User's Guide Frequency Inverter Guía del Usuario Convertidor de Frecuencia Manual do Usuário Inversor de Freqüência Bedienungsanleitung Freqüenzumrichter Guide d'instalation et d'exploitation Variateur de Vitesse Installatie en gebruikshandleiding Frequentie-Omzetter Bruksanvisning Frekvensomriktare
FREQUENCY INVERTER MANUAL
Series: CFW-08 Software: version 4.1X 0899.5242 E/8
04/2006
ATTENTION! It is very important to check if the inverter software version is the same as indicated above.
CONTENTS The table below describes all revisions made to this manual. Revision 1 2 3 4
5
6 7
8
4
Description Section First Edition Item 3.3 - CE Installation Included See item 3.3 General Revision External Parallel Keypad and See item 8.3 Fixs Kit Included and and 8.16 General Revision Description changed of the See item 8.5 Parallel Cable for the External Parallel Keypad. Item 7.5 (Spare Part List) Removed. Parameter P536 included and 6.3.5 and General Revision General Revision Inclusion of new models (22A, 28A and See item 9.1 33A/200-240V; 24A and 30A/380-480V); Addition of new I/O functions See item 3.2.5 on the control board; Modification of circuit breakers table; See item 3.2.3 Modification of Chapter 3 (installation and connections); Modification of parameters See item 4.2.4 incompatibility table; Addition of parameters P253, See item 6.3 P267 and P268 Addition of new functions at parameters P235, P239, P295 and P404; Modification of factory default See item 6.3.3 value of parameter P248; Addition of error code E32; See item 7.1 General Revision; Inclusion of items into the table of See item 4.2.4 parameters incompatibility; Change on the WEG part number See item 8 of the optional devices; Inclusion of the table containing the See item 3.1.3.1 airflow requirements for panel mounting; Inclusion of the following optionals: See items KRS-485-CFW08, KFB-CO-CFW08, 8.11 to 8.14 KFB-DN-CFW08 and KAC-120-CFW08; Inclusion of the new versions See item 2.4 of the control board: A3 and A4
CONTENTS Quick Parameter Reference, Fault and Status Messages I Parameters ............................................................... 10 II Fault Messages ......................................................... 18 III Other Messages ........................................................18 CHAPTER 1 Safety Notices 1.1 Safety Notices in the Manual ....................................19 1.2 Safety Notice on The Product ..................................19 1.3 Preliminary Recommendations ................................ 19 CHAPTER 2 General Information 2.1 About this Manual .................................................... 21 2.2 Software Version .................................................... 21 2.3 About the CFW-08 .................................................. 22 2.3.1 Differences between the old line and the New CFW-08 ...................................................26 2.4 CFW-08 Identification ............................................. 31 2.5 Receiving and Storing ............................................. 34 CHAPTER 3 Installation 3.1 Mechanical Installation............................................. 35 3.1.1 Environment ..................................................... 35 3.1.2 Mounting Specifications ....................................35 3.1.3 Positioning and Fixing ...................................... 38 3.1.3.1 Panel Mounting ........................................ 39 3.1.3.2 Surface Mounting ..................................... 40 3.2 Electrical Installtion .................................................40 3.2.1 Power / Grounding Terminals .............................40 3.2.2 Location of the Power Terminals, Grounding Terminals and Control Terminal Connections ......42 3.2.3 Wiring and Circuit-Breakers for the Power and Grounding Connections .............................. 43 3.2.4 Power Connections ........................................... 44 3.2.4.1 AC Input Connection............................... 46 3.2.4.2 Output Connections ................................. 47 3.2.4.3 Grounding Connections ........................... 47 3.2.5 Control Wiring .................................................. 49 3.2.5.1 Digital inputs as low level active (S1:1 to OFF).......................................... 53 3.2.5.2 Digital Input as high level active (S1:1 to ON) ............................................53 3.2.6 Typical Terminal Connections ............................ 55 5
CONTENTS 3.3 European EMC Directive - Requirements for Conforming Installations..................................... 58 3.3.1 Installation......................................................... 58 3.3.2 Emission and Immunity Levels Description ........ 59 3.3.3 Inverter Models and Filters ................................ 61 3.3.4 EMC Filters Characteristics Filter ...................... 63 CHAPTER 4 Keypad (HMI) Operation 4.1 Keypad (HMI) Description ....................................... 68 4.2 Use of the Keypad HMI............................................ 69 4.2.1 Keypad Operation ............................................ 70 4.2.2 Inverter Status ................................................... 71 4.2.3 Read-Only Variables ......................................... 71 4.2.4 Parameter Viewing and Programming ............... 72 CHAPTER 5 Start-up 5.1 Pre-Power Checks .................................................. 75 5.2 Initial Power-up ....................................................... 75 5.3 Start-up ... ............................................................... 76 5.3.1 Start-up Operation via Keypad (HMI) Type of Control: Linear V/F (P202=0) ................ 77 5.3.2 Start-up Operation via Terminals Control Mode: Linear V/F (P202=0) .................. 78 5.3.3 Start-up Operation via Keypad Control Mode: Vector (P202=2) ......................... 79 CHAPTER 6 Detailed Parameter Description
6
6.1 Symbols ...... ........................................................... 84 6.2 Introduction ............................................................. 84 6.2.1 Control Modes .................................................. 84 6.2.2 V/F Control ....................................................... 84 6.2.3 Vector Control (VVC) ........................................ 85 6.2.4 Frequency Reference Sources .......................... 86 6.2.5 Commands ...................................................... 89 6.2.6 Local/Remote Operation Modes ........................ 89 6.3 Parameter Listing ................................................... 90 6.3.1 Access and Read Only Parameters P000 to P099................................................... 91 6.3.2 Regulation Parameters - P100 to P199 ............. 93 6.3.3 Configuration Parameters - P200 to P398 ....... 103 6.3.4 Motor Parameters - P399 to P499................... 127 6.3.5 Special Function Paramaters - P500 to P599 .. 130 6.3.5.1 PID Introduction ...................................... 130 6.3.5.2 Description ............................................ 130 6.3.5.3 PID Start-up Guide ................................. 136
CONTENTS CHAPTER 7 Diagnostics and Troubleshooting 7.1 Faults and Possible Causes .................................. 139 7.2 Troubleshooting .................................................... 142 7.3 Contacting WEG ................................................... 143 7.4 Preventive Maintenance ........................................ 143 7.4.1 Cleaning Instructions ....................................... 144 CHAPTER 8 CFW-08 Options and Accessories 8.1 HMI-CFW08-P ...................................................... 147 8.1.1 Instructions for Insertion and Removing of the HMI-CFW08-P .......................................... 147 8.2 TCL-CFW08 ......................................................... 147 8.3 HMI-CFW08-RP.................................................... 148 8.3.1 HMI-CFW08-RP Installation ............................. 148 8.4 MIP-CFW08-RP.................................................... 149 8.5 CAB-RP-1, CAB-RP-2, CAB-RP-3, CAB-RP-5, CAB-RP-7.5, CAB-RP-10 .................................... 149 8.6 HMI-CFW08-RS.................................................... 149 8.6.1 HMI-CFW08-RS Installation ............................. 150 8.6.2 HMI-CFW08-RS Start-up ................................. 150 8.6.3 Keypad Copy Function .................................... 151 8.7 MIS-CFW08-RS.................................................... 151 8.8 CAB-RS-1, CAB-RS-2, CAB-RS-3, CAB-RS-5, CAB-RS-7.5, CAB-RS-10 .................................... 151 8.9 KCS-CFW08 ........................................................ 152 8.9.1 Instructions for KCS-CFW08 Insertion/Removal ........................................... 153 8.10 KSD-CFW08 ...................................................... 153 8.11 KRS-485-CFW08 ............................................... 154 8.12 KFB-CO-CFW08 ................................................ 155 8.13 KFB-DN-CFW08 ................................................ 156 8.14 KAC-120-CFW08, KAC-120-CFW08-N1M1 KAC-120-CFW08-N1M2 ..................................... 158 8.15 KMD-CFW08-M1 ................................................ 159 8.16 KFIX-CFW08-M1, KFIX-CFW08-M2 ................... 160 8.17 KN1-CFW08-M1, KN1-CFW08-M2 ..................... 161 8.18 RFI Filters ........................................................... 162 8.19 Line Reactor ....................................................... 163 8.19.1 Application Criteria ...................................... 164 8.20 Load Reactor...................................................... 166 8.21 Dynamic Braking ................................................ 167 8.21.1 Resistor Sizing ............................................ 167 8.21.2 Installation ................................................... 168 8.22 Serial Communication......................................... 169 8.22.1 Introduction ................................................. 169 8.22.2 Interfaces Description .................................. 170 7
CONTENTS 8.22.2.1 RS-485 ............................................ 171 8.22.2.2 RS-232 ............................................ 172 8.22.3 Definitions .................................................. 172 8.22.3.1 Used Terms ...................................... 172 8.22.3.2 Parameter/Variables Resolution ....... 173 8.22.3.3 Character Format ............................. 173 8.22.3.4 Protocol ........................................... 173 8.22.3.5 Execution and Message Test ............ 175 8.22.3.6 Message Sequence ......................... 176 8.22.3.7 Varaiable Code................................ 176 8.22.4 Message Examples .................................... 177 8.22.5 Variables and Errors of the Serial Communication .......................................... 177 8.22.5.1 Basic Variables ................................ 177 8.22.5.2 Messages Examples with Basic Variables .......................................... 180 8.22.5.3 Parameters Related to the Serial Communication .................................. 181 8.22.5.4 Errors Related to the Serial Communication ................................ 182 8.22.6 Times for Read/Write of Messages .............. 182 8.22.7 Physical Connection RS-232 and RS-485 Interface ......................................... 183 8.23 Modbus-RTU ...................................................... 184 8.23.1 Introduction to Modbus-RTU Protocol ........... 184 8.23.1.1 Transmission Modes ........................ 184 8.23.1.2 Message Structure in RTU Mode ...... 184 8.23.2 Operation of the CFW-08 in the Modbus-RTU Network ................................. 187 8.23.2.1 Interface Description ........................ 187 8.23.2.2 Inverter Configuration in the Modbus-RTU Network ...................... 187 8.23.2.3 Access to the Inverter Data ............... 188 8.23.3 Detailed Function Description ..................... 191 8.23.3.1 Function 01 - Read Coils .................. 191 8.23.3.2 Function 03 - Read Holding Register 192 8.23.3.3 Function 05 - Write Single Coil ......... 193 8.23.3.4 Function 06 - Write Single Register .. 194 8.23.3.5 Function 15 - Write Multiple Coils ...... 194 8.23.3.6 Function 16 - Write Multiple Registers 195 8.23.3.7 Function 43 - Read Device Identification .................................... 196 8.23.4 Communication Errors ................................ 198 8.23.4.1 Error Messages .............................. 199
8
CONTENTS CHAPTER 9 Technical Specifications 9.1Power Data ........................................................... 200 9.1.1 200 - 240V Power Supply ...............................200 9.1.2 380 - 480V Power Supply ...............................201 9.2 Electronics/General Data ...................................... 204 9.3 WEG Standard IV Pole Motor Data........................ 205
9
CFW-08 - QUICK PARAMETER REFERENCE QUICK PARAMETER REFERENCE, FAULT AND STATUS MESSAGES Software: V4.1X Application: Model: Serial Number: Responsible: Date: / /
.
I. Parameters Parameter P000
P002 P003 P004 P005 P007 P008 P009 (1) P014 P023 P040
P100 P101 P102 P103 P104
Function Parameter Access
0 to 4 = Read 5 = Alteration 6 to 999 = Read READ ONLY PARAMETERS - P002 to P099 Fequency Proportional Value 0 to 6553 (P208xP005) Motor Output Current 0 to 1.5xInom DC Link Voltage 0 to 862 Motor Output Frequency 0.00 to 99.99 100.0 to 300.0 Motor Output Voltage 0 to 600 Heatsink Temperature 25 to 110 Motor Torque 0.0 to 150.0 Last Fault 00 to 41 Software Version x.yz PID Process Variable 0 to 6553 (Value % x P528) REGULATION PARAMETERS - P100 to P199 Ramps Acceleration Time 0.1 to 999 Deceleration Time 0.1 to 999 Acceleration Time Ramp 2 0.1 to 999 Deceleration Time Ramp 2 0.1 to 999 S Ramp 0 = Inactive 1 = 50 2 = 100
P120
Frequency Reference Digital Reference Backup
P121 P122 P124 P125 P126 P127 P128 P129 P130 P131
Keypad Reference JOG Speed Reference Multispeed Reference 1 Multispeed Reference 2 Multispeed Reference 3 Multispeed Reference 4 Multispeed Reference 5 Multispeed Reference 6 Multispeed Reference 7 Multispeed Reference 8
10
Adjustable Range
0 = Inactive 1 = Active 2 = Backup by P121 (or P525 - PID) P133 to P134 0.00 to P134 P133 to P134 P133 to P134 P133 to P134 P133 to P134 P133 to P134 P133 to P134 P133 to P134 P133 to P134
Factory Setting 0
Unit
Page
-
User Setting -
-
-
-
91
-
A V Hz
-
91 91 91
-
V °C % -
-
91 92 92 92 92 92
5.0 10.0 5.0 10.0 0
s s s s %
93 93 93 93 93
1
-
94
3.00 5.00 3.00 10.00 20.00 30.00 40.00 50.00 60.00 66.00
-
94 94 95 95 95 95 95 95 95 95
91
Summary of Revisions
Parameter P133 P134 P136
(2)(*)
P137 (2) P138 (2) P142 (2)(3) P145 (2)(3)
P151
P156 P169 P178 (1)
P202 (3)
P203 (3) P204 (3) P205 (3)
P206 P208 P215
(3)(4)
P219 (3) (*)
Function Speed Limits Minimum Frequency (F min) Maximum Frequency (Fmax) V/F Control Manual Torque Boost (IxR Compensation) Aut. Torque Boost (Aut. IxR Compensation) Slip Compensation Maximum Output Voltage Field Weakening Frequency (Fnom )
Factory Setting
Unit
0.00 to P134 P133 to 300.0
3.00 66.00
Hz Hz
96 96
0.0 to 30.0
5.0 or 2.0 or 1.0 (*) 0.00
%
96
-
97
0.0 100 50.00Hz or 60.00Hz depending on the market
% % Hz
98 99 99
V
100
A
101
A
101
%
101
-
103
-
104
-
105
-
105
s -
105 105 106
Hz
107
Adjustable Range
0.00 to 1.00 0.0 to 10.0 0.0 to 100 P133 to P134
DC Link Voltage Regulation DC Link Regulation Level 200V models: 325 to 410 380 400V models: 564 to 820 780 Overload Current Motor Overload Current 0.2xInom to 1.3xInom 1.2xP401 Current Limitation Maximum Output Current 0.2xInom to 2.0xInom 1.5xInom Flux Control Rated Flux 50.0 to 150.0 100 CONFIGURATION PARAMETERS - P200 to P398 Generic Parameters Control Mode 0=Linear V/F Control (Scalar) 0 1=Quadratic V/F Control (Scalar) 2=Sensorless Vector Special Function Selection 0=No function 0 1=PID Regulator Load Factory Setting 0 to 4=No Function 0 5=Loads Factory Default Display Default Selection 0=P005 2 1=P003 2=P002 3=P007 4, 5=Not used 6=P040 Auto-Reset Time 0 to 255 0 Reference Scale Factor 0.00 to 99.9 1.00 Keypad Copy Function 0=Not Used 0 1=Copy (inverter to keypad) 2=Paste (keypad to inverter) Switching Frequency 0.00 to 25.00 6.00 Reduction Point
User Setting
Page
The factory default of Parameter P136 depends on the inverter model as follows: - models 1.6-2.6-4.0-7.0A/200-240V and 1.0-1.6-2.6-4.0A/380-480V: P136=5.0%; - models 7.3-10-16A/200-240V and 2.7-4.3-6.5-10A/380-480V: P136=2.0%; - models 22-28-33A/200-240V and 13-16-24-30A/380-480V: P136=1.0%.
11
CFW-08 - QUICK PARAMETER REFERENCE Parameter P220 (3)
P221 (3)
P222 (3)
P229 (3)
P230 (3)
P231 (3)
P234 P235
(3)(5)
P236 P238 (5)
Function Local/Remote Definition Local/Remote Selection Source
Adjustable Range
0=Always Local 1=Always Remote 2=HMI-CFW08-P or HMI-CFW08-RP keypad (default: local) 3=HMI-CFW08-P or HMI-CFW08-RP keypad (default: remote) 4=DI2 to DI4 5=Serial or HMI-CFW08-RS keypad (default: local) 6=Serial or HMI-CFW08-RS keypad (default: remote) Frequency Local Reference 0 = Keypad and Selection 1 = AI1 2, 3 = AI2 4 = E.P. (Electronic Pot.) 5 = Serial 6 = Multispeed 7 = Add AI 0 8 = Add AI Frequency Remote Reference 0 =Keypad and Selection 1 = AI1 2, 3 = AI2 4 = E.P. (Eletronic Pot.) 5 = Serial 6 = Multispeed 7 = Add AI 0 8 = Add AI Local Command Selection 0 = HMI-CFW08-P or HMI-CFW08-RP keypad 1 = Terminals 2 = Serial or HMI-CFW08-RS keypad Remote Command Selection 0 = HMI-CFW08-P or HMI-CFW08-RP keypad 1 = Terminals 2 = Serial or HMI-CFW08-RS keypad Forward/Reverse Selection 0 = Forward 1 = Reverse 2 = Commands Analog Input(s) Analog Input AI1 Gain 0.00 to 9.99 Analog Input AI1 Function 0 = (0 to 10)V/(0 to 20)mA (-10 to +10)V** 1 = (4 to 20 )mA 2 = DI5 PNP 3 = DI5 NPN 4 = DI5 TTL 5 = PTC Analog Input AI1 Offset -120 to +120 Analog Input AI2 Gain 0.00 to 9.99
Factory Setting
Unit
User Setting
Page
2
-
108
0
-
109
1
-
109
0
-
109
1
-
109
2
-
110
1.00 0
-
110 111
0.0 1.00
% -
112 112
** Only available on the Control Board A2 (see item 2.4). For programming instructions, please, refer to the parameter P235 detailed description.
12
CFW-08 - QUICK PARAMETER REFERENCE
Parameter
Function
P239
Analog Input AI2 Function
P240 (6) P248
Analog Input AI2 Offset Analog Inputs Filter Time Constant Analog Output Analog Output AO Function
(3)(5)(6)
P251 (6)
P252 (6) P253
Analog Output AO Gain Analog Output (AO) Signal
P263 (3)
Digital Inputs Digital Input DI1 Function
P264 (3)
Digital Input DI2 Function
P265 (3)(7)
Digital Input DI3 Function
Adjustable Range 0 = (0 to 10)V/(0 to 20)mA (-10 to +10)V** 1 = (4 to 20 )mA 2 = DI5 PNP 3 = DI5 NPN 4 = DI5 TTL 5 = PTC -120 to +120 0 to 200
0=Output Frequency (Fs) 1= Input Reference (Fe) 2=Output Current (Is) 3, 5, 8 = Not used 4=Motor Torque 6=Process Variable (PID) 7=Active Current 9=PID Setpoint 0.00 to 9.99 0 = (0 to 10)V/(0 to 20)mA 1 = (4 to 20)mA 0 = No Function or General Enable 1 to 7 and 10 to 12 = General Enable 8 = Forward Run 9 = Start/Stop 13 = FWD Run Using Ramp 2 14 = Start (3-wire) 0 = Forward/Reverse 1 = Local/Remote 2 to 6 and 9 to 12 = Not used 7 = Multispeed (MS2) 8 = Reverse 13 = REV Run - Ramp 2 14 = Stop (3-wire) 0 = Forward/Reverse 1 = Local/Remote 2 = General Enable 3 = JOG 4 = No External Fault 5 = Increase E.P. 6 = Ramp 2 7 = Multispeed (MS1) 8 = No Function or Start/Stop 9 = Start/Stop 10 = Reset
Factory Setting 0
Unit
User Setting
Page
-
112
0.0 10
% ms
112 113
0
-
113
1.00 0
-
113 113
0
-
114
0
-
114
10
-
114
** Only available on the Control Board A2 (see item 2.4). For programming instructions, please, refer to the parameter P235 detailed description.
13
Summary of Revisions
Parameter
Function
P266 (3)
Digital Input DI4 Function
P267 (3)(5)
Function of the Digital InputDI5 (only displayed when P235 = 2,3 or 4)
P268 (3)(5)
Function of the Digital Input DI6(only displayed when P239 = 2,3 or 4)
14
Adjustable Range 11, 12 = Not used 13 = Flying Start Disable 14 = Multispeed (MS1) Using Ramp 2 15 = Manual/Automatic PID) 16 = Increase E.P. with Ramp 2 0 = Forward/Reverse 1 = Local/Remote 2 = General Enable 3 = JOG 4 = No Extrernal Fault 5 = Decrease E.P. 6 = Ramp 2 7 = Multispeed (MS0) 8 = Not used or Start/Stop 9 = Start/Stop 10 = Reset 11, 12 and 14, 15=Not Used 13 = Flying Start Disable 16 = Decrease E.P. with Ramp 2 0 = FWD/REV 1 = Local/Remote 2 = General Enable 3 = JOG 4 = No external fault 5 = Increase E.P. 6 = Ramp 2 7 = Multispeed (MS2) 8 = Not used or Start/Stop 9 = Start/Stop 10 = Reset 11, 12 and 14, 15=Not Used 13 = Disables Flying Start 16 = Increase E.P. with Ramp 2 0 = FWD/REV 1 = Local/Remote 2 = General Enable 3 = JOG 4 = No external fault 5 = Decrease E.P. 6 = Ramp 2 7 = Multispeed (MS2) 8 = Not used or Start/Stop 9 = Start/Stop 10 = Reset 11, 12 and 14, 15=Not Used 13 = Disables Flying Start 16 = Decrease E.P. with Ramp 2
Factory Setting
Unit
User Setting
Page
8
-
114
11
-
114
11
-
114
CFW-08 - QUICK PARAMETER REFERENCE
Parameter P277 (3)
P279 (3)(6)
P288 P290 P295(3)
P297 (3)
P300 P301 P302 P303 P304 P306 P308 (3)
P310 (3)
Function Relay Output RL1 Function
Relay Output RL2 Function
Fx and Ix Fx Frequency Ix Current Inverter Data Rated Inverter Current (Inom)
Switching Frequency
Adjustable Range Digital Output(s) 0 = Fs>Fx 1 = Fe>Fx 2 = Fs=Fe 3 = Is>Ix 4 and 6 = Not used 5 = Run 7 = No Fault 0 = Fs>Fx 1 = Fe>Fx 2 = Fs=Fe 3 = Is>Ix 4 and 6 = Not used 5 = Run 7 = No Fault 0.00 to P134 0 to 1.5xInom 300 = 1.0A 301 = 1.6A 302 = 2.6A 303 = 2.7A 304 = 4.0A 305 = 4.3A 306 = 6.5A 307 = 7.0A 308 = 7.3A 309 = 10A 310 = 13A 311 = 16A 4 = 5.0 5 = 2.5 6 = 10 7 = 15 (*) DC Braking 0.0 to 15.0 0.00 to 15.00 0.0 to 130
Factory Setting 7
DC Braking Time DC Braking Start Frequency DC Braking Current Skip Frequencies Skip Frequency 1 P133 to P134 Skip Frequency 2 P133 to P134 Skip Band Range 0.00 to 25.00 Serial Communication Interface I Inverter Address 1 to 30 (Serial WEG) 1 to 247 (Modbus-RTU) Flying Start and Ride-Through Flying Start and Ride-Through 0 = Inactive 1 = Flying Start 2 = Flying Start and Ride-Through 3 = Ride-Through
User Setting
Page 119
-
0
119
-
3.00 1.0xInom 312 = 22A 313 = 24A 314 = 28A 315 = 30A 316 = 33A
Unit
Hz A
121 121 121
According to the inverter model -
4
121 kHz
0.0 1.00 0.0
s Hz %
123 123 123
20.00 30.00 0.00
Hz Hz Hz
124 124 124
1
-
125
0
-
125
(*) It is not possible to set P297=7 (15 kHz) in vector control mode (P202=2) or when the external serial keypad (HMI-CFW08-RS) is used.
15
CFW-08 - QUICK PARAMETER REFERENCE
Parameter P311 P312 (3)
P313
P314
P399 (1)(3) P400 (1)(3) P401 P402 (1) P403 (1)(3) P404 (1)(3)
16
Function
Adjustable Range
Voltage Ramp 0.1 to 10.0 Serial Communication Interface II Serial Interface Protocol 0= Serial WEG 1= Modbus-RTU 9600 bps without parity 2= Modbus-RTU 9600 bps with odd parity 3= Modbus-RTU 9600 bps with even parity 4= Modbus-RTU 19200 bps without parity 5= Modbus-RTU 19200 bps with odd parity 6= Modbus-RTU 19200 bps with even parity 7= Modbus-RTU 38400 bps without parity 8= Modbus-RTU 38400 bps with odd parity 9= Modbus-RTU 38400 bps with even parity Serial Interface Watchdog 0 = Disabling by ramp Action 1 = General disable 2 = Shows only E28 3 = Goes to local mode Serial Interface Watchdog 0.0=Disables the function Timeout 0.1 to 99.9 = Set value MOTOR PARAMETERS - P399 to P499 Rated Parameters Rated Motor Efficiency 50.0 to 99.9 Rated Motor Voltage 0 to 600 Rated Motor Current 0.3xInom to 1.3xInom Rated Motor Speed 0 to 9999 Rated Motor Frequency 0.00 to P134 Rated Motor Power 0 = 0.16HP / 0.12kW 1 = 0.25HP / 0.18kW 2 = 0.33HP / 0.25kW 3 = 0.50HP / 0.37kW 4 = 0.75HP / 0.55kW 5 = 1HP / 0.75kW 6 = 1.5HP / 1.1kW 7 = 2HP / 1.5kW 8 = 3HP / 2.2kW 9 = 4HP / 3.0kW 10 = 5HP / 3.7kW 11 = 5.5HP / 4.0kW 12 = 6HP / 4.5kW 13 = 7.5HP / 5.5kW 14 = 10HP / 7.5kW 15 = 12.5HP / 9.2kW 16 = 15HP / 11,0kW 17 = 20HP / 15,0kW
Factory Setting 5.0
Unit
User Setting
Page
s
125
0
-
126
2
-
127
0.0
s
127
% V A rpm Hz -
127 127 128 128 128 128
According to inverter model (motor matched to the inverter see item 9.3) and sales market
CFW-08 - QUICK PARAMETER REFERENCE
Parameter P407
(3)
Function Rated Motor Power Factor
P408 (1)(3)
Measured Parameters Self-Tuning
P409 (3)
Motor Stator Resistance
P520 P521 P522 P525 P526 P527 P528 P536
SPECIAL FUNCTION - P500 PID Regulator PID Proportional Gain PID Integral Gain PID Differential Gain Setpoint Via Keypad of the PID Regulator Process Variable Filter PID Action Process Variable Scale Factor Automatic Setting of P525
Adjustable Range 0.50 to 0.99
Factory Setting According to inverter model
Unit
User Setting
Page
-
129
0
-
129
According to inverter model
129
0.000 to 7.999 0.000 to 9.999 0.000 to 9.999 0.00 to 100.0
1.000 1.000 0.000 0.00
%
137 137 137 137
0.01 to 10.00 0 = Direct 1 = Reverse 0.00 to 99.9
0.10 0
s -
137 137
1.00
-
138
0
-
138
0 = No 1 = Yes 0.00 to 99.99
to P599
0=Active 1=Inactive
Notes found on the Parameters Quick Reference. (1) This parameter is only displayed in vector mode (P202=2). (2) This parameter is only displayed in scalar mode P202=0 or 1. (3) This parameter can be enchanged only when the inverter is disabled (stopped motor). (4) This parameter is only available with HMI-CFW08-RS. (5) The analog input value is represented by zero when it is not connected to an external signal. (6) This parameter is only available in the CFW-08 Plus version. (7) The parameter value changes automatically when P203=1.
17
CFW-08 - QUICK PARAMETER REFERENCE II. Fault Messages
III. Other Messages
Display E00 E01 E02 E04 E05 E06 E08 E09 E10 E14 E22, E25, E26 and E27 E24 E28 E31 E32 E41
Display rdy Sub dcbr auto copy past
18
Description Output Overcurrent/Short-Circuit DC Link Overvoltage DC Link Undervoltage Inverter Overtemperature Output Overload (Ixt Function) External Fault CPU Error (Watchdog) Program Memory Error (Checksum) Keypad Copy Function Error Self-tuning Fault Serial Communication Error Programming Error Serial Interface Watchdog Timeout Error Keypad Connection Fault (HMI-CFW08-RS) Motor overtemperature (External PTC) Self-Diagnosis Fault
Page 139 139 140 140 140 140 140 140 140 140 140 140 140 140 140 141
Description Inverter is ready to be enabled Power suplly voltage is too low for the inverter operation (Undervoltage) Inverter in DC braking mode Inverter is running self-tuning routine Keypad Copy Function in Progress (only available in the HMI-CFW08-RS) - inverter to keypad Keypad Copy Function in Progress (only available in the HMI-CFW08-RS) - Keypad to Inverter
CHAPTER 1 SAFETY NOTICES This Manual contains necessary information for the correct use of the CFW-8 Variable Frequency Drive. This Manual has been written for qualified personnel with suitable training and technical qualification to operate this type of equipment. 1.1 SAFETY NOTICES IN THE MANUAL
The following Safety Notices will be used in this Manual: DANGER! If the recommended Safety Notices are not strictly observed, it can lead to serious or fatal injuries of personnel and/or material damage. ATTENTION! Failure to observe the recommended Safety Procedures can lead to material damage. NOTE! The content of this Manual supplies important information for the correct understanding of operation and proper performance of the equipment.
1.2 SAFETY NOTICE ON THE PRODUCT
The following symbols may be attached to the product, serving as Safety Notice: High Voltages Components sensitive to electrostatic discharge. Do not touch them without proper grounding procedures.
Mandatory connection to ground protection (PE) Shield connection to ground
1.3 PRELIMINARY RECOMMENDATIONS DANGER! Only qualified personnel should plan or implement the installation, start- up, operation and maintenance of this equipment. Personnel must review entire Manual before attempting to install, operate or troubleshoot the CFW-08.
19
CHAPTER 1 - SAFETY NOTICES These personnel must follow all safety instructions included in this Manual and/or defined by local regulations. Failure to comply with these instructions may result in personnel injury and/or equipment damage. NOTE! In this Manual, qualified personnel are defined as people that are trained to: 1. Install, ground, power up and operate the CFW-08 according to this Manual and the local required safety procedures; 2. Use of safety equipment according to the local regulations; 3. Administer Cardio Pulmonary Resuscitation (CPR) and First Aid. DANGER! The inverter control circuit (ECC3, DSP) and the HMI-CFW08-P are not grounded. They are high voltage circuits. DANGER! Always disconnect the supply voltage before touching any electrical component inside the inverter. Many components are charged with high voltages, even after the incoming AC power supply has been disconnected or switched OFF. Wait at least 10 minutes for the total discharge of the power capacitors. Always connect the frame of the equipment to the ground (PE) at the suitable connection point. ATTENTION! All electronic boards have components that are sensitive to electrostatic discharges. Never touch any of the electrical components or connectors without following proper grounding procedures. If necessary to do so, touch the properly grounded metallic frame or use a suitable ground strap.
Do not apply High Voltage (High Pot) Test on the Inverter! If this test is necessary, contact the Manufacturer.
NOTE! Inverters can interfere with other electronic equipment. In order to reduce this interference, adopt the measures recommended in Section 3 “Installation”. NOTE! Read this entire Manual carefully and completely before installing or operating the CFW-08. 20
CHAPTER 2 GENERAL INFORMATION This chapter 2 defines the contents and purposes of this manual and describes the main characteristics of the CFW-08 frequency inverter. Identification, receiving inspections and storage requirements are also provided. 2.1 ABOUT THIS MANUAL
This Manual is divided into 9 Chapter, providing infornation to the user on how receive, install, start-up and operate the CFW08: Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter
1 2 3 4 5 6 7 8 9
-
Safety Notices; General Information and receiving the CFW-08; Installation; Start-up, steps to follow; Keypad HMI Operation; Detailed Parameter Description; Diagnostic and Troubleshooting; CFW-08 Options and Accessories; Technical Specifications;
This Manual provides information for the correct use of the CFW -08. The CFW-08 is very flexible and allows for the operation in many different modes as described in this manual. As the CFW-08 can be applied in several ways, it is impossible to describe here all of the application possibilities. WEG does not accept any responsibility when the CFW-08 is not used according to this Manual. No part of this Manual may be reproduced in any form, without the written permission of WEG. 2.2 SOFTWARE VERSION
It is important to note the Software Version installed in the Version CFW-08, since it defines the functions and the programming parameters of the inverter. This Manual refers to the Software version indicated on the inside cover. For example, the Version 3.0X applies to versions 3.00 to 3.09, where “X” is a variable that will change due to minor software revisions. The operation of the CFW-08 with these software revisions are still covered by this version of the Manual. The Software Version can be read in the Parameter P023.
21
CHAPTER 2 - GENERAL INFORMATION 2.3 ABOUT THE CFW-08
TThe CFW-08 VFD provides two control options: vector control (VVC: voltage vector control) or V/Hz (scalar); both types of control can be set according to the application. In the vector control mode, the motor performance is optimized relating to torque and speed regulation. The "Self-Tuning" function, available in vector control, permits the automatic setting of the inverter parameter from the identification (also automatic) of the parameters of the motor connected at the inverter output. The V/F (scalar) mode is recommended for more simple applications such as pump and fan drives. In these cases one can reduce the motor and inverter losses by using the "Quadratic V/F" option, that results in energy saving. The V/F mode is also used when more than one motor should be driven simultaneously by one inverter (multimotor application). There are two CFW-08 versions: Standard: it has 4 digital inputs (DIs), 1 analog input (AI) and 1 relay output. CFW-08 Plus: compared to the standard version it has one additional analog input and one additional relay output. It has also an analog output (AO). For power ratings and further technical information, see Chaper 9. O blocodiagrama a seguir proporciona uma visão de conjunto do CFW-08.
22
CHAPTER 2 - GENERAL INFORMATION
Rsh1 NTC Power Supply
R S T
U V W
Motor
RFI Filter
PE
PE
Rsh2 POWER CONTROL
HMI-CFW08-RP
HMI-CFW08-P
POWER SUPPLIES AND CONTROL / POWER INTERFACES
or Interface MIP-CFW08-RP KRS-485
HMI-CFW08-RS RS-485
or Interface MIS-CFW08-RS
or
PC-Software SuperDrive
"ECC3" CONTROL BOARD WITH DSP
KFB-CO or KFB-DN
CANopen or DeviceNet
Interface RS-232 KCS-CFW08
Digital Inputs (DI1 to DI4)
Analog Output (AO)
Analog Inputs (AI1 and AI2)
Relay Output (RL1 and RL2)
Figure 2.1 - Block diagram for the models: 1.6-2.6-4.0-7.0A/200-240V and 1.0-1.6-2.6-4.0A/380-480V
23
CHAPTER 2 - GENERAL INFORMATION Braking Resistor (External and Optional) +UD
BR
Pre-Charge
Rsh1 RPC Power Supply
R S T
RFI Suppressor Filter (optional)
U V W
Motor
RFI Filter
HMI-CFW08-RP
PE -UD
Rsh2
HMI-CFW08-P
Voltage Feedback
PE
POWER CONTROL POWER SUPPLIES AND CONTROL / POWER INTERFACES
or Interface MIP-CFW08-RP
HMI-CFW08-RS
KRS-485
or Interface MIS-CFW08-RS
or
PC-Software SuperDrive
RS-485
"ECC3" CONTROL BOARD WITH DSP
KFB-CO or KFB-DN
CANopen or DeviceNet
Interface RS-232 KCS-CFW08
Digital Inputs (DI1 to DI4) Analog Inputs (AI1 and AI2)
Figura 2.2– Block diagram for the models: 7.3-10-16-22A/200-240V and 2.7-4.3-6.5-10-13-16A/380-480V Note: Model 16A and 22A/200-240V is not fitted with RFI filter (optional).
24
Analog Output (AO) Relay Output (RL1 and RL2)
CHAPTER 2 - GENERAL INFORMATION
DC Link Inductor (optional)
+UD
DCR
Braking Resistor (optional) BR
Pre-Charge
RPC Power Supply
R S T
RFI Suppressor Filter (optional)
U V W
PE HMI-CFW08-RP
Motor
RFI Filter
-UD
Voltage Feedback
Rsh1
HMI-CFW08-P
PE
POWER CONTROL POWER SUPPLIES AND CONTROL / POWER INTERFACES
or Interface MIP-CFW08-RP KRS-485
HMI-CFW08-RS or Interface MIS-CFW08-RS
or
PC-Software SuperDrive
RS-485
"ECC3" CONTROL BOARD WITH DSP
KFB-CO or KFB-DN
Interface RS-232 KCS-CFW08
Digital Inputs (DI1 to DI4) Analog Inputs (AI1 and AI2)
CANopen or DeviceNet
Analog Output (AO) Relay Output (RL1 and RL2)
Figure 2.3 – Block diagram for the models: 28-33A/200-240V and 24-30A/380-480V Note: Model 28A and 33A/200-240V is not fitted RFI filter (optional)
25
CHAPTER 2 - GENERAL INFORMATION 2.3.1 Differences between the old line and the new CFW-08
This section aims at showing the differences between the old line and the new CFW -08. The information below are addressed to user that are used to line. Table below shows the equivalence between the accessories of the old line an the new CFW-08.
Acessoriy line Local Keypad (parallel) IHM-8P (417100258) Remote serial Keypad IHM-8R (417100244) Remote parallel Keypad Interface for remote serial Keypad MIR-8R (417100259) Interface for remote parallel Keypad Interfaces for serial communication MCW-01 (417100252) RS-232 Interface for RS-485 MCW-02 (417100253) serial communication RS-485
CFW-08 HMI-CFW08-P(417118200) HMI-CFW08-RS (417118218) HMI-CFW08-RP (417118217) MIS-CFW08-RS (417118219) MIP-CFW08-RP (417118216) KCS-CFW08 (417118212) KRS-485-CFW08 (417118213)
Table 2.1 – Options for the mline and equivalents for the new CFW-08.
Product Appearance Besides the internal electronics, also the exterrnal product appearance have changed, which are: - The frontal lettering on the plastic covers (formerly: line, now: CFW-08 vector inverter); - WEG logo is now indicated on all accessories of the CFW-08 line (keypad, communication modules etc). Figure below makes a comparison:
a) line
b) CFW-08
Figure 2.4 a) b) - Comparison between line a CFW-08 appearance
Version of Software The new CFW-08 starts with Software Version V3.00. Thus, the software versions V1.xx and V2.xx are exclusive for line. Besides the inverter control has been implemented in a DSP (Digital Signal Processor), which enables a more sophisticated control with more parameters and functions. 26
CHAPTER 2 - GENERAL INFORMATION Accessories With the migration from the 16 bits microcontroller to the DSP of the newCFW-08, the power supply of the electronic circuits was changed from 5V to 3.3V. Consequently, the accesories (keypads, communication modules, etc) of the old line CAN NOT BE USED with the new CFW-08 line. As general rule, use only accessories with WEG logo, as already informed above. Expansion of the Power Range The power range of the old line (0.25-2HP) has been expanded to (0.25 to 20)HP with the new CFW-08 line. Control Modes Only the CFW-08 line has: - Voltage Vector Control (VVC) that improves the inverter performance considerably - adding the parameters P178, P399, P400, P402, P403, P404, P407, P408 and P409; - The quadratic curve V/F improves the systema energy saving capability when loads with quadratic torque x speed characteristics are driven, like pumps and fans. Frequency Resolution The new CFW-08 has a frequency resolution 10 times higher than the old line, i.e., it has a resoltion of 0.01Hz for frequencies up to 100.0Hz and of 0.1Hz for frequencies higher than 99.99Hz. Switching Frequencies of 10kHz and 15kHz When the new CFW-08 is used, one can set the inverter switching frequency to 10kHz and 15kHz, which enables an extremly quiet operation. The audible noise level generated by the motor with 10 kHz is lower with the CFW-08, when compared with the line. This is due to the PWM modulation improvements of the CFW-08. Inputs and Outputs (I/Os) The CFW-08 Plus line has more I/Os than the old line, while the CFW-08 is equivalent to the line in terms of I/Os. See table below: I/O Digital Inputs (*) Analog Input(s) Analog Outputs Relay Outputs
line 4 1 1 (REV contatct)
CFW-08 4 1 1 (REV contact)
CFW-08 Plus 4 2 1 2 (1 NO contact, 1 NC contact)
(*) Two additional digital inputs are available when the digital inputs are used. (See Parameter P235 and P239).
Table 2.2 – Number of digital inputs on the mline, on CFW08 and on the CFW08 Plus. 27
CHAPTER 2 - GENERAL INFORMATION But the control connections (terminals XC1) differ between the line and the CFW-08 line. Table below shows theses pin differences: I/O Digital Input DI1 Digital Input DI2 Digital Input DI3 Digital Input DI4 0V for Digital Inputs +10V Analog Input AI1 voltage signal Analog Input AI1 current signal or PTC input 0V for analog input(s) Analog Input AI2 voltage signal Analog Input AI2 current signal or PTC input Analog Output AO Current signal Analog Output AO Current signal Relay Ouput RL1 Relay Output RL2
line 1 2 3 4 5 6 7 9
CFW-08 CFW-08 Plus 1 1 2 2 3 3 4 4 5 5 7 7 6 with switch 6 with switch S1:3 S1:3 at pos. OFF at position OFF 6 with switch 6 with switch S1:3 S1:3 at pos. ON at position ON
8
5
5
not available not available
not available not available
8 with switch S1:4 at position OFF 8 with switch S1:4 at position ON
not availablel not availablel 10(N.C.), 11(C) and 12 (N.O.) not available
not availablel not availablel 10(N.C.), 11(C) and 12 (N.O.) not available
9 with switch S1:2 to position ON 9 with switch S1:2 to position OFF 11-12 (N.O.) 10-11 (N.C.)
Table 2.3 – Differences between the control pin location on the mline, the line CFW08 and on the CFW08 Plus.
Parameters and Functions: Parameters that are already used in line but have been changed a) P136 - Manual Torque Boost (IxR Compensation): Besides the parameter name, also the way the user enters the IxR compensation value has been changed. In the old line, the parameter P136 had a family of 10 curves (value range: 0 to 9). In the new CFW-08, the IxR Compensation is set by entering a percent (relating to the input voltage) that defines the output voltage for an output frequency equal to zero. So larger curve set and a larger variation range is obtained. Table below shows the equivalence between which was programmed in the old line and which must be programmed in the new CFW-08 to obtain the same result. 28
CHAPTER 2 - GENERAL INFORMATION P136 set in line 0 1 2 3 4 5 6 7 8 9
P136 to be set in the CFW-08 0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5
Table 2.4 – Equivalent values in the P136 programming for the old mline and the new CFW08
b) Automatic Torque Boost (Automatic IxR Compensation) and Slip Compensation: In the line only the rated motor current (P401) was used in the Automatic IxR Compensation and the Slip Compensation functions. In the line the rated motor power factor of the motor was considered as a fixed value and equal to 0.9. Now in the new CFW-08, are used the parameters P401 and P407 (rated motor power factor). Thus: P401
line
. 0.9 = P401 x P407
CFW-08
Example: When in an application with the line the following setting was required: P401=3.8A, now with the new CFW-08 you must perform the following setting: P401=3.8A and P407=0.9 or P407= rated cos of the used motor and P401=3.8 x 0.9 P407 c) Quick Inputs: In the new CFW-08, the response time of the the digital inputs is 10ms (max.). In addition, the minimum acceleration and deceleration time was reduced from 0.2s (line) to 0.1s (CFW-08). Besides the DC braking process can be interrupted before it has been concluded, for instance, when a new enabling is required. d) Other changes: P120=2 - digital reference backup via P121 independently of the reference source. P265=14 - DI3: multispeed using ramp 2. 29
CHAPTER 2 - GENERAL INFORMATION New Parameters and Functions: The reference 1 of the multispeed that was in Parameter P121 (in line) is now in Parameter P124 (in CFW-08). The DC link regulation level (ramp holding) can now be programmed in Parameter P151 - in the line this level was fixed to 377V for the 200-240V line and 747V for the 380-480V line. Also the programming way of parameter P302 has changed. In the line P302 was related to the voltage applied to the output during the DC braking, now in the new CFW-08, P302 defines the DC Braking Current. PID regulator. Suammarizing, the new parameters are: P009, P040, P124, P151, P178, P202, P203, P205, P219, P238, P239, P240, P251, P252, P279, P399, P400, P402, P403, P404, P407, P408, P409, P520, P521, P522, P525, P526, P527, P528 and P536.
30
CHAPTER 2 - GENERAL INFORMATION 2.4
CFW-08 IDENTIFICATION Software Version Hardware Revision CFW-08 Model
Rated Input Data (Voltage, Number of Phases Current, Frequency)
Rated Output Data (Voltage, Frequency)
Serial Number
WEG Part Number
Manufacturing Date
Lateral label of the CFW-08
WEG Part Number Seriel Number
CFW-08 Model Manufacturing Date Hardware Revision Software Version
Frontal Nameplate of the CFW-08 (under the keypad)
Note: To remove the keypad, see instructions in 8.1.1 (Figure 8.2).
Certification Stiker
Figure 2.5 - Description and location of the nameplates on the CFW-08 31
32
38 0 a 4 80V: 00 10=1 .0 A 00 16=1 .6 A 00 26=2 .6 A 00 27=2 .7 A 00 40=4 .0 A 00 43=4 .3 A 00 65=6 .5 A 0 100= 10A 0 130= 13A 0 160= 16A 0 240= 24A 0 300= 30A
22 0 a 2 40V: 00 16=1 .6 A 00 26=2 .6 A 00 40=4 .0 A 00 70=7 .0 A 00 73=7 .3 A 0 100= 10A 0 160= 16A 0 220= 22A 0 280= 28A 0 330= 33A
R ated Output Cu rren t for
0040
S= single phase T=three phase B= single ph ase or three phase
Number of ph ases o f the p ower suppl y:
B
2024 = (200 to 24 0)V 3848 = (380 to 48 0)V
Powe r Suppl y:
2024
P= Portug. E= English S= Spani sh
Manual Lan guage:
E
__ Degree of Protection:
__ Human Machine Interface:
S= stan da rd O= with Blank = Blank= opti ions stand ard N1= Nema 1 standar d SI= without i nter face ( wi th dummy pa nel)
Options:
O
Blank = sta ndard control A1= control 1 (Plus Versio n) A2= control 2 (Plus Version wi th Als +/10 V) A3 =co ntr ol bo ard 3 (Plus ve rsi on with the C ANo pen pr oto col) *1 A4 =co ntr ol bo ard 4 (Plus ve rsi on with the DeviceN et pr oto co l) * 1
Control Boa rd:
__
HOW TO SPECIFY THE CFW -08 MODEL: __
witho ut filte r FA= Class A RFI fi lter (inter na l or footprint)
RFIF ilter: Bla nk=
__
Blank = non e
Spe ci al Ha rdwar e:
__
Bla nk = none
Speci al Softwar e:
Z End C ode
Thus , for instance if the produc t above is required with NEMA 1 degree of protection: CFW 080040S2024EON1Z = CFW-08 inverter, 4A, single-phase, 200-240V input, with manual in English language and with kit for NEMA 1 degree of protec tion.
If the CFW-08 is equipped with any optional devices, y ou must fill out all fields in the correc t sequence up to the last optional device, the model number is completed with the letter Z.
NOTES! The option field (S or O) defines if the CFW-08 is a standard version or if it will be equipped with any optional devic es. If the standard version is required, the spec ific ation code ends here. The model number has always the letter Z at the end. For example: CFW 080040S2024ESZ = s tandard 4.0A CFW -08 inverter, single-phase at (200 to 240)V input, with manual in English.
*1 - T he versio ns A3 and A4 of the co ntrol board shall be used o nly with the KF B-CO -C FW0 8 and with the KFB-DN-CFW 08, respe ctively (refer to item 8.12 and 8 .13). The parallel keypa d, the seria l remote keypad, the parallel re mote keypa d, and the serial protocol (Modbus and W EG ) cannot be used wi th these versions of the control b oard.
WEG Series 0 8 F re qu ency Inverter
C FW -08
CHAPTER 2 - GENERAL INFORMATION
CHAPTER 2 - GENERAL INFORMATION For the effect of this code, the standard product is conceived as follows: - CFW-08 with standard control board. - Degree of protection:NEMA 1 for the models 22A, 28A and 33A/ 200-400V and too 13A,16A, 24A and too 30A/380-480V; IP20 for the other models. CFW-08 Plus - A1 is composed of the drive and the control board A1. Example: CFW080040S2024POA1Z. CFW-08 Plus - A2 is composed of the drive and the control board A2. Example: CFW-080040S2024POA2Z. These models are factory set for bipolar analog inputs (-10V to +10V). This configuration is lost when the factory default parameters are loaded (P204 = 5). Refer to the detailed description of parameters P204 and P235 for further information. CFW-08 Plus - A3 is composed of the drive, the KFB-COCFW-08 kit and the CANopen communication protocol. Example: CFW-080040S2024POA3Z. CFW-08 Plus - A4 is composed of the drive, the KFB-DWCFW-08 kit and the eviceNet communication protocol. Example: CFW-080040S2024POA4Z. 7.0A, 16.0A, 22A, 28A and 33A /200-240V and for all 380480V models are just available with three-phase power supply. A RFI Class A filter (optional) can be installed inside the inverter in models 7.3 and 10A/200-240V (single-phase) and 2.7A, 4.3A, 6.5A, 10A, 13A, 16A, 24A and 30A/380480V. Models 1.6A, 2.6A and 4.0A/200-240V (singlephase) and 1.0A, 1.6A, 2.6A and 4.0A/380-480V can be provided mounted on a footprint RFI Class A filter (optional). The listing of the existing models (voltage/current) is shown in item 9.1.
33
CHAPTER 2 - GENERAL INFORMATION 2.5 RECEIVING AND STORING
The CFW-08 is supplied in cardboard boxes. The outside of the packing box has a nameplate that is identical to that on the CFW-08. Please check if the CFW-08 is the one you ordered. Check if the: CFW-08 nameplate data matches with your purchase order. The equipment has not been damaged during transport. If any problem is detected, contact the carrier immedately. If the CFW-08 is not installed immediately, store it in a clean and dry room (storage temperatures between –25°C and 60°C). Cover it to protect it against dust, dirt or other contamination. ATENTION! When the drive is stored for a long time, it is recommended to power the drive up and keep it running for 1 hour every year. Make sure to use a power supply with the following characteristics for all models (200-240V or 380-480V): 220V, single-phase or three-phase, 50 or 60Hz (for three-phase power supply), without connecting the motor to the drive output. After powering up the drive, keep it off for 24 hours before using it again.
34
CHAPTER 3 INSTALLATION This chapter describes the procedures for the electrical and mechanical installation of the CFW-08. These guidelines and suggestions must be followed for proper CFW-08 operation. 3.1 MECHANICAL INSTALLATION 3.1.1 Environment
A The location of the inverter installation is an important factor to assure good performance and long useful life for its components. For proper installation, we make the following recommendations: Avoid direct exposure to sunlight, rain, high moisture and sea air; Avoid exposure to gases or explosive or corrosive liquids; Avoid exposure to excessive vibration, dust, oil or any conductive particles in the air; Environment conditions: Temperature: 0 to 40ºC (32 to 104ºF ) - nominal conditions. From 0 to 50ºC (32 to 122ºF) - with 2% current derating for each 1ºC (1.8ºF) degree above 40ºC(104ºF). Relative Air Humidity: 5% to 90% - non-condensing. Maximum Altitude: 1000m (3,300 ft) - nominal conditions. From 1000 to 4000m (3,300 to 13,200 ft) - with 1% current reduction for each 100m (330ft ) above 1000m (3,300ft). Pollution Degree: 2 (according to EN50178 and UL508C)
3.1.2 Mounting Specifications CFW-08
The Figure 3.1 and the table 3.1, provides external mounting specifications, and external fixing holes of the do CFW-08.
35
CHAPTER 3 - INSTALLATION
- ONLY REMOVE TERMINAL CO VER WARNING AF TER 1 MIN. PO WER HAS BEEN DISCONNECTED.
- READ T HE INST RUCTIONS MANUAL. - SOMENTE REMOVA A TAMPA 1 MIN. APÓS A DESENERGIZAÇÃO.
ATENÇÃO - L EIA O MANUAL DE INSTRUÇÕ ES.
VIEW OF THE MOUNTING BASE
FRONTAL VIEW
Figure 3.1 – CFW-08 Mounting Specifications
36
LATERAL VIEW
CHAPTER 3 - INSTALLATION
Inverter Model 1.6A / 200-240V 2.6A / 200-240V 4.0A / 200-240V 7.0A / 200-240V 7.3A / 200-240V 10A / 200-240V 16A / 200-240V 22A/200-240V 28A/200-240V 33A/200-240V 1.0A / 380-480V 1.6A / 380-480V 2.6A / 380-480V 2.7A / 380-480V 4.0A / 380-480V 4.3A / 380-480V 6.5A / 380-480V 10A / 380-480V 13A / 380-480V 16A / 380-480V 24A/380-480V 30A/380-480V
Width L mm (in) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) 115 (4.53) 115 (4.53) 115 (4.53) 143 (5.63) 182 (7.16) 182 (7.16) 75 (2.95) 75 (2.95) 75 (2.95) 115 (4.53) 75 (2.95) 115 (4.53) 115 (4.53) 115 (4.53) 143 (5.63) 143 (5.63) 182 (7.16) 182 (7.16)
Dimensions Height H Depth P mm mm (in) (in) 151 131 (5.95) (5.16) 151 131 (5.95) (5.16) 151 131 (5.95) (5.16) 151 131 (5.95) (5.16) 200 150 (7.87) (5.91) 200 150 (7.87) (5.91) 200 150 (7.87) (5.91) 203 165 (7.99) (6.50) 290 196 (11.41) (7.71) 290 196 (11.41) (7.71) 151 131 (5.95) (5.16) 151 131 (5.95) (5.16) 151 131 (5.95) (5.16) 200 150 (7.87) (5.91) 151 131 (5.95) (5.16) 200 150 (7.87) (5.91) 200 150 (7.87) (5.91) 200 150 (7.87) (5.91) 203 165 (7.99) (6.50) 203 165 (7.99) (6.50) 290 196 (11.41) (7.71) 290 196 (11.41) (7.71)
Fixing base A B C mm mm mm (in) (in) (in) 64 129 5 (2.52) (5.08) (0.20) 64 129 5 (2.52) (5.08) (0.20) 64 129 5 (2.52) (5.08) (0.20) 64 129 5 (2.52) (5.08) (0.20) 101 177 7 (3.98) (6.97) (0.28) 101 177 7 (3.98) (6.97) (0.28) 101 177 7 (3.98) (6.97) (0.28) 121 180 11 (4.76) (7.08) (0.43) 161 260 11 (6.33) (10.23) (0.43) 161 260 11 (6.33) (10.23) (0.43) 64 129 5 (2.52) (5.08) (0.20) 64 129 5 (2.52) (5.08) (0.20) 64 129 5 (2.52) (5.08) (0.20) 101 177 7 (3.98) (6.97) (0.28) 64 129 5 (2.52) (5.08) (0.20) 101 177 7 (3.98) (6.97) (0.28) 101 177 7 (3.98) (6.97) (0.28) 101 177 7 (3.98) (6.97) (0.28) 121 180 11 (4.76) (7.09) (0.43) 121 180 11 (4.76) (7.09) (0.43) 161 260 11 (6.33) (10.23) (0.43) 161 260 11 (6.33) (10.23) (0.43)
D Mounting Weigth Degree of kg mm Screw Protection (lb) (in) 6 M4 1.0 IP20 / NEMA1 (0.24) (5/32) (2.2) 6 M4 1.0 IP20 / NEMA1 (0.24) (5/32) (2.2) 6 M4 1.0 IP20 / NEMA1 (0.24) (5/32) (2.2) 6 M4 1.0 IP20 / NEMA1 (0.24) (5/32) (2.2) 5 M4 2.0 IP20 / NEMA1 (0.20) (5/32) (4.4) 5 M4 2.0 IP20 / NEMA1 (0.20) (5/32) (4.4) 5 M4 2.0 IP20 / NEMA1 (0.20) (5/32) (4.4) 10 M5 2.5 IP20/NEMA1 (0.39) (3/16) (9.8) 10 M5 6 IP20/NEMA1 (0.39) (3/16) (2.36) 10 M5 6 IP20/NEMA1 (0.39) (3/16) (2.36) 6 M4 1.0 IP20 / NEMA1 (0.24) (5/32) (2.2) 6 M4 1.0 IP20 / NEMA1 (0.24) (5/32) (2.2) 6 M4 1.0 IP20 / NEMA1 (0.24) (5/32) (2.2) 5 M4 2.0 IP20 / NEMA1 (0.20) (5/32) (4.4) 6 M4 1.0 IP20 / NEMA1 (0.24) (5/32) (2.2) 5 M4 2.0 IP20 / NEMA1 (0.20) (5/32) (4.4) 5 M4 2.0 IP20 / NEMA1 (0.20) (5/32) (4.4) 5 M4 2.0 IP20 / NEMA1 (0.20) (5/32) (4.4) 10 M5 2.5 IP20 / NEMA1 (0.39) (3/16) (5.5) 10 M5 2.5 IP20 / NEMA1 (0.39) (3/16) (5.5) 10 M5 6 IP20 / NEMA1 (0.39) (3/16) (2.36) 10 M5 6 IP20 / NEMA1 (0.39) (3/16) (2.36)
* These models are NEMA1 only with the KN1_CFW-08_MX optional. Table 3.1 – CFW-08 dimensions for mechanical installation of the several models.
37
CHAPTER 3 - INSTALLATION 3.1.3 Positioning and Fixing
When installing the CFW-08, allow free space around the inverter as indicated in Figure 3.2. Table 3.2 shows the required free spaces. Install the inverter in vertical position as described below. 1) Install the inverter on a flat surface. 2) Do not install heat sensitive components immediately above the inverter. ATTENTION! W hen inverters are installed side by side, maintain the minimum recommended distance B. when inverters are installed top and bottom, maintain the minimum recommended distance A + C and deflect the hot air coming from the inverter below. ATTENTION! Provide independent conduits for signal, control and power conductors. (Refer to Electrical Installation). Use separate conduits or trunking for control and power wiring (see item 3.2 - Electrical Installation).
Figure 3.2 – Free spaces for cooling
38
CHAPTER 3 - INSTALLATION CFW-08 Model 1,6A / 200-240V 2,6A / 200-240V 4,0A / 200-240V 7,0A / 200-240V 1,0A / 380-480V 1,6A / 380-480V 2,6A / 380-480V 4,0A / 380-480V 7,3A / 200-240V 10A / 200-240V 16A / 200-240V 2,7A / 380-480V 4,3A / 380-480V 6,5A / 380-480V 10A / 380-480V 22A / 200-240V 13A / 380-480V 16A / 380-480V 28A/200-240V 33A/200-240V 24A/380-480V 30A/380-480V
A
B
C
D
30 mm
1,18 in
5 mm
0,20 in
50 mm
2 in
50 mm
2 in
35 mm
1,38 in
15 mm
0,59 in
50 mm
2 in
50 mm
2 in
40 mm
1,57 in
30 mm
1,18 in
50 mm
2 in
50 mm
2 in
50 mm
2 in
40 mm
1,57 in
60 mm
2,36 in
50mm
2 in
Table 3.2 – Recommended free spaces
3.1.3.1 Panel Mounting
When inverters are installed inside closed metallic panels or boxes provide suitable air exhaustion by ensuring that the ambient temperature remains within the allowed range. For Watt losses refer to Item 9.1 of this Manual. For reference, table 3.3 shows the cooling airflow for each inverter model. Inverter Cooling Method: Internal fan, flow direction from the bottom to the top. CFW-08 Inverter Model 4.0A, 7.0A/200V 2.6A, 4.0A/400V 7.3A, 10A, 16A/200V 6.5A, 10A/400V 13A, 16A/400V 22A/200V 28A/200V 24A/400V 33A/200V 30A/400V
3
CFM 6.0
I/s 2.8
m /min 0.17
18.0
8.5
0.51
18.0 22.0 36.0
8.5 10.4 17.0
0.51 0.62 1.02
44.0
20.8
1.25
Table 3.3 – Cooling Air Flow requirements
39
CHAPTER 3 - INSTALLATION 3.1.3.2 Surface Mounting
Figure 3.3 shows the surface installation procedures of the CFW-08.
AIR FLUX
Figure 3.3 – Mounting procedures for CFW-08
3.2
ELECTRICAL INSTALLATION
DANGER! The information below will be a guide to achieve a proper installation. Follow also all applicable local standards for electrical installations. DANGER! Be sure the AC input power has been disconnected before making any terminal connection. DANGER! Do not use the CFW08 as an emergency stop device. For this purpose provide other additional mechanical means.
3.2.1 Power / Grounding Terminals
The power connection terminals can be of different sizes and configurations, depending on the inverter model, as shown in Figure 3.4. Description of the Power Terminals: L/L1, N/L2 and L3 (R, S ,T): AC Power supply. The models of the line voltage 200-240 V (excepting 7,0A, 16A, 22A, 28A, and 33A) can be operated on two phases (single-phase operation) without rated current reduction. In this case the AC power supply can be connected to any 2 terminals of the 3 inputs terminals. U, V, W: Connection to the motor.
40
CHAPTER 3 - INSTALLATION -UD: negative pole of the DC link circuit is not available on the models 1,6A-2,6A-4,0A-7,0A/200-240V and models 1,0A-1,6A-2,6A-4,0A/380-480V. It is used when the inverter supplied by CD voltage (with the terminal +UD). To avoid wrong connection of the braking resistor (mounted external do the inverter), the inverter is factory delivered with a rubber plug which must be removed when the use of the -UD terminal is required. BR: Connection for the braking resistor. Not available on the models 1,6A-2,6A-4,0A-7,0A/200240V and on the models 1,0A-1,6A-2,6A-4,0A/380-480V. +UD: positive pole of the DC link circuit, not available on the models 1,6A-2,6A-4,0A-7,0A/200-240V and on the models 1,0A-1,6A-2,6A-4,0A/380-480V. It is used to connect the barking resistor (with the –UD terminal) or when the inverter shall be supplied by with DC voltage (jointly with the –UD terminal. DCR: Connection for the external DC link circuit inductor (optional). It is only available on the models 28A and 33A/ 200-240V and on the models 24A and 30A/380-480V. a) 1,6-2,6-4,0-7,0A/200-240V and 1,0-1,6-2,6-4,0A/380-480V Models
L/L1
L3
N/L2
U
V
W
b) 7,3-10-16A/200-240V and 2,7-4,3-6,5-10A/380-480V Models
L/L1
N/L2
L3
U
V
W
-Ud
BR
+Ud
c) 22A/200-240V and 13-16A/380-480V Models
1 R
2 S LINE
3 T
4 U
5 6 V W MOTOR
7 -UD
8 BR
9 +UD
Figure 3.4 a) to c) - Power terminals 41
CHAPTER 3 - INSTALLATION d) 28-33A/200-240V and 24-30A/380-480V Models
1 R
2 S LINE
3 T
4 U
5 6 7 8 9 10 V W -UD BR +UD DCR MOTOR
Figure 3.4 cont. d) - Power terminals a) 1,6-2,6-4,0-7,0-7,3-10-16A/200-240V and 1,0-1,6-2,6-2,7-4,0-4,3-6,5-10A/380-480V Models
3.2.2 Location of the Power Terminals, Grounding Terminals and Control Terminal Connections
Control XC1
Power
Grounding
b) 22-28-33A/200-240V and 13-16-24-30A/380-480V Models
Control XC1 Power Grounding
Figure 3.5 a) b) – Location of the Power, grounding and control connections 42
CHAPTER 3 - INSTALLATION 3.2.3 Wiring and CircuitBreakers for the Power and Grounding Connections. ATTENTION! Install the inverter and power cables distant from sensitive equipment and wirings by 0,25m, for instance PLCs, temperature controllers, thermocouple cables, etc. Use the recommended wire cross section and circuit breakers as shown in Table 3.3. Use only copper wire (70ºC). Rated Inverter Current [A]
Power Cables 2 [mm ]
Grounding Wiring 2 [mm ]
Maximum Power Cable 2 [mm ]
Maximum Grounding Wiring 2 [mm ]
Current
W EG Model
1,0 (200- 240V) (380- 480V) (200- 240V) (380- 480V) 2,7 4,0 (200- 240V) 4,0 (380- 480V) 4,3 6,5 7,0 7,3 10,0 (200- 240V) 10,0 (380- 480V) 13,0 16,0 22,0 24,0 28,0 30,0 33,0
1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 2,5 2,5 4,0 4,0 4,0 4,0 4,0 4,0 4,0 6,0 6,0 6,0
2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,5 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 6,0 6,0 6,0
2,5 4,0 2,5 4,0 2,5 4,0 4,0 2,5 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 10,0 10,0 10,0 10,0
4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 6,0 6,0 6,0 6,0
1,6 5,5 2,5 9,0 4,0 4,0 13,5 6,3 6,3 10 12 25 32 16 20 25 40 44 50 50 63
MPW 25-1,6 MPW 25-6,3 MPW 25-2,5 MPW 25-10 MPW 25-4,0 MPW 25-4,0 MPW 25-16 MPW 25-6,3 MPW 25-6,3 MPW 25-10 MPW 25-16 MPW 25-25 MPW 25-32 MPW 25-16 MPW 25-20 MPW 25-25 DW 125H -40 DW 125H -40 DW 125H -50 DW 125H -50 DW 125H -63
1,6 1,6 2,6 2,6
Circuit Breaker
Table 3.4 – Recommended wiring and circuit-breakers – use only copper wire (70ºC).
NOTE! The wire sizing in Table 3.4 shall be used as reference values only. The exact wire sizing depends on the installation conditions and the maximum acceptable line voltage drop. The recommended tightening torque is shown in table 3.5. ATTENTION! The use of mini circuit breakers (MBU) is not recommended due to the level of the magnetic protection.
43
CHAPTER 3 - INSTALLATION Model 1,6A / 200-240V 2,6A / 200-240V 4,0A / 200-240V 7,0A / 200-240V 7,3A / 200-240V 10,0A / 200-240V 16,0A / 200-240V 22,0A / 200-240V 28,0A / 200-240V 33,0A / 200-240V 1,0A / 380-480V 1,6A / 380-480V 2,6A / 380-480V 2,7A / 380-480V 4,0A / 380-480V 4,3A / 380-480V 6,5A / 380-480V 10,0A / 380-480V 13,0A / 380-480V 16,0A / 380-480V 24,0A / 380-480V 30,0A / 380-480V
Grounding Wiring N.m Lbf.in 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34 0,5 4,34
Power Cables N.m Lbf.in 1,0 8,68 1,0 8,68 1,0 8,68 1,0 8,68 1,76 15,62 1,76 15,62 1,76 15,62 1,76 15,62 1,76 15,62 1,76 15,62 1,2 10,0 1,2 10,0 1,2 10,0 1,76 15,62 1,2 10,0 1,76 15,62 1,76 15,62 1,76 15,62 1,76 15,62 1,76 15,62 1,76 15,62 1,76 15,62
Type of Screwdriver for the Power Terminal Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Pozidriv Number PZ2 Pozidriv Number PZ2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Philips Number PH2 Pozidriv Number PZ2 Pozidriv Number PZ2
Table 3.5 - Recommended tightening torque for power and grounding connections
3.2.4 Power Connections a) 1,6-2,6-4,0-7,0A/200-240V and 1,0-1,6-2,6-4,0A/380-480V Models - Three Phase Power Supply
PE
PE
Q1
R
S
T
U
V
W
PE
PE
T
R S T Power Supply Disconnect
Shielding
Figure 3.6 a) - Power and Grounding Connections
44
W
V
U
CHAPTER 3 - INSTALLATION b) Models 7,3-10-16-22A/200-240V and 2,7-4,3-6,5-10-13-16A/380-480V - Three Phase Power Supply
PE
PE
Q1
R
S
T
U
V
W -Ud BR
+ Ud
PE
T
Braking Resistor (see item 8.21)
PE
W
V
U
R S T Power Supply
Shielding
Disconnect
c) Models 1,6-2,6-4,0-7,3-10A / 200-240V - Single Phase Power Supply
PE
PE
Q1
T
R
S
T
U
V
W -Ud BR
+ Ud
PE
Braking Resistor (**) (see item 8.21)
PE
W
V
U
Phase Power Supply Neutral
Disconnect (*)
Shielding
Note: (*) In case of single-phase power supply with phase and neutral cable, connect only the phase cable to the disconnecting switch. (*) In teh 1,6A -2,6A and 4,0A models, the terminals to connect the braking resistor are not available. Figure 3.6 b) c) - Power and Grounding Connections 45
CHAPTER 3 - INSTALLATION d) Models 28-33A / 200-240V and 24-30A / 380-480V - Three Phase Power Supply
PE
PE
Phase
Q1
R
S
T
U
V
W -Ud BR
Disconnect
DCR
PE
T
R S T
Power Supply
+Ud
Braking Resistor
DC Link Inductor (Optional)
PE
W
V
U
Shielding
Figure 3.6 d) - Power and Grounding Connections
3.2.4.1
AC Input Connection DANGER! Provide an AC disconnecting switch to switch OFF the input power to the inverter. This device shall disconnect the inverter from the AC input supply when required (e. g. during maintenance services). ATTENTION! The AC input for the inverter must have a grounded neutral conductor. NOTE! TheAC input must be compatible with the inverter rated voltage Power Supply Line Capacity: The CFW-08 is suitable to be used in circuits which can not supply more than 30.000A rms symmetrically (240/480V). If the CFW-08 is installed in networks which can supply more than 30.000Arms, you must provide suitable protection circuits such as fuses and circuit breakers.
46
CHAPTER 3 - INSTALLATION DC Link Inductor / Line Reactors The requirements for use of line reactors depend on several application factors. Refer to Section 8.19. NOTE! Capacitors for power factor correction are not required at the input (L/L1, N/L2, L3 or R, S, T) and they must not be connected at the output (U, V, W). 3.2.4.2
Output Connections
The inverter is provided with electronic protection against motor overload. This protection must be set according to the specific motor. When the same inverter drives several motors, use individual overload relays for each motor. Maintain the electrical continuity of the motor cable shield. ATTENTION! If a disconnect switch or a contactor is inserted in the motor supply line, do not operate them with motor running or when inverter is enabled. Maintain the electrical continuity of the motor cable shield. Dynamic Braking (DB) When inverters with dynamic braking (DB) are used, the DB resistor shall be mounted externally. Figure 8.29 shows how to connect the braking resistor. Size it according to the application, not exceeding the maximum current of the braking circuit. For the connection between inverter and the braking resistor, use twisted cable. Provide physical separation between this cable and the signal and control cables. When the DB resistor is mounted inside the panel, consider watt loss generated when the enclosure size and required ventilation are calculated.
3.2.4.3
Grounding Connections DANGER! The inverter must be grounded to a protective earth for safety purposes (PE). The earth or ground connection must comply with the local regulations. For grounding, use cables with cross sections as indicated in Table 3.4. Make the ground connection to a grounding bar or to the general grounding point (resistance 10 ohms). DANGER! Do not share the ground wiring with other equipment that operates with high currents (for instance: high voltage motors, welding machines, etc). If several inverters are used together, refer to Figure 3.7. 47
CHAPTER 2 - GENERAL INFORMATION
GROUNDING BAR INTERNAL TO THE PANEL
Figure 3.7 – Grounding connections for more than one inverter.
ATTENTION! The AC input for the inverter must have a grounded neutral conductor. EMI – Electromagnetic Interference When electromagnetic interference (EMI), generated by the inverter, interferes in the performance of other equipment, use shielded wires, or install the motor wires in metallic conduits. Connect one end of the shielding to the inverter grounding point and the other end to the motor frame. Motor Frame Ground always ground the motor frame. Ground the motor in the panel where the inverter is installed or ground it to the inverter. The inverter output wiring must be laid separately from the input wiring as well as from the control and signal cables. NOTE! Do not use neutral conductor for grounding purposes.
48
CHAPTER 2 - GENERAL INFORMATION The control wiring (analog inputs/outputs, digital inputs and relay outputs is made on the XC1 connector of control board (see location in Figure 3.5, Section 3.2.2). There are two configurations for the control board: standard version (CFW-08 line) and Plus version (CFW-08 Plus line), as shown below:
3.2.5 Control Wiring
XC1Terminal 1 2 3
4
5
CCW 5k
6
CW 7 8 9 10 Factory default settings
11 12
Description Factory Default Function Digital Input 1 General Enable Digital Input 2 FWD / REV Digital Input 3 Reset Digital Input 4
Specifications
4 Isolates digital inputs - Logic NPN Minimum high Level: 10Vdc DI2 Maximum Low Level: 30Vdc Maximum Low Level: 3Vdc DI3 - Logic PNP Maximum Low Level: 10Vdc Minimum high Level: 21.5Vdc DI4 Maximum high Level: 30Vdc Start/Stop Input Current: -11mA Max. Input current: -20mA GND 0V Reference Not connected to PE Analog Input 1 or Digital Input 5 ( 0 to10) Vdc (0 to 20)mA (4 to 20)mA (fig. 3.10) or PTC Input Impedance: 100k (voltage input) and AI1 or 500(current input). DI5 or Frequency / Speed Reference - Linearity error < 0,25% PTC1 (remote mode) - Maximum voltage input: 30Vdc For further information refer to P235 detailed parameter description +10V Potentiometer reference +10Vdc, ± 5%, capacity: 2mA Not Used Not Used Relay Output 1 - N.C. contact 10 12 N.C. Not Fault (P277=7) Relay 1 Commom Relay outputs common points 11 Relay Output 1 - N.O. contact N.O. Contact capacity: No Fault (P277=7) 0.5A / 250Vac DI1
Note: Normally Closed Contact, NO= Normally Open Contact (See item 2.4)
Figure 3.8 - XC1 control terminal description (standard control board - CFW-08)
49
CHAPTER 3 - INSTALLATION Connector XC1
CW
1
DI1
2
DI2
3
DI3
4
DI4
5
GND 0V Reference
CCW 10k
10 k
CCW
6
CW
-
7
RPM
+
8
9 10 11
Factory default settings
Description Factory Default Function Digital Input 1 General Enable Digital Input 2 FWD / REV Digital Input 3 Reset Digital Input 4
12
Start/Stop
Specifications 4 Isolates digital inputs - Logic NPN Minimum high Level: 10Vdc Maximum Low Level: 30Vdc Maximum Low Level: 3Vdc - Logic PNP Maximum Low Level: 10Vdc Minimum high Level: 21.5Vdc Maximum high Level: 30Vdc Input Current: -11mA Max. Input current: -20mA Not connected to PE
Analog Input1 or Digital Input 5 (0 to10) Vdc (0 to 20)mA (4 to 20)mA and (-10 to +10)Vdc* (fig. 3.10) or PTC1 Input Impedance: 100k (voltage input) and AI1 or 500(current input). DI5 or Frequency/Speed Reference - Linearity error < 0,25% PTC1 (remote mode) - Maximum voltage input: 30Vdc For further information refer to P235 detailed parameter description +10Vdc, ± 5%, capacity: 2mA +10V Potentiometer reference Analog Input2 or Digital Input (0 to10) Vdc (0 to 20)mA (4 to 20)mA Digital 6 or PTC2 Input and (-10 to +10)Vdc* (fig. 3.10) Impedance: 100k (voltage input) and AI2 or 500 (current input) - linearity error DI6 or < 0,25% Maximum voltage input: PTC Not Used 30Vdc For further information refer to P239 detailed parameter description Analog output (0 to 10)Vdc, RL 10k AO Output Frequency (Fs) Resolution: 8bits Linearity Error < 0,25% Relay Output 2 - N.C. contact 12 10 N.C Fs>Fx (P279=0) R elay R elay Commom Relay outputs common points 1 2 Relay Output 1 - N.O. contact 11 N.O. Contact capacity: Not Fault (P277=7) 0.5A / 250Vac
Note: NC=Normally Closed Contact, NO= Normally Open Contact (See item 2.4) *
This option is available only for version A2 of the control board (see item 2.4). In version A2 the
linearity error is smaller than 0.50%.
Figure 3.9 - Description of the XC1 connector for the control board A1 (CFW-08 Plus), control board A2 (CFW-08 Plus with AI’s -10V a +10V), control board A3 (CFW-08 with CANopen protocol) and control board A4 (CFW-08 with DeviceNet protocol). Refer to item 2.4 (CFW-08 identification) for additional information on the control boards.
50
CHAPTER 3 - INSTALLATION
ON
DI AO AI1 AI2 DANGER! PELIGRO! !
PERIGO!
- MAY CAU SE SH OC K OR P ERS ONAL I NJU RY.
S1
ON ER R OR 12V XC 5+
-
- PU ED E C AU SAR D ESC ARGA PNP X~20m A ELEC TRIC A O LES ION. DI AOAI1 AI2 S1 - POD E C AU SAR C HOQUE OU FER IMEN TO. NP N 0 . . . 10V
OFF
- ON LY REMOVE TER MIN AL COVE R
WARNING
AFTE R 1 MI N. POWER HA S BE EN D ISC ON N ECTE D. - RE AD THE IN STRU CTI ON S MANU AL. -S OMENTE RE MOVA A TA MPA 1 MIN . A PÓS A D ESE NER GIZAÇ ÃO.
ATENÇÃO- LEIA O
MANU AL D E I NSTR UÇ ÕES.
Figure 3.10 – Jumpers position for selecting the analog inputs and outputs operation mode (voltage - 0 to 10Vdc or current - 0 to 20mA / 4 to 20mA) as well as the digital inputs operation mode (high logic level - PNP or low logic level - NPN). Refer to the digital inputs definition on items 3.2.5.1 and 3.2.5.2.
As a default, the analog inputs are set to voltage mode (0 to 10V)dc and the digital inputs are set to active (NPN logic). Change it by using dipswitch S1 on the control board and by setting parameters P235, P239 and P253 (see Table 3.6). I/O
Factory Deafult Setting
DI1 to DI4
See P263, P264, P265 and P266 Output frequency
AO AI1 AI2
Frequency / Speed Reference (remote mode) No function
Dip Switch S1:1 S1:2 S1.3 S1.4
Selection OFF: Digital inputs as low active (NPN) ON: Digital inputs as high active (PNP) OFF: (0 to 10)Vdc ON: (4 to 20)mA or (0 to 20)mA OFF: (0 to 10)Vdc or DI5 ON: (4 to 20)mA or (0 to 20)mA or PTC OFF: (0 to 10)Vdc or DI6 ON: (4 to 20)mA or (0 to 20)mA or PTC
Table 3.6- Dip switch configuration
NOTE! If it's used a (4 to 20)mA signal, set parameter P235, P239 and P253 that defines the signal type at AI1, AI2 and AO respectively. The parameters related to the analog inputs are: P221, P222, P234, P235, P236, P238, P239, P240, P251, P252, P253. For more details, please refer to Chapter 6.
51
CHAPTER 3 - INSTALLATION During the signal and control wire installation note please the following: 1) Cable cross section: (0.5 to 1.5)mm²/(20 to 14) AWG 2) Max. Torque: 0.50 N.m (4.50 lbf.in). 3) XC1 wiring must connected with shielded cables and installed separately at a distance of 10 cm each other for lengths up to 100m and at distance of 25cm each other for lengths over 100m. If the crossing of these cables is unavoidable, install them perpendicular, maintaining a mimimum separation distance of 5 cm (2 in) at the crossing point. Connect the shield as shown below: Insulate with tape Inverter side
Do not ground Connect to earth: bolts are located on heatsink Figure 3.11 - Shield connection
4) For wiring distances longer than 50 m ( 150 ft), it's necessary to use galvanic isolators for the XC1:5 to 9 analog signals. 5) Relays, contactors, solenoids or eletromagnetic braking coils installed near inverters can generate interferences in the control circuit. To eliminate this interference, connect RC suppressor in parallel with the coils of AC relays. Connect free-wheeling diode in case of DC relays. 6) When external keypad (HMI) is used (refer to Chapter 8), separete the cable that connects the keypad to the inverter from other cables, maintaining a minimum distance of 10cm (4 in) between them. 7) When analog reference (AI1 or AI2) is used and the frequency oscillates (problem caused by eletromagnetic interference) XC1:5 connect to the inverter heatsink. 52
CHAPTER 3 - INSTALLATION 3.2.5.1
Digital Inputs as Low Level Active (S1:1 to OFF)
This option can be selected when a PLC is used with relay or transistor output is used (low logic level to activate the DI). a) Example using a PLC relay - output
COM
Connector XC1 1 DI1 2 DI2 3 DI3 4 DI4 5 GND
PLC Output Relay b) Example using a PLC - NPN transistor Output
Connector XC1 1 DI1 2 DI2 3 DI3 4 DI4 5 GND PLC Output NPN
GND (PLC)
Figure 3.12 a) b) - Digital inputs as low logic level configuration.
In this option, the equivalent circuit at inverter side is: (See Figure 3.13) S1:1 in OFF GND
XC1:1
1
2k
10V SMD Optocoupler
DI1
XC1:2 DI2
+12V
2
2k
10V SMD Optocoupler
Figure 3.13 - Equivalent Circuit – Digital Inputs as low logic level.
53
CHAPTER 3 - INSTALLATION 3.2.5.2
Digital Input as High Level Active (S1:1 to ON)
This option can be selected when a PLC is used with PNP transistor output PNP (high logic level to activate the DI) or PLC with relay output is used. For this last alternative you must apply an external power supply 24V +/- 10%. a) Example using a PLC relay - output 24V (external)
Conector XC1 1 DI1 2 DI2 3 DI3 4 DI4 5 GND PLC Output Relay
GND (Source External 24V)
b) Example using a PLC - PNP transistor Output 24V (internal PLC)
PLC output PNP
Connector XC1 1 DI1 2 DI2 3 DI3 4 DI4 5 GND GND (PLC)
Figure 3.14 a) b) – Configuration of the active digital inputs as high logic level.
In this option, the equivalent circuit at the inverter side is:
+12V
XC1:1
1
2k
10V SMD Optocoupler
DI1
XC1:2 DI2
S1:1 in ON
2
2k
10V SMD Optocoupler
Figure 3.15 – Equivalent Circuit - Digital Inputs as high logic level. 54
CHAPTER 3 - INSTALLATION NOTES! The inverter is factory default programmed with the digital inputs as low level active (S1:1 in OFF). When the digital inputs are used as high level active, you must set the jumper S1:1 to ON. The jumper S1:1 selects the HIGH level or LOW level active for all 4 digital inputs. You can not select them separately.
3.2.6 Typical Terminal Connections
Connection 1 - Keypad Start/Stop (Local Mode) With the factory default programming, you can operate the inverter in local mode with the minimum connections shown in Figure 3.6 (Power) and without control connections. This operation mode is recommended for users who are operating the inverter for the first time. Note that there is no need of connection of control terminals. For start-up according to this operation mode, refer to Chapter 5. Connection 2 - Wire Start/Stop (Remote Mode)
6
7
8
NO
5
Common
4
NC
AI1
3
AO1
COM
2
AI2
DI4 - No Function or Star t/Stop
1
+10V
DI3 - Reset
S2: Reset
DI2 - F WD / REV
S1: FWD / REV
No Function or Gener alEnabling
Valid for factory default programming and inverter operating in remote mode. For the factory default programming, the selection of the operation mode (local/remote) is made via the key (default is local). The figure below shows the inverter terminal connection for this type of driving.
9
10
11
12
S3: Start / Stop R1: Potentiometer for speed setting
S1
S2
S3 R1 5k
Figure 3.16 - XC1 wiring for connection 2 55
CHAPTER 3 - INSTALLATION NOTE! For the proper operation of configuration 2, terminal 5 shall be connected to terminal 1 (general enable). The frequency reference can be sent via AI1 analog input (as shown in figure above), via keypad HMI-CFW08-P, or via any other source (as described of the parameters P221 and P222). When a line fault occurs by using this type of connection with switch S3 at position "RUN", the motor will be enabled automatically as soon asthe line is re-established. Connection 3 - Wire Start/Stop Function enabling (three wire control): Set DI1 to Start: P263=14 Set DI2 to Stop: P264=14 Set P229=1 (command via terminals) if you want the 3-wire control in local mode. Set P230=1 (command via terminals) if you want the 3-wire control in remote mode.
7
8
9
NO
6
Common
5
NC
COM
4
AO1
DI4 - F WD / REV
3
AI2
DI3
2
+10V
DI2 - Stop (3-wire)
1
AI1
DI1 - Start ( 3- wir e)
The Figure 3.17 below shows the connections at VFD terminals for this type of configuration.
10
11
12
S1: Start S2: Stop
S1
S2
Figure 3.17 - XC1 wiring for connection 3
56
CHAPTER 3 - INSTALLATION NOTE! S1 and S2 are push buttons, NO and NC contact, respectively. The speed reference can be via Analog Input AI1 (as in connection 2), via keypad (HMI-CFW08-P), or via any other source (as described of the parameter - P221 and P222). When a line fault occurs by using this connection with the motor running and the S1 and S2 switches are in original position (S1 openned and S2 closed), the inverter will not be enabled automatically as soon as the line is rerestablished. The Start/Stop function is described in Chapter 6. Connection 4 - FWD RUN / REV RUN
AO1
NC
Common
NO
6
AI2
5
+10V
4
AI1
3
COM
2
DI4 - No Function/ Star t/Stop
1
DI3
DI2 - Reverse Run
S1 open: Stop S1 closed: Forward Run
DI1 - Forward Run
Parameter to be programmed: Set DI1 to Forward Run : P263 = 8 Set DI2 to Reverse Run: P264 = 8 Make sure the inverter commands are via terminals, i.e., P229=1 to local mode or P230=1 to remote mode. The figure 3.18 below shows the inverter terminal connection for this type of driving.
7
8
9
10
11
12
S2 open: Stop S2 closed: Reverse Run
S1
S2
Figure 3.18 - XC1 wiring for connection 4
NOTE! For the proper operation of configuration 4, terminal 4 shall be connected to terminal 5 (Start/Stop). The speed reference can be via Analog Input AI1 (as in connection 2), via keypad (HMI-CFW08-P), or via any other source (see description of parameters P221 and P222 in Chapter 6). When a line fault occurs, this connection with switch S1 or switch S2 is closed, the motor will be enabled automatically as soon as the line is re-restablished.
57
CHAPTER 3 - INSTALLATION 3.3
European EMC Directive - Requirements for Conforming Installations
3.3.1 Installation
The CFW-08 inverter series was designed considering safety and EMC (ElectroMagnetic Compatibility) aspects. The CFW-08 units do not have an intrinsic function until connected with other components (e. g. a motor). Therefore, the basic product is not CE marked for compliance with the EMC Directive. The end user takes personal responsibility for the EMC compliance of the whole installation. However, when installed according to the recommendations described in the product manual and including the recommended filters and EMC measures the CFW-08 fulfill all requirements of the EMC Directive (89/336/EEC) as defined by the EMC Product Standard for Adjustable Speed Electrical Power Drive Systems EN61800-3. Compliance of the CFW-08 series is based on the testing of the representative models. A Technical Construction File was checked and approved by a Competent Body. Figure 3.19 below shows the EMC filters connection. Controling and Signal Wiring
Input CM Choke
External Input RFI Filter
Transformer
Output CM Choke
XC11 to 12
L1/L L1
L1/L
L2/N L2
L2/N V CFW - 08 L3 W
L3 E
L3 E
PE
U Motor
PE
Metallic Cabinet (when required) PE
Ground Rod/Grid or Building Steel Structure
Protective Grounding - PE
Obs.: Single-phase input inverters use single-phase filters and only L1/L and L2/N are used. Figure 3.19 - EMC filters connection - general condition
The following items are required in order to have a conforming installation: 1) The motor cable must be armored, flexible armored or installed inside a metallic conduit or trunking with equivalent attenuation. Ground the screen/metallic conduit at both ends (inverter and motor). 2) Control (I/O) and signal wiring must be shielded or installed inside a metallic conduit or trunking with equivalent attenuation. 58
CHAPTER 3 - INSTALLATION 3) The inverter and the external filter must be mounted on a common metallic back plate with a positive electrical bond and in close proximity to one another. Ensure that a good electrical connection is made between the heatsink (inverter) / frame (external filter) and the back plate. 4) The length of the wiring between filter and inverter must be kept as short as possible. 5) The cable’s shielding must be solidly connected to the common back plate, using a metal bracket. 6) Grounding as recommended in this manual. 7) Use short and thick earthing cable to earth the external filter or inverter. When an external filter is used, only use an earth cable at filter input - the inverter earth connection is done by the metallic back plate. 8) Earth the back plate using a braid, as short as possible. Flat conductors (e.g. braids or brackets) have lower impedance at high frequencies. 9) Use cable glands whenever possible. 3.3.2 Emission and Immunity Levels Description EMC phenomenon
Basic standard for test method
Level
Emission: “First environment” (* 1) unrestricted distribution (* 3) Class B, or; Conducted emissions (mains terminal “First environment” (* 1) restricted distribution ( *4.5) disturbance voltage - freq band 150kHz Class A1, or; to 30MHz) IEC/EN61800-3 “Second environment” (* 2) unrestricted (* 3.6) ClassA2. Radiated emissions (electromagnetic “First environment” (*1), restrited distribution (*4,5) “Second environment” (*2), restrited distribution (*3) radiation disturbance - freq band 30MHz to 1000MHz) Immunity: IEC 61000-4-2 6kV contact discharge Electrostatic discharge (ESD) 4kV/2.5kHz (capacitive clamp) input cable; 2kV/5kHz control cables; 2kV/5kHz (capacitive clamp) Fast transient-burst IEC 61000-4-4 motor cable; 1kV/5kHz (capacitive clamp) external keypad cable 0.15 to 80MHz; 10V; 80% AM (1kHz) - motor control Conducted radio-frequency IEC 61000-4-6 and remote Keypad cable 1.2/50 s, 8/20s; common mode 1kV coupling line to line; Surge IEC 61000-4-5 2kV coupling line to earth Radio-frequency electromagnetic field
IEC 61000-4-3
80 to 1000MHz; 10V/m; 80% AM (1kHz)
Table 3.7 – Specification of the Emission and Immunity levels
59
CHAPTER 3 - INSTALLATION Obs.: 1) First environment: environment that includes domestic premises. It also includes establishments directly connected without intermediate transformers to a low-voltage power supply network which supplies buildings used for domestic purposes. 2) Second environment: environment that includes all establishments other than those directly connected to a lowvoltage power supply network which supplies buildings used for domestic purposes. 3) Unrestricted distribution: mode of sales distribution in which the supply of equipment is not dependent on the EMC competence of the customer or user for the application of drives. 4) Restricted distribution: mode of sales distribution in which the manufacturer restricts the supply of equipment to suppliers, customers or users who separately or jointly have technical competence in the EMC requirements of the application of drives. (source: these definitions were extracted from the product standard IEC/EN61800-3 (1996) + A11 (2000)) 5) For installation with inverters that complies class A1 (first environment restricted distribution), note that this is a product of the restricted sales distribution class according to IEC/EN61800-3 (1996) + A11 (2000). In a domestic environment this product may cause radio interference in which case the user may be required to take adequated measures. 6) For installation with inverters that complies class A2 (second environment unrestricted distribution), note that this product is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if used on such a network.
60
CHAPTER 3 - INSTALLATION 3.3.3 Inverter Models and Filters
Id 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Inverter Model
Table 3.8 below shows the inverter models and the respective RFI filter and the EMC class. A description of each EMC class is given in item 3.3.2. The characteristics of the footprint and external input RFI filters are given in item 3.3.4. Input RFI Filter
CFW080016S2024 ... FAZ CFW080026S2024 ... FAZ CFW080040S2024 ... FAZ Built-in filter CFW080016B2024 ... FAZ [ FEX1-CFW08 (single-phase input) (footprint filter) ] CFW080026B2024 ... FAZ (single-phase input) CFW080040B2024 ... FAZ (single-phase input) CFW080073B2024 ... FAZ (single-phase input) Built-in filter CFW080100B2024 ... FAZ (single-phase input) CFW080016S2024 ... CFW080026S2024 ... CFW080040S2024 ... CFW080016B2024 ... FS6007-16-06 (single-phase input) (external filter) CFW080026B2024 ... (single-phase input) CFW080040B2024 ... (single-phase input) CFW080016B2024 ... (three-phase input) CFW080026B2024 ... FN3258-7-45 (three -phase input) (external filter) CFW080040B2024 ... (three -phase input) CFW080070T2024 ... FN3258-16-45 (external filter) CFW080073B2024 ... FS6007-25-08 (single-phase input) (external filter) CFW080073B2024 ... FN3258-16-45 (three-phase input) (external filter) CFW080100B2024 ... FS6007-36-08 (single-phase input) (external filter) CFW080100B2024 ... FN3258-16-45 (three-phase input) (external filter) FN3258-30-47 CFW080160T2024 ... (external filter) CFW080010T3848 ... FAZ Built-in filter CFW080016T3848 ... FAZ [ FEX2-CFW08 CFW080026T3848 ... FAZ (footprint filter) ] CFW080040T3848 ... FAZ CFW080027T3848 ... FAZ CFW080043T3848 ... FAZ CFW080065T3848 ... FAZ Built-in filter CFW080100T3848 ... FAZ CFW080130T3848 ... FAZ CFW080160T3848 ... FAZ
Conducted Emission Level
Class A1 or Class A2
Radiated Emission Level
Class A2
Class B Class A1
Class A1 or Class A2
Class A2
61
CHAPTER 3 - INSTALLATION Id
Inverter Model
34 35 36 37 38 39 40 41
CFW080010T3848 ... CFW080016T3848 ... CFW080026T3848 ... CFW080040T3848 ... CFW080027T3848 ... CFW080043T3848 ... CFW080065T3848 ... CFW080100T3848 ...
42
CFW080130T3848 ...
43
CFW080160T3848...
44
CFW080240T3848...
45
CFW080300T3848...
46 47
CFW080240T3848...FAZ CFW080300T3848...FAZ
Input RFI Filter
Conducted Emission Level
Radiated Emission Level
Class B
Class A1
FN3258-7-45 (external filter)
FN3258-16-45 (external filter) FN3258-30-47 (external filter) FN-3258-30-47 (external filter) FN-3258-55-52 (external filter) Built-in filter
Class B Class A2 Class A1 Class A2
Class A2
Table 3.8 - Inverter models list with filters and EMC category
Observe the following notes for the models presented on table 3.8: NOTE! 1)Class B drives (for conducted emission) shall be mounted inside a metallic cabinet so that the radiated emissions stay below the limits for residential applications (“first environment”) and restricted distribution (refer to item 3.3.2). Class A1 drives (for conducted emission) do not require installation inside metallic cabinets. Exception: models 7 and 8, that need to be mounted inside a cabinet to pass in the radiated emission test for second environment and unrestricted distribution (see item 3.3.2). When a metallic cabinet is required, the maximum length of the remote keypad cable is 3m. In this case, the control (I/ O) and signal wiring must be located inside the cabinet and the remote keypad can be installed in the cabinet front door (see items 8.6.1 and 8.8). 2)The maximum switching frequency is 10kHz. Exception: 5kHz for models 24 up to 33 and models 44 to 47. For Class A1 systems see also note 7. 3)The maximum motor cable length is 100m for models from 46 and 47, 20m for models from 9 to 23, and from 34 to 37,44 and 45, 10m for models from 1 to 8, 24 to 27 and 38 to 43 and 5m for models from 28 to 33. For class A1 systems see also note 7.
62
CHAPTER 3 - INSTALLATION 4)In models 28, 29, 30 and 31 (see also note 7), a CM choke at inverter output is required: TOR1-CFW08, 1 turn. The toroid is mounted inside the N1 kit that is provided with these models. For installation see figure 3.19. 5)In models from 38 to 43, a CM choke at filter input is required: TOR2-CFW08, 3 turns. For installation see figure 3.19. 6)In models 38, 39, 40 and 41, it is required to use a shielded cable between the external filter and the inverter. 7)Class A1 drives were also tested using the limits of conducted emission for industrial applications (“second environment”) and unrestricted distribution, i.e., Class A2 (see notes 2 and 3 in item 3.3.2 for definitions). In this case: - the maximum cable length is 30m for models from 1 to 8, 32 and 33 and 20m for models from 24 to 31; - the maximum switching frequency is 10kHz for models 28, 29, 30 and 31 and 5kHz for models from 1 to 8, 24 to 27, 32 and 33; - models 28, 29, 30 and 31 do not require any CM choke at inverter output (as stated in note 4). 3.3.4 EMC Filters Characteristics Dimensions (Width x Height x Depth)
Drawings
0.6kg
79x190x51mm
Fig. 3.20
0.9kg 1.0kg 1.0kg 0.5kg 0.8kg 1.2kg 1.8Kg
85.5x119x57.6mm
Fig. 3.21
85.5x119x57.6mm
Fig. 3.22
Filter
WEG P/N
Rated Current
FEX1-CFW08 FEX2-CFW08 FS6007-16-06 FS6007-25-08 FS6007-36-08 FN3258-7-45 FN3258-16-45 FN3258-30-47 FN3258-55-52
417118238 417118239 0208.2072 0208.2073 0208.2074 0208.2075 0208.2076 0208.2077 0208.2078
10A 5A 16A 25A 36A 7A 16A 30A 55A
TOR1-CFW08
417100895
-
80g
TOR2-CFW08
47100896
-
125g
Weight
40x190x70mm 45x250x70mm 50x270x85mm 85x250x90mm e=35mm, h=22mm e=52mm, h=22mm
Fig. 3.23
Fig. 3.24 Fig. 3.25
Table 3.9 - EMC filters characteristics
63
CHAPTER 3 - INSTALLATION a) Footprint Filter
Lateral Right View
Front View 79
b) Footprint Filter and Inverter Bottom View
190
17 5
53
Front View
Lateral Right View
53
79
175
Terminal block for flexible and rigid cable of 4mm2 or AWG 10. Max. torque: 0.8Nm
Bottom View
190
50
185
79
Figure 3.20 a) b)- FEX1-CFW08 and FEX2-CFW08 footprint filter drawing 119 109
57.6
3.7
51
40
6.3x0.8
8 4.5 66
85.5
98.5
4.4
1.2
Type /05 Fast-on terminal 6.3 x 0.8mm
Figure 3.21 - FS6007-16-06 external filter drawing
64
15.6
CHAPTER 3 - INSTALLATION 119 113
57.6
98.5
3.7
40
51
84.5 66
85 .5
M4
1.2
4.4
P/N
15.6
E
Bolt type 08=M4
Figure 3.22 - FS6007-25-08 and FS6007-36-08 external filter drawing
Mechanical Data
41,8 30,3 1 9,3
Rated Current
11,5
Type/45 Terminal block for 6mm2 solid cable, 4mm2 flexible cable AWG 12. 55,5
Side View
Top View
D
D
I
I
15 Type/47 Terminal block for 16mm2 solid wires, 10mm2 flexible wires AWG 8.
F H
E
23,5
40,5
Connector
G
C
Front View Line L1 L2 L3 E
A
Figure 3.23 - FS3258-xx-xx external filter drawing
65
CHAPTER 3 - INSTALLATION Toroid: Thornton NT35/22/22-4100-IP12R (WEG P/N 0208.2102) 35
22
22
Plastic clamp: HellermannTyton NXR-18 (WEG P/N 0504.0978) 19.3 33.3 to 38.1
30
1.5
5.8
Figure 3.24 - TOR1-CFW08 drawing
Toroid: Thornton NT52/32/20-4400-IP12E (WEG P/N 0208.2103)
Figure 3.25 - TOR2-CFW08 drawing
66
32
52
20
CHAPTER 4 KEYPAD (HMI) OPERATION This chapter describes the CFW-08 operation via standard keypad or Human-Machine Interface (HMI), providing the following information: general keypad description (HMI); use of the keypad; parameter programming; description of the status indicators. 4.1 KEYPAD (HMI) DESCRIPTION
The standard CFW-08 keypad has a LED display with 4 digits of 7 segments, 4 status LEDs and 8 keys. Figure 4.1 shows the front view of the keypad and indicates the position of the display and the status LEDs.
LED Display
Led "FWD" Led "REV"
Green Led "Local" RedLed"Remote"
Figure 4.1 - CFW-08 standard keypad
Functions of the LED Display: The LED display shows the fault codes and drive status (see Quick Parameter Reference, Fault and Status), the parameter number and its value. For units of current, voltage or frequency, the LED display shows the unit in the right side digit [U=volts, A=ampères, ºC=Celsius Degree] Functions of the “Local” and “Remote” LEDs: Inverter in Local Mode: Green LED ON and red LED OFF. Inverter in Remote Mode: Green LED OFF and red LED ON. Functions of the FWD/REV LEDs - Direction of Rotation Refer to Figure 4.2
68
CHAPTER 4 - KEYPAD (HMI) OPERATION FWD/REV control selection t FWD / REV
Forward
Forward Reverse
t
HMI LED Situation t OFF ON FLASHING Figure 4.2 - Direction of rotation (FWD/REV) LEDs
Basic Functions of the Keys: Starts the inverter via acceleration ramp. Stops (disables) the inverter via deceleration ramp. Also resets inverter after a fault has occurred. Toggles the LED display between parameter number and its value (number/value). Increases the frequency, the parameter number or the parameter value. Decreases the frequency, the parameter number or the parameter value. Reverses the direction of motor rotation between Forward/ Reverse Toggles between the LOCAL and REMOTE modes of operation . Performs the JOG function when pressed. Any DI programmed for General Enable (if any) must be closed to enable the JOG function. 4.2 USE OF THE KEYPAD HMI
The keypad is used for programming and operating the CFW-08, allowing the following functions: indication of the inverter status and operation variables; fault indication and diagnostics; viewing and programming parameters; 69
CHAPTER 4 - KEYPAD (HMI) OPERATION operation of the inverter (keys , , ) and speed reference setting (keys 4.2.1 Keypad Operation
, and
and ).
All functions relating to the CFW-08 operation (Start/Stop, Direction of Rotation, JOG, Increment/Decrement of the Speed (Frequency) Reference, and selection of LOCAL/REMOTE mode) can be performed through the HMI selection. For factory default programming of the inverter, all keypad keys are enabled when the LOCAL Mode has been selected. These same functions can be performed through digital and analog inputs. Thus you must program the parameters related to these corresponding inputs. NOTE! The control keys , and are only enabled if: P229=0 for LOCAL Mode operation P230=0 for REMOTE Mode operation The key depends of the parameters above and if: P231=2 Keypad keys operation description: When enabled (P220 = 2 or 3), selects the control input and the speed reference (speed) source, toggling between LOCAL and REMOTE Mode. When pressed, starts the motor according to acceleration ramp up to the speed (frequency) reference. The function is similar to that performed through digital input START/STOP, when it is closed (enabled) and maintained enabled. Stop disables the inverter via deceleration Ramp.The Function is similar to that performed through digital input START/STOP, when it is open (disabled) and maintained disabled. When the JOG key is pressed, it accelerates the motor according to the acceleration ramp up to the JOG speed programmed in P122. This key is only enabled when the inverter digital inputs, programmed to general enable (if any) are closed. When enabled (refer to the note above), reverses the motor direction of rotation. Motor speed (frequency) setting: these keys are enabled for speed setting only when: the speed reference source is the keypad (P221 = 0 for LOCAL Mode and/or P222 = 0 for REMOTE Mode); the following parameter content is displayed: P002, P005 or P121.
70
CHAPTER 4 - KEYPAD (HMI) OPERATION Parameter P121 stores the speed reference set by these keys. When pressed, it increases the speed (frequency) reference. When pressed, it decreases the speed (frequency) reference. Reference Backup: The last frequency reference set by the keys the and is stored when inverter is stopped or the AC power is removed, provided P120 = 1 (reference backup active is the factory default). Tochange the frequency reference before starting the inverter, the value of the parameter P121, must be changed. 4.2.2 Inverter Status
Line voltage is too low for inverter operation (undervoltage condition). Inverter is READY to be started. Inverter is in a Fault condition. Fault code is flashing on the display. In our example we have the fault code E02 (refer to chaper Maintenance). Inverter is applying a DC current on the motor (DC braking) according to the values programmed at P300, P301 and P302 (refer to Chapter 6). Inverter is running self-tuning routine to identify motor parameters automatically. This operation is controlled by P408 (refer to Chapter 6). NOTE! The display also flashes in the following conditions, besides the fault conditions: trying to change a parameter value when it is not allowed. inverter in overload condition (refer to Chapter Maintenance).
4.2.3 Read-Only Variables
Parameters P002 to P099 are reserved for the display of readonly values. The factory default display when power is applied to the inverter is P002 (frequency proportional value in V/F control mode and motor speed in rpm in vector control mode). Parameter P205 defines the initial monitoring parameter, i.e., defines the read-only variable that will be displayed when the inverter is powered up. For further information refer to P205 description in Chapter 6. 71
CHAPTER 4 - KEYPAD (HMI) OPERATION 4.2.4 Parameter Viewing and Programming
All CFW-08 settings are made through parameters. The parameter are shown on the display by the letter P followed by a number: Exmple (P101): 101 = Parameter Number Each parameter is associated with a numerical value (parameter value), that corresponds to the selected option among the available ones for this parameter. The parameter values define the inverter programming or the value of a variable (e.g.: current, frequency, voltage).For inverter programming you should change the parameter content(s). It is necessary to set P000=5 before to change a parameter value. Otherwise you can only read the parameter values, but not reprogram them. For more details, see P000 description in Chapter 6. HMI DISPLAY DESCRIPTION
ACTION Turn ON the inverter
Press the
key
Use the keys reach P100 Press the
and
to Select the desired parameter Numerical value associated with the parameter (4)
key
Use the keys keys Press the
Inverter is ready to be started
and
key
Set the new desired value (1) (4)
(1) (2) (3)
NOTE! (1) For parameters that can be changed with the motor running, the inverter will use the new value immediately after it has been set. For parameters that can be changed only with motor stopped, the inverter will use this new value only after the key is pressed. (2) By pressing the key after the reprogramming, the new programmed value will be stored automatically and will remain stored until a new value is programmed. 72
CHAPTER 4 - KEYPAD (HMI) OPERATION (3) If the last programmed value in the parameter is not functionally compatible with other parameter values already programmed, E24=Programming Error - will be displayed. Example of programming error: Programming of two digital inputs (DI) with the same function. Refer to Table 4.1 for list of programming errors that can generate an E24 Programming Error. (4) To allow the reprogramming of any parameter value (except for P000 and P121) it is required to set P000=5. Otherwise you can only read the parameter values, but not reprogram them. For more details, see P000 description in Chapter 6. Programming Error – E24 JOG Local/ Remote Disables Flying Start Reset On/Off Direction of rotation FWD/REV
Multispeed
Electronic Potentiometer
Rated current Nominal DC Braking and Ride-through PID
Ramp 2
Model Input Analog
P265=3 and other(s) DI(s) Start-Stop or FWD and REV or ON and OFF P266=3 and other(s) DI(s) Start-Stop or FWD and REV or ON and OFF P267=3 and other(s) DI(s) Start-Stop or FWD and REV or ON and OFF P268=3 and other(s) DI(s) Start-Stop or FWD and REV or ON and OFF Two or more parameters between P264, P265, P266, P267 and P268 equal to 1 (LOC/REM) P265=13 and P266=13 or P267=13 or P268=13 P265=10 and P266=10 or P267=10 or P268=10 P263=14 and P26414 or P26314 and P264=14 Two or more parameters P264, P265, P266, P267 and P268 = 0 (direction of rotation) P263=8 and P2648 and P26413 P263=13 and P2648 and P26413 P2638 and P26313 and P264=8 P263=8 or 13 and P264=8 or 13 and P265=0 or P266=0 or P267=0 or P268=0 P263=8 or 13 and P264=8 or 13 and P2312 P221=6 or P222=6 and P2647 and P2657 and P2667 and P2677 and P2687 P2216 and P2226 and P264=7 or P265=7 or P266=7 or P267=7 and P268=7 P221 = 4 or P222 = 4 and P265 5 or 16 and P266 5 or 16 and P267 5 or 16 and P2685 or 16 P221 4 or P222 4 and P265 = 5 or 16 or P266 = 5 or 16 or P267 = 5 or 16 or P268 = 5 or 16 P265=5 or 16 and P2665 or 16 and P2685 or 16 P266=5 or 16 and P2655 or 16 and P2675 or 16 P267=5 or 16 and P2665 or 16 and P2685 or 16 P268=5 or 16 and P2655 or 16 and P2675 or 16 P295 incompatible with the inverter model P300 0 and P310 = 2 or 3 P203=1 and P221=1,4,5,6,7 or 8 or P222=1,4,5,6,7 or 8 P265=6 and P266=6 or P265=6 and P267=6 or P265=6 and P268=6 P266=6 and P267=6 or P267=6 and P268=6 or P266=6 and P268=6 P265=6 or P266=6 or P267=6 or P268=6 and P263=13 P265=6 or P266=6 or P267=6 or P268=6 and P264=13 P265=6 or P266=6 or P267=6 or P268=6 and P263=13 P265=6 or P266=6 or P267=6 or P268=6 and P264=13 P221=2,3,7 or 8 and standard inverter P221=2,3,7 or 8 and standard inverter P221=1 or P222=1 and P235=2, 3, 4 or 5 P221 or P222=2 or 3 and P2392, 3, 4 or 5
Table 4.1 - Incompatibility of parameters - E24 73
CHAPTER 4 - KEYPAD (HMI) OPERATION NOTE! It is possible that during programming occurs the error E24 caused by incompatibility between some parameters already programmed. In this case do not stop with the parameter setting. If at the end of the parameter setting does not disappear, check table of Incompatibilities (Table 4.1).
74
CHAPTER 5
START-UP This Chapter provides the following information: how to check and prepare the inverter before power-up; how to power-up and check for proper operation; how to operate the inverter when it is installed according to the typical connections (refer to Section 3.2 - Electrical Installation). 5.1 PRE-POWER CHECKS
The inverter shall be installed according to Chpater 3 Installation and Connection. If the drive project is different from the typical suggested connections, follow the procedures below. DANGER! Alaways disconnect the AC input power before making any connections. 1) Check all connections Check if the power, grounding and control connections are correct and well tightened. 2) Check the motor Check all motor connections and verify if its voltage, current and frequency match the inverter specifications. 3) Uncouple the load from the motor If the motor can not be uncoupled, make sure that the direction of rotation (FWD/REV) can not cause damage to the machine.
5.2 INITIAL POWER-UP
After the inverter has been checked, AC power can be applied: 1) Check the power supply Measure the line voltage and check if it is within the specified range (rated voltage: -15% / +10%). 2) Power-up the AC input Close the input circuit breaker or disconnect switch. 3) Check if the power-up has been succesful - Inverter with keypad (HMI-CFW08-P or HMI-CFW08-RS) The keypad display will show:
75
CHAPTER 5 - START-UP The four LEDs of the keypad remains ON during this procedure. Inverter runs some self-diagnosis routines. If no problems are found, the display shows:
This means that the inverter is ready (rdy = ready) to be operated. - Inverter with dummy panel (TCL-CFW08 or TCRCFW08). The LEDs ON (green) and ERROR (red) are ON. Inverter runs some self-diagnosis routines. If no problems are found the LED ERROR (red) turns OFF. This means that the inverter is now ready to be operated. 5.3 START-UP
This Section describes start-up procedures when operating via the keypad (HMI). Two types of control will be considered: V/F and Vetor Control: The V/F control is recommended in the following cases: several motors driven by the same inverter; rated current of the motor is lower than 1/3 of rated inverter current; for test purposes, inverter is start-up without load. The V/F control can also be used in applications that do not require fast dynamic responses, accurate speed regulations or high starting torque (speed error will be a function of the motor slip); when you program parameter P138 - rated slip you can obtain a speed accuracy of 1%. For the most applications, we recommend the vector control mode, that permits a higher speed control accuracy (typical 0.5%), higher starting torque and a faster dynamic response. The necessary adjustments for the operation of the vector control are performed automatically. In this case the motor shall be connected to the CFW-08. DANGER! Even after the AC power supply has been disconnected, high voltages may be still present. Wait at least 10 minutes after powering down to allow full discharge of the capacitors.
76
CHAPTER 5 - START-UP 5.3.1 Start-up Operation via Keypad (HMI)- Type of Control: Linear V/F(P202=0)
The sequence below is valid for the connection 1 (refer to Section 3.2.6). Inverter must be already installed and powered up according to Chapter 3 and Section 3 and 5.2. Connections according to Figure 3.6.
ACTION
HMI DISPLAY
DESCRIPTION
Power-up the inverter
Inverter is ready to be operated
Press the
Motor accelerates from 0Hz to 3Hz* (min.frequency), intheforward(CW)direction of rotation (1) * 90rpm for 4 pole motor.
key
Press the key and hold it depressed until 60 Hz is reached
Motor accelerates up to 60Hz* (2) * 1800rpm for 4 pole motor
Press the
key
Motor decelerates (3) down to 0 rpm and then reverses the direction of rotation CWCWW accelerating back to 60Hz
Press the
key
Motor decelerates down to 0 rpm
Press the depressed
Release the
key and hold it
key
Motor accelerates up to JOG frequency given by P122. Ex: P122 = 5.00Hz. Reverse (CCW)
Motor decelerates down to 0 rpm
NOTE! The last frequency reference (speed) vale set via the and keys is saved. If you wish to change this value before inverter enabling, change parameter P121 (Keypad Reference). NOTES: (1) If the direction of rotation of the motor is not correct, switch off the inverter. Wait at least for 10 minutes to allow complete capacitor discharge and then swap any two wires at the motor output. (2) If the acceleration current becomes too high, mainly at low frequencies, set the torque boost (IxR compensation) at P136. Increase/decrease the content of P136 gadually until you obtain an operation with constant current over the entire frequency range. For the case above, refer to Parameter Description in Chapter 6. (3) If E01 fault occurs during deceleration, increase the deceleration time at P101 / P103. 77
CHAPTER 5 - START-UP 5.3.2 Start-up Operation Via Terminals Control Mode: Linear V/F (P202=0) ACTION See Figure 3.16 Switch S1 (FWD / REV)=open Switch S2 (Reset)=open Switch S3 (Start/Stop)=open Potentiometer R1 (Ref.)=totally CCW Power-up inverter
Press the
key.
This procedure is not necessary when inverters were delivered dummy panel, since it will be automatically in remote mode.
Close S3 – Start/Stop
Turn potentiometer totally CW.
Clse S1 – FWD / REV
Open S3 – Start / Stop
78
Connections are according to Figures 3.6 and 3.16. HMI DISPLAY DESCRIPTION
Inverter is ready to be operated.
Led LOCAL switches OFF and led REMOTE switches ON. Control and Reference are are switched to REMOTE(via terminals). NOTE: To maintain inverter permanently in REMOTE mode, set P220=1. If the inverter is switched off and afterwards switched on, it will now operate in local mode because P220=2 (factory setting). This setting means that the local/remote selection source is via keypad and the default mode (that is the mode when the inverter is switched on) is local. For further information see description of P220 in Chapter 6. Motor accelerates from 0Hz to 3Hz* (min. frequency), CW direction (1) * 90rpm for 4-pole motor The frequency reference is given by the potentiometer R1. Motor accelerates up to the the maximum frequency (P134 = 66Hz) (2) Motor decelerates (3) down to 0 rpm (0Hz), reverses the direction of rotation (CW CWW) accelerating back up to the maximum frequency (P134=66Hz). Motor decelerates (3) down to 0 rpm.
NOTES! (1) If the direction of roation of the motor rotation is not correct, switch off the inverter. Wait 10 minutes to allow a complete capacitor discharge and the swap any two wires at the motor output. (2) If the acceleration current becomes too high, mainly at low frequencies, set the torque boost (IxR compensation) at P136.
CHAPTER 5 - START-UP Increase/decrease the content of P136 gadually until you obtain an operation with constant current over the entire frequency range. For the case above, refer to Parameter Description in Chapter 6. (3) If E01 fault occurs during deceleration, increase the deceleration time at P101 / P103. 5.3.3 Start-up Operation via Keypad Control Mode: Vector (P202=2)
The sequence below is based on the following inverter and motor example: Inveter: CFW080040S2024ESZ Motor: WEG-IP55 Power: 0.75HP/0.55kW; Frame size: 71; RPM: 1720; Number of Poles: IV; Power factor (cos ): 0.70; Efficiency (): 71%; Rated Current at 220V: 2.90A; Frequency: 60Hz. NOTE! The notes in Table below can be found on page 59.
ACTION
HMI DISPLAY
Power-up inverter
DESCRIPTION Inverter is ready to be operated
Press key. Press the key until P000 is reached. You can also use the key to reach the Paramater P000.
Press the key to enter into the programming mode. Use the keys and set the passowrd value.
P000=access for changing parameters
Enter the programming mode
to P000=5: permits parameter changing
Press the key to save the selected option and to exit the programming mode.
Exit the programming mode
Press the key P202 is reached.
This parameter defines the control type 0=V/F Linear 1=V/F Quadratic 2=Vector
or
until
Press the key to enter into the programming mode.
Enter the programming mode
79
CHAPTER 5 - START-UP ACTION Use the and to select the control type
HMI DISPLAY keys
Press the to save the selected option and to start the tuning routine after changing to Vector Control mode Press the key and use the keys and to set the correct rated motor efficiency (in this case 71%) Press the key to save the selected option and to exit the programming mode Press the next parameter
key to go to the
Press the key and use the keys and to set the correct rated motor voltage Press the key to save the selected option and exit the programming mode Press the next parameter
key to go to the
Press the key and use the keys and o set the correct rated motor current (in this case 2.90A) Press the key to save the selected option and to exit the programming mode Press the parameter
to go to the next
Press the key and use the keys and the to set the correct motor speed (in this case 1720rpm) Press the key to save the selected option and exit the programming mode Press the next parameter 80
key to go to the
DESCRIPTION P202=2: Vector
Motor efficiency: 50 to 99,9%
Set motor efficiency: 71%
Exit the programming mode
Rated motor voltage range: 0 to 600V
Set rated motor voltage: 220V (the default value is maintained)(2)
Exit the programming mode
Rated motor current range: 0.3 x Inom to 1.3 x Inom
Set rated motor current: 2.90A
Exit the programming mode
Rated motor rpm range: 0 to 9999 rpm
Programmed rated motor rpm: 1720 rpm
Exit the programming mode Rated motor frequency: 0 to F max
CHAPTER 5 - START-UP ACTION
HMI DISPLAY
DESCRIPTION
Press the and use the keys and to set the correct value for the motor frequency.
Set rated motor frequency: 60Hz (the default value is maintained) (2)
Press the key to save the selected option and exit the programming mode
Exit the programming mode
Press the next parameter
Rated motor power range: 0 to 15 (each value represents a power value)
key to go to the
Press the key and use the keys and to set the the correct motor power.
Selected rated motor power: 4 = 0.75HP / 0.55kW
Press the key to save the selected option and exit the programming mode
Exit the programming mode
Press the next parameter
Motor power factor range: 0.5 to 0.99
key to got to the
Press the key and use the keys and to set the correct motor power factor (in this case 0.70)
Set motor power factor: 0.70
Press the key to save the selected option and exit the programming mode
Exit the programming mode
Press the next parameter
key to go to the
Parameter estimation? 0 = No 1 = Yes
Press the key and use the keys and to authorize or not the start of the parameter estimate
1 = Yes
Press the key to start the self-tuning routine. While the selftuning routine is running, the display shows "Auto”. The running of the Self-Tuning Routine can last until 2 minutes and after ending display will show “rdy” (ready), when the motor parameter were acquired with success. Otherwise the fault “E14” is shown. In this case refer to Note (1) below.
Self-tuning is running
Inverter finished the self-tuning routine and is ready for operation
OR
or Running of self-tuning routine has not been realized with success (1) 81
CHAPTER 5 - START-UP ACTION Press the
HMI DISPLAY
key
Press the
key and hold it
depressed until the speed of 1980rpm is reached Press the
Press
Motor accelerates up to 1980rpm (for IV pole motor - maximum speed) Motor decelerates (4) tom 0 rpm and the reverses the direction of rotation accelerating back to 1980rpm
key
Motor decelerates down to 0 rpm
key
Press the key depresed
Release the
DESCRIPTION Motor accelerates up to 90rpm (for IV pole motor - minimum speed) in CW direction of rotation (3)
and hold it
key
Motor accelerates from 0 rpm up to the JOG speed set at P122. Ex: P122 = 5.00Hz that corresponds to 150rpm for IV-pole motor. Reverse (CCW) direction of rotation Motor decelerates down to 0 rpm
NOTE! The last speed reference value set via key and keys is saved. If you wish to change this value before enabling of inverter, change the value of the Parameter P121 - Keypad Reference; The self-tuning routine can be cancelled by pressing the key. NOTES: (1) If during the running of the Self-Tuning Routine the display shows E14, this means that the motor parameters were not acquired correctly by the inverter. The most common reason for this fault may be that the motor has not been coupled to the inverter output. However motors with very lower currents than the used inverter, or incorrect motor connection may also cause the fault E14. In this case, operate the inverter in V/F mode (P202=0). When the motor is not connected and the fault condition E14 is indicated, proceed as follows: Switch off the inverter. Wait at least 5 minutes to allow a complete discharge of the capacitors. 82
CHAPTER 5 - START-UP Connect the motor to the inverter output. Switch on the inverter. Set P000=5 and P408=1. Follow from now on the start-up procedures described in Section 5.3.3. (2) For each inverter type, the parameters P399 to P407 are set automatically to the rated motor data, considering a standard WEG motor, IV poles, 60Hz. W hen different motors are used, you must set the parameters manually, according to the motor nameplate data. (3) If the direction of rotation of the motor is not correct, switch off the inveter. Wait at least 5 minutes to allow a complete discharge of the capacitors and then swap any two wires at the motor output. (4) If fault E01 occurs during deceleration, you must increase the deceleration time at P101/P103.
83
CHAPTER 6 DETAILED PARAMETER DESCRIPTION This chapter describes in detail all CFW-08 parameters and functions. 6.1 SYMBOLS
Please find below some symbols used in this chapter: AIx = Analog input number x. AO = Analog output. DIx = Digital input number x. F* = Frequency reference. This is the frequency value that indicates the desired motor speed at the inverter output. Fe = Input frequency of the acceleration and deceleration ramp. Fmax = Maximum output frequency, defined at P134. Fmin = Minimum output frequency, defined at P133. Fs = Output frequency - frequency applied to the motor. Inom = Rated inverter output current (rms), in Ampères (A). This value is defined in P295. Is = Inverter output current. Ia = Active current at inverter output, i.e., it is the compoment of the total motor current proportional to active electric power absorbed by the motor. RLx = Relay output number x. Ud = DC link voltage in the DC link circuit.
6.2 INTRODUCTION
This section describes the main concepts related to the CFW-08 frequencyinverter.
6.2.1 Control Modes
As already informed in section 2.3, CFW -08 has in the same product a V/F control and a sensorless vector control (VVC: “voltage vector control”). The user must choose one of them. Please find below a description of each control mode.
6.2.2 V/F Control
This control mode is based on the constant V/F curve(P202=0 - linear V/F curve). Its performance is limited at low frequencies as function of the voltage drop in the stator resistance, that causes a significant magnetic flow reduction in the motor air gap and consequently reducing the motor torque. This deficiency should be compensated by using manual and automatic boost torque (IxR compensations), that are set manually and depend on the user experience. In most applications (for instance: centrifugal pumps and fans) the setting of these functions is enough to obtain the required performance. But there are applications that require a more sophisticated control. In these cases it´s recommended the use of the sensorless vector control, that will be described in the section below.
84
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION In V/F control, the speed regulation, that can be obtained by setting properly slip compensation can be maintained within 1% to 2% of the rated speed. For instance, for a IV pole motor/60Hz, the minimum speed variation at no load condition and at rated load can be maintained between 18 and 36rpm. There is still a variation of the linear V/F control: the quadratic V/F control. This control mode is suitable for applications like centrifugal pumps and fans (loads with quadratic torque x speed characteristics), since it enables a motor loss reduction, resulting in an additional energy saving by using an inverter. For more details about the V/F control mode, please refer to the description of the parameters P136, P137, P138, P142 and P145. 6.2.3 Vector Control (VVC)
The CFW-08 vector control is sensorless, i.e., it does not require a signal of the speed feedback through tachogenerator or encoder coupled on motor shaft. To maintain the magnetic flux in the motor air gap constant, and consequently the motor torque, within the whole speed variation range (from zero up to the field weakening point), a sophisticated control algorithm is used that considers the mathematic model of the induction motor. Thus one can maintain the magnetic flux in the motor air gap approximately constant at frequencies down to approximately 1 Hz. In vector control mode one can obtain a speed regulation of 0.5% (relating to the rated speed). Thus, for instance, for a IV pole motor/60Hz one can obtain a speed variation in the range of 10rpm (!). Other advantage of the vector control is its easy setting procedure. The user needs only to enter in the parameters P399 and P407 the information about the used motor (nameplate data) and runs the self-tuning routine (by setting P408=1) and the inverter configures itself to the required application. So the inverter is ready to be operated in an optimized manner. For more information, refer to the description of the following parameters: P178 and P399 to P409.
85
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION 6.2.4 Frequency Reference Sources
The frequency reference (i.e., the desired output frequency, or alternatively, the motor speed) can be defined in several ways: The keypad - digital reference that can be changed through the keypad (HMI), by using the keys and , (see P221, P222 and P121); Analog input - the analog input AI1 (XC1:6) or the AI2 (XC1:8) can be used, or both (see P221, P222 and P234 to P240); Multispeed - up to 8 preset digital references (see P221, P222 and P124 to P131); Electronic potentiometer (EP) - another digital reference, its value is defined by using 2 digital inputs (DI3 and DI4) see P221, P222, P265 and 266; Via serial. Figure 6.1 shows through a diagram block the frequency reference definition to be used by the inverter. NOTE! AI2 is only available in CFW-08 Plus version. With S1:1 OFF and when connected to 24V(external) with S1:1 to ON. DIs ON when connected to 0V (XC1:5). When F*0
P239=1 0 2V/ 4m A 10V/ 20m A
2 or 3 - AI2 P240
Figure 6.1 - Block diagram of the frequency reference
87
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION The block diagram in Figure 6.2 shows the inverter control.
P151 DC Link Regulation
Power Supply
Ud P151
Ud
P100 P101 P133P134 Fe
P136, P137,P138, P202 P295 P142, P145
Acceleration & Deceleration Ramp
P102 P103
Frequency Reference Limits
Acceleration& Deceleration Ramp 2
Inverter Control (V/F or Vector)
I PWM Vs
P178 Motor Parameters (P399 to P409)
Vs
Is IM 3Ø
Command via Digital Input (DI)
P169
I P169 s Output Current Limiting
Is
Figure 6.2 - Block diagram of the inverter control
NOTE! In V/F control mode (P202=0 or 1), Fe = F* (see Fig. 6.1) if P138=0 (slip compensation disabled). If P1380, see Figure 6.9 for the relation between Fe and F*. In vector control mode (P202=2) always Fe = F* (see Figure 6.1).
88
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION 6.2.5 Commands
The inverter has the following commands: PWM pulse enabling/ disabling, definition of the direction of rotation and JOG. As the reference, the inverter commands can de defined in several ways. The command sources are the following: via keypad - keys , , and via control terminals (XC1) - digital inputs; via serial interface.
;
The inverter enabling and disabling commands can be defined as follows: via keypad and of the HMI; via serial; start/stop (terminals XC1 - DI(s) - see P263 to P266); general enable (terminals XC1 - DI(s) - see P263 to P266); forward run (terminals XC1 - DI(s) - see P263 to P264), it defines also the diretion of rotation; ON/OFF (3-wire controls) (terminals XC1 - DIs - see P263 and P264). The definition of the direction of rotation can be defined by using: the key of the keypad; serial; digital input (DI) programmed for FWD/REV (see P264 to P266); digital inputs programmed as FWD / REV, that defines both inverter enabling or disabling and direction of rotation (see P263 e P264); analog input - when the reference is via analog input and a negative offset is programmed (P236 or P2400
(
, DI, serial, etc)
F* REFERENCE
0 Keypad (HMI-CFW-08-P and HMI - CFW-08- RP) 1 Bornes XC1 (DIs) 2 Serial or HMI- CFW08-RS keypad
COMMANDS
REMOTE
Frequency Reference P222
Controls P230 (stop/run, FWD/REV and JOG)
0 Keypad (HMI-CFW-08-P, HMI - CFW-08- RP and HMI-CFW-08-RS) 1 AI1 2 or 3 AI2 4 EP 5 Serial 6 Multispeed 7 Add AI 8 Add AI>0 0 Keypad (HMI-CFW-08-P and HMI - CFW-08- RP) 1 Bornes XC1 (DIs) 2 Serial or HMI- CFW08-RS keypad
Figure 6.3 - Block diagram of the local and remote operation mode
6.3 PARAMETER LISTING
In order to simplify the explanation, the parameters have been grouped by characteristics and functions:
Read-Only Parameters
Variables that can be viewed on the display, but can not be changed by the user.
Regulation Parameters
Programmable values used by the CFW08 functions.
Configuration Parameters
Motor Parameters
Special Function Parameters
90
They define the inverter characteristics, the functions to be executed, as well as the input/output functions of the control board. Data about the applied motor: data indicated on the motor nameplate and those obtained during the running of the self-tuning routine. Here are included parameters related to special functions, like PID regulator.
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Following notes may appear in some parameters during the detailed description: Notes found on the Parameters Quick Reference. (1) This parameter is only displayed in vector mode (P202=2). (2) This parameter is only displayed in scalar mode P202=0 or 1. (3) This parameter can be enchanged only when the inverter is disabled (stopped motor). (4) This parameter is only available with HMI-CFW08-RS. (5) The analog input value is represented by zero when it is not connected to an external signal. (6) This parameter is only available in the CFW -08 Plus version. (7) The parameter value changes automatically when P203=1. 6.3.1 Access and Read Only Parameters - P000 to P099
Parameter P000 Parameter Access
Range [Factory Setting] Unit Description / Notes 0 to 999 Releases the access to change the parameter values. [ 0] The password is 5. 1 The use of the password is always active. Indicates the value of P208 x P005. When the vector control mode is used (P202=2), P002 indicates the actual motor speed in rpm. In case of different scales and units, use P208.
P002 Frequency Proportional Value
0 to 6553 [ -] 0.01 (99.99); 0.1 (100.0); 1 (1000)
P003 Motor Output Current
0 to 1.5 x Inom [ -] 0.01A (9.99A); 0.1A (10.0A)
Indicates the inverter output current in Amps (A).
0 to 862 [ -] 1V
Indicates the inverter DC Link voltage in volt (V).
P004 DC Link Voltage P005 MotorOutput Frequency
0 to 300 [- ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P007 Motor Output Voltage
0 to 600 [ -] 1V
Indicates the inverter output frequency in Hertz (Hz).
Indicates the inverter output voltage in Volts (V).
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CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter P008 Heatsink Temperature
Range [Factory Setting] Unit Description / Notes 25 to 110 [- ] 1oC
Indicates the current power at the heatsink in Celsius degrees (°C). The inverter overtemperature protection (E04) acts when heatsink temperature reaches: Inverter P008 [°C] @ E04 1.6-2.6-4.0-7.0A/200-240V 103 1.0-1.6-2.6-4.0A/380-480V 90 7.3-10-16A/200-240V 90 2.7-4.3-6.5-10A/380-480V 103 13-16A/380-480V 103 22-28-33A/200-240V 104 24-30A/380-480V 104 Tabla 6.1 - The temperature to act the overtemperature protection
P009 (1) Motor Torque
0.0 to 150.0 [- ] 0.1%
Indicates the torque developed by motor in percent (%) relating to the set rated motor torque. The rated motor torque is defined by the parameters P402 (motor speed) and P404 (motor power). I.e.: Tnom = 716 .
Pnom nnom
where Tnom is given in kgf.m, P nom is the rated motor power in watts - HP - (P404), and nnom is the rated motor speed in rpm - P402. P014 Last Fault
P023 Software Version
P040 PID Process Variable
92
00 to 41 [ -] -
Indicates the code of the last occured fault. Section 7.1 shows a list of possible faults, their code numbers and possible causes.
x.yz [ -] -
Indicates the software version installed in the DSP memory located on the control board. Parameter P040, P203, P520 to P528 are only available from the software version V3.50 on.
0 to P528 [ -] 1
Indicates the value of the process variable used as PID feedback, in percent (%), (value % x P528). The PID function is only available from the software version V3.50 on. The indication unit can be changed through P528. See detailed description of the PID regulator in Section 6.3.5 - Special Function Parameters.
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION 6.3.2 Regulation Parameters - P100 to P199
Parameter
Range [Factory Setting] Unit Description / Notes
P100 Acceleration Time
0.1 to 999 [ 5.0s ] 0.1s (99.9s); 1s (100s)
P101 Deceleration Time
0.1 to 999 [ 10.0s ] 0.1s (99.9s); 1s (100s)
P102 Acceleration Time Ramp 2
0.1 to 999 [ 5.0s ] 0.1s (99.9s); 1s (100s)
P103 Deceleration Time Ramp 2 P104 S Ramp
0.1 to 999 [ 10.0s ] 0.1s (99.9s); 1s (100s) 0 to 2 [ 0 - Inactive ] -
This set of parameters defines the time to accelerate linearly from zero up to the rated frequency and to decelerate linearly from the rated frequency down to zero. The rated frequency is defined by parameter: - P145 in V/F control (P202=0 or 1); - P403 in vector control (P202=2). When factory setting is used, inverter always follows the time defined in P100 and P101. Ramp 2 is used, the the acceleration and deceleration times follow the values programmed at P102 and P103, use a digital input. See parameters P263 to P265. Depending on the load inertia, too short acceleration times can disable the inverter due to overcurrent (E00). Depending on the load inertia, too short deceleration times can disable the inverter due to overvoltage (E01). For more details, refer to P151.
The ramp S reduces mechanical stress during the acceleration and deceleration of the load. Ramp S Inativa 50% 100%
P104 0 1 2
Table 6.2 - S Ramp Configuration
Output frequency (Motor speed) Linear 50% rampa S 100% rampa S Accel Time (P100/P102)
t (s) Decel Time (P101/P103)
Figure 6.4 - S or linear ramp
It is recommended to use the S ramp with digital frequency/speed references. 93
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter P120 Digital Reference Backup
Range [Factory Setting] Unit Description / Notes 0 to 2 [ 1 - active ] -
Defines if the inverter should save or not the last used digital reference. This backup function is only applicable to the keypad reference. P120 0 1 2
Reference Backup Inactive Active Active, but always give by P121, independently of the sorce reference
Table 6.3 - Digital Reference Backup configuration
If the digital reference backup is inactive (P120=0), the reference will be equal to the minimum frequency every time the inverter is enabled, according to P133. When P120=1, inverter saves automatically the digital reference value, independent of the reference source, keypad, EP or serial). P120=2, could be helpful when the reference is via EP and the user do not want to start at the minimum frequency nor at the last frequency. It is desirable to start at a fixed value, that should be set in P121. After finishing the acceleration ramp the reference is passed to EP again. P121 Keypad Reference
P133 to P134 [ 3.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
Allows the setting of the output frequency to the motor through and keys. This setting may also be performed while visualizing parameters P002 and P005. The keys and are enabled if P221=0 (in local mode) or P222=0 (in remote mode).The value of P121 is maintained at the last set value, even when inverter is disabled or turned OFF, provided P120=1 or 2 (backup active).
P122 JOG Speed Reference
P133 to P134 [ 5.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
Defines the frequency reference (speed) for the JOG function. The JOG function can be activated in several ways: The The
94
P229=0 (local model) or P230=0 (remote mode) key of the HMI-CFW08-RS P229=2 (local model) or P230=2 (remote mode) P265=3 and P229=1 (local) DI3 or P230=1 (remote) P266=3 and P229=1 (local) DI4 or P230=1 (remote) P229=2 (local mode) or Serial P230=2 remote mode) Table 6.4 - JOG reference configuration key of the HMI-CFW08-P
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [Factory Setting] Unit Description / Notes To operate JOG function works, the inverter must be disabled by ramp (stopped motor). Thus if the control source is via terminal, there must be at least one digital input programmed as start/stop enabling (otherwise E24 will be displayed), which must be OFF to enable the JOG function via digital input. The direction of rotation is defined by parameter P231.
P124 Multispeed Ref. 1
P133 a P134 [ 3.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P125 Multispeed Ref. 2
P133 a P134 [ 10.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P126 Multispeed Ref. 3
P133 a P134 [ 20.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P127 Multispeed Ref. 4
P133 a P134 [ 30.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
Multispeed is used when the selection of a number up to 8 pre-programmed speeds is desired. It allows the control of the output speed by relating the values programmed by the parameters P124 to P131, according to the logical combination of the digital inputs programmed for multispeed. Activation of the multispeed function: - ensure that the reference source is given by the multispeed function, i.e., set P221=6 in local mode or P222=6 in remote mode; - program one or more digital inputs to para multispeed, according to table below: DI DI2 DI3 DI4 DI5
Programming P264 = 7 P265 = 7 P266 = 7 P267 = 7
Note: Digital inputs DI2 and Dl5 shall not be set for multispeed function simultaneously. In case it happens, the VFD will indicate an E24 error (programming error).
P128 Multispeed Ref. 5
P133 a P134 [ 40.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P129 Multispeed Ref. 6
P133 a P134 [ 50.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P130 Multispeed Ref. 7
P133 a P134 [ 60.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P131 Multispeed Ref. 8
P133 a P134 [ 66.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
Table 6.5 - Parameters setting for defining the multispeed function through digital inputs.
The frequency reference is defined by the status of the digital inputs programmed to multispeed as shown in table below: 8 speeds 4 speeds 2 speeds DI4 Freq. Reference Open P124
DI2 Open
DI3 Open
Open Open
Open 0V
0V Open
P125 P126
Open 0V
0V Open
0V Open
P127 P128
0V 0V 0V
Open 0V 0V
0V Open 0V
P129 P130 P131
Table 6.6 - Frequancy Reference 95
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [Factory Setting] Unit Description/Notes The multispeed function has some advantages for the stabibilty of the fixed preprogrammed references and the immunity against electrical noises (digital references and insulated digital inputs). Output frequency
P131 P130 P129 P128
P127
Acceleration Ramp
P126 P125 P124
DI2 or DI5 DI3 DI4
Time 0V open 0V open 0V open
Figure 6.5 - Time diagram of the multispeed function
P133 Minimum Frequency (Fmin)
0.00 to P134 [ 3.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P134 P133 to 300.0 Maximum [ 66.00Hz ] Frequency (Fmax) 0.01Hz (99.99Hz); 0.1Hz (100.0Hz) P136 (2) Manual Torque Boost (IxR Compensation)
96
0.0 to 30.0 [ 5.0% for 1.6-2.6-4.0-7.0A/ 200-240V and 1.0-1.6-2.6-4.0A/ 380-480V; 2.0% for 7.3-10-16A/ 200-240V and 2.7-4.3-6.5-10A/ 380-480V; 1.0% for 22-28-33A/ 200-240V and 13-16A/380-480V]
Defines the maximum and minimum output frequency (motor) when inverter is enabled. It is valid for any type of speed reference. The parameter P133 defines a dead zone when analog inputs are used - see parameters P234 to P240. P134 and the gain and offset of the analog input(s) (P234, P236, P238 and P240) define the scale and the range of the speed variation via analog input(s). For more details see parameters P234 to P240. Compensates the voltage drop due to the motor stator resistance. It acts at low speeds by increasing the inverter output voltage, in order to maintain a constant torque during the V/F operation. The best setting is to program the lowest value for P136 that still permits the motor start satisfactorily. If the value is higher than required, an inverter overcurrent (E00 or E05) may occur due to high motor currents at low speeds.
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [factory Setting] Unit Description / Notes a) P202=0 Output Voltage (% of the line voltage)
P142
P136xP142
0
P145
Output Frequency
b) P202=1 Output Voltage (% of the line voltage)
P142
P136
0
P145
Output Frequency
Figure 6.6 a) b) - V/F curve and details of the manual torque boost (IxR compensation)
P137 (2) Automatic Torque Boost (Automatic IxR Compensation)
0.00 to 1.00 [ 0.00 ] -
The automatic torque boost compensates for the voltage drop in the stator resistance as a function of the active motor current. The criteria for setting P137 are the same as for the parameter P136.
Speed Reference (F*) Output Active Current (Ia)
Manual Torque Boost P136
P007
Motor Voltage
Automatic Torque Boost P137
Filter
Figure 6.7 - Block diagram of the automatic torque boost function
97
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [factory Setting] Unit Description / Notes Output Voltage Maximum (P142)
Compensation Zone
0
Output Frequency 4Hz
Field Weakening (P145)
Figure 6.8 - V/F curve with automatic torque boost (automatic IxR compensation )
P138 (2) Slip Compensation
0.0 to 10.0 [0.0] 0.1%
The parameter P138 is used in the motor slip compensation function. This function compensates the drop of the motor speed due to load, which is a inherent characteristic relating to the operation principle of the induction motor. This speed drop is compensated by increasing the output frequency (and voltage) (applied to the motor) as a function of the increase of the active motor current, as shown in the block diagram and in the V/F curve below. Ramp Input Frequency (Fe)
Frequency Reference (F*) Output Active Current (Ia)
Slip Compensation Filter
F
P138
Figure 6.9 - Block diagram of the slip compensation function
98
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [factory Setting] Unit Description / Notes Output Voltage
(function of the motor load) Output Frequency Figure 6.10 - V/F curve with slip compensation
To set the parameter P138 use the following procedure: - run the motor without load up to approximately half of the application top speed; - measure the actual motor or equipment speed; - apply rated load to equipment; - increase parameter P138 until the speed reaches its no-load speed.
P142(2) (3) Maximum Output Voltage
0 to 100 [ 100% ] 1%
P145(2) (3) P133 to P134 Field Weakening [ 60.00Hz ] Frequency 0.01Hz (99.99Hz); (Fnom) 0.1Hz (100.0Hz)
Define the V/F curve used in V/Fcontrol (P202=0 or 1). These parameters allow changing the standard V/F curve defined at P202 - programmable V/F curve. P142 sets the maximum output voltage. This value is set as a percent of the inverter supply voltage. Parameter P145 defines the rated frequency of the motor used. The V/F curve relates the inverter output voltage and frequency (applied to the motor) and consequently the magnetizing flux of the motor. The programmable V/F curve can be used in special applications where the motors used require a rated voltage and/or frequency different than the standard ones. Examples: motor for 220V/400Hz and a motor for 200V/60Hz. Parameter P142 is also useful in appplications that require rated voltage different from the inverter supply voltage. Example: 440V line and 380V motor.
99
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [factory Setting] Unit Description / Notes Output Voltage P142
0
0.1Hz
Output P145 Frequency
Figure 6.11 - Adjustable V/F curve
P151 DC Link Voltage Regulation Level
325 to 410 (line 200-240V) [ 380V ] 1V 564 to 820 (line 380-480V) [ 780V ] 1V
The DC link voltage regulation (ramp holding) avoids overvoltage trips (E01) during deceleration of high inertia loads and/or short deceleration times. It acts in order to increase the deceleration time (according to load - inertia), thus avoiding the E01 activation.
DC Link voltage P151 Rated Ud
E01 - Overvoltage CI limitation
Cl Voltage Ud (P004) Time Output Frequnecy (Motor speed) Time Figure 6.12 - Deceleration curve with DC Link voltage limitation (regulation)
100
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [Factory Setting] Unit
Description / Notes By this function an optimized deceleration time (minimum) is achieved for the driven load. This function is useful in applications with medium inertia that require short deceleration times. In case of overvoltage trip during the decelearation, you must reduce gradually the value of P151 or increase the time of the deceleration ramp (P101 and/or P103). The motor will not stop if the line is permanently with overvoltage (U d>P151). In this case, reduce the line voltage, or increase the value of P151. If even with these settings the motor does not decelerate within the required time, you will have the following alternatives - use the dynamic braking (for more details, see Item 8.21); - if inverter is being operated in V/F control, increase P136; - if inverter is being operated in vector control, increase P178. NOTE! When dynamic braking is used, set P151 to the maximum value.
P156 0.2xPInom to 1.3xPInom Motor Overload [ 1.2xP401 ] Current 0.01A ( 9.99A); 0.1A ( 10.0A)
This function is used to protect the motor against overload (Ixt function - E05). The motor overload current is the current level above which the in verter will consider the motor operating under overload. The higher the difference between the motor current and the overload current, the sooner the Ixt function - E05 - will act. Motor Current (P003) Overload Current 3,0 2,0 1,5 1,0 Time (s) 15 30
60
90
Figure 6.13 - Ixt function – Overload detection
101
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [Factory Setting] Unit
Description / Notes Parameter P156 must be set from 10% to 20% higher than the rated motor current (P401). Always P401 is changed, P156 is adjusted automatically to 1.1xP401.
P169 0.2xPInom to 2.0xPInom Maximum [ 1.5xP295 ] Output Current 0.01A ( 9.99A); 0.1A ( 10.0A)
Prevents motor stalling during an overload. If motor load increases its current will increase too. If the motor current attempts to exceed the value set at P169, the motor speed will be decreased by following the deceleration ramp until the current becomes lower than P169. As soon as the overload condition disappears, the motor speed is resumed. Motor Current P169
Time Speed acceleration ramp (P100/P102)
decel. ramp
accel. ramp
Deceleration ramp (P101/P103) Time during during during acceleration cont. duty deceleration
Figure 6.14 – Curves showing the actuation of the current limitation
The current limitation function is disabled when P169>1.5xP295. P178 (1) Rated Flux
102
50.0 to 150.0 [ 100% ] 0.01( 9.99); 0.1( 10.0)
Defines the flux in the motor air gap, when in vector control. It is expressed as a percentage (%) of the nominal flux. Generally it is not necessary to change P178 of the default value (100%). But in some specific cases, different values at P178 may be set.These conditions may be: - to increase the inverter torque capacity (P178>100%). Examples: 1) to increase the motor starting torque and thus ensure faster motor starts; 2) to increase the inverter braking torque and thus allow faster stops, without using dynamic braking. - to reduce the inverter energy consumption (P178 Fx ] -
Check possible options on table below and details about each function operation on Figure 6.21. P279 Output/Parameter P277 Function (RL1) (RL2) Fs > Fx 0 0 Fe > Fx 1 1 Fs = Fe 2 2 Is > Ix 3 3 Not used 4 and 6 4 and 6 Run (inverter enabled) 5 5 No fault 7 7 Table 6.23 – Functions of the relay outputs
Notes about the functions of the relay outputs: 1) When the definition in the function name is true, the digital output will be activated, i.e., the relay coil is energized. 2) When the option 'Not used' has been programmed, the relay output(s) will be disabled, i.e., the coil is not energized. 3) CFW-08 Plus has 2 relay outputs (1 NO and 1 NC contact). It is possible to emulate a reversal contact relay by setting P277 = P279. Definitions of the used symbols in the functions: - Fs = P005 - output frequency (motor) - Fe = reference frequency (ramp input frequency) - Fx = P288 - Fx frequency (user selected frequency point) - Is = P003 - output current (motor) - Ix = P290 - Ix current (user selected current point)
119
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION The charts below give provide actuation and operating description of the of the relay output: b) Fe > Fx
a) Fs > Fx
Fx (P288)
Fs
Fx (P288)
Fe
Time
Time ON
ON Relay
OFF
Relay
c) Fs = Fe Fe
OFF
d) Is > Ix Is
Fs
Ix (P290) Time
Time ON
ON OFF
Relay
OFF
Relay
f) No Fault
e) Run Motor running
s/ E0X
Stopped motor or running by inertia
Ready/Run State ON
Time
ON
Fault State (Exy) Time
Relay Relay
OFF Figure 6.21 - Details about the operation of the digital relay output fucntions
120
OFF
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter P288 Fx Frequency
Range [Factory Setting] Unit Description / Notes 0.00 to P134 [ 3.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P290 Ix Current
0 to 1.5xP295 [ 1.0xP295 ] 0.01A (9.99A); 0.1A (10.0A)
P295(3) Rated Inverter Current (Inom)
300 to 316 [ According to the rated inverter current Inom) ] -
Used in the relay output functions Fs>Fx, Fe>Fx and Is>Ix (see P277 and P279).
The rated inverter current can be programmed according to the table below. P295 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316
Rated Inverter Current (Inom ) 1.0A 1.6A 2.6A 2.7A 4.0A 4.3A 6.5A 7.0A 7.3A 10A 13A 16A 22A 24A 28A 30A 33A
Table 6.24 – Definition of the rated inverter current.
P297(3) Switching Frequency
4 to 7 [ 4 - 5kHz ] -
Defines the switching frequency of the IGBTs in the inveter. P297 4 5 6 7
Switching Frequency (fsw) 5kHz 2.5kHz 10kHz 15kHz
Table 6.25– Definition of the switching frequency.
The switching frequency is a comprimise between the motor acoustic noise level and the inverters IGBTs losses. Higher switching frequencies cause lower motor acoustic noise level, but increase the IGBTs losses, increasing the 121
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [Factory Setting] Unit Description / Notes drive components temperature and thus reducing their useful life. The predominant frequency on the motor is twice the switching frequency setat P297. Thus, P297=4 (5kHz) results in an audible motor noise corresponding to 10kHz. This is due to the used PWM technique . The reduction of the switching frequency also contributes to the reduction of instability and ressonance that may occur in certain application conditions, as well as reduces the emission of electromagnetic energy by the inveter. The reduction of the switching frequencies also reduces the leakage currents to ground, which may avoid the nuisance activation of the ground fault protection (E00). The option 15kHz (P297=7) is not available in vector control mode or when the external serial keypad (HMICFW-08-RS) is used. Use currents according to table below: Inverter Model CFW080016S2024 ... CFW080016B2024 ... CFW080026S2024 ... CFW080026B2024 ... CFW080040S2024 ... CFW080040B2024 ... CFW080070T2024 ... CFW080073B2024 ... CFW080100B2024 ... CFW080160T2024 ... CFW080220T2024... CFW080280T2024... CFW080330T2024... CFW080010T3848 ... CFW080016T3848 ... CFW080026T3848 ... CFW080027T3848 ... CFW080040T3848 ... CFW080043T3848 ... CFW080065T3848 ... CFW080100T3848 ... CFW080130T3848 ... CFW080160T3848 ... CFW080240T3848... CFW080300T3848...
15kHz 2,5kHz 5kHz 10kHz (P297=5) (P297=4) (P297=6) (P297=7) 1.6A 1.6A 1.6A 1.6A 1.6A 1.6A 1.6A 1.6A 2.6A 2.6A 2.6A 2.1A 2.6A 2.6A 2.6A 2.6A 4.0A 4.0A 4.0A 3.4A 4.0A 4.0A 4.0A 4.0A 6.3A 7.0A 7.0A 7.0A 7.3A 7.3A 7.3A 7.3A 10A 10A 10A 10A 12A 16A 16A 14A 22A 22A 18A 15A 28A 28A 22A 18A 33A 33A 25A 21A 1.0A 1.0A 1.0A 1.0A 1.6A 1.6A 1.6A 1.6A 2.3A 2.6A 2.6A 2.6A 2.7A 2.7A 2.7A 2.7A 2.8A 4.0A 4.0A 3.6A 3.0A 4.3A 4.3A 3.9A 6.5A 6.5A 6.5A 6.3A 10A 10A 8.4A 6.4A 13A 13A 11A 9A 16A 16A 12A 10A 12A 24A 24A 15A 13A 30A 30A 16A
Table 6.26 – Current values for P297.
122
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter P300 DC Braking Time P301 DC Braking Start Frequency P302 DC Braking Current
Range [Factory Setting] Unit Description / Notes 0.0 to 15.0 [ 0.0 ] 0.1s 0.00 to 15.00 [ 1.00Hz ] 0.01Hz
The DC braking feature provides a motor fast stop via DC current injection. The applied DC braking current, that is proportional to the braking torque, is set at P302, and is adjusted as a percentage (%) relating to the rated inverter current. The figures below show the DC branking operation at the two possible conditions: ramp disabling and general disabling.
0.0 to 130 [ 0.0% ] 0.1%
DC CURRENT INJECTION P300
Motor Speed P301 Output Frequency
Time DEAD TIME
DI - Start/Stop
0V open
Figure 6.22 - DC braking after ramp disabling
DC CURRENT INJECTION P300
Motor Speed Output Frequency
Time DEAD TIME 0V
DI - General Enable open Figure 6.23 - ADC braking after general disabling
123
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [Factory Setting] Unit Description / Notes Before DC braking starts, there is a "Dead Time" (motor runs freely) required for the motor demagnetization. This time is function of the motor speed at which the DC braking occurs. During the DC braking the LED display flashes If the inverter is enabled during the braking process, this process will be aborted and motor operates normally. DC braking can continue its braking process even after the motor has stopped. Pay special attention to the dimensioning of the motor thermal protection for cyclic braking of short times. In applications where the motor current is lower than the rated inverter current, and where the braking torque is not enough for the braking condition, please contact WEG to optimize the settings.
P303 Skip Frequency 1
P133 to P134 [ 20.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P304 Skip Frequency 2
P133 to P134 [ 30.00Hz ] 0.01Hz (99.99Hz); 0.1Hz (100.0Hz)
P306 Skip Band Range
0.00 to 25.00 [ 0.00 ] 0.01Hz
This feature (skip frequencies) prevents the motor from operating permamently at speeds where the mechanical system enters into resonance, causing high vibration or noise levels. The enabling of this function is performed by setting P306 0.00. Output Frequency
P304
2 x P306
2 x P306
P304
P303
P303
Frequency Reference
Figure 6.24 - Skip Frequency curves
The passage through the skip frequency band (2xP306) uses the programmed acceleration/deceleration ramps. This function does not work properly if two skip frequencies overlap. 124
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter P308(3) Inverter Address
Range [Factory Setting] Unit Description / Notes 1 to 30 Sets the address of the inverter for theserial communication. (WEG Protocol) Maximum allowable value for WEG serial protocol is 30 1 to 247 and maximum allowable value for Modbus-RTU protocol (Modbus-RTU) is 247. [1] See item 8.22 and 8.23. 1 The serial interface is an optional inverter accessory. See items 8.9, 8.10 and 8.14 for detailed information.
P310(3) Flying Start and Ride-Through
0 to 3 [ 0 - Inactive ] -
P311 Voltage Ramp
0.1 to 10.0 [ 5.0s ] 0.1s
The parameter P310 selects the active function(s): P310 0 1 2 3
Flying Start Ride-Through Inactive Inactive Active Inactive Active Active Inactive Active
Table 6.27– Activation of the function Flying Start and Ride Through by the parameter P310.
Parameter P311 sets the time required for the motor restart, both for flying start function and the ride-through function. In other words, it defines the time to set the output voltage starting from 0V and up to reaching the rated voltage. Operation of the flying start function: - It allows the motor to start when it is running. This functions acts only when the inverter is enabled. During the start, the inverter will impose the speed reference, creating a voltage ramp with time defined at P311. - The motor can be started in conventional form, even when the flying start has been selected (P310=1 or 2), adjusting one of the digital inputs (D13 or D14) to 13 (flying start disable) and driving it (0V) during the motor start. Ride-Through operation: - Permits the inverter recovery, without disabling by E02 (undervoltage), when a momentary voltage drop in the line occurs. The inverter will be disabled only by E02, if the voltage drop is longer than 2.0s. - When the ride-through function is enabled (P310=2 or 3) and if a voltage drop in the line occurs, so the link circuit voltage becomes lower than the permitted undervoltage level, the output pulses will be disabled (motor runs freely) and the inverter waits up to 2s for the line re-establishment. If the line returns to is normal status within this time, the inverter will enable again the PWM pulses, imposing the frequency 125
CHAPTER 6 - DETAILED PARAMETER DESCRIPTION
Parameter
Range [Factory Setting] Unit Description / Notes reference instantaneously and providing a voltage ramp with time defined at P311. - There is a dead time before this voltage ramp is started, required for the motor demagnetization. This time is proportional to the output frequency (motor speed). DC link voltage Undervoltage level (E02) tdisabled. >tdead
Enabled
time
Disabled t410V - 200-240V models Ud>820V - 380- 480V models Load inertia too high or deceleration ramp too short. Setting of P151 too high. Load inertia too high and acceleration ramp too short (vector control - P202=2)
Table 7.1 – Errors, possible causes and reset ways 139
CHAPTER 7 - DIAGNOSTICS AND TROUBLESHOOTING FAULT E02 DC Link Undervoltage
RESET (1)
POSSIBLE CAUSES
Power-on Manual (key Auto-reset DI
Power supply voltage too low, causing a DC link voltage higher than the allowed value (read the value in parameter P004): Ud
