0178-7010, USER'S GUIDE for the CDS INVERTER DRIVES for 0.75kW to 2.2kW INDUSTRIAL and HVAC APPLICATIONScos Safety at Work The voltages present in CDS drive modules are capable of inflicting a severo olactric shock, and may be lethal. itis the responsibilty of the owner or user to ensura that the installation of the CDS and the way in which it is operated and maintained ‘complios with the requirements of the Health & Safety at Work Act in the United Kingdom and applicable legislation and regulations and codes of practice in the UK or olsewhers. Only qualified personnol should install this equipment, after first reading and Understanding the information in this Guide. The installation instructions should be adhered to. Any question or doubt should be referred to the supplior of the ‘equipment. Safety Waring The drive software incorporates optional auto-stant and restart features. Users and ‘operators must take all necessary precautions, i operating the drive inthis mode, 0 prevent damage to equipment and especially to prevent the risk of injury to Personnel working on or near tothe motor and the driven equipment. ‘The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional ‘operating parameters of the equipment, or from mismatching of the CDS drive to the motor. ‘The contonts of this Guide are believed to be correct at the time of printing. In the interests of a commitment to a policy of continuous development and improvement, the manufacturer reserves the right fo change the spectication of the product or its performance or the contents ofthe Usor’s Guide without notice. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical including photocopying, recording, or by any information storage or retrieval system without permission from the publisher in writing. ‘Electronic’ stoo should not be relied on for safety ourooses. the drive must bo isolated from the mains supply, Copyright @ 1992 Control Techniques ple PERRO Olro-7010 USER'S GUIDE for the COS INVERTER DRIVES FOR INDUSTRIAL and HVAC ‘APPLICATIONS 0.75KW to 2.2kW secos Oe Chapter 1 CONTENTS Introduction Features ‘Theory of Inverter Drivos Drive Specifications Ratings ‘Specifications - General ‘Specifications - Control Installation - Mechanical Drive Mounting Location Cooling and Ventilation Installation - Electrical Installation Safety Power Connections Control Connections Drive Configuration Operating Procedures Configuration Examples Diagnostics and Fault Finding Parameters and Switch ‘Operating Parameters BIT Paramotors DIL Switch Links - Parameter Quick Reference Serlat Communications Connecting Serial Comms. Components of Messages Structure of Messages Configuring the Drive Through Serial Communications Logle Diagrams 7a 79 7.15 724 prelim?ee eeeeeSSSSSSSSSSSSSSSSFhFeFeFFeseee ° Braking (Dynamic Brake, 1BD-2) Principlos of Operation Operation of Braking Unit Specification Braking Resistor Sizing Mechanical installation Electiical installation Operating Procedures 10 EMC EMC Immunity The Nature of Drive Emissions Immunity of Sensitive Circuits Precautions for Drive Installation 11 Parameter Setting Record Parameter Setting Record 12 Control Techniques Worldwide Illustrations Fig.No Title "1 CDS Drive 12 Variable Motor Speed Characteristics 13 ‘Motor Speed - Flux to Frequency Relationship 14 Voltage Boost at CDS - Drive Mounting Dimensions 32 Cubicle 33 Minimum Ventilation Distances at Power Connections 42 Terminal Block TB1 43 Terminal Block TB2 44 Connector PLE 45 Terminal Block TBS 54 Configuration of Driva Paramatar Manis 52 Basic Application 5:3 HVAC Application 54 Serial Communications Example 64 ‘Accoloration Time Pr2 62 Decoleration Time Pra 63 Overcurrent Protection 64 Ixt Characteristics 65 Voltage (torque) Boost Pré 66 Applications of Presel Speed pretime 93 95 95 97 99 940 944 10-3 10-3 10-4 10-7 10-9 Illustrations Title Page 17 Injection Braking et Inverter Output Profiing - Pro and ULF 634 Fixed/Dynamic Vf Ratio 637 S292 Serial Communications Link Connections RS422/485 Commurications Link Connections FRS485 Mulicrop Link Connections Standard RS422 Connections Standard RS485 Connections IBD-2 Braking Duty with 30 Socond Timo Mounting Dimensions Mounting Postion Position of CDS Connectors for use with IBD-2 ‘Component Layout on 1BD-2 Interconnection of I8D-2 and CDS “Typical Connections RF Curront Paths - Drive with No Special Precautions Wiig and Layton Sense Systoms ing and Layout for Sonsitive Systems Cunant Pats wih Suppl Fir and Steoned Motor Cable pretims1 Introduction scmeceennerasie a 1.1 Features 1.2 Theory of Inverter Drives pretiot 4Figure 1-1 ‘cos Introduction 1.1 Features Full digital control. ‘and low powor consumption. + Choice of up to four switching frequencies i High output frequency. Up to 960Hz availabl + Variable and fixed VF charactoristics. Digital adjustment of most drive parameters. Irevlated gate bipolar transistor (IGBT) output bridge for high speed switching in range 2.9 to 11.7 kHz + intemal monitoring and protection includes txt overload, current limit, peak fmt, instantaneous overcurrent and Isolation between control and power indhidual IGBT protection. jectronics. Abily to start ve into coasting motor, rotating in either direction with no large transient torques or current, + 150% current. + DC injection braking. + 3 Preset speeds or jog facility. + Auto restart after trip. + Last fault indication. + Security code protection. + Selectable relay function. + Selectable ‘Wireproot’ Mode. + RS4B5 serial communications interface. + Single ase mains supply. Wide range of input voltage. Voliage control or both constant and speed dependent torque applications, Sinusoidal wavetorm at all output frequencies.cos 1.2 Theory of Inverter Drives 1.2.1 Induction Motor Characteristics Standard industrial squirel cage induction motors. are wound to match the supply voltage and frequency which prevails in the country where they will be used or are manufactured. When tis desired to oparate an induction motor at variable speed, is necessary to consider the effect of voage and frequency on fux and torque, ‘An induction motor depends for ts operation on the rotating flald created in the stator winding. The magnitude ofthe field is controlled by the supply voltage applied to the stator windings. The impedence of the stator windings is low, 20 the volt drop across them is small, therofore the internally induced emf has to be approximately equal to the supply voltage, This emt depends on the product of three factors: the total ux por pole, the total number of turns por phase ofthe field winding, and the rate of field rotation. ‘The emt can be expressed.as E = kgNf (From Faradays Law) (1) where E is the induced emt, {1s the total flux per pole, Nis the number of turns por polo, isthe frequency, and kis a constant, If the applied voltage is increased, the emt must increase to balance, and if the {frequency is hold constant the flux por pole must increase also, since the number of turns por pole is fixed. Torque is approximately proportional to current mutiplied by flux and for economy of ‘material, the magnetic circuits of standard motors are designed to operate very close to saturation at rated volage and frequency. This is the optimum condition for the proauction ot maximum torque, 1 ee For optimum acceleration, of rapid response to an increase in load torque, 6 should bbe maximum to maximise the torque, as the designer intended. Equation (1) can be restated as — ee reiexeee) @) in t This shows that, since N is fixed and k is constant, a linear relationship must be maintained between emf (and consequontly the applied voltage) and frequency, it flux is to remain constant at diferent speeds. This linear relationship is known as ‘constant Vf (or V/H2), Drives possessing this essential feature are usually called ‘variable voltage variable frequency’ (vwv1) drives. Generally an increase in voltage above the linear vl ratio doos not cause much increase in torque because of magnetic saturation but does cause a significant incroase in current and ‘consequently to losses. ‘Aithough constant Vf control is an important underlying principle, departures from it tenable 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 voltage remains constant at maximum value. The VA charactorstc s typically as shown in Fig.t-2. Since V is constant above ‘base speed, the flux fale asthe frequency increases, Fig. 1-3 in direct proportion to the Vif ralio. The abilty of the motor to produce torque is correspondingly reduced; full load current produces Jess torque as speed increases, and in fact the power ‘output remains approximately constant. There are many applications which are well suited by the constant power characteristic inthe region above base speed. TWpical mains ‘supp me He Variable motor speed — ideal voltage- to-requency (Vil or V/Hz2) characteristic. Figure 1-2 Variable Motor Speed Characteristics 152 Drive Specification rec ma ‘Base speed’ : Variable motor speed — typical flux-to- 2-1 Ratings frequency relationship. 1002/00] 2.2 Specifications - General Figure t-3 2.3 Specifications - Control Motor Speed - Flux o Frequency Relationship The second operating condition where departure from a constant VA ratio is beneficial is at low speeds, where the volage drop arising from stator impedanco 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 the stator IR drop. To maintain a constant flux in the motor at low speeds the voltage ‘must be increased to compensate for the stator impedance effect. Compensation for stator impedance is called ‘voltage boost’, Fig. 1-4, and most drives offer some form ff adjustment. It is also normal to taper the boost to match the linear characteristic asthe frequency increases. Fig Vottage Boost 168 ee22 Drive Specification 2.1 Ratings The CDS (0.75-2.2kW) range is rated for current output, therefore the actual power output depends on the output voltage, which in turn depends on the supply voltage. 2.1.4 Power Supply Input supply voltage range and frequency’ 200- 240V AC: 10%, 4B- 62H. singlo phase Minimum supply soute impedance: 0.09 Ohms (@ deve terminals) 2.4.2 Output Ratings ‘The dtive system is for general purpose industrial drives which require short term ‘overload capability of 180% for 60 seconds refer to Table 2-1. TABLE 2-1, CDS (0.75-2.2kW) Industrial Drive OUTPUT. woTOR [___wpur | OVERLOAD | RATING OVERLOAD kw ) 60 : 105 145 105 107 25.9 cps 220 23cos DRIVE | DISPLACEMENT | POWER MODEL FACTOR FACTOR | SWITCHON | TOF SWITCH (appx) 4) ‘SURGE A PEAK | ON SURGE A2S 3) 6) ‘Ds 75 0.95 082 cps 150 0.95 052 Ds 220 0.95 053 NOTE (1) Typical motor power for stated output current, based on a typical 6 pole machine at 220V. (2) With 220V supply and minimum source impedance. () Displacement factor Is the cosine of the phase angle between fundamental voltage and fundamental current and approximates to unity with a low impedance supply. (4) Power factor is (average power supplied) + (Vrms x Irms). The value shown is at 220V and minimum source impedance. (6) With 240V + 10% supply and minimum source impedance. 24 2.2 Specifications - General 22:1 Losses 222 Altitude ‘Above 1000 meters above sea level ‘above sea Rated up to 1000 meters above dorate FLC by 1%/100 meiers to a maximum altitude of 4000 met level. RELEVANT SPECIFICATION IEC 146-2, Section 3.1 VDE 0160, Section 5.2. UL508, Section 52.2 CSA 22.2, Section 6.2.3 Parte 22.3 Ambient Temperature and Humidity Rated ambient temperature: -10°C to +40°C Maximum operating ambient temperature 0°C to +50°C ‘Maximum storage ambient temperature: -25°C to +50°C Humidity: Non condensing. - 22.4 Environmental Protection Ingress protection 1F10 (ringer protec 225 Materials ‘At plastics have flammabily rating UL94 VO. 28cos 226 Welghts Module weigh, including chassis, i 2.99. 22.7 Response Time Time to energise output stage Is 20 ms (maximum) using electronic ‘star terminal, ‘or 100 ms (maximum) from application of power to the input terminal block TB1 (Auto-start modo). 2.2.8 Current loop Response Time Fastest selectable accoloration and deceleration times 0.2 seconds to upper limit frequency. Current loop response is fast enough to prevent tripping an fastest acceleration setting or instantaneous application of a load of 150%. 22.9 Electromagnetic Compatibility EMC Tho drive is designed 10 facilitate compliance with EMC requirements such as EC Directive 89/396/EEC, IMMUNITY, Moots IEC801 without significant disturbance to operation at the following level Part 4 (Transient Burst) Level 4 at all terminals, Refer also to Chapter 10 (EMC). 26 2.3 Specifications - Control 23.1 Analogue Inputs (1), Local speed reference (TB2/11): unipolar 0 to +5V, 100K input impedance (2) Local speed reference (TB2/9) 0 to +10V, 200K input impedance (2) Remote speed reference: (current) 440 20mA, 100 Ohms input impedance (7B2/15) or 2010 4mA, 100 Ohms input impedance or 00 20mA, 100 Ohms input impedance extornal resistor connected to OV Voltage out < 2.5V, capabie of protecting 6 standard 250R machine thormistors ‘connected in series. Trip resistance 3k * 15%, reset 1k8 215%. Trip whan resistance < 100R + 15%. (4) Motor thermistor (PL6/2): NOTE ‘An intornal 1kSohm resistor is connected via LKé across this input. the user wishes {0 use this Input LK4 must be removed, 23.2 Analogue output Frequency (Speed) (TB2/13): 0 to 5Vde, or 1mA capability; OV = OHz, SV = Prt. Accuracy + 3%. OV «no load, SV =+150% Accuracy # 15% (Hardware DIL sw Load (Torque) (TB2/13): 23.3 Digital Inputs Each digital input has an internal 1Kohm pull up resistor to SV. momentary low = start (N/O contact 10 OV ‘commen) (1) Stan (78274 low = not stop, momentary high » stop (NVC contact to OV common) (2), Stop (1825): (8) ForwardRoverse (TB2/6): low = select reverse direction (contact to 0V common) high = select forward direction 27cos (4) Jog/Preset Speed (PL6/4): low = jog/preset 1 speed (contact to OV common) NOTE This Input can be software selectable by bit parameter b4 to give either jog input oF a preset 1 spacd select input. (6) External Trip (PL6/8): low = not stoptrip (N/C contact to OV common) ‘momentary high = stop/rip, (6) Reset (182/10): momentary low = reset (NO contact to OV ‘comman), edge triggered input (7) LocavRemote (PLE): Low = remota, i. all inputs useable High = local, .0. speed reference from B20 or 11 only. (8) Preset Speed 2 input (PLEV6): Lows active 2.34 Digital outputs Drive Relay (TB2/1, 2 and3): Volt free contact, Rated 110V ac, 7A. resistive. ‘Switch configured (SW1 A, B) for STATUS/AT ‘SPEED/ZERO SPEED, or RUN RELAY function. ‘Changeover type relay. 23.5 Serlal Communications interface S485, S422. Protocolis ANSI 3.28 -25-A4 Hardware intertacing is 5 wita, RS485 which is upwardly compatible with RS422, S232 can be accomodated with some systems see Chapter 7 for details, Tho hardware supports mulidrop operation with a maximum of 32 recelver channels connected to any one transmit channel. The hardware isnot isolated. tertace cable details, refer to Chapter 4 “Installation — Electrical. SERIAL COMMUNICATIONS in Differential Input: 0 10 Vdc, input impedance 3.5k. W(A-Al) > #0.2V = Logic high at the receive. WA-Al) <-0.2V « Logic low at the receiver. 28 Difforential Output Transmiting: Output is 0.7 to 4Vde with no load, current capability + 60mA. Logic high at the microprocessor A = 4V, Al = rv. Logic low at the microprocessor A = 0.7V, Al = av. {.e. the diferential votage is + 3.3V on no load. Maximum input voltage 12V wrt OV Minimum input voltage -7V wet OV 29cos (03 23.6 Accuracy Frequency: + accuracy + 0.01% full scale + resolution 0.1% full scala NOTE “These figures imply: ‘Crystal controlled internal reference Display resolution 0.1Hz 23.7 Resolution When parameters ara sot from the keypad or serial communications link, resolution is £ 0.1 unit oxcopt for the folowing: Value > 100 units + 1.0 unit, keypad mode ‘Acceleration and deceleration rates: resolution becomes coarser towards 600 seconds. Pro, Pri, P17: +0.2Hz for ULF = 240Hz. :£0.4Hz for ULF = 480Hz. :£ 0.8Hz for ULF = 960Hz. Pré: 40.4% Display resolution + 0.1Hz. 23.8 Auxillary Supplies and References (1) 45V42%, 0.5mA @) 0V common (Qty 3) 210 3 Installation —Mechanical 3.1 Drive Mounting 3.2 Location 3.3 Cooling and Ventilation otcos a2 3 Installation — Mecha 3.1 Drive Mounting Principal dimensions are as shown in Fig. 3-1. The drive must be mounted in the ‘orientation as shown, ie with the terminals at the bottom. Any other mounting position may intertare withthe drive cooling. 3.2 Location “The installation should be located ina place free from dust, corosive vapours, gases and all liquids. Care must also be taken to avoid condensation of vaporised liquids, Including atmospheric moisture, W the drive is to be located where condensation is likely to occur when the drive is ‘ot in use, a suitable anti-condensation heater must be installed. The heater must be switched OFF when the dive is energised. An automatic changeover switching arrangement is recommended. CDS drives are not to be installed in classified hazardous areas unless correctly ‘mounted in an approved enclosure and certified (refer to "Hazardous Areas" Chaptor 4"Installation - Electrical’). 3.2.1 IP Rating The tive enclosure conforms to international enclosure specification 1P10 it is therefore necessary to consider the location of the module in the light of local safety tequlations applicable to the type of installation, 3.2.2 Hazardous Areas e ‘Ths appteation of vraba spend cvs and ot eta ofall ypae may nvalite protected squirrel cage induction motors. Approval and certification should be obtained for the complete installation of motor and drive. a8a4 ig Figure 3-1 CDS - Drive Mounting Dimensic 3.3. Cooling and Ventilation 3.3.1 Enclosure minimum dimensions ‘Care must be taken that the onciosure in which the drive is sited is of adequate size {0 dissipato the hoat gonerated by the drive and any other equipment. A minimum Clearance of 100mm all around the drive is essential (refer to Fig. 3-3). All equipment in the enclosure must bo taken into account in calculating the internal temperature 60 ‘a8 not to raise the internal temperature ofthe cubicle above the maximum allowable {or the drive 3.3.2 Effective heat-conducting area ‘The required surtace area Ag for an enclosure containing equipment which whoo Ag = _Etfective heat-conducting area, in m2, equal to the ‘sum of the areas of the surfaces which are not in ‘contact with any other surface. k= Heat transmission costficient of the material from which the enclosure is made. T, = _ Maximum permissible operating temperature of the = [Oi]. ‘caused by capacitative leakage ettocte, “7wus 4.3 Control Connections For control connections use cable of 0.5mm? screened. Connect screen to ‘earth’ AT DRIVE ONLY using a very short connaction (SOmm Max.). Aways segregate contro and power cabling. Connections to terminals are shown in Fig. 42 to 46 and should ‘be made to ‘earth’ at sending end # long cables are used (i. greater than Sm). n with all inverter drives, the unit will produce a certain level of Radio Interference. It is the users’ responsibility, to ensure compliance with local for RFI control. Filters specifically designed for use with the inverter are. from your supplier. In some cases general purpose mains supply RFI fitters ‘be sufficient. Note that lowest lavets of RFI emissions occur at the lowest Fewrching frequencies, For further Information see Chapter 10 (EMC). 43.1 Terminal Block TB1 Figure 4-2 Terminal Block TB1 Terminal No. 1 YY ona oanw acs t0% 2 uw | 48 Hz - 62 Hz singla phase Minimum supply source impedance:- 0.09 ohms (@ drive terminals) Earth connection is via heatsink,cos 43.2 Terminal Block T82 2[el2l2jelelejele| Zoe se7s own 20 M6 Figure 43 ‘Terminal Block TB2 “0 Terminal UO Namo Speciication i No, | 1 ° Relay NC , 2 ° Relay NO 110V ac, 7A, t 30 Relay common} norvinductive i 4 1 Start Input Momentary low to start (ow = OV) } 5 1 Stop input Momentary high to stop ! 6 1 Forward ev Low to select reverse direction 7 0 ©V common e 0 4+5V reference SV. 2% tolerance, 05 mA potentiometer OF 9 1 80 10V input wo Reset input Momentary iow to reset " 1 010 8V input 9. via 10K potentiometer 2 0 0V.common 3 ~O Froquencyfload 0 SV (>100K source impedance) Output of, 0- 1 mA (<5000 source i impedance) to 100% spocd (Prt) i oF 150% load. i 4 0 OV common i 15 1 Current oop input 0-20 mA, 4-20 mA, 20-4 mA ! i All contactor coils, solenoids and brake colls must be suppressed with an RC network or equivalent. The control electronics will be intertaceable with other industrial control products referenced to potentials within + SOV (peak) relative to earth of the drives mains supply input. Load signal: For a positive load, only gives an indication for positive load. motoring, the dig ‘negative load, ie. regenerating, the display flashes. The analogue output, TB2/13 solectabie by bit 14 (b11) | shows a steady value. For on Aeneancos 4.3.3. Connector PLE (2) To prevent the drive tripping the ‘Et’ trip is disabled via a jumper lnk fied betwoen PLE pins 8 and 10. I features associated with PLE are required then ths ink can be removed and the connection made elsewhere, (8) Serial communications VO Differential input: 0 to 5Vde, input impedance 3.5k. V(A-A\ > +0.2V = Logic high at the recoiver. V(A-Al) <-0.2V « Logic low at the receiver. Differential Output Output is 0.7 to 4Vde with no load, current Transmitting: capability + 6OmA. ‘Logic high at the microprocessor A = 4V, Al = O7v. Logic low at the microprocessor A = 0.7V, A\= | wv. he differential vokage is + 3.2V on no load. (4) If the tocalremote facility (Pin 9) is to be used thon link § must bo removed. Figure 4-4 Connector PLE Connector Pin vO § ‘Sotil Link receive At Motor thermal protection thermistor input (rt.Noto(1)) Setial Link recoive A { 7 Jog/Prasat 1 input ‘Serial Link transmit A\ ‘reset spoca z Sorial Link transmit A\ Extoral trp (raf Nota(2)) Localemote (low = remote) (Ref Note 4) (OV common no ' t ° goooco00 >o > ° ' I ° NOTES (1) tt motor thermistor is fited then remove link 4 (by PL). + a 41343.4 Terminal Block TB3 Terminal VO Name ‘Specttcation No. u © Motor phase O/P U v 9 Motorphase OPV} Max. Output nominally equal w © Motor phase O/P W 4 to supply input voage. Variable trequancy. Motor Speed: WARNING: Standard induction motors are not designed to operate at 240, 480 or 960 Hz. ‘Any attempt to run such a motor at above twice synchronous speed may result {in catastrophic motor fallure. Consult your motor supplier for advice and dotalls of epecial high frequency motors. | ans5 Drive Configuration _eseeeonanne sey 5.1 Operating Procedures 5.2 Configuration Examples 5.3 Diagnostics and Fault Finding 515 Drive Configuration Operating Procedures lars are the means by which the operating charactoristics of a system are ‘eontrolled and monitored, The two principal kinds of parameter of a digital drive are {he operating parameters and the bit parameters. Operating paramotors have a real-value range, for example from 0 to 150%, Bit parameters are used for selecting different control configurations and are ‘eith oF functions. ‘The response of the drive and the motor depends fundamentally on the set up of the Oo sig Ly drive parameters, These values are accessible through the keypad, and additionally by signals through the serial communications link from a host computer, programmable logic controler, or thar communicating device. terminal, a | tn gp can tf te al ay pat; atpanmaten am | a et at gece a aeieted an aad Sea ee ae aaa Sete hereon tomes wonenen oes | = Operating parameters can be adjusted while the motor is running. Bit parameter adjustment requires the motor to be stopped and the display to show rdY, or to bo tipped, whan the display will lash the Trip Code indicating the condition. NOTE In the keypad mode, adjusting the parameters while the drive is tipped will reset the dive 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, All parameiors can be allowed 1o remain at thir dofaut values, or as sot atthe factory during final test, oF ean be adjusted in any sequence fo su speci applications, Defaut values are settings to which all paramoters can be caused to | ‘atom a wil and af sted in the Parameters Gulek Reference (Chapter 6) The ! Values set at the factory (as delivered values) may, for special customer roauirements, dite: rom detail valves 62 7cos 5.1.1 Manipulating the Parameters via the Keypad TO SELECT A PARAMETER ‘Tho MODE key enables a parameter numbor to be selected. When the MODE key is pressed, a parameter numbor is displayed, and akernates with the parameters value. With the parameter number altrmating with its value, press the UP or the DOWN key nee to solect the NEXT parameter, To scroll through parameter numbers press UP or DOWN repeatedly. f there is a delay of more than 8 seconds in pressing another ey, the display will dataut to tho Presont Indication (see below) of tho output of the Give, Pressing MODE again returns to the parameter selected. TO READ A PARAMETER Seloct a parameter by pressing the MODE key once. The display will show the Pr humber, alternating with the value, of whichever parameter was last read of adjusted, The display will alternate betwoon the parameter number and its value for 8 pariod of 8 seconds, after which it wll default to the Present Indication. ita ciferent parameter is required, select as explained above, The new paramater wil alternate With its value in the display for 8 seconds. 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, of «the dtive has tippad, then the Trip Code wil flash in the display. ‘To stop the drive, press the DOWN Key until the display shows 0 ifthe drive isin Keypad control mode (B90), or open the STOP terminal TB2/S in Terminal control mode (b9=1). Wait unti the display shows rdY. ‘Select the required parameter and pross the MODE key once more. The display will hold the parameter value steady. ta further keystroke is not made within 8 seconds, the displayed value will defaut fo the Present Indication. ‘The values of all Pr parameters can be adjusted whether the motor is running oF not Change the parameter value by pressing the UP or the DOWN key. A single koystvoke changes the vaive by plus or minus one digt. Press ethor Key repeatedly fo Increase or decrease through the parameter values to the maximum or minimum callable, The parameter change acts immediately on the internal setting. It the drive is operating the motor, the motor responds to the change as i is being made. The fast parameter value set is stored if the powar supply is disconnocted, and is restored when next the drive is energised. wus parameter MENU SELECT value of parameter ENTER value of Figure 5-1 onfiguration of Drive Parameter Menus 55cos (C0s ee 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. ACCESS TO PARAMETERS: Figure 5-1 shows an example setting Parameter 0 (Pro) to 28.0 Hz. To adjust other parameters the user can use the UP (a) and DOWN (¥) keys to scroll through the parameter menu loop. — ws, a §.2 Configuration Examples 521° Sofety Safety procedures must be properly observed itis advisable particularly to take care to check the direction of rotation of the motor Ensure that... “+ the porson in charge of the tral run is fully competent to perform or supervise the mechanical and the electrical installation. + the motor rating is compatible with the inverter rating. + the motor is securely bolted down. «the inverter is firmly attached in an upright position and is properly ventilated. Preliminary For access to the power and control terminals, refer to Chapter 4 “Installation ~ Electric + Electrical supply connections must be earthed in accordance with loc industrial safety regulations, + Protective hre fuses oF a circuit breaker of the correct rating must be installed in the supply, ror to Chapter 4 “Installation ~ Electrical’. 57cos cos — See $22 Bt Ne Application Itis required to drive a 1.1 KW, 4.48 indication motor to 60 Hz frequency. Basic control of speed and direction is required, with a controlled ramp to stop. 'No motor thermistor is fted. Connections. ‘Typieal connections are shown in Fig. 5:2. Commissioning [ACDS 150 is chosen to run the 1.1 kW, 4.4A motor. In order to provide some motor thermal protection the in-built thermal model is to be re-scaled. Power up the drive and set parameter 5 (maximum continuous currant) 0 4.4/7.0 x 400 = 63%. The drive can now be run by closing the run switch. Speed can be contrallad by the setting of the speed potentiome iebeekePieb bie] speed adjustment (Pr0, Prt) and also acceleration and deceleration ratas (Pr2, Prd), Frequency can be monitored on the 3 digit display. SOMONE ie Figure 5-2 Basic Application 59wes saa SES COLIN PRESET SPEED CURVE Figure 5-3 HVAC Application cos ee 52.3. HVAC Application It is required to drive a 1.5 kW (6A) motor to 70 Hz frequency for a HVAC application. Noise is a primo consideration and an automatic 1 requited to restart the drive in tho event of a spurious tip. tart facility is Three fan speeds are required (30, 50 and 70 Hz) and an indication of ‘at speed! is also required. Connections: Typical connections are shown in Fig. 5-3. NOTE ‘When using PL6 the jumper link (LK4) has to be removed and the external trip, connection 1 made externally across pins 6 and 10. Commissioning CDS 150 is chosen to drive the 1.5 kW motor and the motor i ‘operation at 70 Hz. Parameters. Automatic start is required and is set by bt to 0. ‘Automatic reset is required and is set by bO to 0. NOTE is suitable for Will automatically start the motor in the event of a trip. See detailed parameter description in Chapter 6 ‘The ability to catch a spinning motor is required and is carried out by setting 65 to 1 NOTE ‘Sen willbe displayed when run. Bit parameter b14 is adjusted to the maximum allowable switching frequency. ‘Switches 1A and 1B are set to ‘ON’ 10 configure the relay as an ‘at ‘Switch 10 is set to 'ON'to set dynamic vA characteristic to quieten the toad, Switch IF is set to on to select Pr0 as a preset speed. speac! relay. motor on light ‘By configuring the control switchas in a binary sequence the preset speeds can be selectad as set in paramelers 0, 1 and 7, (S89 graph shown in Fig. 5-9}off off o of on 30 on off 50 on on 70 * Assumes no connection is made to analogue inputs, e.g. terminal 11 NOTE Parametor 7 must be set to the range Pr0 < Pr7 < Prt as Pro and Prt will act as a clamp on P17. 5-12 5-19cos eusegsuree Figuro 5-4 Serlat Communications Exemple we 5.2.4 Serial Communications Application his roquired to drive two 0.55 KW motors from one drive. The motors are connected in parallel and are configured identically for load and environmental conditions Control is via a resident PLC using RS485 tine. Connections: ‘Typical connections are shown in Fig. 5-4. NOTE “The cable screen is to be earthed at one ond only. Commissioning A.CDS 150 dtive is used to power the two 0.55 KW motors and allows 20% and fesdroom for aceeleration. The drive is to be configured for serial communications by setting the following param: ‘Adjust parameters b2, b10 and Prd to match the host PLC: 12 baud rate 4800 oF 9600 bid even or od8 parity Pr9 serial address Select serial communication control via bé to 1. For further details see SERIAL COMMUNICATIONS Chapter 7. 5455.3. Diagnostics and Fault Finding DISPLAY does not illuminate and drive does not run. ‘CHECK mains supply, supply fuses or circuit breaker Rioplace supply fuses if blown, or reclose circuit breaker, butt supply fuses blow 6 breaker trips again contact the supplier ofthe drive. I key pad is remote mounted, check extension cable wiring. MOTOR does not stat, display shows rdY. Drive isin MANUAL start mode, ‘Operato UP key, or START pushbutton CHECK the control wiring, and that external stop/runttip contacts and circuits ae in order. MOTOR doos not start, display shows 0. CHECK wiring ‘of speed reference, and that the correct mode (REMOTE/LOCAL) has been selected. it in KEYPAD mode press UP key. ‘Check preset spead is not selacted with a setting of °° Hz. (Check max frequency parameter (Prt) is not 0" Hz. TRIP CODE at display ‘Note that: + Thermal trip devices should not be continvaly tripped and reset. + Olttip can be caused by shock load, cable or motor ineviationfauls, langth of cable to motor too great, or attempting to accelerate too large a motor. + Oland OU trips may be caused by decelerating too quickly: when operating below motor base speed — OI tip ‘whan operating above motor base spaed — OU tip Increase the valuo of Prd and chack that b2 and B7 are set for ramp stop. + 11S or Err are displayed, ty disconnecting the drive from the supply, wat 2 ‘seconds, reconnect and run the drive. If the fault persists, contact the ‘supplier of the drive. MOTOR fails to turn the load, and is noisy Fixed boost setting too high (Pr6). Also check the settings of currant limits Pr4 and Pr5. Check mechanical load is free to tur. DRIVE fails to respond to serial communications CHECK serial communications mode (b6), parity (b10), baud rate (b12), and serial address (Pr9) are sot correctly. CHECK the wiring and termination of the serial ink. DRIVE appears to be set to an unusable state Sot b13 = 1 to reset all parameters to default values. ws eee If, alter performing any of the above checks, the drive stil! malfunctions, contact the supplior for assistance. {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 external trip Et can be forced by the operator. 53.1 Trip Codes ot 4220mA current loop loss. The current has fallen to<3.5mA when bt t= 4, 20 oF 20. 4. ‘When b11 = 0.20 currant loop loss trp is inactive. ers Hardware fault within the dtive. Oocurs only at power-up. Is 2 lock-out condition — no reset. Hardware fault: 1 ‘ASIC reading error, 4 = Processor error in serial interrupt. 5 - Keyboard fault 6 - — NOVRAM initialised. 7 = Current sense circuitry has too high positive offset at power up. 8 = Current sense circuitry has too high negative offset ‘at power up. a External trip is operated by terminal PL6/B or via the serial ‘comms word CW. w Integrating overload (Ixt) trip. The output current as defined by Ped and Pr5 has reached the allowable time limit on Host sink overtemperature, The heatsink has reached its upper safe working limit due to loss of cooling air or cooling air too hot. a Instantaneous overcurrent trip. Excess current flowing in the IGBT inverter bridge, caused by short circuit, low impedance ‘earth fault or excessive shock load, ou DC bus evervottage. Caused by main supply overvoltage (even if momentary), oF high impedance earth fauit, or excessive regeneration due to a high rate of deceleration. ps“ Internal power supply faut. 5475.27 5-18 th Motor thermistor (if fitted) impedance high due to sensing ‘xcoss temperature, or impedance less than 100A due to cable short citcut or similar. to ‘timeout’. Trip to indicate that the auto raset function has failed to reset the drive after the third attempt to start with the same trip fault vu The internal power supply voltage has fallen below the ‘operating range. The drive trips instantaneously. UU ttip can also be caused by a failure of intornal components of the. These conditions require expert attention. Please consult the supplier of tho drive. Healthy Indications 1¥ Motor stopped, drive enargised. Numerical Motor speed (H2) or load (%FLC) dependent on value the sotting of b8 or a parameter value if accessed. displayed deb ‘de braking active, inh Motor coasting to rest, IGBT bridge inhibited. Son Spinning motor software is solected and the drive is, ‘scanning for the correct motor frequency before catching the motorfioad and taking them to the set speed. Flashing This indicates that the drive Is in the Ist region decimal point cos 6 Parameters & Switches 6.1 Operating Parameters 6.2 BIT Parameters 6.3 DIL Switch 6.4 Links 6.5 Parameter Quick Reference 6162 Parameters & Switches 6.1 Operating Parameters Parameters are listed In the sequence which they appeer in the keypad display when the UP key Is used. Parameter: Pro Minimumy/Prosot 2 ‘The lowor limit of inverter frequency: ‘output frequency, determining the minimum speed of the motor. Range: oltz < PrO.< Prt Default value: oz Serial mnemonic: MN Minimum speed is set by parameter Pr0, which can be any valve less than or equal to Pri. The logic does not allow the value of Pr to be greater than Prt. The 0 to "TeV range of tho external relerence operates on the difference between Pro and Bri, For example, f PrO = 10, the inverter output is 1OHz when the minimum speed eteronce ig OV. If Pri = 50, then when the speed reference is SV the output jequency is SOHz. For values of speed reference voltage between 0 and SV, the output frequency Is given by— f= (Prt = Pro) V+ Pr 5 NOTE - 1 = frequency eg. tV=25 then f = (50-10) 25+ 10 = 30Hzcr if switch SW1.F is ‘on’ Minimum/Preset 2 frequency becomes the value of the second 5 ‘energised from torminal 6 of PLE. preset speed wen NOTE ‘Tho minimum frequency is automatically sot o zero OHz in this mode. ‘Soe Pr7 description for further details on preset speeds. Parameters Pr0 and Pr apply to both forward and reverse operation. FREQUENCY RELATIONSHIP ‘The ULF, tho full speed frequency Prt, and the minimum sf related as folows:— ” eed teauenoy Pro we oz < Pro < Pri < ULF FREQUENCY RESOLUTION 010 120H2 = O.tHz Oto240H2 —O.2Hz Otod80Hz 0.42 0t0960H2 —O.8Hz 6-4 ee Parameter: Prt MaximunvPreset 3 ‘The value of fraquency in Hz above A which the motor is not to operate. ‘Additionally, is the set speed as energised by preset spood 3. Range: Pro < Prt < ULF Default val ‘S0H2 Sorial mnemonic: MX ‘Voltage and load. Control of sped is achieved primariy by controll frequency. The tdve can supply any frequency up to the maximum for which tis designed (960Hz). thcan also reverse the direction of field rotation and so reverse the direction of the motor. Motor full speed frequency is selected by adjusting the value of parameter Pr. For ‘Sxample, PH = 50 makes the maximum output frequency equal to SOHz, Prt cannot ‘be greater than ULF, or lass than Pr0, ‘Also if terminals 4 and 6 of PL6 are both energised then preset speed 3 is sot as per Prt_ See parameter 7 description for further details on preset speeds. 65Parameter: Pr2 Acceleration time: The time to accelerate from OHz to the selected value of ULF; } Deceleration time Pr3. The time ¢ 10 decelerate from 11 to 2 depends on the value selected for the ULF as well as for Pr3. rae Figure 6-2 Deceleration Time Pr3 od Parameter: Pré Current limit: Maximum level of current overload. Range: PrS s Pr4 < 150%FLC for Industrial rating drives Detautt values: 150% FLC for Industrial rating drives. Serial mnemonic: TR CURRENT LIMIT ‘The level of controled maximum current output is set by Pr4. ts maximum value is 150% of inverter FLC. Pr4 can bo set to any value between Pr5 and 150%. OVERCURRENT “The ative logic recognises three levels of high transient currant above the current limit Pré, such as might be caused by sovere shock loading, or by short circuit or ‘earth fault in tho motor or cable, “The logic responds to transionts protecting the motor, the cable and the drive by shutting down the invertar IGBT bridge. The speed of electronic fault detection is ‘greatly superior to the performance of hrc fuses. INSTANTANEOUS 'SHOCK-LOAD LMT Ei corte Limi Prt Caninvaus curren Ps o see) ‘Overcurrent protection by intemal electronic monitoring Figure 6-3 Overcurrent Protection 69Parameter: PrS Max. continuous Porcantage of FLC at which current; ‘current can be supplied continuously; threshold level of timed eurrent imi Range: 10% to 105%FLC, and not greater than Pra Defaut value: 100%FLC. Serial mnemonic: TH CURRENT & PROTECTION CONTINUOUS CURRENT LIMIT {An inverter is usually selected with a maximum continuous current rating to match that of the motor. To prevent overheating at full load the motor full load current (FLC) rating must not be exceeded. The continuous current limit is parameter PrS and its value is the ratio of the motor rated FLC to the inverter FLC, percentage: — PIS = (motor FLG / inverter FLC) x 100 PrS isthe lower threshold of the iavetse timo-current protection of the motor and its cable. Current in excess of PrS starts the | xt integration and is signaled al the isplay by flashing of the unused decimal points and will il sustained, result in tripping of tho inverter. Curves are shown in Fig. 64 Trip time = k x PrS J (actual % currant -PrS) in seconds, where k= 257 6-10 rencentace bear cos Shree. rme ro mp ~ 90sec TSE PSA oats ro mp = sasee 105% 90% 70% 50% Figure 6-4 ct Characteristics (NOT TO SCALE) 6-11Maximum level of voltage boost ‘at zero frequency. 0 10 25.5% of main supply voltage 9.8% BO VOLTAGE (roRauE) 0087 Saree the gue eval for satin tonal ads and 0 compensate or the ncrense in motor losses at low speeds is vstul i Torque i booted imate ae an rb a Tang tm Oz The dive citar wo aeratv way of aE boost, selected by parameter b3. " oa AUTO boost is selected by b3 = 0 — FIXED boost by b= 1 The dagree or amount of boost is dotermined by paramtor Pr6, which ven any value up to 25.5% of main supply voltage. me - wien canbe give i | | i m3 S = \otago (torque) boost Pr. (a) High fvel of boost, paring o 8.8% at OME. Note that boos s maintained at high level downto a equoncy of oe sixeenit of Pre. (2) Low level boost — tapers eveny kom Pr when Pris <.6% of maximum volage casei Figure 6-5 Voltage (torque) Boost Pré 6-12 When the value of Pr6 is set below 9.6% the boost Wt of max output voltage at 0 Hz and tapers lin characteristic at a frequency of Pro, Fig. 6. 2 tthe normal Vit When the value of Pr6 is set above 9.8% the boost characteristic has a break point ata frequency of Pre/16, The boost tapers from this braak point to 9.6% of maximum Sutput volage at 0 Hz and to the normal VA charactarisic at a frequency of Prc/t6, Fig. 6-5. itis best to choose the lowest effective degree of boost as too high a value may Cause the eurrent to reach the current limit level. This has the effect of sopping any fnerease in frequency, and the motor appears to stall, For this reason it is a reenmended that Pr6 should be increased in small steps from a low valve until the motor starts smoothly and with minimal hesitation. the drive applies a voltage increase proportional to ‘tage of the chosen value of maximum continuous When AUTO boost is s the load demand as a perc ‘current PrS. Hf, for example: the selected value of Pr6 is 20% the selected value of Pr5 is 105% FLC ‘and the actual current demand is 90% FLC then the dtive calculates the voltage boost at OHz a (0.2 x 0,901 1.08) = 17.1%. “This is tapered to zero boost at 50% of MVF (io at 0.5 x Pre) FIXED boost Is the better choice for constanttorque loads requiring a very high Slarting torque and high ineria loads where rapid acceleration is required i, in Sivations where the machine Is more susceptible to staling. AUTO boost is beter saraatiabletorque loads whore the load at starting is also variable i.e. where the is loss susceptible to stalling. - 6.13eee Parameter: Pr7 Jog frequency/ Proset frequency: "Bit parameter b4 = 0 Jog frequancy : The frequency that the drive will run at when the Jog/preset terminal is active from rdy mode (i.e dive will start from rdy and attain the frequency set by Pr7). Bit parameter ba = 1 Preset frequency: The frequency that the drive will run at when the preset terminals select this preset speed (only i the 3 ee Le] a} E 3 — # HB) § g al 8 3 62” x a q| Ze al 28 6 es reg] | 27 areca figure 7 1S485 Multidrop Link Connections Fee 7.2.2 S422 Connection Rotor to Figs. 7-2 and 7-4 Using a S422 standard limits the number of receivers to a maximum of 10, also all ‘must be connected at the end of the cable and NOT along its length. The jarminated at the receiver end cable must be braided screen, 100 Ohm, twisted pai by a 100 Ohm resistor. mpeance (as tang 1200) Figure 7-4 Standard RS422 Connections NOTE The 100 Ohm terminating resistor (R113) can be fited into one of the CDS Drives, For Sarial Port pin connections, reter to Fig. 7-27.2.3 RS486 Connection Roler to Figs. 7-2, 7-9 and 7-5, ‘The standard connection used is S485 which must use a braided screened 120 ‘Ohm twisted pair cable, terminated at aach and with a 120 Ohm resistor. Eauerert tn Aes pon 10 v0 upnarh Seed wt pa win nth 4 pon {mpedance as engin 12000) Figure 7-5 Standard RS485 Connections Stub connections to the equipment from the main cable must be as short as possible. a CDS Drive is connected at the end of a cable the terminating resistor can be fited into the CDS Drive (R113} NOTE Resistor Value; 120 Ohm 0.25Watt 7.2.4 RS232 Connection Reter to Fig. 7-1 The serial por on the CDS Drive can be configured to interface with an RS232 link. Using this contiguration only one drive and receiver can be connacted togathar. A terminating resistor is not used, The user should note that the CDS is not specified to be compatible with RS232. Some PLC's or computers generate and accept voltage levels outside of the Specification of this product, For users requiing reliable connection S485 or S422 shouid be used, 1 7.3. Components of Messages Digital communications systems such as RS485 communicate by means of binary logic. Binary logic is ‘wo state’, and is readily implemented by an electrical circuit which Is either “on” of “off, The two diffrent states represont two distinct bits of data, either binary digit (bit) 0 or 1. By fixing a time duration for each bit, a sories of bts transmitted can be recognised by a receiver. Ifa group of bits contains the sama number of bits it becomes possible to construct a variety of diferent ‘charactors’ that the receiver can recognise and decode. A group of four bits has sixteen possible variants — 0000, 0001, 0010, and 80 0n fo 1111, Each of the sixteen variants represents one ‘hexadecimal charactor- Unit — the dacimal numerals 0 to 9 followed by the six lottars A to F — making 16 differant and distinct characters. ‘Two hexadecimal characters each of four bits, making eight bits in all, are known as 2 byte’. Each byte can be used to represent a character of data. ‘The character set used in CDS drives is the ‘low’ American Standard Code for information interchange (ASCII), comprising 128 characters. In the Yow’ ASC! set only 7 data bits are used in he byte to represent the characters, refer to Table 7-2. ‘Tho first 32 characters in the ASCII set (hex 00 to IF, ‘NUL’ to ‘OS') are used to represent special codes. Thase are the Control Codes, each of which has a panicular meaning refer to Table 8-1. For example, ‘start of text’is STX, and, from a koyboard, is made by holding down the Control key and striking B once (Control-B) This is hex 02, and the actual transmission is the binary byte 0000 0010. The drive i programmed to know that this character signals that a command will follow: Table 7-1 details the only control codes that the CDS drive will respond to, other control codes and the ‘space’ character (20h) should not be used when communicating with the COS drive.Table 7-1 Control Characters in CDS Drives Character | Meaning ‘ASCII code hex— cot | Reset o ° ENO —| Enquiry, interrogating the drive 05 E st | Startoftext 02 8 ETx End of text 03 © Ack — | Acknowledge (message 06 ascoptay os messee . Nak — | Negative acknowledge 18 u {message not understood) ‘Tho components of all messages betwoon the host and a CDS drive are formed of ASCII characters, Each ASCII charactor that is transmitted oF received has a start bit prior to the 7 ASCII bits, a parity bit and a stop bit. The 3 extra bits are necessary to synchronis data transmission and provide error checking. The convention is that the start bit is a (and the stop bit a 1. The parity bt is prasent to allow the receiver of the charactor to chack that the character is valid. The format (Le. time sequence) of the ASCII characteris shown diagrammatically. ‘Low’ ASCII charactor byte Start ‘Seven data bits, variable Parity | Stop] bit bit | bit o | i msb 1 tat | and 2 : +} = | ath | om | roth op se ts ———— Time Each bit is transmitted for a set dofinad time as indicated by the baud rate ( per seconds) bits a 7.3.1 Control Characters ‘To conform to the standard structure of a message, the stages of @ message are signalled by control characters. SERIAL ADDRESS Each drive is given @ unique identity or address (Pr) so that only the driv ‘addressed will respond. For securiy, the format is that each digit of the two-digt ed, thus the address of drive number 23 is sent as four EET ‘The serial address follows immediately after the first control character of the message. DATA MNEMONICS To identity which operating parameter a message relates to, tho parameters aro represented by a data mnemonic (refer to Table 7-3), which is a simple two- character code. When data is being communicated, it is preceded by the ‘appropriate mnemonic. The data mnenonic 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 two different forms ‘a8 a plain numerical value, or as a Hox Code Word. Most of the operating parameters of the dive, are numerical data, such as a value of frequency, load, current, etc. For example, speed is given as frequency in the range +960.0 10 - 960.0Hz. The value ‘9SHz in a reverse direction’ is sent as Data of of s] Jo GharaciorNanber | 7] 2] 3] 4] PL © ‘To enable the state of bit-parameters (and Prd) to be transmitted conveniently, 2- byte and 4-byle Hex Code Words are used, as described fully under Hex Code Words below. Each byte dacodes to describe the status of the bit parameter in dotail, Use of a code for this purpose enables blocks of complex data to be handle« ‘Quickly and economically and avoids long series of messages to cover the many bit parameters,ws eS BLOCK CHECKSUM BCC To permit the drive and the host fo ensure that messages from one to the other have. hot become corrupted in transmission, all communications other than ‘acknowledgements are terminated by a block checksum character. pa Table 7-2 “Low” ASCIl Character Set mex wmf 0 [1 [? [3 [* [se [ss [7 sz, [ enay oor [ono [ons @ | 0000 ee + | oo oof * of 8 2 | oo oe a_| oon 8 of © ol * + | 0100 Tid ol ty 5 | ov Ul @ el Y 6 | ono v 7 | om w | 000 x 2 | 00 ¥ a | s010 z 8 | son i ce | 1100 vd alg © | 110 1 gt malt E | 110 a ee fam = of of Hy NOTE Control characters also marked as (*D), 719ee eseSeeeSSsSsSSSSSSSSSSSSSSSSS Table 7-3 Data Mnemonics in Alphabetical Order mena = Teta | Bad Rca a oe tripped 1a | Reus tonony | aummiagy [> . AC | Reames | nmr ma ta ee eo wn | oc emote | Soca? ms = | gaoaee mee fy |e cw Command word hex code Powe OL Doceloration time ‘umere (6) Pra rece cree . P| Benet acing | EES > Bee o | =. . . (% of FLC) oroeme ww | sara regener | RE rodeo x | tminarieaney | sete ot aris Pt Presovjog frequency numeric (Hz). or sc ‘Security code with sign hex pr ‘SE Sorial addres cmd ratzdiees | tae | ‘SP ‘Set point frequency numeric (Hz) oe ore sw ‘Status word hex. . P HH | Fhermatcoentinn | ROR ra ere TR Transient current limit numeric 2 rs Parameters associated wih seal communication a ial communication ae aso rad-o 612, Itis not possible to read or write to b13. "788,810, m4 nd 7.4 Structure of Messages 7.41 Introduction HOST TO DRIVE ‘A massage cannot be sent to two or more more addresses simultaneously. Mt the ‘same request oF instruction is to be sent to more than one drive, it must be repeatad with the new addross each time. ‘Messages from host tothe drive are of two kinds: ‘a request for information (Reading data), or ‘a command (Sending data) DRIVE TO HOST Messages {rom the drive to the host are of two kinds: a reply to a data request, (s0e section “Reading Data’) or acknowledgement of a message. (see section “Sending Data’) DRIVE/HOST SET-UP The following drive/host set-up is important to ensure correct and satisfactory ‘communications, Each drive requires a unique dentty number, or serial address set by parameter Pr9. The baud rato b12, and the parity bit B10, require fo be set to match the host. Data, drive status and the parameter sol-up can be road from the Grive in any mode, provided only that the drive is energised, and the above Conditions met. To enable the host to control the drive or to change parameter settings, the drive mode must have the above settings and be adjusted as follows NOTE Local/Remote must be in remote to enable serial comms to write to parameters. Four parameters are required to be set to enable operation of the Serial Communications Link — : + Party bit to be adjusted to suit the host bi0=0 bi0=1 even parity ‘odd parity, Baud rate to suit the host 12-48 4800 baud bi2=96 9600 baud 745wes. + Sorial address Pro = 01099, + Analogue inpuvserial communications mode to be set as follows — cr 1 if parameters are to bo adjusted by the host. 6 ~ 0 allows parameters to be read by the host. 74.2 Sending Data (Irom Host to Drive) NOTE ifthe data to be sant is one of the followin, Drive Configuration DS ‘or PWM Switching Frequency FO ‘or Max. Voltage Frequency BS the drive must also be in the rd¥ or tripped stat oF tripped. ‘The format of the command from host to drive is:- Host command — reset - address - start of text - mnemonic - 6 characters - end - BCC I the intended message to the drive is, for example, “change set frequency of drive ‘number 14 to 47.6Hz in reverse", it would be sent ‘CONTROL ADDRESS | CONTROL | MNEM ‘DAT conTROL ‘Bcc TA P| -fo]«]7] |e] ex conto ‘The drive wil reply with an acknowledgement, either:— cor |i] s]s]a] sm Control Control [ACK if the message is understood (whether implemented or not), or NAK if the message is invalid, the data is too long, ot the BCC is incorrect it a value sent is outside the limits for a parameter, the drive will set the maximum valve Parameters which cannot be writen to are: 'b6, b10 and b12 (contained in DS), AC, C1, LD, SE, SW. 746 3 Reading Date “The format of a data request message is:— Host request: reset - address - mnemonic - end For example, to find the spoed set point SP of drive number 12, send — CONTROL] ADDRESS | MNEM| — CONTROL cor | i] +] 2} 2]syP ENO Control-D Controle ‘The drive raplies in the following form: start - mnemonic - 6 characters of data - ond - BCC. For exampio:— CONTROL] MINE DATA control] BCC sx | sfp] +{ oft] t 2] ex ControlB Control-C| The reply first confirms that the data sent Is the speed set point, SP: the six Gharactors immediately folowing give the present setting in Hz. The first character is, Sither + oF -10 Indicate direction of rotation; the remainder is the numerical value — “forward at 11,2Hz" inthis example. ‘The host may now request more information by:— (or starting @ new request as described above), i) Repeat Enquiry (From Host) = ‘The negative acknowledgement NAK (Control-U) sent by the host causes the dtive to repeat the data sent for the same mnemonic. This process can ine swpeated a3 oft loseary hy tha host ii) Next Parameter (Enquiry From Host) ‘To obtain data trom the same drive for the next mnemonic in the mnemonic table (s00 below) send the positive acknowledgement ACK (Control-F). The drive will respond by transmitting the data relating to the next mnemonic in sequence.Mnemonic sequence with ACK response is as follows:- ‘SP AC—eLD, MN, MX, AL, DL, TA, TH, BO, PI, BR, SE, SC, SW, DS, Fa, BS, CW, C1 INVALID MNEMONIC (FROM HOST) ithe host sends a mnemonic which the drive does not recognise, og XY, the drive will raspond by repeating back the unrecognised characters in a message of the form:— start of text - unrecognised mnemonic - reset Thus:— six |X] ¥]_ cor Control-B| Control-D| 7.4.4 Block Checksum (BCC) To ensure that data received can be verified, 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 derived in the following manner. First a binary exclusive-OR is performed on al nine characters of the message after the star-of-text command mnemonic (but excluding the patly, stop and start bits). For example, if the massage to be sent to drive number 14 is “set frequency to 47.6Hz in r itis sent as:— RESET EOT (Control-D) Serial Address 1144 Stan of text STX (Contro-B) Not included in BCC calculation ‘BCC calculation starts here Sat frequency mnemonic SP] SP Heverse = (a minus sign 478 047.6 End of message ETX (Control-C) finally, the calculated BCC 718 Each of the nine separate digits, age epee “0e4t'7* ractor and calculated ly for each character oer SOR show pene 786i ry Code XxOR 3 fom conf = p | oror 000 | 0000 ott rious, | 0010 s101 | 0019 1110 | oor 0000 | ooo: r110 4 | oott 0100 | ote soto 7 [oor otss | oor t101 (decimal) | 010 1110 | 0011 0011 6 [on o1r0 | 0000 orot erx | ov00 oott | gogo oa (Control-C) ‘The final XOR, under exceeds 32 decimal ‘space’, are used only for control cod 1 6" and “Control-C’, is in binary as shown in the ined, is the BOC provided that its equivalent decimal valve {20 hex). As tho ASC characters from hex 00 to IF plus decimal. Whenever the XOR produc 32 is added. Thus, in the above exampl (0000 0110 = 6 decimal, so thal the BCC must be:— 6 + 32 = 38 dacimal, {or which the ASCII characteris “8 ‘Thus the complete message 10 set ine speed of he BCC has to exceed the value of 32 ‘decimal equivalent) number less than 32, bor 14 ta 47.6Hz in [Control-D tor api yaya] SK Control ey etx Controle = (gCo) 749ews SERIAL COMMUNICATION RESPONSE TANG ansmiting and recoing mossagos taka it ino, ; init im, to which futher tin eed th iv aes tw hrm, To end an ve parameter also wil take 435m at 800 baud or 25,8me at 9600 baud. To read a ove parameter will take 47.7ms at 4800 baud, or 27.9ms at 9600 baud. 7.20 cos 7.5 Configuring the Drive Through Serial Communications git numbers, however Most drive mnemonic parameters can be expressed by six imal code digits= the following mnemonic ara expressed by two oF four hexad SE Serial Address (Pr9) SC Security Code (Prb) SW Status Word, SW DS Drive Setup FQ PWMSwitching Frequency and ULF (b14) CW Command Word C1 Configuration Word “Tho drive configuration (0S), for example, oxpresses the stato of each of the 19 saarmoters bO fo B12 indusive. This simplifies the programming ot such Changes earetmnables blocks of relatively complex data to be delvared by one message ¥Si°g two-byte hexadecimal 'word' codes. Hox Code Words aro transmitted in ASCII format, but are always procoded by the Symbol ">" which enables the receiving divemhost 1o decode ther in & ‘spacial way. aye past explained by an llusration of each ofthe above special mnemonics 7.51 SE—Serlal Address (2 Hoxadecimal Digits) ‘This isa road-only paramotor. To read SE for dive number 22, for example, send — OT Control-D ControbE PEELE ECF The dtive will reply — six |sle ie] ex Control-B Control-C (sce) ‘The data folowing the > symbol is hex 16, which is 22 decimal, confirming the Sorat Address, 75.2 SC- Secutlty Code par75.3 SW—Status Word (4 Hexidecimal Digs) Status Word SW Example ‘This isa 2-byte hox valuo word which enables the status or previous trp Ingiattons Dig | Fiage end Tee Code ox | tout | [Hox | eine Tine drive to be road. Ils toad only). The four characters decode to Indicate the eames status of — | Postion Yo | eens Last trip — Error Flag — Trip Flag — Run/Ready status Fa Drive overtemperature OF ° 1 ° 1 ovortonporato : ° ‘Thus, to read the state of drive number 11, ser La pea ° Letovedond w {oof 460) cor Ji] ]s]t] sp] exo - Control Control curontpooktip =F | 1 | € | tenses Poworsupoiyane PS | 1 | Oo 1 and “The drive replies, for examplo:— uv ee ale aie ' six |S >poy el iyo] etx > Overvoliage tip __ OU 1 ° sb) Control ontro-c (Bcc) Not Used - 1 ‘Ofmsb) curenteopess ct | oo | 3 ° ‘The four characters following the > symbol are treated as hex digits and are further ool = 0 fl A decoded into their binary equivalents — aa hoped tag of: 1 0 — 0000, E — 1110, 1 — 0001, C— 1100 epee Fun tag, 1 = eto00 soo rv | | c | Hemet) Comparing each charactor with the appropriate section of the Status Word table — ‘enables the message to be translated as tag, tudhe c ‘0 _means not tripped on any of the trips defined by the 1st hex digit. eee ee ° E [aot trip was overvotage ti. 1 ttipped tag indeatng a faut Not used SS st) © _ dive tipped; indicating RESET and tip code flashing on Keypad display. Run / Ready States : Run | Ready | Statue indicated ' : «| rive stooping on ramp contol | >| + | vive sonata nt | 1 0 Drive running: | ' + | vive tipped, awaiting RESET, and | Tip Code flashing on the keypad disp i 722 729wee Note that trip states are held in PrA even attor a reset and will be changed only by & ‘subsoquent trip. The trip itself, however, continues to exist only if the tripped flag ‘equals taut To detect an external trip (PrA = Et), note that the tripped flag indicates 1 while all other indications and flags are ok — not faulty. 75.4 DS —Drive Setup (4 Hexadecimal Digits) This is a 2-byto hox-value word enabling the stato of bit-parameters BO to b12 inclusive tobe read or changed. Parameters b6, b8, b10 and b12 are read-only and cannot be changed. The four charactors following the > symbol decode into binary states, in a similar way as for the Status Word, to Indicate the value of the bit parameters. For example, to read DS for drive number 11, send: cot | if qa] af ena Control. Controhe ‘The drive replies, tor example:— sm Jo]s| ]>[4]r[e] 4] ex | + Control Controkc (ace) ‘The data following the > character are treated as hex digit, follows:— 1nd decode to binary as 4—0100, F — 1111, 8 — 1000, 4— 0100 ‘The massaga decodes, trom the Drive Setup table, as — speed control mode — auto start made — coast to stop — fixed boost — jog input — catch spinning motor disabled — serial mode — frequency (speed) display — keypad control — even parity bt — 4/20mA speed reference — Baud rate 4800, Jo wnite to drive number 11, sending tne same parameter setungs as wi tiw provivus ‘example, which is a complete set-up command, the message would be:— cor | 1] 4] 4 stx |ds| Contro-D Controt-8} ala) ETx 1 Control-c (8c) 7-24 ; id data understood, of NAK rt (wien “po ave vpn ACK fhe traamitad data understood, The ie rks A ating te chaacaeo nth format the message). witan the dive trough he Note that paramatore bé, b10 and bt2 cannot be wit one Noe that parame eta atnough thay must be included to form a comple Savial Commun ete tase whan fected, but dose notre them when Frerogeted about the drveconiguation Drive Setup DS Example Digit | Bi parameter ° 1 Position Wat Used = a eS ‘Auto rset b0 | onabied | disabled 1 ia 5 Start mode br | auto | manual stopping mode tbe [ve Stopping Mode tbl] oni) Boost mode 3 | au | treo F | temsby sog/Presot va | fog | poset 1 and Catch spinning motor b5 | disabled | enabled 1 ‘Analogue inpusorial cont ve | ensiae} sat se) Sig naa [on pau] | @ | TT Di vs | ronmey] ed ° se Control modo bs keypad | terminal o Pasty vo] oven | ows ous Frarogue wteranes a bt 4 | ofmsby an [Analogue rteronce : bn : Not Used oe aud rato wiz | 4800 | 9600 4s)Thore are four possibe states of There are four possiblo “The settings of these frequency parameters can be changed by an operator Analogue Relerence states of Stopping Mode TConputon orby a pe programmad to send the FQ codes, To sat the frequency (eters of five number 15 05 9KHz and 120Hz, the complete message is— Anaiogue | Speed Paremelor Reterence_| Reference {out ve | 7 Ci) cor Ji}]s]s|_ st Fla ap fol em + Contro-D ControlB Control oo ° oO or20mA 0 ° ‘Standard ramp ez) o | + | soma o | 1 | Coast FQ codes 1 nj Word PWM o | 20ama 1] 0 | Inject de ee ee 1 1 Ur 1 1 High level ramp, Frequency + 7.5.5 FQ— PWM Switching Frequency & ULF (2 Hexadecimal digits) 00 ake se FQ is a one-byte word, The status of PWM switching Irequency and ULF are given of zone | 24otiz by the following FQ codes 10 okt s2oHz To read FO for rive numbar 18, send:— " sontz | 24ottz cor |i]+]s]s] Flo] eno Control Contol€ 2 soxtz | dao 20 sone | 1208 ‘The drive replies, for example:— ° piles, for example: at sante | 24oHz six ]F]Q| yoy em ] + Control-B Control-C 2 8.0kHe oe (eco) 30 44.7KHZ 120Hz ‘Tho two charactors folowing the symbol > require no further translation. They are 3 tmz | 24H compared with the codes in tho table 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 32 14.7KHz, 480Hz - "20H a razz | _ 96082 7-267.5.6 CW— Command Word (2 Hexadecimal Digits) Example This is @ ono-byte hexvalue word enabling the dtive to be controll through the Command Word CW serial ink. It fs important to note that some of the terminal inputs are not disabled, aaileiemet “Toxine ap eats Wor | Binoy ven wien bG=1 thoy romain operaive (START, STOP, RESET, EXTERNAL TRIP, pot LOCAUREMOTE). ° 1 ‘Tho two digits decode into states which contol the principal command functions of Wot Used = = Oe the drive, 9s follows — ° Not Used - os RESET, TRIP (external), STOP, START oe an open | cosod (tat) ° CW allows the drivo to state the direction of rotation as set by the contol terminal Emergone sop! Forward/Reverse (11/6) in reply to interrogation, but cannot be used to reverse th External to open osod ‘8b) rotation, REVERSE command is given by using a nogative speed reference SP (860 (wipped) table of mnemonics). pas opon wad) | ctosedtion | | 6 | otmsty A nd To ead GW for drive number 11, sond: vcaronost | opon fecay | cts, ; rom cor |t Tye] wy] ena Contro-D Contro-E stop ‘open (stop) coved ‘ ‘Start open | osed um) 0.) : * Cannot be changed through the Serial Communications Link using CW st™ |olw >pife] ex T . Contiol8 rok core aco) Typical Values of Command Word CW B ‘The data following the character > decodes trom hex to binary, to mean -— awa GW valves during .. Nota ho Jot re ‘not resot — emergency stop/external trip input closed — direction sat to forward rea | power | start | Stop | Reset | Ext Trip | Not trip —jog/preset terminal closed — not stop — not run ae forward | 16 7 14 36 06 16 remote | reverse | 1E 1 1c 3E oF 1€ \ 5 i forward | 12 13 10 2 02 2 local reverse | 1A 1B 18 3A on 1A local aL 729 7287.5.7 C1 —Drlve Configuration Word 1 (2 Hexadecimal Digits) This is a one byte hex value word (two hoxadecimal digits) onabling the state of the dil switch and internal link 0 to be read. (It is read only). The two digits following the > symbol decode into binary states to indicate the stato of the dil switch and link 0. For example, to read C1 for drive number 11, send:-— cor [1]1][1]1][c]s] ena ControkD Control The drive replies, for examplo:— sx | [>| of7] etx 4 Control Control-c (BCC) The data following the > character are treated as hex characters, and decode to binary as follows — 0 — 0000, 7— 0111 The message decodes, trom the C1 table, as — LkO in — SW1F ON — SWIE ON — SW1D ON — SW1C OFF — SW1B OFF — ‘SWIA OFF (see Chapter 6 for full definition ofthe switch functions). (C1 — CONFIGURATION WORD Digit Example Position | Function ° 1 raey | Not Used . - ° 0 (Msb) ist Lo N our 0 Wie ‘ON OFF 0 Sue on FE ish) swiD oN OFF 7 © (Msb) and | SWIC ON OFF 1 SwiB oN OFF 1 SWiA ON OFF 1 (sb) 7.90 8 Logic Diagrams _ ems enemas ‘To be issueda2 scram ss 9.1 Principles of Operation 9.2 Operation of the Braking Unit 9.3 Specification 9.4 Braking Resistor Sizing 9.5 Mechanical Installation 9.6 Electrical Installation 9.7 Operating Procedures 9 Braking9 Braking (Dynamic Brake, IBD-2) 9.1 Principles of Operation ‘A decolarating AC motor regenerates energy into the inverter drive as the load A eerelis! the machine. Th regenerated energy can only be dissipated within the driva, it cannot be returned to the AC supply by thé CDS. If the regenerated power cries fam the losses of the system, the drive wil perform satistactorly. it the «rad power le more than the losses of the system, the drive wil trip on tage Unless the optional braking unit i ted. Typicaly a crive wil dissipate sreor 3% of its rated power as losses, and as such will tolerate about 3% ‘ogonerative power without a braking unt and without tipping the drive Factors which influence the amount of regenerative power are: ‘Tho inertia of the machine and load ‘The maximum speed of the machine and foad ‘The requiced deceleration rato of the drive ‘The mode ol dive deceleration set by °b2" and 7" I ‘The power rating of the dive From theory the amount of regenerative powor‘P for a constant rate of deceleration ‘a1 for a given inertia , and at a certain speed ‘sis ™ : o vwnore Pisin wats aah | 3 is inads | tis in kg.m2 For a drive with a given dec above equation becomes: tion time (sat in Pr3) and a certain speed in Hz the 94 2 3Pa120wi(axy 2a owl (4) where w= spood in Hz P = number of machine poles (0.9. 2, 4, 6 otc) {= deceleration time set in Pr’ for 120 Hz upper limit frequency. (If b14 set for upper limit frequency other than 120 Hz, modily constant of 120 to correct upper limit frequency) From the above equation it can be seen that the regenerative power is directly dependent on the machine/load inertia and the drive speed of operation. The lower the value of Pr3, the greater the regenerative powor by the inverse relationship. This equation therefore explains the first three of the factors which influence the regenerative power. The influence of the *b2' and ‘b7" settings only has a small influence on the egenerative power produced during 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 valid for all ‘speed reductions. When 'b2' and 'b7" are both ‘0’ the intemal ramp is stopped whenever the drive's DC bus voltage exceeds about 30V above the normal working value, and this also corresponds to whon tho optional braking unit will urn on the dumping resistor. This mode of operation extends the deceleration ramp to reduco the likelihood of the drive tripping on overvoltage. In this mode of operation as the DC bus voltage rises the appliad voltage fo the machine will increase by the same percentage rise. This has the added consequence of increasing the magnetizing current to the machine which will increase the dissipation capability of the machine/drive for regenerative power. Unfortunately this may also cat ‘overcurrent tripping if the DC bus voltage rises too much increasing the magnetizing ‘current up to the trip level of the drive. Typically ‘b2" and 'b7' set to zero provides extra drive regenerative dissipation capability and reduced sensitivity to the Pr3 setting without the need for the optional braking unit. Whan tho! anh?! are hath 4! the internal ramp is maintained af tha sot rato even if tho drive's DC bus voltage exceeds the 30V margin above the normal working value. In this mode of operation as the DC bus voltage rises the applied voltage 1o 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 overvotage tripping it the DC bus voltage rises too much. Typically 'b2’ and 'b7’ set to"! is characterised for use with the optional braking unit 94 se ‘Tho above explanation details how the °b2' and 'b7” influence the braking capability of the drive. Finally the drive rating has an influence on the regenerative capabilty o! the drive in that regenerative power relates directly to drive current, and as such the drive will trip out on over currant ifthe current exceeds 150% of the drive rating during regeneration. Therefore the drive rating determines the maximur tegenorative capability of the drive 9.2. Operation of the Braking Unit The IBD-2 is effectively a power switch which controls the current in the braking resistor. When the DC bus exceeds a prosat level the braking resistor is connected ‘across the DC bus and when the DC bus drops by SV the resistor is disconnected ‘The power dissipated in the resistor Is automatically regulated to match the regenerated power. “The IBD-2 has a LED to indicate whon the braking transistor is switched on. It takes its power supply and control signals from the CDS. 9.3. Specification Maximum continuous braking power dissipation = 439W (derived from RMS transistor rating and minimum braking resistance) Instantaneous powor dissipation capability = 9.5kW (for a maximum time of 2 milliseconds derived from 47, -10%, ohms across 385VDC. Temperature Range ‘The operating ambient temperature range is O°C 10 50°C. Braking Resistor Minimum resistance = 47 ohms (-10%) Indication The IRN.? has one LED to indicate when the unit is operating CONNECTIONS POWER DC - VE connection o drive -DC BUS 0+ VE ‘connection to drive +0C BUS D.B.RES +VE connection to brake resistor D.B.RES- VE connection to brake resistor ocos os CONTROL, OV signal oV from drive (isolated wrt OVG) DB _ control signal from drive (isolated wet OVG) +15VG_ +15V supply from drive OVG OV supply from drive BRAKING DUTY 10% duty cycle at 2.2 KW with a braking timo of 30s, ia the brake is on for 30s followed by a 270s off time, See Fig 9-1 for duty cycle at other powers. {based on using the minimum braking resistance of 47R - 10%) PROTECTION Thermal protection of the IBD-2 must be provided by the user, typically by using a thermal circuit breaker with auxiliary contacts. ‘eg Weber Series T12, type T12-221SN 2.5A ratod, Figure 9-1 1BD-2 Braking Duty with 30 Second Ti+ 96 ace 9.4 Braking Resistor Sizing Firstly the peak power dissipation roquirement must be determined from the machine/load inertia, the maximum operating drive speed, and the minimum required docaloration time. From the previously stated equation, but modified for maximum conditions: Prax * 120 Wimax (4x) Ain Whore Wmax = maximum operating speed in Hz of drive p= _ number of machine poles (0.9. 2, 4,6, 8 etc) Tin = minimum required deceleration time set in Pr3 for 320 Hz maximum frequency. ( b14 set for upper limit frequency other than 120 Hz, madity constant of 420 to corract upper limit frequency). Pmax must be less than 1.5 times the drive rating to ensure the drive can handle the braking duty. Pmax must also be loss than the peak power dissipation of the braking resistor when applied to the maximum DC link voltage level o! 385VDC: Prax <= (385), where R= _ Braking resistor value in ohms Secondly the average power rating of the braking resistor must be determined. (We currently know its resistance value and peak power dissipation capability). The average power rating of the rasistor 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 ions = (05) 1x) 4?-Wo"l where wy = _highest operating speed in Hz Wp = speed decelerated to in Hz (possibly 0 Hz i the machine is stopping or reversing} 97cos It this event takes ty seconds to occur and repeats after tz seconds, the cycle time is ty + tg, the average power dissipation in the braking resistor is: Pavloss = Eioss!(ti + ta) Pavloss defines the average power loss in the braking resistor Provided the braking resistance value satisfies the above three equations, and is ‘teater than the minimum rosistance of 47 ohms requirements of the application. 98 the resistor will meet the power 9.5 Mechanical Installation ‘The overall dimensions and fixing holes are shown in Fig 9-2 | Le DIMENSIONS IN mm NOTE : Mounting pillars are MA clearance Figure 9-2 Mounting dimensions‘Tho 18D-2 boatd is mounted external to the CDS, either to the loft hand side of the CDS or above the left hand comer of the CDS, sae Fig 9-3. The limitation on the ‘mounting position is governed by the length of the two power connections, OC + VE ‘and DC = VE, from the IBD-2 to the CDS. Figure 9-3 ‘Mounting Position 9.6 Electrical Installation 9.6.1 Safety WARNING: ‘The voltages present in the power cables, the OVG and the +15VG cables and most of the parts of the circuit board are at mains potential and are capable of causing ELECTRIC SHOCK RISK! It the CDS has boon energised before installation of the 1BD-2 it MUST be ISOLATED before work may continue. A period of ten minutes MUST elapse after isolation to allow the internal capacitors to discharge fully. Until the discharge period hhas passed, dangerous voltages may present within the CDS. 9-10 ‘Thermal protection of the braking resistor must be provided by the user. This is necessary to avoid the resistor causing a fire hazard if the braking transistor fails the on condition. Any thermal protection must disconnect the AC supply to the drive ‘and braking unit 96.2 Connections The IBD-2 unit makes use of internal plugs on the CDS PL3, PL4, s0C BUS and -DC BUS. To gain access to the internal plugs, release the four screws securing the over taking care to disconnect the cable from PL2, The loads to the IBD-2 board are routed underneath the cover when itis r-fited. The positions of PL, PL4, +DC BUS , -DC BUS are shown in Fig 9-4 = Ol 0c aus Figure 9-4 Position of CDS connectors for use with 1BD-2PL1 on the IBD-2 has two connectors which plug into the CDS, the 2-way one connectors to PL3 and the 3-way ono connects to PLS, refer to Fig. 9-4. DC + VE on the 180-2 plugs onto the +DC BUS fasion tab on the CDS and DC + VE plugs onto -DC BUS, reler to Fig. 9. Ensure no wires come into contact with TRD!, the big black disc at the top left hand ‘corner of the CDS circuit board Connect the leads D.8. RES + VE and D.B, RES - VE of the IBD-2 to the power resistor, via a thermal trip, refer to Fig. 9-5 Ensure the leads do not touch the surface of the power resistor. The heat generated by the power resistor can burn the insulation of the wires if they come into contact. ‘Note that the power resistor is not polarity sensitive. The IBD-2 is not short circuit protected betwoon the braking resistor connections “+” ‘and *" or between the braking connections to earth. (A short circuit would cause damage to the unit). The ID-2 is not thermally protected and should always be Used in conjunction with a suitable thermal trip. Operating outside specification ‘could damage the inverter and braking card. Fig 9-5 shows the position of the connections and the layout of the IBD-2. Figure 9-5 Component Layout on IBD-2 cx Figure 96 Intorconnection of IBD-2 and CDS Figure 9-7 Typical connections 0439.7. Operating Procedures To operate the braking unit, the drive will need to be turning the machine at a reasonable spaed and a rapid dacolaration condition must be created. Ifthe iner is significant the DC bus voltage should rise and cause 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 bus. If the deceleration is not fast tenough, or the drive speed is not high enough, or the machine inertia is not large ‘enough the ‘brake resistor on’ LED may not be illuminated. ons 10.1 10.2 10.3 10.4 10.5 10 Electroma agnetic Compatibility (EMC) seaneneneoneen EMC Immunity The Nature of Drive Emissions Immunity of Sensitive Circuits Precautions for Drive Installation 10-410 Electromagnetic Compatibility (EMC) 10.1 EMC The drive is designed to facilitate compliance with EMC requirements such as EC Directive 89°336/EEC, 10.2. Immunity Moots IEC801 without significant disturbance to operation atthe folowing levels Part 4 (Transient Burst) Level 4 all terminals The immunity of drives to externally generated interference is very good. Usually no special precautions are required beyond normal good practice. It is recommended particularly that the coils of DC-onergised contactors associated with drives be suppressed with a diode or similar device since they can generate very severe ‘electrical transients. In areas subject to frequent lightning strikes, and where supplies are carried on lines ‘above ground, additional surge suppression is advisable beyond that fitted to drives. ‘Suitable varistors (MOVs) connected between each line and earth should be used, 103— 10.3 The Nature of Drive Emissions 10.3.1 Frequency Range Switching takes place in the range 1-30KHZ In AC and servo drives. Because the Switching is fast, harmonics may be generated upto frequencios of several MHz Te most important frequency range is the Radio Frequency (RF) range 100kH2 to SMHz, because the energy can be propagated over quite long distances, and a variety of other citcuts may be sensitive to disturbance inthis range. 10.3.2 Propagation Routes |v is important to appreciate that tho drive itself does not radiate much RF nergy. Within about 100mm ofthe drive there are quite high electric and magnetic fields, but these diminish by an inverse cube law with distance and are insignificant at 300mm, The main mechanism for propagation of RF energy out of the drive is by conduction through its connections. Fig. 10-1 iilustrates the main routes. The connections in order of emission level are: THE MOTOR CABLE This carries high RF voltage and current, and may disturb a nearby circuit. However the electric and magnetic fields fall off rapidly with increasing distance {rom the cable, ‘THE SUPPLY CABLE Although this carries a lower RF voltage than the motor cable, itis connected to a widespread network. This means that it can act as an effective transmitting aerial, and also it conducts emissions into a wide varialy of other equipment. The supply ‘cable Is the single most important route for emissions into victim equipment. The length of the motor cable affects tho omission into the supply from the drive. the motor cable exceeds about 50m then the supply emission will be particularly severe. The drive earth wire carries the RF current returning from the motor. Because the inductance of the wires is significant at high frequencies, both the drive earth and the ‘motor frame may cary RF voltage. This may be a probiom i sensitive circuits share these earth connections, 10-4 MOTOR CABLE Figure 10-1 [RF Current Paths - Drive with No Special Precautions 105eo THE CONTROL CONNECTIONS Inside the drive the control circuits have stray coupling to the power circuit. The RF levels are much less than on the power connections, and the source impedance is high, so problems do not often occur with these connections. The drive may be thought of as a source of RF current which leaves its output, terminals. ‘The capacitance of the output cable and the motor windings to earth Present quite a low impedance to the RF frequencies, so current flows from tho ‘output to earth. it then has to find its way back to the drive earth and power input terminals. If it doos not have a well-defined, low impedance path then it may flow in unexpected directions and disturb nearby sensitive equipment. The principle of good layout for emission control is to provide a direct, low impedance path for this current. 10-6 10.4 Immunity of Sensitive Circuits In many drive installations there are either no sensitive circuits vulnerable to disturbance, or else the sensitive circuits have been designed by the manufacturer to have good immunity. To avoid unnecessary cost through reducing drive emissions i is useful to be able to assess the likelihood of other circuits being disturbed, and to bbe aware of standard methods for ensuring immunity The following ist indicates the rolative sensitivity ofa variety of electronic circuits and systems. The list cannot cover all possibilties, and some degree of judgment will be required in assessing a given situation 10.4.1 Not sensitive Purely electrical circuits, relays, contactors, electromechanical instruments, 10.4.2 Not significantly sensitive Many elactronic systems are insensitive to drive omissions. Computers, PLCs, all digital electronic circuits and analogue circuits using high levels (over 1V) a Unlikely to be disturbed unless they include components which fall into category stalled 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; particularly if the connections are very long andor unscreened. Analogue measuring circuits using high levels (over 1V), only if the connections are very long and/or unscreened or they are required to give vary high resolution (better than 1 in 1000), Analogue circuits which have very fast response or wide band-width, eg audio circuits. (Most industrial systems have intentionally slow rasponse to minimise disturbance by transient offacts.) Digital data links, only if they are unscreened or in an unusual configuration Conventional S232, RS485 and fast links such as “Ethernet” have good immunity when correctly installed with high-screening cable. Proximity sensors which raly on high-trequency oscillators, particularly capacitance ‘ypes. 10-7