ac wave 2 power frequency inverter - Eltexmanuali.eltex.biz/Manuali_Reel/WAVE2 en/AC W2 Power rel2_0...

ac wave 2 power frequency inverter

«SPECIFIC PRODUCT SECTION»

Instruction and user’s manual

Release 2.0 of 99/09

REEL S.r.l. Electronic Power Drives Via Riviera Berica, 42 36024 Ponte di Nanto - Vicenza - ITALY Tel. +39 0444 730003 - Fax +39 0444 638213 internet: www.reel.it - e-mail: [email protected]


CONTENTS

1. GENERAL REMARKS 1.1 A.C. motor drives 1.2 Technical features

2. INSTALLATION 2.1 Power connections 2.2 Control connections

2.2.1 Standard board for connector P3 2.2.2 Standard board for connector P4 2.2.3 Board version D: connector P2

2.3.Serial drive encoding

3. COMMISSIONING 3.1 General remarks 3.2 Main speed set point 4÷20mA 3.3 Speed set points “jog 1 - jog2” 3.4 Auxiliary set point “R2”

3.4.1 Algebraical summation 3.4.2 Absolute summation 3.4.3 PID summation

3.5 Drive’s torque control 3.5.1 Working principle 3.5.2 Setting on “torque control” system

3.6 “Catching in flight” handling 3.6.1 Working principle 3.6.2 System setting

3.7 Product version

1

2

3


4. DRIVE PROGRAMMING 4.1 General remarks 4.2 Off-line parameters 4.3 On-line parameters 4.4 Module programming with PC

5. OPTIONALS 5.1 Optional I/O board

5.1.1 Static mSR output 5.1.2 Static Ok output

5.2 Ac wave 2,version 8KHz

6. ANOMALY SOLUTION GUIDE

6.1 General remarks 6.2 Alarm description 6.3 Luminous signals

7. ENCLOSURES 7.1 Sizes of ac wave 2 power 7.2 Sizes of ac wave 2 power D 7.3 Sizes of ac wave 2 power FP 7.4 Place occupied 7.5 Power module map 7.6 Block diagram of power module 7.7 Application diagram 7.8 Electric power connections

4

5

6

7


1 1. GENERAL REMARKS 1.1 A.C. motor drives

A.C. motors are doubtless widely used in many industrial applications, are extremely versatile ad easily adaptable to all different needs of a market in constant technical evolution. Their use is made easy by their simple plan characteristics. In fact their movement mechanics allows easy balancing and exceeding rated speed without any particular device; the lack of brushes guarantees long lasting reliability and takes away the high costs of programmed maintenance interventions. Last but not leas, an advantage is given by the structure compactness, allowing high degree insulation, permitting construction for immersion as well. The disadvantage of the machine is however depending on the torque curve, which, through “direct” mains connections, is very low in proximity of “zero revolution” finding then its peak not far from synchronism speed. To allow a total management of the asynchronous motor couple according to speed, REEL offers the frequency inverter called ac wave 2. This converter presents most modern project technology. Developed in two versions, “MODULAR” and “SA” (stand alone), it has a totally digital regulation that, together with the VVC (Voltage Vector Control) control system, allows to obtain the motors nominal torque at 1Hz, respecting rated current without speed feedback. The voltage control to the motor is a vectorial one, which means that the rotating vector is directly controlled. In this way, the voltage components are the ones needed by the motor to carry out its work immediately. An innovative modulation system called “Pwm Random”, delays in time the modulation frequency in a casual way, scanning more frequencies and mixing them together so that the annoying “swhiistleo”, due to circling current switching, is taken away. It achieves a “white” sound well mixing up with the typical noises of industrial environments. Such system allows to modulate at low frequencies, so to reduce heat dissipation (also proportional to the number of switching per sec of power components) and ease interference emissions (also strongly affected in intensity by modulation frequency).


1 1.2 Technical features

Input voltage rating Three-phase 380÷440V +/-15%

Input rated frequency 45÷65Hz

Max. output voltage Three-phase max. voltage equal to input voltage rating with possible 5% increase

Output frequency range 0÷500Hz

Output frequency resolution • 1/128Hz with digital speed set from serial port RS485

• 0,1%with analog speed set point

Overload 150% for 1’ every 10’ 200% for 10’’ every 10’’

Speed variation from no load to rated torque condition

1% without feedback value refers to max. programmed speed

Speed control accuracy 0,01% with feedback

Mains micro switches Different operating solutions possible

Output wave form Sinusoidal with Voltage Vector Control (VVC)

PWM modulation frequency Adjustable from 1KHz to 5KHz

RANDOM modulation frequency Three different types of modulation available as an alternative to the PWM system (RPWM1, RPWM2, RPWM3)

V/Hz feature Linear with continuously adjustable boost, square-law, semicubic curve

Speed compensation Based on sensor-less estimate of slip frequency


1 Voltage compensation Based on variations of supply voltage

Serial transmission baud rate Settable at 9600 - 19200 - 38400 - 76800 baud

Main analog set point 0,1÷10V o 4÷20Ma with 0,3% accuracy 10 bit resolution

Main serial set point 16 bit

Auxiliary set point +/-10V with 0,5% accuracy 9 bit resolution

Jog1, Jog2 The internal speed set points are programmable from 0 to max. frequency

Acceleration / deceleration time 0.1÷1000 sec with independent setting

Speed feedback From unidirectional or bi-directional encoder with period measuring up to max. frequency 40KHz

DC braking During from 0,1 to 10 seconds with a current value settable from 0 to max. deliverable current

Dynamic braking With optional circuit that can be installed in the supply module (dissipation resistors are available on demand)


1


2

2. INSTALLATION 2.1 Power connections

• The drives are constructed in several types, differing in size and overall dimensions. See

enclosures for dimensions and sizes. • The fixing of power cables changes according to the different sizes:

− sizes 01÷06 and 91÷96: three-pole terminal board with max. allowed section for connections of 4mm2

− sizes 06÷08: three-pole terminal board with max. allowed section for connections of 10mm2

− sizes 09÷12: connecting on bolt terminal M6

− sizes 13÷16: connecting on double terminal with M6 bolt

• Please refer to chapter “Electrical power connecting” to find map, overall dimensions

and connecting diagram. 2.2 Control connecting

The ac wave 2 power module is available in two versions:

− standard − “D” version − The standard version supports a board h=120mm, able to receive all controls either

from hardware, that means from the connection terminals or through serial port RS485. This version has two signal 10 pin connectors. The first one called “P3” is defined as basic connector, having the essential controls for standard run/stop; the second one called “P4” is defined as optional connector, having application controls such as auxiliary set point, speed feedback, etc.

− The “D” version supports a board h=80mm, having only the software controls through serial port RS485. It has one single 6 pin connector for the possible connecting of speed feedback and auxiliary set point E2.


2

2.2.1 Standard board: connector P3

PIN DENOMINATION REMARKS TECHNICAL FEATURES

1 -R1 Negative input of analog speed set point

(differential through +R1) can be enabled at 4÷20mA

Reference 0Vdc for pin 2 Input impedance 40KΩ

or 4÷20mA input impedance 241Ω

2 +R1 Positive input of analog speed set point

(differential through -R1) can be enabled at 4÷20mA

0÷10Vdc Input impedance 40KΩ

or 4÷20mA input impedance 241Ω

3 0A Zero volt set point of analog outputs

0Vdc

4 TH Analog output proportional to output frequency or speed if

with feedback

+/-10Vdc 7 bit resolution impedance output 330Ω

IMAX 1mA, (10V=FMAX)

5 CUR Analog output proportional to supplied current

+/-10Vdc 7bit resolution output impedance 330Ω

IMAX 1mA, (10V=IMAX)

6 -C Common optoinsulators input for the drive’s hardware

enablements

0Vdc

7 EN1 Starting input for main set point +/-R1

Optoinsulated OFF = <3Vdc

ON = 15÷28Vdc Impedance 2,2KΩ

8 ON Enablement input for current supply to the single drive


ON = 15÷28Vdc Impedance = 2,2KΩ

9 CCW Motor rotation reversal enablement



10 JG1 Impulse speed no.1 enablement (internal set point 1)




2

2.2.2 Standard board : connector P4


1 IG Zero Volt of digital circuits supply

0V with impedance 10Ω

2 IG Zero Volt of digital circuits supply

0V with impedance 10Ω

3 EN2 Enablement input for auxiliary set point +/-R2



4 JG2 Enablement input for impulse speed no.2

internal set point 2)


ON = 15÷28Vdc

5 RES Alarm reset input of the single converter


ON = 15÷28Vdc

6 COM Common cable for optoinsulators of speed

feedback

0Vdc

7 B Channel “B” input of speed feedback (optional, only for

bi-directional encoders)

Optoisolato OFF = <3Vdc

ON = 15÷28Vdc Max. frequency = 40KHz

Impedance = 3,3KΩ

8 A Channel “A” input of speed feedback

(connection for unidirectional encoder)



Impedance = 3,3KΩ

9 +R2 Positive input of auxiliary set point “R2”

(differential through -R2)

+/-10Vdc input impedance 48KΩ

10 -R2 Negative input of auxiliary set point “R2”

(differential through +R2)

+/-10Vdc input impedance 48KΩ


2

2.2.3 Board version “D”: connector P2


1 A Channel “A” input of speed feedback

(connection for unidirectional encoder)



Impedance = 3,3KΩ

2 B Channel “B” input of speed feedback

(optional connection; only for bi-directional encoders)



Impedance = 3,3KΩ

3 COM Common cable for optoinsulators of speed

feedback

0Vdc

4 DG Supply Zero Volt of digital circuits

0Vdc

5 -R2 Negative input of auxiliary set point “R2”

(differential through +R2)

+/-10Vdc Input impedance 100KΩ

6 +R2 Positive input of auxiliary set point “R2”

(differential through -R2)

+/-10Vdc Input impedance 100KΩ

Notes: - all signal and feedback cables must be screened through connection to signal

ground (described in general section, chapter on grounding) - do not ground supply zero (0A; IG; DG)

2.3 Serial drives encoding It is possible to connect up to 31 modules in a single serial node. The drives shall be encoded; Reel has a progressive encoding, the first drive on the tunnel’s top having serial code 1. The sequence can be changed and the tunnel customised with DIP switches put on the adjustment board of each drive. The DIP switches can be found in the maps and have following functions: 1-2 Connecting the termination resistors of the serial line. They must be selected on the

farthest drives from the supply module. There can be max. two modules on one and the same serial line.


2

3÷7 Encoding the module’s serial address. Used to encode module for communication with a master (programmer or MAC external unit). Up to 31 addresses are available.

8 Forcing the serial communication line’s baud rate to 9.600. Adjustment board of inverter module - standard version

SERIAL ADDRESS CONFIGURATION (SW1)

Adjustment board for inverter module - “D” version

SERIAL ADDRESS CONFIGURATION (SW1)


2

The following chart shows the serial address, where 1 = DIP ON DIP3 DIP4 DIP5 DIP6 DIP7 ADR. DIP3 DIP4 DIP5 DIP6 DIP7 ADR.

0 0 0 0 0 not used

0 0 0 1 0 8

1 0 0 0 0 1 1 0 0 1 0 9

0 1 0 0 0 2 0 1 0 1 0 10

1 1 0 0 0 3 1 1 0 1 0 11

0 0 1 0 0 4 0 0 1 1 0 12

1 0 1 0 0 5 1 0 1 1 0 13

0 1 1 0 0 6 0 1 1 1 0 14

1 1 1 0 0 7 1 1 1 1 0 15

Addresses 16÷31 following can be taken from chart.


3

3.COMMISSIONING 3.1 General remarks

The general section describes conditions and precautions about the first putting under voltage. This section describes the drive’s application context as electromechanical equipment being an automation product. A careful reading of general section is recommended before the drive is started for run. Attention!: The drive is supplied only with laboratory’s settings. The installer shall see to specific configuration according to the motor used and the specific kind of automation.

3.2 Main speed set point 4÷20mA Some information requires current speed setting in order to interface with PC or PLC. Reel offers for the standard version some DIP SWITCHES for configuration of the converter’s main set point 4÷20mA. They are shown on the following map. Adjustment board for standard inverter module

SPEED SET CONFIGURATION 10V/4-20mA (SW2) Dip 1 Not used

Dip 2 Input of load resistance for set point 4÷20mA

Dip 3-4 Input gain selection for set point 4÷20mA • Dip 2 - 3 - 4 = OFF: 0÷10V • Dip 2 - 3 - 4 = ON : 4÷20mA


3

3.3 Impulse speed “Jog1 - Jog2” A further automation support is given by the possibility of having two internal, presettable speeds. The inverter module, depending on enablement of one or two jogs, supplies the motor with the frequency pre-set in jog1 and jog2. The motor decelerates when jog is disconnected. • The jogs follow time pre-set in the “ramp” variable.

• When both jogs are enabled the drive carries out the sum of values set in the respective variables.

3.4 Auxiliary set point R2

Automation often requires speed adjustment of a movement according to other machine organs. Therefore some functions may be necessary, implemented by Reel through an auxiliary set point. It is to be stated first that auxiliary set point R2 has no ramps (acting directly on supply frequency without being influenced by values set in ACC - DEC or RAMP). Four variables are associated to the auxiliary set point: E2A, E2P, E2I, E2D; many functions can be obtained by setting one or more variables adequately. Some possibilities of common use are described in the following lines.

3.4.1 Algebraical summation E2A = 0% E2P = XX% E2I = 0% E2D = 0% Drive carries out the sum or subtraction of speed set point R1 and auxiliary set point R2. The result is directly proportional to the analog voltage value of differential input +/- R2, to percentage set in variable “E2P”, and to the R1 value itself. • Max. adjustment = 99,9% of main set point (with E2P = 99,9% and +/-R2 = +/-

10V).

3.4.2 Absolute summation E2A = XX% E2P = 0% E2I = 0% E2D = 0% Drive carries out sum or subtraction of main set point R1, depending only on percentage set in E2A and voltage value of input +/-R2. • Max. adjustment = 99,9% of MAXF set (with E2A = 99,9% and +/-R2 = +/10V).


3

3.4.3 PID summation E2A = 0% E2P = XX E2I = XX E2D = XX Drive carries out adjustment of main set point aiming to voltage value of auxiliary set point R2 equal to zero volt, meaning that an auxiliary PID is carried out, using set point 2 as feedback. This system is essential for speed synchronism of two movements or particular handling such as “dancer“ rolls and “loading stores”. Variables E2P, E2I, E2D shall be set according to the dynamic performances to be obtained. • Max. adjustment = 100% of main set point

3.5 Torque control Some automations require the setting of a torque set point in order to limit the torque available for the shaft. The adjustment software for the ac wave is set for torque control and can be enabled by selecting the «T.V/Hz» variable, which shall have function “torque”. • The torque handling needs speed feedback from bi-directional encoder. We suggest

choosing an encoder ensuring a good rev. resolution without exceeding max. frequency 40KHz.

3.5.1 Working principle Drive controls the motor running and supplies it with: − synchronic frequency when torque set is zero − slip proportional to required torque set • Torque can be set on auxiliary set point (+/-R2) with 0÷+10Vdc

• The main set point determines torque direction through: − braking torque when R1 = 0V or set is lower than instant motor speed − forwarding torque when R1 = MAX o set higher than instant motor speed

NOTE: If torque setting is higher than load requires, the motor will increase revolutions up to the number set on R1 for speed adjustment. Slip is controlled according to formula:

slip = Slipnom x IMAX x %R2 INOM where: slip is resulting

Slipnom is set slip (synchrony speed -nominal speed)

IMAX is max. set current

INOM is set rated current

%R2 is the auxiliary set point’ percentage with 10V = 100%.


3

3.5.2 Setting of torque control system The system does not need particular measures, variables FNOM, VELNOM, IMAX and INOM have just to be set according to the motor’s setting parameters. It is recommendable to set variable T.V/Hz in PID first and, after optimising the dynamic performances of speed control through variables KP, KI, KD, select «Torque» function. Speed set point “R1” will determine torque as braking or forwarding as well as speed limit in case of load missing; set point “R2” determines max. slip and so shaft torque.


3

3.6 “Catching in flight” Sometimes, after a supply interruption, the possibility of “catching” the motor again is demanded (motor may have been left previously, missing the mains or being disabled), while it is still rotating due to a driving force. The motor takes then speed again or is stopped by control. Reel can supply this function on demand. It needs particular controls and setting for “catching in flight” enablement , as described below.

3.6.1 Working principle When such function is enabled, the inverter starts searching the physical motor speed by scanning the possible supply frequencies. The searching starts with the frequency value set in variable “FMAX”, and goes through the whole range “FMAX”÷“FMIN”. At this step, motor is run down in order to reduce the absorbed current. As soon as supply frequency corresponds exactly to the physical motor speed, the absorbed current is reduced considerably and changes then sign (from absorbed to delivered) when frequency gets below. The drive will so pick out the real speed, run the motor down (according to set V/Hz set) and control it. Searching voltage as well as searching time can be set.

3.6.2 System setting Previous selection: Set variable “JOG2” = 0 Set variable “HOLD” = 1 or 2 Searching motor speed: Start up “jog2” in order to enable searching function. The speed searching starts as soon as inputs “jog2” (pin 4 of P4) and “ON” (pin 8 of P3) are enabled; once the synchronism speed is reached, the motor is driven to the speed corresponding to set value on differential input “RIF1” (pin 1-2 of P3). Should this input be disabled (EN1 = OFF), the motor is driven to zero revolutions. Searching speed, the inverter sets on motor a decreasing frequency starting from FMAX. Once the synchronism frequency is found, the inverter catches up he motor and carries out the required setting. The searching current is “indirectly” determined by variable “X1”; searching time is determined by variable “X2”. X1 is in fact a percentage of standard Volt/Hertz. The setting range is 0÷500, 500 being 50% of linear Volt/Hertz.


3

The diagram below shows the searching voltage values with a «380V 50Hz» motor.

Recommended value: 150 X2 is the searching ramp; low values take a longer searching time, high values make searching short.

Recommended vallue: 8 ( corresponding ot search ramp of 2 seconds) Setting range = 0÷500 Recommended value: 8 (corresponding to a searching ramp of about 2 seconds). Searching precision is obviously directly proportional to ramp length and searching current value. Note: By leaving input “jog2” constantly on, the inverter will search every time it will be ready to start.


3

3.7 Product version The different product versions are to be taken into accouont in case of order or spare part demand. − 090 Analog/digital power module − 100 Digital power module − 190 Digital power module − 110 Digital power module h= 80 mm − 290 Analog/digital small-size power module − 300 Digital small-size power module


3


4

4. DRIVE PROGRAMMING 4.1 General remarks

The general section describes all programming and supervising systems supplied by Reel for interfacing with the own products. A thorough reading of that section is therefore necessary before starting with drive programming. There are to kinds of ac wave 2 power module parameters:

− «OFF LINE» parameters: they cannot be modified while motor is running, as they belong to primary configuration and change the drive’s behaviour essentially.

− «ON LINE» parameters: can be modified while motor is running so that their efficacy can be checked immediately. Such parameters are speed PID, auxiliary PID, dynamic compensations (V0, KCUR, KSLIP), etc.

4.2 OFF-LINE Parameters SIZE This value range (1÷16) determines the size of power modules and is set during test. Please refer to following chart if you want to check it. A wrong setting may affect the electronic thermal protection and make the compensatory constants ineffective.

SIZE MOTOR POWER SIZE MOTOR POWER

01 1.1 Kw 09 22 Kw

02 2.2 Kw 10 30 Kw

03 3 Kw 11 37 Kw

04 5.5 Kw 12 45 Kw

05 7.5 Kw 13 55 Kw

06 11 Kw 14 75 Kw

07 15 Kw 15 90 Kw

08 18.5 Kw 16 132 Kw

FPWM Setting of modulation frequency. The value sets frequency reconstructing the current sinusoid. The available range is 1,0KHz - 5,0KHZ. When exceeding 2KHz, a de-rating of the max. available current is carried out, that is 10% for every KHz. High FPWM values reduce the “whistling” i caused by modulation and the current sinusoid ripple as well. There a modulation types called “RANDOM” are available; this system (selected when exceeding 5,0KHz) reduces the annoying “whistle” considerably by moving the modulation frequency within a set range so to change the whistle into a rustling.


4

The first RANDOM frequency oscillating between 1KHz and 2KHz, does not derate IMAX; the second one between 2KHz and 3KHz carries out a de-rating of 5%; the third one between 3,3KHz and 4,3KHz carries out a de-rating of 17,5%.

Setting range: 1.0÷5.0KHz e RND1; RND2; RND3. Warning • If some filters are installed on the drive’s output, do not use “RANDOM” frequency, as

filters are calculated for a precise frequency; different frequencies may lead to the drive’s protection stop or to filter’s breaking.

• Choosing the frequency, the module’s thermal dissipation and its IMAX have to be considered. Another important parameter is the max. motor frequency (“FMAX”). The higher frequency, the higher modulation frequency must be set, in order to obtain for current a good form factor. The following setting is suggested: − FPWM between 2 and 3KHz (or random2) for FMAX values between 60 and 100Hz

− FPWM between 3 and 4KHz (or random3) for FMAX values between i 100 and 300Hz

− FPWM between 4 and 5KHz for FMAX values higher than 300Hz

PWM When function “DISS. RID = Reduced dissipation” is set, a particular modulation sequence for power IGBT is activated that reduces the drive’s thermal dissipation. This selection must be avoided in case of motors with high dynamic performances.

Setting field: DISS.RID / STANDARD PWM IMAX Max., transitory deliverable current by the module. For correct setting please refer to chart in chapter “Sizes and overall dimensions”.

Setting range: from INOM to IMAX, available according to size INOM Rated motor current (value for electronic thermal protection of motor to be started). Setting range: 0÷I rated current of inverter module (refer to size chart) FNOM Motor rated frequency. Setting range: 50Hz÷500Hz For software versions following 15318138 the setting range is: 10Hz÷÷÷÷500 Hz VEL.NOM Motor revolutions at rated frequency (considered at rated motor slip). Setting range: 0÷30000 revolutions/min


4

COSFI Power factor of motor used.

Setting range: 0,50÷0,95 FMIN Minimum frequency in Hz at which inverter starts working. If parameter is set at 0,0 the drive, when enabled, will deliver a DC to motor proportional to value set in “V0” (see the following).

Setting range: 0,0Hz÷400,0 Hz FMAX Max. frequency at which inverter reaches max. speed set point.

Setting range: 0,1 (or FMIN)÷500Hz JOG1 Impulse speed value to be enabled with input having the same name.

Setting range: 0,0Hz÷500Hz (limited by FMAX from an operating point of view) JOG2 Impulse speed value to be enabled with input having the same name.

Setting range: 0,0Hz÷500Hz ( limited by FMAX from an operating point of view) mSR Speed threshold in Hz; beyond this value inverter switches the output having the same name. In the modular system the single “mSR” s add up to one summation in a single general supply module output.

Setting range: 0,3Hz÷FMAX T.V/Hz Selecting of Volt/Hertz feature, according to the function of motor used. Following options can be chosen: LINEAR, PID, SQUARE -LAW, SEMICUBIC, TORQUE. • LINEAR: is used in most cases, not needing any speed feedback. Transmits voltage to

the motor according to working frequency, and is compensated by the V0 parameter (described later);

• PID: speed feedback through a unidirectional or bi-directional encoder allowing a higher precision degree;

• SQUARE-LAW and SEMI-CUBIC: for particular applications, when motor controls fans, pumps, etc.;

• TORQUE: set for future applications


4

IMP./G. Impulse number per motor revolution regarding speed feedback. Choosing the device, take into account that max. feedback frequency must not exceed 40KHz.

Setting range: 0,4÷1024,0 impulses/revolution ENCODER With regard to speed feedback, it must be specified whether the encoder is unidirectional or bi-directional.

Setting field: UNIDIRECTIONAL / BIDIRECTIONAL DC BRAKE DC braking enablement during stop. When set, motor will be stopped by inserting direct current and not according to pre-set deceleration ramp.

Setting field: NO / YES T BRAKE Determines DC inserting time while stopping (when “DC BRAKE” is on).

Setting range: 0,1÷20,0sec. RIF1 Speed set point input for 0÷10V or 4÷20mA signal. Setting has to be completed through selection of the DIP SWITCHES on adjustment board (see regarding section).

Setting range: 0÷10V / 4÷20mA STALLO - DEADLOCK During standard working, when speed set point is missing, the inverted will be disabled. When this parameter is on, the motor does not stop, but keeps running at minimum frequency (provided it is not 0).

Setting field: YES / NO START Variable available for future applications. RIF2 Variable available for future applications.


4

SETUP The drive can be controlled through releases and set-points from serial port.

Setting range: 0÷255 decimal or 0÷FF hexadecimal with: 0 = releases and set points from terminal board 255 = releases and set points from serial line Intermediate values assign mixed features. A numeric value is assigned to each release. When set, it leads to passing from hardware to software; the sum of release values to be enabled as software is the variable value to be set. Assignment as follows:

DECIMAL HEXADEC. DECIMAL HEXADEC.

ON=

1 1 SET POINT = 32 20

EN1=

2 2 BY PASS FUNCTION K= 64 40

EN2=

4 4 CW/CCW= 128 80

EN3=

8 8

For example: when ’EN1, SPEED SET POINT and CW/CCW function has to be carried out with serial control, the number for SETUP is:

DECIMAL HEXADECIMAL

ON: 1 + 1 +

EN1: 2 + 2 +

SET POINT : 32 + 20 +

CW/CCW: 128 = 80 =

163 A3

Other functions shall be started from terminal board. SECURITY Enables a particular sequence for drive’s software stopping, increasing security level against uncontrolled disabling and releasing the drive from disabled at the same time as ID=0.

Setting field: ENABLED/ DISABLED


4

4.3 ON-LINE PARAMETERS These parameters can be changed while motor is running (on line). They are used for the inverter’s dynamic compensation. Compensations are available according to selected V/Hz feature. ACC Value in sec to reach speed of speed set point. Determines the motor’s accelerating curve.

Setting range: 0,0÷1000,0sec. For software versions following after 15318138 setting range 0,0÷÷÷÷6000sec DEC Time taken for the motor to stop; set time refers to speed decreasing at the moment when input EN1 is disabled.

Setting range: 0,0÷1000,0sec. For software versions following after 15318138 setting range 0,0÷÷÷÷6000sec RAMPA - RAMP Time of set point moving. It is set referring to a ramp of 0÷50Hz.

Setting range: 0,0÷1000,0sec. For software versions following after 15318138 setting range 0,0÷÷÷÷6000sec Note: value is used also during rotating direction reversing. V0 % value of voltage boost needed to reach the nominal torque at low rpm. The action reaches its maximum level about the 0 speed, and is cancelled out at about 60% of the motor’s rated frequency. For a correct value setting the following is suggested: While motor is idling reach 3-4% of rated frequency and modify V0 value in order to reach 80-90% of the motor’s rated value. Such operation compensates the motor’s internal resistance which is influenced by temperature. It is therefore recommended to set motor while being under its usual thermal conditions. Setting range: 0÷200; 200 corresponds to 20% increase of rated voltage. KCUR Voltage compensation. • If implemented, the PID working allows the decrease of V0 action proportionally to the

slip measured by the inverter, so to optimize absorbing at low speed. This function is off when set=0; when set=100 and nominal slip is given, it adds a multiple constant of 1.

• When LINEAR working, this parameter acts as multiple constant of V0 during acceleration. It can modify V0 up to max. 200% of set value.

Setting range: 0÷200%


4

KSLIP Frequency compensation. This parameter reduces the motor speed loss when shifting from load-less to load condition. To put in a correct value, motor speed with a considerable load variation must be measured, until a decrease of measured slip is obtained. Slip should not be zeroed completely, so to avoid annoying oscillating. Such compensation does not affect the speed loop while running with feedback.

Setting range: 0÷200% KP Proportional compensation constant of speed loop. It adjusts speed loop proportionally to error between set and real speed.

Setting range: 0÷200 KI Integral compensation constant of speed loop. Adjusting according to error duration.

Setting range: 0÷200 KD Derivative compensation constant of speed loop, adjusting instant error proportionally to its variation speed.

Setting range: 0÷200 E2A Absolute effect of adjustment signal +/-R2, not depending on speed. See chapter «auxiliary set point R2» for setting.

Setting range: 0÷99,9% E2P E2I E2D Dynamic constants referring to the three components (proportional, integral, derivative) adjusting main set point with auxiliary input R2. Such compensations are proportional to motor speed. See chapter «auxiliary set point R2» for setting.

Setting range: 0÷99,9% X1 Parameter used in case of mains failure:

• it determines the voltage applied to motor through DC injection near the“zero revolutions“ during the “mains failure control”;

• it determines the search current for “SPEED MOTOR” during the “CATCHING IN FLIGHT” function ( see chapter “Catching in flight”

Setting range: 0÷500 where 500 corresponds to 50% of nominal voltage.


4

X2 Variable used for function “catching in flight”; see chapter “Commissioning: catching in flight” for setting.

Setting range: 0÷500 HOLD By setting this parameter it is possible to select the inverter performance in case of temporary power failure.

HOLD = 0 Standard setting: controlled deceleration, in synchronism with the other connected power modules

HOLD = 1 Inverter is switched off

HOLD = 2 Inverter keeps running without changing speed

HOLD = 3 Inverter stops according to pre-set deceleration ramp

In any case the inverter will try to restore the previous working condition as soon as the mains voltage is restored. VER This variable shows the software version installed on converter.


4

4.4 Module programming with personal computer The PC software offers the advantage of having all parameters on the screen, together with frequency, currents and possible alarm. This is a very practical aspect, especially when equipment is being started. All variables are described in the same way on keyboard and all other programming units supplied by Reel. The general section of this manual gives all information for starting and using the communication software for PC. We suggest therefore reading the whole section. The following lines describe differences between keyboard and personal computer programming. Following variables were added or opened to direct access: BAUD Transmission speed of serial communication. Available options: 9600, 19200, 38000 B.p.s. Note: The baud changing in the drive means automatically changing all drives connected on the same serial line. Warning!: the personal computer has no communication at 76800 B.p.s.; if the drive (previously connected to a keyboard or other supervisors) is set at mentioned speed, it must be set at a lower speed before being connected to the PC. KAPPA Line speed: this parameter can modify speed of all movements at the same time, when more drives are connected on a single serial line, by selecting serial address “0”. All motors will have their speed increased or decreased by keeping their speed ratio unchanged.

Setting range: 0÷FFFF RIFER Software set point. If variable Set-up has the possibility of handling speed set point through serial port RS485, speed can be set as follows:

0 = zero revolution and FFFF (hexadecimal)= frequency set in parameter “FMAX”.

Setting range: 0÷FFFF


4


5

5. OPTIONALS 5.1 Optional I/O board

This board increases I/O number and makes particular functions, such as “mSR” and “OK” available on connector, which can be useful for automation.

5.1.1 Static “mSR” output The “mSR” output is a ON - OFF optoinsulated signal, buffered by a NPN transistor. It allows to set speed threshold through “mSR” variable.

5.1.2 Static “OK” output This board enables output (and takes back to terminal 09 voltage of terminal 10) when drive is ready to start. Output is off when there is an alarm on drive.

PIN CONNECTOR DENOMINATION DESCRIPTION FEATURES

1 NC not connected -----






7 NC non connected -----

8 mSR static output of “minimum speed relays”

ON = Vdc on +C OFF = open emitter

IMAX=50mA

9 OK static output “ready to start ”

ON = Vdc on +C OFF = open emitter

IMAX=50Ma

10 +C DC voltage input to be carried to static outputs 02-BRK

5÷30V max. dc (common to optoinsulators)


5

5.2 ac wave 8KHz version (optional) Special applications require the installing of a ∆V/∆t limiting filter between inverter and motor. The filter is necessary in order to satisfy the very restrictive limit features required by some motors.

The filter dimensions and its costs are inversely proportional to modulation frequency, that means to the frequency of inverter building up the current sinusoid.

Reel has developed the possibility of modulation to 8KHz with ac wave 2 in order to satisfy also particular demands. • This possibility is given only for some sizes demanding limited dimensions and filter

costs. The option is available for the following sizes:

T07 15Kw INOM = 25A IMAX = 30A T11 37Kw INOM = 76A IMAX = 91A T12 45Kw INOM = 90A IMAX = 108A T13 55Kw INOM = 112A IMAX = 134A

• ac wave power 8KHz is supplied only in the D (digital) version, only allowing running

control from serial line. Please refer to chapter “D version board” for all information.

• All peculiarities of ac wave 2 characterise also the “8KHz” range, including particular managing like mains missing control; the max. overload was limited to 120% of the module’s rated current.

Attention!: - while programming take notice that «FPWM» parameter is fixed at RND300

and cannot be changed on 8KHz selection. - modulation at 8KHz must be required when the product is ordered.


6

6. ANOMALY SOLUTION GUIDE 6.1 General remarks

When the inverter, while running, finds one or more anomalies, it stops at once by disconnecting modulation towards motor. At the same time the display shows the stopping reason and set alarm by switching on the LED signal “ALR” on the drive adjustment board. All specific drive alarms are described below; please refer to specific supply sections for general tunnel alarms as well as for the specific ones.

6.2 Alarm description Message Possible causes Test

wrong setting of the motor's rated current

parameter

check and possibly change "INOM" set

motor overload reduce load

very steep acceleration check and maybe increase set

too high voltage boost (V0)

check and maybe reduce set

too charged dynamic PID constants and consequent

current oscillationstabilize system

Motor Relay electronic

thermal relay intervention to protect motor


6

lacking ventilationcheck working of

radiator's fan

weak heat exchangecheck cooling air and

control board temperature

too heavy working cycle

check average current of working cycle to be correct according to set

parameters

Thermal sensor intervention of

thermal sensor placed on power dissipator

short circuit at motor's ends or towards ground

check connection cables and take cause away

too sharp accelerationsincrease

ACC/DEC/RAMPA parameters

too charged PID modify PID parameters

wrong "FNOM" parameter setting

check and modify set

wrong setting of motor's "VEL.NOM" parameter

check and modify set

too high current leakage within the motor

check motor's insulator and if necessary replace

Overload intervention of the

short circuit protection of power

section


6

wrong V/Hz control feature setting carry out correct setting

encoder failure or wrong connection

check encoder and connections (if encoder is

bidirectional inverter channel A and B)

Feedback alarm speed retroaction

missing

6.3 Light signals The power modules’ adjustment boards have some signal LEDS showing that hardware inputs are on (releasing) and the appearing of a generic alarm. The board of “D” version does not have a hardware release and therefore only shows the generic alarm LED. LEDS are very useful during commissioning and diagnostics, in order to find out the missing of the hardware run releases immediately. The LEDS of standard adjustment board are shown on the map:

INPUT LEDS


6

ABBR. FUNCTION

ALR Inverter failure

EN1 Main set point enabled

JG1 Inner speed “1” enabled

JG2 Inner speed “2” enabled

ON Inverter running enabled

CCW Rotation reversal required

EN2 Speed adjustment enabled

RES Alarms reset required

The failure LED (ALR) of version “D” board can be found on the map below:

ALARM LED


7

7. ENCLOSURES 7.1 ac wave 2 power module sizes

POWER MODULE

ABSORBED MOTOR RATED MAX. DIMENSIONS

TYPE SIZE POWER POWER CURRENT CURRENT L H P

01 2 KVA 1.1 KW 3.2A 4A 260 120 230

02 3.5 KVA 2.2 KW 5.5A 8A 260 120 230

03 5 KVA 3 KW 8A 15A 260 120 230

04 8 KVA 5.5 KW 12.5A 24A 260 120 230

05 10 KVA 7.5 KW 16.7A 32A 260 120 230

06 15 KVA 11 KW 25A 48A 260 120 230

ac wave 07 20 KVA 15 KW 31A 60A 260 120 230

2 08 24 KVA 18.5 KW 39A 60A 260 200 230

power 09 29 KVA 22 KW 45A 85A 260 200 230

10 39 KVA 30 KW 62A 120A 260 200 230

11 48 KVA 37 KW 76A 120A 260 320 230

12 56 KVA 45 KW 90A 170A 260 320 230

13 68 KVA 55 KW 112A 210A 260 320 230

14 92 KVA 75 KW 150A 280A 260 320 230

15 112 KVA 90 KW 180A 250A 260 320 230

16 160 KVA 132 KW 260A 360A 260 520 230


7

7.2 ac wave 2 D power module sizes

POWER MODULE D



01 2 KVA 1.1 KW 3.2A 4A 260 120 230

02 3.5 KVA 2.2 KW 5.5A 8A 260 120 230

03 5 KVA 3 KW 8A 15A 260 120 230

04 8 KVA 5.5 KW 12.5A 24A 260 120 230

05 10 KVA 7.5 KW 16.7A 32A 260 120 230

06 15 KVA 11 KW 25A 48A 260 120 230

07 20 KVA 15 KW 31A 60A 260 120 230

08 24 KVA 18.5 KW 39A 60A 260 200 230

ac wave 09 29 KVA 22 KW 45A 85A 260 200 230

2 D 10 39 KVA 30 KW 62A 120A 260 200 230

power 11 48 KVA 37 KW 76A 120A 260 320 230

12 56 KVA 45 KW 90A 170A 260 320 230

13 68 KVA 55 KW 112A 210A 260 320 230

14 92 KVA 75 KW 150A 280A 260 320 230

15 112 KVA 90 KW 180A 250A 260 320 230

16 160 KVA 132 KW 260A 360A 260 520 230

91 2 KVA 1.1 KW 3.2A 4A 260 80 230

92 3.5 KVA 2.2 KW 5.5A 8A 260 80 230

93 5 KVA 3 KW 8A 15A 260 80 230

94 8 KVA 5.5 KW 12.5A 24A 260 80 230


7

7.3 ac wave 2 power FP module sizes

POWER MODULE FP



51 3.5 KVA 2.2 KW 5.5A 6.5A 260 120 230

52 6.5 KVA 4 KW 10A 12A 260 120 230

53 10 KVA 7.5 KW 16.7A 20A 260 120 230

54 15 KVA 11 KW 25A 30A 260 120 230

55 20 KVA 15 KW 31A 36A 260 120 230

ac wave 56 29 KVA 22 KW 45A 52A 260 200 230

2 57 39 KVA 30 KW 62A 70A 260 200 230

power 58 56 KVA 45 KW 90A 102A 260 320 230

59 68 KVA 55 KW 112A 126A 260 320 230

60 92 KVA 75 KW 150A 170A 260 320 230

61 130 KVA 100 KW 200A 240A 260 320 230

62 190 KVA 160 KW 290A 350A 260 520 230

NOTE: Module type “FP” is made for particular applications (fan control and pump control)

where load is such not to require high torque at start/stop. Overload current is slightly higher then the module’s rated current.


7

7.4 Overall dimensions The overall dimensions change according to module size. See below for ac wave 2 power modules:

POWER S.91-96(1,1 - 11KW)

L=260H=80P=230

POWER S.01-06(1,1 - 11KW)

L=260H=120P=230

POWER S.07-08(15 - 18.5KW)

L=260H=120P=230

POWER S.09-10(22 - 30KW)

L=260H=200P=230

POWER S.11-15(37 - 90KW)

L=260H=320P=230

POWER S.15(132KW)

L=260H=520P=230


7

7.5 Power module map As example the map of sizes 01÷06 is shown to identify inner parts. The other sizes 07÷16 can be drawn from analogy.

INTERCONNECTINGSUPPLY

+ DC BUS POWER

- DC BUS POWER

FLAT CABLE FORPOWER

CONNECTION

CONTROLBOARD

POWERCONNECTION

CAPACITOR BOARDPOWER BOARD

IGBT MODULE

HEAT SINK


7

7.6 ac wave 2 power module block diagram

ς


7

7.7 Application diagram


7

7.8 Electric power connections

EMI/RFI FILTER DECOUPLINGREACTOR

LINEINSERTIONS

ULTRA-QUICKBREAKFUSES

OUTPUT FILTER TO LIMIT dV/dT SCREENING(IF NEEDED)

POWERBUS

ac wave 2 power frequency inverter - Eltexmanuali.eltex.biz/Manuali_Reel/WAVE2 en/AC W2 Power rel2_0...

Documents

Transcript of ac wave 2 power frequency inverter - Eltexmanuali.eltex.biz/Manuali_Reel/WAVE2 en/AC W2 Power rel2_0...