—- Drive Running = IGBTs being switched inthe inverter bridge, Minimum speed = Quput frequency greater than PrO and IGBTs being switched 625PARAMETERS CD75-750 Fixed or Dynamic Vit Ratio B54 = 0 FIXED VA ratio (default) B54 = 1 DYNAMIC VA ratio . Provides the option of load sensitive voage response, with energy saving and reduced noise at light loadings. At no toad, the applied vokage is 50% of the normal full vokage. As the load increases the ‘applied voltage increases in proportion, to a maximum of the normal voltage at full load, Auto boost and fixed boost (b3) and Pr6 function as for a higher value of Pre. FRED Vivato, 654= 0) [DYNAMIC Virati, B54 = 1 tect Pre when BA» (2-212) re when load is < Prs. When load 2 Pr5, efective Pre = Pre 35. In dynamic VA mode the Vl ratio is proportional to load. (Not to scale) 6-26CD75-750 PARAMETERS 6.4 Parameter Quick Reference and Setting Record Parameter Facey Feschage ‘Second Charge Deteut sates ‘Dao Sorby Dam Satby Po |eeatewmrey [ote Prt | Max trequency | SOHz Pr2 | Acceleration time | § seconds Pra | Decelaration time | 10 seconds Pet | Current timit 150/120% FLE Pes [Max contin txt | 100% FLC 5.1% oltz Ps | DC braking level | 150/120% FLC 5 a Co a xs eae ae Soc ea ae os Tres | rane noae [eee Pras | Failure mode Blank Pra-S | Failure mode Blank |OpeniGlosed loop anve |_| MasterSlave master b7 | Stop mode with b2 | 0 = standard ramp re bo | Torque or speed | 1 = speed bi [Arena san [ = manal pe bo _[asotasdteon [or ase be [unenaret —[reunsour | bs .Fat Charge ‘Second Change ‘ate Sat bie | Pw 2a bie | ULF 20H2 Pre | MVE soHe 50 | Menu access Pri0 | Skip frequency 1 | oltz Prit | Skip frequency 2 | oftz Pri2 | Skiprequency 3 | oft Prt3 | Stipiteg. band 1 | £0.5H2 ria | Skipireg. band 2 | 20st Preset speed 7 227 | Jog speed 15H 220 [presser [onpgancs | | 3 presets and Jog | presets Ba | STOpreser T= sandard ramps b22 | Preset speed Ow torminal reverse source 4 reverse sou Bia] Menu access PO | Preset 1 accel, | S seconds Prat | Preset 2 accel. | S seconds 6-28 CD75-750 SecaCD75-750 PARAMETERS Pr33 | Preset-4 accel, _| 5 seconds Prad | Preset S accel. _| 5 seconds Pras | Prosot 6 accel. | 5 seconds Pra6 | Proset 7 accel. _| 5 seconds og acest, 0.2 seconds Pra0 | Proset 1 decel. | 10 seconds Prat | Preset2decel.__| 10 seconds Pra7 | Jog decal 36%50| Menu access Reset attempts | 0 Reset delay 1 second Drive heathy’ | 0 = drive heathy at speed relay | relay Prs0 Pst 50 bst | FWDREVKey — | 0 disable bs2 53 bse disable Spinning motor} 0 disable Runmin speed | 0 = drive Status output unning Dynamic WF or | 0 = fixed VIF fixed VIF NOTE — On all CDV drives the following detauts wil ater: 'b52 Spinning motor = 1 enabled 'b54 Dynamic VIF = 1 dynamic V/F enable 629(CD75-750 DIAGNOSTICS 7 Diagnostics and Fault Finding 7.1 Fault Finding 7.2. Control Pod Trip Codes 7.3. Healthy Indications 4DIAGNOSTICS D75-750 72 7 Diagnostics and Fault Finding 7.1 Fault Finding DISPLAY doos not illuminate and drive does not run ‘CHECK control pod is connected to drive module ‘CHECK mains supply, supply fuses or circuit breaker Replace supply fuses if blown, or reclose circuit breaker, but it supply fuses blow or breaker trips again contact the supplier of the drive. Weontrol pod is remote mounted, check extension cable wiring MOTOR does not star, display shows rd¥ Drive is in MANUAL start mode, Operate RUN key, or START pushbutton CHECK the control wiring, and that external stop/rurvtrip contacts and circuits are in order. MOTOR does not start, display shows 0. CHECK wiring of speed reference, and that the correct mode (REMOTE/LOCAL) has been selected, ‘CHECK that KEYPAD mode is not selected. Check praset speeds are not selected with dofault seting i.e. “O" Hz. Check max frequency parameter {Pr 1) is not atthe “O° Hz. FAULT CODE at display REFER to Operational Control for possible cause, Note that: + Thermal rp devices should not be continually tipped and reset. + Oltrip can be caused by shock load, cable or motor insulation fauts, length of cable to motor 100 ‘reat, or attempting o accelerate too large a motor. + Ol and OU trips may be caused by decelerating too fast: when operating below motor basa speed — OI tip ‘when operating above motor basa speed — OU trp Increase the value of Pr3 and check that b2 and b7 are set correct. + IPS or Err ae displayed, ty disconnecting the dive from the supply, wat 2 minute, reconnect and run the drive. the faut persists, contact the supplier ofthe dive. MOTOR fails to turn the load, and is noisy Fixed boost setting too high (Pré). Try auto-boost also, ‘Also check the settings of current limits Pr4 and PrS. DRIVE fails to respond to setial communications CHECK loca/remote, mastor/stave (b6), parity (b10), baud rato (b12), and serial address (Pr9) are set correctly. (CHECK the wiring and termination ofthe serial ink. DRIVE appears to be set to an unusable state tthe security code is known— Enter the securty code (Prb) to gain access to b13. ‘Set b13 = 1 to reset all parameters to defaut values. I the code is not known — the code can be accessed from the serial communications link. Ht, after partorming any of the above checks, the drive still malfunctions, contact the ‘supplier of the drive for assistance.CD75-750 DIAGNOSTICS eee ree eee eee ne Eee ne 7.2 Control Pod Trip Codes ‘Any trip, internal or external, immediately stops the drive. ‘The IGBT bridge is no longer active, and the motor coasts to rest Internal protection trips are always active and cannot be disabled ‘An extomal trip Et can be forced by the operator. ob eee et on Ph pee uu AcuU. 4/20mA current oop loss. The current has fallen to<3.5mA when b1 = 4. 20 or 20, 4, When bt1 = 0.20 current loop loss trp is inactive. Hardware fault within the drive. Occurs only at power-up. Is a lock-out condition — no reset (power can be removed then re-applied). External tip is operated by (terminal 12) or via the serial comms word CW. bit 4. Integrating overload (bx) trip. The output current as defined by Pr4 and PrS has reached the allowable time it Hoat sink overtemperature. The heatsink has reached its upper safe Working limit due 10 loss of cooling air or cooling air too hot. Instantaneous overcurrent tip. Excess currant towing inthe GBT verter biog, ‘caused by short circuit, low impedance earth fault or excessive shook DC bus overvotage. Caused by main supply overvoiage (even ft momentary). or high impadance earth faut, or excessive regenaration due toa high rato 0! deceleration Can be caused by loss of one or two phases, or low phase voltage (<380V -15%). Intamal power supply fauk. Motor thermistor (f fited) impedance high due to sensing excess temperature, or impedance less than 100R due to cable short circuit or similar DC link voltage has fallen below the operating range. The drive trips instantaneously. 'ACUU willbe displayed when the input vols tothe drive falls 15% Below the nominal value of balow the operating vokage lava (360V = 15%). The ciepioy roma ae tong ‘8 the condtion persists. The condition does not trip the drive running, but causes t to ramp down to zero speed. f corrected before zero speed is reacted ramp up to whatever speed raterence apples and operate normally. Ze speed is _Teached betore the condtion is corrected, there will be a 15 seco"d delay and then UU trip can also be caused by a failure of internal components of the tive These conditions require expert attention. Please consult the supplier of the drive, ealty hxScatons overeat 23DIAGNOSTICS CD75-750 74 7.3 Healthy Indications rd¥ Numerical value displayed de inh ‘SCAN Flashing decimal points, Motor stopped, 4 Motor spoed (Hz) or load (%FLC) dependent on the setting of bs. (Get speed is cisplayed only in Keypad mode). ‘de braking active. nergised. ‘Motor coasting to rest; IGBT bridge inhibited. ‘Spinning motor software is selected and the drive is scanning for the correct ‘motor frequency before catching the motor/ioad and taking them fo the set speed. This indicates that the drive isin the 1x t region,CD75-750 SERIAL COMMUNICATIONS 8 Serial Communications 8.1 Introduction 8.2 Fundamentals 8.3 Components of Messages 8.4. Structure of Messages 85 Configuring the Drive Through Serial Communications attees GS ERR sce RRR AR aaa La oc SERIAL COMMUNICATIONS CD75-750 Unique drive sorial addrass * Terminate with S485 MULTIDROP LINK FN2S resistor ee cecetieee eres R = Receiver input T= Transmitter output 36 Basic RS485 Serial Communications arrangement ‘and sora address. Unique kentty code for up 0 32 ‘rives per communications port atthe host. Receive } Transmit Re A ow 23|c1} to OV (pret) 01 Differential GND from host twisted-pair cable ‘ransmiier 37 RG4BE oF S422 serial communicatrions _38_RS232_ serial communicatrions ink Tink connections. Cable must be screened. ‘connections. Cable must be screened. 82CD75-750 SERIAL COMMUNICATIONS 8 Serial Communications 8.1 Introduction ‘A communications link is standard in all CD76-750 and CDV7S-750 drives. it is a machine-machine link, tenabling one or more drives to be used in systems controlied by a host such as a programmable logic ‘contrallar (PLC) or computer. CD75-750 and CDV75-750 drives can be directly controled, their operating configuration can be altered, and their status can be interrogated by such a host, and continuously ‘monitored by data logging equipment. A host can operate up to thiny-wo drives, refer to Fig. 36, and up to 9 if ine buffers are used. ‘The communication port of the drive module is the four terminals 20 to 23, and the OV terminal C1. The standard connection is four wire S485 or RS422, Fig. 37. Three wire S232 can also be used, Fig. 38. ‘The serial communications protocol used is ANSI x 328 - 2.5 Ad which is standard for many industrial interfaces. 82 Fundamentals Digital communications systems such as RS485 communicate by means of binary logic. Binary logic is ‘two state’, and is readily implemented by an electrical circuit which is ether ‘on” or “off”. The two diferent states raoresant two distinct bis of data, either binary digh (bt) 0 or 1. By fixing a time duration for each bit, a series of bits transmitied can be recognised by a receiver. Hf, & ‘group of bits contain the same number of bits k becomes possible to construct a variety of diferent ‘characters’ that the receiver can recognise and decode. A group of four bits has sixteen possible variants = 0000. 0001, 0010, and so on to 1111. Each of the sixteen variants represents one ‘hexadecimal’ ccharacter-unit — the decimal numerals 0 10 9 followed by the six letters A to F — making 16 diferent and distinct characters, ‘Two hexadecimal characters each of four bits, making eight bits in all are known as a ‘byte’. Each byte ‘can be used to represent a character of data ‘The character set used in CD75-750 drives is the ‘low’ American Standard Code for Information Interchange (ASCII), comprising 128 characters. In the low ASCII set only 7 data bits are used in the byte 10 represant the charactors, refer to the Table of Control Characters overleat. ‘The first 32 characters in the ASCII set (hex 00 10 1F and the ‘space’ character, decimal 32) are used to represent special codes. These are the Control Codes, each of which has a particular meaning. For example, ‘stat of text’ is STX, and, from a keyboard, is made by holding down the Control key and striking B once (ControbB). This is hex 02, and the actual transmission is the binary byte 0000 0010. The drive is programmed to know that this character signals that a command will folow. The codes for the CD drives ‘are shown inthe table on page 8-5. 83ee ee ibis ‘ SERIAL COMMUNICATIONS (CD75-750 ‘Low’ ASCII Character Set nex =, | O 1 2 3 4 8 6 7 let, Binary | 000 [oor | ov | or [soo [sor [uo | a 0 | 0000 | NUL | DLE ,,/Space,| O 4) @ g] P ol © ol Pie Ty [oor [sow jfocr oft alt gl A os] 2 wn) 2 ol] 9 as | 2 | oo | stx ,)0c2 41 * a) 2 2) B | R wl © of 6 0 | 3 joo ferx joes.) # 5) gf So] S wo] © wo] & ns Ta [ow [eor .foce .] $ al 4 ol DP gl T a) 4 sol t we 5) 0101 | ENQ | NAK ) % oo) 5 gs) © og] YU os} © im] 4% av 6 [ono jack [syn fe af 6 al Fowl Y ol f ve] ¥ we 7 | ont PEL ET) we] 7 | Son] Mo] 2 10] ™ v0 [| reno BS FCAN A] Cg] 8 se) Hove] X asl ™ toe] © em | Syed ii0o.iea | tertame | emalees ie lea |acSeaee |alee in oaee|Aalateell Yate fa [rw | uF SUB |” sl 2 xm] 2 wf | soe] 2 rz B fw [vt esc a] + gy) tm) K oe) © ol * aor) € oe co [too [FF A) FS sl + ul < wl & wl) wel ! toe se Vp Tar Por fos of sl = nl Mol) wl ™ sol) ces E | 1t0 | SO 4) RS yi - gl > | N oe | " ao] 7 126 [re fu [se ws) Sal / wo] 2 | O mf — 6] 2 faeCD75-750 SERIAL COMMUNICATIONS Contro! Characters in CD75-750 and CDV75-750 Drives Charsctor | Meaning ascilcode | Keyed | hex — Control Eo | ResotorEndot Transmission 04 D EN — | Enquiy, interrogating the drive 05 E st | Statottex 2 8 EK | Endoftet o c ACK — | Acknowledge (message 06 F accopted). NAK | Negative acknowledge 18 u {mdesage not under ood) ‘The components of all messages betwoen the host and a CD75-750 and CDV75-750 drive are formed of ASCII characters. Each ASCII character that is transmitted or received has a start bit prior to the 7 ASCII bts, a parity bit and a stop bit. The 3 extra bits are necessary to synchronise data transmission and provide error checking, ‘The convention is that the start bit is a 0 and the stop bit a 1. The party bit is present to allow the receiver ‘of the character to check that the character is valid. The format (i, time sequence) of the ASCII character ‘shown diagrammaticaly. ‘Low’ ASCII character byte ‘stant ‘Seven data bits, variable Party | Stop bt bit | be 0 | tsb | msb a ast | 2nd ath | om | tm be | be ba | bt | oe ee ire Each bits transmitted for a set defined time as indicated by the baud rate (i, bits per second). asSERIAL COMMUNICATIONS CD75-750 83 Components of Messages CONTROL CHARACTERS To conform to the standard structure of a message, the stages of a massage are signalled by control characters. Serial Address Each dive is given a unique identity or addrass (Pro) so that only the drive that is addressed will respond. For security, the format is that each digt of the two-digit drive address is repeated, thus the address of dive number 23 is sent as four characters — [lelale! ee eer Data Mnemonics To identity which operating parameter a message relatos 10, the parameters are represented by a data mnemonic, which is a simple two-character code. When data is being communicated, it is preceded by the ‘appropriate mnemonic. The data mnemonic follows the serial address characters. Data Data to be sent or requested occupies the next six characters after the data mnemonic. Data is handled in ‘wo diferent forms — ‘a8 a plain numerical value, or ‘as a Hax Code Word. ‘Most of the operating parameters of the drive, are numerical data, such as a value of frequency, load, ‘current, ete. For example, speed is given as frequency in the range +960.0 to - 960.0Hz. The value ‘S5Hz in a reverse direction’ is sent as— E lroulpedieaiealier| ilelalelsle| To enable the state of bit-parameters (and Pr8) 1o be transmitted conveniently, 2-byte and 4-byte Hox Code Words aro used, 2s described fully under Hex Code Words beiow. Each byte decodes to describe the status ofthe bit parametar in tal. Use of a code for this purpose enables blocks of complex data to be handled quickly and economically and avoids long series of messages to cover the many bit parameters. Block Checksum BCC To permit the drive and the host to ensure that messages from one to the other have not become corrupted in transmission, all communications other than acknowledgements are terminated by a block checksum character. 8.4 — Structure of Messages INTRODUCTION Host to Drive ‘A message cannot be sent to two or more more addresses simultaneously. If the same request or instruction is to be sert to more than one drive, it must be repeated with the new address each time. ‘Messages from host to the drive are of two kinds — 1 requast for information (Reading data), or a.command (Sending data) Drive to Host Massages from the drive to the host are of two kinds — a reply to a data request, (see section “Reading Data’) or — ‘acknowledgement of a message. (see section "Sending Data") 86CD75-750 SERIAL COMMUNICATIONS Drive/Host Set-up ‘The folowing driverhost set-up is important to ensure correct and satisfactory communications. Each drive requires & unique identty number, or serial address set by parameter Pr8. The baud rate B12, and the party bit 10, require to be set to match the host. Data, drive status and the parameter set-up can be read ‘rom the dive in any mode, provided only thatthe drive is energised, and the above conditions met. To ‘enable the host io control the drive orto change parameter setings, the dive mode must have the above sotings and be adjusted as folows:~ Four parameters are required to be set to enable operation ofthe Serial Communications Link — + Parity bit to be adjusted to suit the host b10=0 even parity bi0=1 odd parity + Baud rate to sutthe host bi2-42 4900baud bi2=96 9600 baud + Sovial adcress Pro = 01099 + Mosterslave selector tobe set as folows — 6 = 1 and terminal 16 in REMOTE mode (ie closed) it parameters are to be adjusted by the host. 'b6 = 0 oF terminal 16 in LOCAL mode (ie open) allows parameters only to be read by the host. ‘SENDING DATA (trom Host to Drive) NOTE ifthe data to be sent is one of the following:- Driva Configuration DS or PWM Switching Frequency FO ‘or Max. Voltage Frequency BS, or configuration C1 the drive must also be in the rd or tripped state, that is with the motor stopped or tripped. “The formed of the command from host to dive i:- Host command — yS0t- address - start of text - mnemonic - 6 characters - end - BCC 1nded message to the drive is, for example, “change set frequency of drive number 14 10 47.6Hz in reverse’, i would be sent as — connec] nooness [eowrnos | ane conta ee Pyle] em | sly] fe] ex | a coma coms | | come | “The drive will reply with an acknowledgement, either — ‘ACK it the message is understood (whether implemented or not), or NAK if the message is invalid the data is too long, or the BCC is incorrect. 1a value sent is outside the limits for a parameter, the drive will set the maximum value. Parameters which cannot be writen to are:- 'b6, b10, b12 and b13 (contained in DS), AC, LO, SE, SW, TO, Tt to T9.bs biG ies bia ssi habesesotn Niesedalvesilils SERIAL COMMUNICATIONS (©D75-750 READING DATA The format of a cata request message is — Host request — ‘reset - address - mnemonic - end For example, to tind the spaed sot point SP of drive number 12, send — | contro.| appress | MNEM | CONTROL OT Ts[e]2[s]e ENO Contro-D | Control The drive replies in the folowing form — start - mnemonic - 6 characters of data - end - BCC For example — controt | MNEM DATA ‘CONTROL sx |sfe|+|o] +] 2| ex |. | Control | | conto | (co) The reply first confirms that the data sont is the spoed set point, SP; the six characters immediately following give tha present sating in Hz. The first characteris either + oF -, 10 indicate direction of rotation; the remainder is the numerical value — “forward at11.2H2" inthis exampla. The host may new request more information by: (or starting a new request as described above), Repeat Enquiry (From Host) “The negative acknowledgement NAK (Control-U) sent by the host causes the drive to repeat the data sent {for the same mnemonic. This process can be repeated as often as necessary by the host. Next Parameter (Enquiry From Hos!) To obtain data from the same drive for the next mnemonic in the mnemonic table (see below) send the positive acknowledgement ACK (Contral-F). The drive will respond by transmiting the data relating to the ‘next mnemonic in sequence. Mnemonic sequence with ACK response is as follows: ‘SP TP & AC-> LD, MN, MX, AL DL, TR, TH, BC, SL. BR, SE, SC, SW, DS, FO, BS, CW, S1, $2, 'S3, B1, B2, 83, P1, P2, P3, P4, PS, Pé, P7, PJ, Ai, A2, A3, Ad, AS, A6, A7, AJ, D1, D2, 03, D4, D5, 06, D7, DY, C1, PS, RN, RD, RC, TO, T1, T2, T3, T4, TS, T6, 17, T8, T9 -m SP (stan) Invalid Mnemonic (From Host) WY the host sencs a mnemonic which the drive does not recognise, eg XY, the drive will respond by repeating back the unrecognised characters in a message of the form — start of ext - unrecognised mnemonic - reset Thus— stm |x ] y| ET contro controLD 88©D75-750 SERIAL COMMUNICATIONS BLOCK CHECKSUM (BCC) ‘To ensure that data received can be vetted, a block checksum is attached to the end of each command ‘or data response. The BCC is automatically calculated by the sending device (either host or drive) and is " which ‘enables the receiving driva/host to decode them in a special way. This is best explained by an illustration (of each of the above special mnemonics. ‘SE — SERIAL ADDRESS (2 Hexadecimal Digits) ‘Ths is a read-only parameter. To read SE for drive number 22, for example, send — cot | 2] 2/ 2/2 Control E| ea Control The drive wil ropy — sx _| slel S]r]e] er | contrat contro | [eco “The data following the > symbol is hex 16, which is 22 decimal, confirming the Serial Address. SC — SECURITY CODE (2 Hexadecimal Digits) tis possible to find or change the security code of a drive. I the drive address is 11, for example, send — T mye] ae oto | obits ‘The drive will repy. tor example — ax so] |contots °))CD75-750 SERIAL COMMUNICATIONS The data following the > symbol is hex 57, which is 87 decimal The security code for dive number 11 is 87. A security code does not need to be ont ‘communications link. 9d to read or adjust any parameter via the serial ‘SW — STATUS WORD or provious trip words (TO - T9, note TO = SW) (4 Hexidecimal Digits) This is a 2-byte hex value word (of four characters) which enables the status or previous trip indications of the drive to be read, (tis read only). The four characters decode to indicate the status of each of the four states — RUN — LAST TRIP — ERROR — and the PrA Trip Codes ‘Thus, 1o read the state of drive number 11, send — cor [t)*]t]1 |8 Jw] exo Gonttot conte Lit ‘The dive replies, for example — sm |s]™ [>Jole|t|c] ex ] > Control-B | Control-C} LEI (eco) ‘The four ASCII characters following the > symbol are treated as hex characters and are further decoded into their binary equivalents — (0 — C000, £ — 1110, 1 — 0001, C— 1100 ‘Comparing each character with the appropriate section of the Status Word table enables the message to bbe translated as first 4 trips ok — overvoiage tip — tripped status — set to run and drive ready (ie awating reset) ‘The format for TO - 79 is identical to SW with TO and SW boing identical, T1 gives the last but one trip states, T2 gives the last but two tips states etc. and TS gives the previous tenth trips information. entSERIAL COMMUNICATIONS ‘Status Word Sw (with example) ———— Flags and Trip Code -———_°* NOT USED Dive over temperature Motor ovortemperanure x toveroad | Corntsearay Power supply faire Undervotage ip Overvatage ip (dena) | 1 =. Phase oes Current 0p loss | Error tag | Tripped fag (etatis relay) me Fun fag, 1 set mun | Pec tag, 1 ccvereasy | notuseD _—_ | Stats of trina: 16, 0 » LOCAL, 1= REMOTE ° Run / Ready States ‘Status Indicated Drive stopping Drive stopped and ready 10 run (rd) Drive running Drive tipped, awaiting RESET, and “Trip Code flashing on the keypad display CD75-750 ‘ote that trip stags are held in PrA even ater a reset and willbe changed only by a subsequent tip. The #9 conditions wil ripple through the TO to TB las tp storage registers. The trip tsal, however, Continues to exist only #f the tripped flag (status relay) equals ‘aut’. ‘To detect an extarnal trip (PrA = Et), note that the tripped flag (status relay) indicates 1 while all other indications and flags are ok — not faulty. 812CD75-750 SERIAL COMMUNICATIONS DS — DRIVE CONFIGURATION (4 Hexadecimal Digits) This is a 2-byte hex-value word (our characters) enabling the state of bit-parameters bO to b12 inclusive 1» be read or changed. Parameters b6, b9, b10 and b12 are read-only and cannot be changed. The four characters following the > symbol decode into binary states, in a similar way as for the Status Word, to indicate tha value of the bit parameters. For example, to read DS for drive number 11, send — cor | | ofa] a]o]s] eno ControL conto e| ‘The drive replies, for example — sm Jos] |>|e|rlel4] er | t contro ial Controic| | (eco ‘The data following the > character are treated as hex characters, and decode to binary as follows — 4 0500, F— 1111, 8 — 1000, 4— 0100 ‘The message decodes, from the Drive Configuration table, as — ‘speed control mode — auto start mode — coast to stop — fixed boost — unipolar speed reference — ‘open loop feedback — slave mode — frequency (speed) display — keypad control — even parity bit —4/20mA speed reference — Baud rate 4800, ‘There ara four possible states of Stopping Mode Parameter | ree Mode oo | 0 0 | Standard ramp | © 1 | Coast | 1 © | intro | 11 | High teve ramp | ‘To wite to drive number 11, sending the same parameter settings as in the 'S a complete set-up command, the message would be — cample on page 8-11, which cor Tayi] i}a] six ols, Ex t ControLD Contral-B Control-c i I (@c0)| The drive replies ACK if the transmitted data is understood, or NAK if not (in which ease look for an error in wrting the characters or inthe format of the message) >] 4] Fe Note that parameters b6, b10 and b12 cannot be written to the dive through the Serial Communications, link, athough they must be included to form a complate message. The drive ignores these when received, ‘but does nct ignore them when interrogated about the drive configuration, 19Bite scctaen . SERIAL COMMUNICATIONS: CD75-750 DRIVE CONFIGURATION DS Example Bi peremetr Le tex | Bey NOT USED eae 4 | ome) Corel moda vo | ewe cistan | ‘Start mode bt | auto, ° Sepning me 2 [oe Soppre one) Boor mode we) awe F | sme) sr biargmed MA | isa eden | 1 ‘Feedback bs i ‘encoder 1 Master oie be | master te) ‘Seen made Wee Sepprgiccemie |e | tema Diepiay bs | frequency | load (3rd char) ° Cont mode t0 | teyped | eminal | ° ary ie wie | own | att neo) | Current loop b11 | see current loop table 4 O(msb) Current loop. B11 | see current foop table (4th char), 1 nor useD =a - | i wi | 400 | seco one) “Thora aro three possbile states of Current Loop Current oop | Speed | + Reference =]. Input | o lo oma | ° 1 ‘4/20mA io 2ortma anCD75-750 SERIAL COMMUNICATIONS: FQ.— PWM SWITCHING FREQUENCY & MVF (2 Hexadecimal digts) FO is a one-byte, ie two-character, word. The status of PWM switching frequency and ULF are given by te fllowing FO exdes:- Fa codes Word PWM FO Switching | ULF Frequency 00 zoxe | ron ot) eke | eons 10 Sokt2 | 1208 " soKiz | 240He 1 soKiz | 4s0He 20 sakHz | 120K a saz | 24ote a 30 11.7kH2 | 1208 a 11.7KHz | 24oree 2 11.7eH2 | aoe 33 an7KHz | 960: To read FO for dive number 15, send — cot |ii1[s{s]e lo] eno ControlD | controle tt The drive replies, for example — sx Jerla] [ [> hfo] ex [+ Contro-8 1} | contrat Al (@00) ‘The two characters following the symbol > require no further translation. They are ‘compared with the codes in the tabla for FQ. The reply in this example means that drive 15 Is operating at 5.9kHz PWM switching frequency, and the ULF is set at 120H2., ‘The settings of these frequency parameters can be changed by an operator (computer) or by a ple programmed to send the FQ codes. To set the frequency parameters of drive number 15 to 5.9kHz and 120Hz, the complete message is — six Fl (Control-8 { eor [als | ControtD is Is >h Jo] ex + IControLc (eco) asSERIAL COMMUNICATIONS 075-750 816 ‘CW — COMMAND WORD (2 Hexadecimal Digits) Tris is a one-byte hex-value word (two characters) enabling the drive to be controlled through the serial link. is important to note that although the external icalremote control is set to REMOTE as part of the ‘Set-up for serial link operation, the terminal inputs are not disabled — they remain operative. The two characters decode into states which control the principal command functions of the drive, as follows — RESET, TRIP (external), STOP, RUN, GW allows the drive to state the direction of rotation as set by the control terminal in reply to interrogation, ‘but cannot be used to reverse the rotation. REVERSE command is given by using a negative speed reference SP (see table of mnemonics). Extemal LOCALIREMOTE and LOCAL FWD/REV cannet be changed through the serial communication link, but CW permits the state to be read. To read CW for drive number 11, send — bcecot alti |1 fe ]w] eno | control-o | Control €| ‘The drive replies, tor example — sx [cw >|ije] ex Control | | controte L = ‘The data following the character > decodes from hex to binary, to mean — remote direction set to forward — not reset — external trip input closed — local forward — localremote terminal switched to remote — not stop — not run Command Word CW Baampla [tren Temas ve | omy | ° 1 | Tears Soe ee ee ve s200 -|- 4 ° fase con | neocons | | scr} 0 | Exteral rip: open dosed | (sb) a) | FWOREV" open | dosed (rev) 6 O(msb) Local/Remote * open (local) | ‘closed (rem) {2nd char) 1 | os commit) | coe | nat | re con | neti | Q * Carnot be changed through the Serial Communications Link oo atte(©D75-750 SERIAL COMMUNICATIONS ‘Typleal Values of Command Word CW Function CW values during Not start option Not reset sslected | Power | Stat | Stop | Reset | Trip | Nottrip “on toward | 76 | 17 1“ 36 6 | 1 remote roverse | 16 | 1F we | x | oc | te remote | toward | 2 | 18 10 2 a | 2 | bcal | rovers | a | 18 8 aa | on | tA | tocal (C1 — DRIVE CONFIGURATION WORD 1 (4 Hexadecimal Digits) “This is a 2-byte hexvalue word (Jour characters) enabling the state of bit-parameters 20 to BS4 to be read or changed. The four characters following the > symbol decode into binary states, in a similar way as for the DS Word, to indicate the valve of the bit parameters. For example, o read C1 for drive number 11, send — {-eor Jafar [ats fe]s | eno | | conrato Conroe | The drive replies for example — sm [cls] ]>]2]olofo] er conte | | controkc ea (ace) ‘The data following the > character aro treated as hex characters, and decode to binary as follows — 20010, 0—0000, 0— 0000, o— 0000 The message decodes, from the C1 table, as =— Run Status ofp -~ Fixed VIF ratio — spinning motor disabled — FWD/REV key disabled — RL1 is DRIVE HEALTHY — standard accel/dece! rates — 3 presets + jog — terminal reverse control a7SERIAL COMMUNICATIONS (C1 — CONFIGURATION WORD (2 Hexadecimal digits) (CD75-750 f ] T on =o “ Function (atau) |e Characor lane = ° - = Foes Dynamic varato Pun Miimum speed | Open colocor ouput tench ath | Spiming mary syne Disabled Enabled EWDREV key Drive Hoahy Speed Drive Healy’ ‘Atspeod lay | ‘Standard Preset ‘AccevDecel Provetsdog | 7Praset no Jog | Preset Speed puts Terminal Preset Provetroveres ° ° ° ‘oh Character Not used ° | Noted ° Noted ° Not used ° PS — PRESET SPEED SELECTION WORD (2 Hoxadecimal digits) PS is a one-byte, i. two character word that enable the preset speed to be controlled via the serial link. ‘The PS characters decode into the following equivalent states of terminals AIO - A12. Terminal A1t Terminal A12 PS cries | Terminal ATO oo ‘open 91 closed 2 ‘open 03 closed os ‘open 05 closed 95 open o7 closed open open open pen dosed dosed open open closed dosed Hai Relevant only 20-1 NOTE — PS cannot control jog input (terminal A12) i'b20 = 0 but can always read the status of A12 input. To read PS for drive number 15, T fet] y fel ]ele] exe ControkD Control C ‘The drive replies, for example — st |P/s| [> Jo |» | _ ET Contro-B| Control-c| I (eco) ‘The two characters following the symbol > require no further translation. They are compared with the codes in the table for PS, The reply in this example means that dive 15 is operating with terminal A10 closed anc A11, A12 open.CD75-750 SERIAL COMMUNICATIONS RN — RESET NUMBER (2 Hexadecimal Digits) This is a road-write parameter. To read RN for drive number 22, for example, send — 2l2[el[a[n] eno Controbe > ]ol4] ex Control-c| (eco) ‘The data folowing the > symbol is hex 04, which is 4 decimal indicating that 4 resets, as set by Pr50 for ‘example, ara allowed before the trip condition locks out drive operation. FC — RESET COUNTER VALUE (2 Hexadecimal Digits) ‘This is a read only parameter. To read RC for drive 11, for example, send:- cor [alt[+]i [ale] ena ControlD Control ‘The drive wil reply, for example — [sx Jaleo >)ols]_ ex ConroLB Control-c | | (eco) ‘The data folowing the > symbol is hex 03, which is 3 decimal, indicating that # RN = 4, one fife has been sed to reset the drive prior to being reset back to 4 again # the drive resets and works for a given period of time, 319CD75-750 BRAKING 9 Braking Unit (Optional) 91 9.2 aoe 94 9.5 9.6 9.7 98 Introduction Principles of Operation Braking Unit Specification External Braking Resistor Sizing Electrical Installation Mechanical Installation Operating Procedures Diagnostics - Problem SolvingCD75-750 BRAKING 9 Braking Unit (Optional) 91 Introduction ‘This chapter covers the various aspects of the optional braking unit, such as the following points: ‘Why co we need an optional braking unit? How does the unit connect to the CD drive? ‘What are the mechanical requirements for installing the unit? ‘Can we use the in-buit braking resistor or do we need to use an external resistor? How do we size the separate braking resistor? How does the braking unit operate? How do you know when the unit is operating correctly? 9.2 Principles of Operation A decelerating AC motor regenerates energy into the inverter drive as the load ‘overhauls’ the machine. The regenorated energy can only be dslpated within the drive, K cannot be retumed to the AG supply by the CD unt. il the regenerated power isles than the tosses of the CD unt, the unt wil perorm satisfactory. the ragenoated powers more than the losses ofthe CD, the unt wil on ovarokage unless the optional braking unit is fitted. Typically a drive will dissipate about 3% of its rated power as losses, and as such will tolerate about 3% regenerative power without a braking unit and without tripping the drive. Factors which influence the amount of regenerative power are: ‘Tho inartia of the machine and load 1aximum speed of the machine and load Tequired deceleration rate of the drive The mode of drive decelaration sat by ‘62’ and ‘b7* ‘The power rating ofthe drive From theory the amount of regenerative power 'P' for a constant rate of deceleration ‘a, for a given inertia 'T,and at a certain speed ‘sie: Peas! wnere P= watts a= radians st s= radians 5? She kgm2 For a drive with a given deceleration rate (set in Pr3 or Pra0—46) and a certain speed in Hz the above ‘equation becomes: Pa r2001 (CE) x2 T where @= speedin Hz of drive B= number of machine poles (e.g. 2, 4, 6 etc) 1 = deceleration time set in Pr3 or Pr4a0—A6 for 120Hz maximum frequency. (I 'b14 sot for upper limit frequency other than 120Hz, modify constant of 120 to 23nnn TINE Hm SS ERR TSE ETT FNS RS SMR alll BRAKING CD75-750 From the above equation it can be seen that the regenerative power is directly dependent on the machine/ioad inertia and the drive speed of operation. The lower the value of Pr3, the greater th regenerative power by the inverse relationship. This equation therefore explains the fist three of the {factors which influence the regenerative power. The influence of the b2 and b7 settings only has a small influence on the regenerative power produced uring deceleration. it must be noted that regeneration will occur whenever the drive speed is reduced whether or not the drive is stopping. The consequences of b2 and b7 described below are vali for ail Speed reductions. When b2 and b7 are both zero, the internal ramp is stopped whenever the driva's DC. link voltage exceeds about 70V above the normal working value, and this also comesponds to when the ‘optional braking unit will tum on the dumping resistor. This mode of operation extends the deceleration amp to reduce the likelihood of the drive tipping on overvokage. In this mode of operation #s the DG link voltage rises tha applied voltage to the machine wil increase by the same percentage rise, ‘This has the ‘added consequence of increasing the magnetizing current to the machine which will increase the dissipation capabilty of the machine/drive for regenerative power. Unfortunately this may also cause Overcurent tripping f the DC link voltage rises too much, increasing the magnetizing current Up to the trip level ol the drive. Typically b2 and by set to zero provides extra drive regenerative dissipation capability ‘and reduced sensitivity tothe Pr3 setting without the need for the optional braking unt. ‘When b2 and 87 are both set to 1 the internal ramp is maintained at the set rate whether the drive's de link votage excoeds the 70V margin above the normal working value. In this mode of operation, as the de link votage rises the applied volage to the machine is maintained constant. This has the consequence of ‘maintaining the magnetizing current to the machine, which maximises the amount of regenerative power ‘back into the drive. "Unfortunately this may cause overvotiage trioping the de link voltage rises too much ‘Typically b2 anc b7 set to 1 is characterised for use with the optional braking unt. ‘The above explanation details how the b2 and b7 influence the braking capabilty ofthe drive, finaly the ‘ive rating has an influence on the regenerative capabilty of the drive in that regenerative power revaies directly to drive current, and as such the drive will rip out on overcurrent # the current exoseds 150% of the drive rating during regeneration. Therefore the drive rating determines the maximum regenerative capabiity ofthe drive. Operation of the Braking Unit ‘The braking unit is a seit contained unit that contains the braking resistor and the control electronics for Controling the braking resistor. The unt powers itsel from two phases of the three phase supply used for the drive, and uses the vottage of this incoming supply to determine the correct vottage for applying the ‘braking resistor across the de lnk from the CD drive. The braking unit continuously monitors the CO's internal DC link votage and compares it o the incoming ‘supply voltage. When the DC link voltage exceeds a set margin (approximately 70Vée) above th ‘expected value the braking resistor is applied across the DC link. When the voltage reduces back to the. ‘expected value tne braking resistor is removed from circuit ‘The braking unit automatically adjusts itself according to the AC supply for the drive, anywhere from 380 to 480Vac + 10% 93 Braking Unit Specification ‘Summary ‘The CD external braking unit is an optional unit that is completaly sel-contained with the inclusion of a standard braking resistor. The minimum electrical connections to the unit will be the DC supply ‘connections from the CD unit, two AC supply connections from the CD unit for power and voltage sensing, and a relay output for indicating heafthyfault conditions. The internal resistor has a power dissipation capabilty of 220W + 10%, however if this is not sufficient the internal resistor can be easily inked out and a customer supped resistor connected instead. ‘AC Input Supply ‘The same range as the CD unit:- ‘380 - 480Vac (three-phase) 4 10% ‘However all input frequencies from SOHz to 60Hz + 2 Hz willbe tolerated o4(CD75-750 BRAKING In-bullt Braking Resistor “The resisto: rating is nominally 220W. The resistor is capable of sustaining pulses of energy switched from a 850Vde source (15.4 KW instantaneous up to 2 mill-s@conds), with 11 KW dissipation for 1 sec repeated every 50 seconds. The resistance value is 47 Ohms + 10%. Isolation Withstand Voltage ‘The braking unit will tolerate 2.5 KV ac, SOHz for 1 minute betwoen all electrical terminals and the ‘electrical earth connection. ‘Temperature Range ‘The operating ambiont temperature range is 0°C to +50°C. In-bultt Braking Transistor ‘The transistor is a standard part for 380 - 480Vac supplies, with a peak capability of 20A. Whilst switching 20A the transistor will operate continuously with a 10% on-time duty cycle when the braking unit is in a 50°C ambient, ie. it will tolerate a 1 second on-time followed by a 9 second off-ime on @ continuous, basis. The transistor will also tolerate a 6.3 A rms continuous duty. Protection and Indication “The unit has 4 LED indicators, one for AC control power present, one for DC control power present, one 10 indicate when the braking transistor is ‘on’, and the last one is a brake resistor faut LED. The control Power supoly derived from two AC input phases willbe fused. The unit also has a protection relay that Can be used to de-energise the main incoming supply contactor for the drive and braking unt. “The brake resistor fault LED will indicate two fault conditions:- “The braking transistor has no resistor connection (Le. open circuit). ‘The braking resistor is short-circuited, The unit will need to be powered off to reset either of these faut. ‘The protection relay is used to indicate two fault conditions:- “The irtomal resistor has overheated as measured by a heat detecting davice mounted close to the in- buit resistor. ‘The measured AC supply voltage is bolow specication (380 Vac - 10%). “The above faut conditions de-energise a vot-ree change-over relay for tipping the main drive supply via ts own incoming supply contactor. The braking unit will not operate the braking transistor when the relay is not energised. ‘A aut condition can only be reset by removing power to the drive unit and braking module. f an external braking resistor is used instead of the intemal resistor, thermal protection of this resistor ‘must be provided by the user. This is necessary to avoid the resistor causing a fire hazard the braking transistor fails on. Any thermal protection must disconnect the AC supply to the drive and braking uni External Braking Resistor (Itrequired) Minimum resistance = 47 Ohms +10%. Maximum continuous braking power dissipation = 1.9 KW (derived from rms transistor rating and minimum ‘braking resistande) Instantaneous power dissipation capabilty ~ 15.4 kW (for a maximum time of 2 miliseconds derived from ‘47 Ohms across 850 Vdc.) 95BRAKING CD75-750 9.4 External Braking Resistor Sizing Firstly the peak power dissipation requirement must be determined from the machine/load inertia, the maximum operating drive speed, and the minimum raquired deceleration rate. From the previously stated equation, but modified for maximum conditions: aye Poveda (EY x TI where @max = maximum operating speed in Hz of drive P= number of machine poles (e.g. 2, 4,6, 6 etc) ‘min = minimum required deceleration tie set in Pr for 120 Hz maximum frequency. (i 114 is sat for upper limit troquency other than 120 Hz, modiy constant of 120 10 correct upper equeney.) Prax Must Be loss than 1.5 times the dive rating to ensure the drive can handle the braking duty Prax TUst also be Jess than the pask power dissipation of the braking resistor when appli 10 the maximum DC link voltage level of 850 Vee: e502 Pmax << S508 S R whore Fla Braking rasistor vale in Ohms Provided the braking resistance value satisfies the above equation, and is greater than the minimum resistance of 47 ‘Ohms, the resistor will meet the required application. ‘Secondly the power rating of the braking resistor must be determined. (We currently know is resistance value and Peak power dissipation capabilty.) The power rating of the resistor is dependent on the energy removed from the ‘machine load during deceleration conditions and the repetition rate of this occurrence. The energy removed from the. ‘machine drive for a given speed change is: oe = 05f( E) (m2 - 024] where cy = highest operating speed in Hz ©2 = speed decelerated to in Hz (possibly OH if the machine is stopping or reversing) It this event takes 1, seconds to occur and repeats after tz seconds, the average power dissipation in the braking resistors: Paviees = "RS Watts yt) Pav loss defines the average power loss in the braking resistor. Hf this valua is greater than 220W then an external ‘braking resistor is raquired. Hf the value is greater than 1.9 kW two or more braking units are required to handle the large power dissipation. 96CD75-750 BRAKING ole up— | ep PONE ON| POU on 39 Optional braking und, outing and mounting dmestions and terminals. a7TN PENS URNS 056: de 8 BRAKING CD75-750 95 Electrical Installation Roter to Fig. 40, The braking unit has 2 sats of electrical connections. One set consists of the power connections for ‘onneating to the CD crve (both AC and DC power), and the option of ether using the internal braking resistor of connecting an external resistor. The other set of connections is for the contol relay which i ‘used for protection purposes, ‘The unt can ba connected in one of two ways: ' {or use withthe intemal braking resistor; for use with an external braking resistor. For dimensions, reter to Fig. 39. : < i |ocneut i ruyymert, “eoe Then ' een v tC — eowrnoal [one 0 cai act lie Ge ie as £ —r rau + mu i WS veers i Bene | suet i Sees i SA lu T ier. us foe vee woTon | sRARne UN 4 Sehamatc diagram of baking syst, showing opionaledernl braking un os Freer eseearns: see CD75-750 BRAKING WARNING WHEN CONNECTING DC LINK, ISOLATE UNIT FROM SUPPLY. HIGH VOLTAGES PRESENT. Internal Braking Resistor Employed For the uni to operate correctly the two AC line connections (Lt and L3) must be connected directly to the ‘wo incoming ines (L1 and L3) of the CD drive that the braking unit is operating with. These connections must be made with power cable with at least a 1A rating Le. 0.5 mm?, Referto Fig. 41 ‘The +DC INPUT conection must go directly to the + connection on the CD. The -DC INPUT connection ‘must go éirecty to the - connection on the CD. The INT R connection must be directly linked to the Rt connection. (No connection is to be made to R2.) The above connections must be made with power cable with atleast a 10A rating Le. 1.5 mm?, ‘The EARTH connection must go to the supply earth with a suitably rated power cable specified by local ‘earthing practice. ‘The control relay connections (COMM, N/O and N/C) must be used to trip the incoming supply ‘contactoricrcuit breaker in the event of a protection trip within the braking unit. Typical the COMM and NIC connections would be connected in series with the trip circuit of the cireut breaker, or the contactor ‘oil circuit ofthe contactor. These connections can be made with control cable with 0.5 mm? conduct. ‘CONTROL. ‘SUPPLY — stor START ‘41 Connections to Braking Unit when using the internal braking resistor.RnR REN EA Be: BRAKING CD75-750 External Braking Resistor Employed For the unt to operate correct the two AC line connections (L1 and L3) must be connected directly tothe ‘wo incoming ines (L1 and L3) ofthe CD ctive thatthe braking unt is operating with. These connections ‘must be made with power cable with at least a 1A rating ie. 0.5 mm?, Filer to Fig. 42. The +DC INPUT connection must go directly to the + connection on the CD. The -DC INPUT connection ‘must go directly to the - connection on the CD. (No connection is to be made to INT R.) The Rt ‘connection is to be connected to the external resistor via a suitably rated thermal overioad relay. The R2 ‘connection is to be connected to the other end of the external resistor. The above connections must be ‘made with powar cable with at least a 10A rating ie. 1.5 mm?. ‘The EARTH connection must go to the supply earth with a suitably rated power cable spectied by local ‘earthing practice, The control relay connections (COMM, N/O and N/C) can be used to trip the incoming supply ‘contactor/citcuit breaker in the event of a protection trip within the braking unit. Typically the COMM and NIG connections would be connected in series with the trip circuit of the circuit breaker, or the contactor oil circuit of the contactor. The normally closed contact of the thermal overload relay protecting the ‘external rasistor must also be connected into the above trip circutty. These connections can be made with control cable with 0.5 mm? conductor. sTaRT ‘42 Connections to Braking Unit when using an extemal braking resistor. 10CD75-750 BRAKING WARNING ‘The design of the user's control wiring system must ensure that in the ‘event of a fault being flagged by the fault relay of the braking unit, OR if the external thermal overioad relay operates, the incoming supply ‘contactor will trp to disconnect the drive. 9.6 Mechanical Installation Refer to Fig. 39, page &7. ‘Tho CD braking unit is designed to accept two alternative mounting arrangements. The unit can be mounted either on its back plane (surface mounting) or with the heatsink and resistor projecting through the mounting panel ‘Tho unit must be mounted vertically, and sufficient clearance must be allowed around the unit to allow ‘adequate flow of cooling air over the fins of the heat sink. A minimum of 100mm is required above and bbolow the unit, and some clear space should also be allowed at the sides and front. 9.7 Operating Procedures It power i now applied tothe drive, the associated braking unit should automatically be powered up also. ‘To verity his the ‘AC power on’ and ‘DC power on’ LEDs should light on the braking unit control PCB. it ‘ther LED does not light, power down the drive, wait at least 10 minutes to ensure all vokages have decayed to a sate level, and then check the power connections to the AC supply and the de link. It the ‘braxe resistor fauity’ LED also comes on at power up, this means that ether the braking resistor is ‘ot in-circuit or short or that the uni is faulty. Power down and wait 10 minutes before checking for an ‘pen circu or short circu. Hf the unt is healthy, after power-up, the AC and DC power on LEDs should be I, and the ‘brake resistor ‘on’ and ‘brake resistor faulty’ LEDs should be ‘off. The control relay should also change stato Fall is healthy following power-up. To operate the braking unit, the drive will need to be turning the machine at a reasonable speed and a rapid deceleration condition must be created. I the inertia is significant the dc lik voltage should rise and ccause the braking unit to operate. When the braking unit operates the ‘brake resistor on’ LED should flicker whenever the braking resistor is connected to the dc link. i the deceleration is nt fast enough, or the drive speed is not high enough, or the machine inertia is not large enough the ‘brake resistor’ ‘on’ LED ‘may not come on, ‘The contol relay will de-energise if the internal braking resistor overheats, or there is an intemal faut ‘within the braking unt, To reset the unt the power must be removed from the product long enough for the Unit to power of, Le. when all LED's on the braking unt extinguish. ontIS CN RRC T Te TRS BRAKING 075-750 9.8 Diagnostics - Problem Solving ‘AC Power On LED does not ight (Check that the L1 and L3 inputs are connected to the drive's AC input and AC power is present. (Chock that the fuse on the control PCB is not faulty. i open circuit, replace with an equivalent rated {use and re-power up the unit. Hf the fuse fails again, the unit is probably fauty. DC Power On LED does not ight (Check that the +DC Input and -DC input connection are connected to the drive's DC outputs with the Correct polarity and DC power is present. Drive trips on overvottage ‘OU' whilst decelerating ‘Tha braking unit should be turing on the braking resistor. Check that the ‘braking resistor on’ LED is ‘coming on during deceleration. tft is not the unt is faulty Ian external braking resistor is being used, the resistance value may be too high and needs reducing Provided the resistance does not become lower than the minimum value of 47 Ohme. ‘The deceleration rte i too fast for the drive even with the braking unit functioning correctly, and thus the Pra valve will need increasing. Brake Resistor Faulty LED lights (Chock that the braking resistor is not shor circuit or open circuit. Hf the braking resistor is in-circuit, the unt is faut. Brake Resistor On LED does not light during deceleration ‘The deceleration rate is not fast enough to require the unit to operate. ‘The inertia and load of the machine configuration is such thatthe unit does not need to operate. ' the drive rips on overvotage/overcurrant during deceleration, then the unit is faulty. Drive trips on overcurrent ‘OF during deceleration The deceleration rate is too fast. Reduce Pra. "the drive is set up with b2 and b7 set to both 0, sat to both 1 to perform best with the braking unt 12 oO .CD75-750 10 Electromagnetic Compatibility 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 renner aie Introduction Immunity The Nature of Drive Emissions Immunity of Sensitive Circuits Precautions for Drives Additional Precautions for Sensitive Circuits Optional RFI Filter Installation of Optional RFI Filter 10-4CD75-750 EMC 10 Electromagnetic Compatibility 10.1 Introduction The purpose of this note is to assist system designers to incorporate drives into complete systoms without encountering problems with electromagnetic interference. Because drives use last switching of high voltages and currents to achieve high efficiency and low acaustic noise inthe motor, they generate some ‘agio‘trequancy (RF) energy which has the potential to disturb other circus ‘The majorty of sensitive circuits are deigned to be immune, to a reasonable degree, from the various kinds of aisturbance which may arise, for example, supply disturbances, fast electrical Wansients caused by switches, relays and contactors, and radio trequency fields caused by radio transmiters. Many of these sources are random in occurrence. It often arses thatthe first sign of inadequate immunity ina Circuits 's when disturbance is caused by a drive or other powerful electrical circuit during the commissioring procedure. Athough the drive may wall be blamed in these circumstances, iis Important {o ensure that the immunity of the related crats is adequate. If this is not done, random problems wil ‘cur during subsequent operation trom the various existing sources of disturbance. 10.2. Immunity The immunty of drives to externally generated interference is good. Usually, no special precautions are required beyond normal good installation practice. ft is recommended particulary that the cols of do- energised contactors associated with drive should be suppressed with a diode or similar device, since they can generate severe electrical transionts, In areas subject to frequent lightning strixes, and where supplies are cared on lines above ground, ‘additional surge suppression is advisable beyond that fited to drives as standard. Suitable varisiors (MOVs) connected betwoen each line and earth should be used, 10.3 The Nature of Drive Emissions 10.3.1 Frequency Range ‘Switching takes place in the range 1 to 30kHz in ac variable speed and servo drives. Because the Switching is fast, harmonics may be generated up to frequencies of several MHz. The most important range is the radio-frequency (RF) range, 100kHz to SMHz, because the energy can be propagated over Quite long distances and a varity of other circuts may be sensitive to disturbance in this range. 10.32 Propagation Routes {tis important to appreciate that the drive itsetf does not radiate much FF energy. Within about 100mm of «a drive there are quite high electric and magnetic fiekds, but as they diminish according toa cube law, they ‘are insignificant at 300mm. ‘Tha main mechanism for the propagation of RF energy produced by drives is by conduction through ‘lectrical connections. The main routes are ilustrated in Fig. 43. ‘The connections in order of emission level are — (@) The Motor Cable ‘This carties high RF vokage and current, and may disturb a nearby circuit. However, the electric. ‘and magnetic fields falloff rapidly with increasing distance from the cable. 103EMC ©D75-750 mm MII === Corto connections 5 : 43. RF current paths for drive with no special precautions. (©) The Supply Cable ‘Atthough this carries a lower AF vokage than the motor cable, it ie connected to a widespread network. This means that # can act as an effective transmitting aerial. Also, t conducts omissions into a wide variety of other equipment. The supply cable is the single moet important route for ‘emissions. into victim equipment. Tho length of the motor cable affects the emission into the supply cable. It the motor cable ‘@xceeds about 50m, the emission trom the supply cable will be particularly severe. (¢) The Earth System The drive earth wire carries the RF current returning from the motor, Because the inductance of the wie is significant at high frequencies, both the drive earth and the motor frame may carry RF voltage. This may be a problem i sensitive circuits share these earth connections. (€) The Contro! Connections Inside the drive the control circuits have stray couplings to the power circuit. The AF levels are ‘much less than on the power connections and the source impedance is high, so problems do nct ‘often acest with these connections, A drive may be tought of as a source of RF current which leaves its output terminals. The capacitance of the output cables and motor windings with respect to earth present quite a low impedance to the RF frequencies, s0 the current flows from the output to earth. it then has to find ts way back to the drive arth and powe’ input terminals. If t does not have a low-impedance path i may flow in unexpected directions and disturb nearby sensitive equipment. The principle of good layout for emission control is 10 Provide a direct, iow-impedance path for this current. 10-4CD75-750 10.4 Immunity of Sensitive Circuits In many drve installation there are either no sensitive circuits vulnerable to disturbance, or the sensitive circus have been designed by their manufacturers to have good immunity. To avoid unnecessary costs, through reducing drive emissions it is useful to be able to assess the likelihood of other circuts being disturbed and to be aware of standard methods for ensuring immunity The following ist indicates the relative sensitivity of typi ‘ot cover ail possibilities, and some degree of judgment willbe required in assessing a given situation. electronic ct 10.4.1 Not Sensitive Purely-electrical circuits comprising only relays, contactors and ‘loctromechanical instruments, 10.42 Not Significantly Sensitive Many electronic systems are insensitive to drive emissions — computers, PLCs, all digital electronic circuits, and analogue circuits using high levels (over 1V), are unlicely to be disturbed unless they include components which fall into the ‘Sensitive’ category, below, o are installed in such a way that they are closely-coupled to drive emissions, 10.4.3 Sensitive Analogue measuring circuits using low levels, such as thermocouples, resistive temperature sensors, strain gauges, pH and similar instruments: particulary it the connections are long andlor unscreened. Analogue measuring circuits using high levels (over 1V) only if the ‘connections are long and/or unscreened or they are required to give high resolution (better than 1 in 1000). ‘Analogue circuits which have very fast response or wide band-width, for ‘example, audio circuits. Most industrial systems in fact have intentionally ‘low response to minimise disturbance by transiont effects. ‘Video circuits, such as closed-circuit v, and possibly computer monitors. Digital data links, but only if they are unscreened or in an unusual ‘configuration. Conventional RS232, RS485 and fast links such as ‘Ethernet’ have good immunity when correctly installed with high-screening cable, Proximity sensors which rely on high-frequency oscillators, particularly ‘capactiance types. 10.4.4 Very Sensitive Only systems which are specifically designed to be sensitive to ‘electromagnetic radiation in the 100kHe to SMHz range are included here — Radio receivers — long and medium wave only Inductive-toop pagers and communications systems. Mains-borne communications systems — But not television, VHF radio receivers, mobile telephones, radio ‘emote-contrlias of other madern radio-based equipment which uses ‘ary high frequencies. EMC its and systems. The list does 105EMC 10.5 Precautions for Drive Installations ‘There are precautions which cost litle to implem ‘summarised inthe following paragraphs and in Fig. 44. 10.5.1 Segregation ‘No signal circuit should be run parallel to an unscreened motor cable or Lunfiterad supply cable with a spacing less than 0.3m and over a distance ‘exceeding tm. . For parallel runs longer than 10m, the spacing should be increased in proportion to the run. For example, for a run of 40m parallelod, spacing should be 0.3 x 40/10 = 1.2m, No signal circuit should pass within less than 0.3m of the dtive itso. If this is ‘unavoidable, an earthed aluminium screen should be erected between the Sircuit and the drive. (This constraint obviously does not apply to signal connection to the drive itself. The immunity of the drive to external imerterence is compatible with its emissions.) 10.5.2 Earthing In any cubicle, a single, low-impedance earth point or busbar should be established, to which circuits are earthed independently and directly, and to which the incoming earth is connected. tt is particularly important that the

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