Série 8v - Manual Inglês

VECTOR CONTROL INVERTERS SERIES 8V

Us er' s Manua Manuall G ener ener al P ar t

Document No. Floppy Disk No. Revision Date Page

MPE1 8VIIIIII 4 0 22/09/1997 2 of 48

VECTOR CONTROL INVERTER SERIES 8V

Us er 's Manua Manuall G ener ener al P ar t

Name

Signature

Date

Prepared by

I. CERA

22/09/1997

Approved by by

A. FORNASA

22/09/1997 22/09/1997

E.E.I. S.r.l. Vicenza 22/09/1997

MPE1 8VIIIIII

SAFETY WARNINGS

WARNINGS

IV

•

ONLY SKILLED (EN60204-1, 3.58) OR INSTRUCTED (EN602041, 3.31) PERSONS ARE ENTRUSTED TO INSTALL, SET UP, USE, AND SERVICE THIS INVERTER.

•

E.E.I. S.r.l. DOES NOT ACCEPT ANY RESPONSIBILITY BY INADEQUATE OR WRONG INSTALLATION, SET UP, USE, OR SERVICE OF THIS INVERTER.

•

THE VOLTAGES ON BARE PARTS OF THE INVERTER MAY CAUSE LETHAL SHOCK.

•

THE INVERTER MAY HAVE ROTATING PARTS (FAN).


MPE1 8VIIIIII

This document, together with its attachments, is property of E.E.I. S.r.l. All rights are reserved. Full or partial reproduction is forbidden.

V


MPE1 8VIIIIII

TABLE OF CONTENTS SAFETY WARNINGS.................................................................................................. IV

Chapter 1 GENERAL DESCRIPTION 1.1 1.2 1.3 1.4

GENERAL......................................................................................................... 1-2 MAIN FEATURES ............................................................................................. 1-2 APPLICATIONS ................................................................................................ 1-3 GENERALITIES ABOUT VECTOR CONTROL ................................................. 1-4

Chapter 2 TECHNICAL SPECIFICATIONS 2.1 TECHNICAL SPECIFICATIONS OF INVERTERS SERIES 8V ......................... 2-2 TABLE 2.1: INVERTERS SERIES 8V.......................................... 2-2 2.2 EMPLOYMENT LIMITS..................................................................................... 2-3 TABLE 2.2: EMPLOYMENT LIMITS ............................................ 2-3 2.3 MECHANICAL DETAILS ................................................................................... 2-4 TABLE 2.3: SHAPES AND DIMENSIONS ................................... 2-5 2.4 CONTROL BOARD LAYOUT............................................................................ 2-7

Chapter 3 POWER CONNECTIONS 3.1 SAFETY WARNINGS........................................................................................ 3-2 3.2 POWER CONNECTIONS FOR INVERTERS SERIES 8V ................................ 3-3 TABLE 3.1: FUSES AND POWER CABLE CROSS-SECTIONS. 3-4

Chapter 4 MAN-MACHINE INTERFACES 4.1 4.2 4.3 4.4 4.5 4.6

GENERAL......................................................................................................... 4-2 PORTABLE PROGRAMMING UNIT ................................................................. 4-3 PC-COMPATIBLE PROGRAMMING SOFTWARE ........................................... 4-3 E.E.I. VIDEOKEYBOARD ................................................................................. 4-4 LOCAL SUPERVISOR WITH PC ...................................................................... 4-4 REMOTE SUPERVISOR WITH PC................................................................... 4-5

Chapter 5 PROTECTIONS 5.1 PROGRAMMABLE PROTECTIONS ................................................................. 5-2 5.2 NON-PROGRAMMABLE PROTECTIONS ........................................................ 5-3

Chapter 6 SERVICING 6.1 INSTALLATION OF NEW APPLICATIONS....................................................... 6-2 6.2 CONTROL CARD REPLACEMENT .................................................................. 6-3 6.3 MAINTENANCE ................................................................................................ 6-4

VI


MPE1 8VIIIIII

App. A CONNECTION AND WIRING SCHEMES FIG. A1: EXTERNAL WIRING AND BLOCK DIAGRAM .................................. A-2 FIG. A2: INTERNAL CONNECTIONS MOD. 8V003021.................................. A-3 FIG. A3: INTERNAL CONNECTIONS MOD. 8V003051.................................. A-4 FIG. A4: INTERNAL CONNECTIONS MOD. 8V203360-8V203500................. A-5 FIG. A5: INTERNAL CONNECTIONS MOD. 8V313750-8V313100................. A-6 FIG. A6: INTERNAL CONNECTIONS MOD. 8V403120-8V513150-8V513200A-7 FIG. A7: INTERNAL CONNECTIONS MOD. 8V613300 .................................. A-8 FIG. A8: INTERNAL CONNECTIONS MOD. 8V703600 .................................. A-9

VII


MPE1 8VIIIIII

chapter 1 GENERAL DESCRIPTION

1.1 1.2 1.3 1.4

GENERAL .........................................................................................................1-2 MAIN FEATURES..............................................................................................1-2 APPLICATIONS.................................................................................................1-3 GENERALITIES ABOUT VECTOR CONTROL .................................................1-4

1-1


MPE1 8VIIIIII

1.1

GENERAL

The EEI inverters series 8V allow an efficient employment of three-phase motors (1 ÷ 450 kW, 2 ÷ 8 poles) for four-quadrant drives, with a good uniformity of motor rotation and low noise.

According to choice, two control techniques are available: Sensorless frequency/voltage control: open loop cotrol of asynchronous motors • without encoder or rotor position sensors. Field oriented control with position & speed feedback from incremental encoder. The • performance of these AC drives becomes comparable to that of DC drives: high static precision and dynamic response of speed and torque (also at zero speed and at strong load variations), use of AC motors at constant torque or at constant torque/power. A 16 bit microcontroller manages the main controls through numeric processings of analog and digital signals. Specific programs are available for several applications (others are made on request). A high number and variety of internal functions, parameters and auxiliary inputs/outputs characterises all program versions. Their flexibility allows to program and control many functions and control types, selfdiagnosis, running and working. Power and versatility of the internal functions make unnecessary hardware variants and external circuitries allowing either single or multiple motor machine control. Serial communication RS 485 allows data storage and parameters adjustment from external units even during running, and a complete visualization and a fast setting from operator. Connection with a bus CAN (Controller Area Network) allows to realise multi-drive configurable architectures, with high-speed digital transmission of references, signals, commands, etc.

1.2

•

• •

•

• •

•

• • •

1-2

MAIN FEATURES

Power circuit with IGBTs (insulated gate bipolar transistors), electrolytic capacitors with life-time longer than 50000 hours, low inductance connections. PWM modulation with 5 kHz frequency. Field oriented control with position and speed feedback from encoder, employment of Hall effect current sensors, Gate Arrays and hybrid circuits. 16 bit microcontroller for general management of drive controls, alarms, diagnostic, digital and analog I/O signals. Several auxiliary configurable digital I/Os, all with optical isolation. Several auxiliary configurable analog I/Os, some differential, others in frequency for position control. Application program resident in Flash memory programmable via serial line. Either standard or specific programs for several applications are available. Dedicated programs may be developed on request. Auxiliary serial multiplexed output for alarm or data transmission. Local signalling with two 7-segment displays and 16 LEDs. Serial line RS485 for communication with host PC or EEI videokeyboard that allow:


•

• •

• •

MPE1 8VIIIIII

- Displaying accurate diagnostic information - Setting parameters and their immediate reading, tuning, restoring after control card replacement - As option, communication with a plant Host Computer provided with Modem for telediagnosis and teleservice. CAN bus (Controller Area Network) for digital high-speed transmission of references, signals, commands, etc. Optional interface unit for serial communication based on PROFIBUS standard. Single DC link for multi-inverter feeding. At this purpose, a large range of AC/DC converters for 380-415V AC line are available: - Non-regenerative with braking resistor - Regenerative with braking energy recovered into mains and sinusoidal current absorption (reactive power and harmonic currents nearly zero). 24 Vdc independent auxiliary supply. Control circuits isolated from power circuits and auxiliary 24 Vdc supply (internal switching power supply).

1.3

APPLICATIONS

The inverters series 8V are dedicated for industrial applications requiring good static and dynamic performances and independent or combined controls of speed, acceleration, torque, space, and eventual. They allow: • • •

Auxiliary transducers management (encoders, dancer arms, force sensors) Choice of several control and running modes (jog, slow and fast run, etc.) Production parameters and data storage.

Typical application areas are: •

•

Single drives, with PID speed regulation, several internal or external speed references, rounded programmable ramps of acceleration, deceleration, normal and quick stop. Multi-drive machines, with internal management of functions as: − Diameter or pull controls for pay-off/take-up − Pull and/or stretching controls − Space controls: positioners and trackings − Controls with absolute electric shaft or with programmable numeric ratio, changeable via serial line.

1-3


1.4

MPE1 8VIIIIII

GENERALITIES ABOUT VECTOR CONTROL

The solidity and reliability of the asynchronous motor, its low cost and no maintenance need, surely account for the success and broad diffusion of this motor in industrial applications. But we do not forgive that all this it has made possible by the technological development reached in static conversion field, and in particular by the vector control inverter. In industrial automation applications, either realised with DC motors or AC motors, the regulation system of the converter carries out the comparison between a speed reference and the actual motor speed detected by suitable transducer. The result of this comparison is then corrected by a cascade of a speed regulator and a torque regulator. The latter gives out a torque demand so to make zero the difference between the wanted speed and the actual speed. From those simple and short considerations, it is easy understanding that the faster a regulation system gives out a torque demand as a consequence of an input speed error, the better is such a regulation system. In a DC motor the torque is proportional to the armature current and thus it can be rapidly varied, when thyristor drives are employed, by increasing or decreasing the firing delay angle of thyristors. Consequently, the dynamic features of these drives are very good. Instead, in an asynchronous motor, the torque is not connected with a directly controllable quantity; in fact, it depends on the slip frequency (difference between the stator voltage frequency and the rotor rotational frequency). By means of traditional inverters it is possible varying amplitude and frequency of the AC voltage output. But acting on the voltage frequency in order to vary the slip frequency, and thus indirectly the torque, surely implies electrical transients on the motor that force not very quick variations of frequency. This explains the poor dynamic performances of the inverters with this type of control. On the contrary, by means of vector control inverters it is possible to act on quantities that directly affect the delivered torque. The stator currents may be decomposed in two vectorial components: one called Id (direct component) displaced according to the direction of the rotor magnetic flux, the other one called Iq (component in quadrature) perpendicular to Id. The component Id is proportional to the magnetic field, Iq is proportional to the torque. The control of an asynchronous motor becomes then similar to that of a DC motor: Id corresponds to the field current and Iq to the armature current. The EEI vector control inverter gains advantage from this method by adopting an indirect control (the amount of slip is forced) with impressed voltage. The dynamic performances obtained reach and overcome the performances given by a DC drive. 

The EEI vector control inverters Series 8V are designed to be fed by an external DC line, instead of to be provided with an internal rectifier. Such a solution allows to supply with a single apparatus several inverters or choppers (DC/DC converters), to install a centralised system for braking energy dissipation, and the exchange of energy between braking and accelerating drives, with consequent saving of energy absorbed from mains.

1-4


MPE1 8VIIIIII

DC feeding is thus supplied by a suitable converter that rectifies the mains voltage. Different converters may be employed, according to the power required and other particular requirements. For instance, EEI produce special converters and automatic systems for filtering and compensation of reactive power, in applications in which it is necessary to improve the power factor and/or limit the harmonic distortion produced by the conversion systems. The standard solution is a half-controlled non-regenerative AC/DC converter: it gradually charges the filtering capacitors of the inverters during starting phase and becomes a simple rectifier, thus with a high power factor, in steady state operation.

1-5


MPE1 8VIIIIII

chapter 2 TECHNICAL SPECIFICATIONS

2.1 TECHNICAL SPECIFICATIONS OF INVERTERS SERIES 8V.......................... 2-2 TABLE 2.1: INVERTERS SERIES 8V ..........................................2-2 2.2 EMPLOYMENT LIMITS .....................................................................................2-3 TABLE 2.2: EMPLOYMENT LIMITS ............................................2-3 2.3 MECHANICAL DETAILS ...................................................................................2-4 TABLE 2.3: SHAPES AND DIMENSIONS ...................................2-5 2.4 CONTROL BOARD LAYOUT ............................................................................2-7

2-1


2.1

MPE1 8VIIIIII

TECHNICAL SPECIFICATIONS OF INVERTERS SERIES 8V TABLE 2.1: INVERTERS SERIES 8V

CODE 8V0nu02l 8V0nu05l 8V0nu07l 8V0nu12l 8V1nu25l 8V2nu36l 8V2nu50l 8V3nu75l 8V3nu10l 8V4nu12l 8V5nu15l 8V5nu20l 8V6nu30l 8V7nu60l 8V8nu75l

kW (1) 1 2 3 5 10 16 22 35 48 60 75 100 150 300 400

kVA (2) 1.5 3 4.5 7.5 15 22.5 30 45 60 75 90 120 180 360 500

Ica [A] (3) 2.5 5 7.5 12.5 25 37.5 50 75 100 125 150 200 300 600 750

Icc [A] W diss (4) (5) 2.4 35 4.8 68 7.3 100 12 140 25 260 37 410 49 650 76 850 102 950 128 990 156 1230 208 1650 311 2540 641 5000 866 6850

Modulo (6) M0 M0 M0 M0 M1 M2 M2 M3 M3 M4 M5 M5 M6 M7 M8

LxHxP (mm) (7) 225x340x255 225x340x255 225x340x255 225x340x255 225x340x255 225x450x255 225x450x255 225x560x255 225x560x255 225x660x255 225x750x285 225x750x285 305x775x285 605x850x285 605x1025x285

n Inverter version code u Input voltage code l Regulation card code

NOTES • The converters are designed for a continuous use with an unity utilisation factor, in the conditions indicated in table 2.1 and 2.2. Other conditions are indicated in IEC EN 60204-1. • The values shown in columns 1 (mechanical power at motor shaft), 2 (motor total input power), 4 (DC current absorbed by the inverter) are indicatives and they refer to the following rated conditions: - Supply voltage: 500 Vdc (from 380 Vac line) - Output three-phase voltage: 350 Vac - 50 Hz - 4-pole three-phase asynchronous motor, with typical efficiency and power factor, running at rated speed, with Iac current indicated in column 3. • Column 3 (Iac) shows the rms rated output current of the inverter, in Amperes; column 4 (W diss) indicates the power dissipated by the inverter, in Watts, at current Iac and Vac = 350 V - 50 Hz. • Columns 6 and 7 indicate shape and dimensions, in mm, shown in details on tables 2.3. • For altitudes above 1000 m up to a maximum 4000 m derate current Iac indicated by 1% per 100 m. • The EEI are at Customer's disposal for advising the choice of inverter-motor configurations and control techniques tailored on the specific application.

2-2


MPE1 8VIIIIII

2.2

EMPLOYMENT LIMITS

TABLE 2.2: EMPLOYMENT LIMITS Quantity

Unit

MIN

MAX

DC supply voltage (Vdc)

Vdc

650

DC line current ripple (1)

%

30

AC output voltage (2)

Vac

0

455

Output frequency

Hz

0

150

Capacitors life (3)

h

50000

Transient overload

%

Auxiliaries 24 Vdc voltage

125

Vdc

20

28

Operating temperature

°C

0

+50

Storage temperature

°C

-25

+70

Altitude

m

1000

Relative humidity (non-condensing)

%

95

Vibrations

g

0.2

NOTES •

The DC line power supply must produce a rms ripple small than 30% of Idc current indicated in table 2.1.

•

The maximum output voltage (Vac max) depends on the available DC voltage Vdc: Vacmax = 0.7 x Vdc

•

The life-time of uncharged capacitors is at least 10 years at 40 °C ambient temperature. It is recommended to replace capacitors before the indicated terms.

2-3


MPE1 8VIIIIII

2.3

MECHANICAL DETAILS

•

Constructive shapes and dimensions of the inverters series 8V are indicated in table 2.1 and, with more details, in table 2.3.

•

Assembly on onboard panel with screws M6.

•

Plate 20/10 enclosure epoxy painted; anodized aluminium external heat-sinks.

•

Models with natural ventilation, with radial or axial fans (see table 2.3).

•

Easy accessibility and maintenance: complete front-door opening for access to interface and power internal circuitries, external control circuitries.

•

Connections by connectors for a rapid replacement of control and interface circuitries.

2-4


MPE1 8VIIIIII

TABLE 2.3: SHAPES AND DIMENSIONS

→

2-5


MPE1 8VIIIIII

NOTES • • • • •

•

2-6

All dimensions are indicated in mm Symbol * indicates interaxial clamp, with screw M6 Power terminals are indicated with letters/symbols R, S, T, +, Ground terminal is indicated with the proper symbol Control terminals and serial line socket are respectively indicated with letters F and L Fans power supply: - Module M1: 24 Vdc, 2.5 W (internal supply) - Module M2: 24 Vdc, 4.5 W (internal supply) - Modules M3 and M4: 24 Vdc, 12 W (auxiliary supply line) - Modules M5 and M6: 380Vac, 350W (external supply line) - Module M7: 380Vac, 2x350W (external supply line).


2.4

MPE1 8VIIIIII

CONTROL BOARD LAYOUT

The following figures show the layout of the mains components on the control board R03 and R06, respectively.

figure 2.1

2-7


MPE1 8VIIIIII

figure 2.2

2-8


MPE1 8VIIIIII

chapter 3 POWER CONNECTIONS

3.1 SAFETY WARNINGS ........................................................................................3-2 3.2 POWER CONNECTIONS FOR INVERTERS SERIES 8V.................................3-3 TABLE 3.1: FUSES AND POWER CABLE CROSS-SECTIONS .3-4

NOTE

In the present manual, only power wiring of inverter is described. Control wiring, since dependent on kind of application installed onboard, is treated in the manual of application.

3-1


MPE1 8VIIIIII

3.1

SAFETY WARNINGS

CAUTION ELECTRIC SHOCK HAZARD •

THE VOLTAGES ON BARE PARTS OF THE INVERTER MAY CAUSE LETHAL SHOCK.

WARNING IN ORDER TO WARRANT THE SAFETY OF PEOPLE, THE INVERTER ENCLOSURE AND THE APPARATUS IN WHICH IT IS INSTALLED MUST BE GROUNDED. IN SUCH A WAY, CURRENT A FAULT MAY GENERATE WILL BE EASILY SCATTERED AND TOUCH VOLTAGES WILL BE REDUCED AT NON-DANGEROUS LEVELS.

CAUTION

ELECTRIC SHOCK HAZARD •

WHENEVER THE DRIVE HAS BEEN ENERGISED, IT MUST BE ISOLATED (DISCONNECTED FROM THE POWER SUPPLY) IF ANY INTERNAL ADJUSTMENTS ARE TO BE MADE. A PERIOD OF 15-20 MINUTES MUST ELAPSE AFTER ISOLATION TO ALLOW THE INTERNAL CAPACITORS TO DISCHARGE FULLY. UNTIL THE DISCHARGE PERIOD HAS PASSED, DANGEROUS VOLTAGES MAY BE PRESENT AT THE TERMINALS AND WITHIN THE MODULE. SUCH A RECOMMENDATION FAILS IF A SINGLE DC LINK IS USED, AS WRITTEN IN IEC EN 60204-1: IN THIS CASE AN APPROPRIATE BLEEDER RESISTOR IS ABLE TO BRING DC VOLTAGE UNDER 60V WITHIN 5 SECONDS.

WARNING IN ORDER TO ENSURE A GOOD COOLING OF THE INVERTER, IT IS NECESSARY TO LET ABOUT 100 mm FREE SPACE OVER AND UNDER THE DRIVE. LACK OF OBSERVANCE OF THIS NOTICE MAY CAUSE DANGEROUS OVERHEATING OF THE DRIVE.

3-2


MPE1 8VIIIIII

WARNINGS •

•

•

•

•

•

3.2

INVERTER INSTALLATION IS A RESPONSIBILITY OF THE USER AND IT MUST BE DONE ACCORDING TO THE SAFETY PROVISION IN FORCE. POWER CABLES AND RELATIVE SHORT CIRCUIT PROTECTION MUST BE CORRECTLY DIMENSIONED, IN ORDER TO GUARANTEE THE SAFETY DURING WORKING. A WRONG CONNECTION MAY DESTROY OR DAMAGE THE DRIVE. ONLY QUALIFIED PERSONNEL CAN PERFORM SETUP OR MAINTENANCE OF THE DRIVE. A CORRECT OPERATION OF THE DRIVE ASSUMES SUITABLE CARRIAGE, INSTALLATION, SET UP, AND MAINTENANCE. KEEP THE DROP-FRONT CLOSED DURING DRIVE OPERATION.

POWER CONNECTIONS FOR INVERTERS SERIES 8V

Terminals + R, S, T

Function

Clamping Screws

DC supply input

M8

AC three-phase output

M8

Ground terminal

M8

3-3


MPE1 8VIIIIII

TABLE 3.1: FUSES AND POWER CABLE CROSS-SECTIONS (*) TYPE

kW

kVA

Iac nom

Iac

Idc nom Fuse

[A]

[A]

[A]

Fuse (code) (**)

Fuse Carrier (code) (**)

DC side Power Cable Cross-section [mm²]

AC side Power Cable Cross-section [mm²]

8V003021

1

1.5

2.5

3

10

170M0158

89090014

1

1

8V003051

2

3

5.0

6

10

170M0158

89090014

1.5

1.5

8V003071

3

4.5

7.5

9

16

170M0159

89090014

2.5

2.5

8V003121

5

7.5

12.5

15

25

170M0161

89090014

4

4

8V103251

10

15

25

30

40

170M0163

89090014

10

6

8V203360

16

22.5

37.5

47

63

170M0165

89090014

16

16

8V203500

22

30

50

63

80

170M0166

89090014

25

16

8V313750

35

45

75

94

125

170M1368

89090014

35

25

8V313100

48

60

100

125

160

170M1369

89090014

70

50

8V403120

60

75

125

150

200

170M2617

89090015 (***)

70

70

8V513150

75

90

150

188

250

170M1371

89090014 (***)

120

70

8V513200

100

120

200

250

350

170M2620

89090015 (***)

20 x 5

120

8V613300

150

180

300

375

500

170M4414

2 x 89090011

30 x 5

25 x 5

8V703600

300

360

600

640

800

170M6462

2 x 89090022

50 x 5

30 x 5

900

(*)

Data referred to the drive rated current. External components. BUSSMAN® fuse codes are shown. (***) With additional bars for cables with cross-section greater than 90 mm². (**)

3-4


MPE1 8VIIIIII

chapter 4 MAN-MACHINE INTERFACES

4.1 4.2 4.3 4.4 4.5 4.6

GENERAL .........................................................................................................4-2 PORTABLE PROGRAMMING UNIT..................................................................4-3 PC-COMPATIBLE PROGRAMMING SOFTWARE............................................ 4-3 E.E.I. VIDEOKEYBOARD..................................................................................4-4 LOCAL SUPERVISOR WITH PC.......................................................................4-4 REMOTE SUPERVISOR WITH PC ...................................................................4-5

4-1


MPE1 8VIIIIII

4.1

GENERAL

A programming and supervision unit can talk to several converters through a single serial line RS 485 that connect the unit with all the drives and the other microprocessor cards optionally connected. The communication is bidirectional (from unit to drives and vice-versa) with the programming unit as 'master' and the drives and other microprocessor cards as 'slaves'. The programming unit can: - receive and display a large number of data about drive operation (memorised parameters, measurements, operating states, alarms, diagnostic information) - ask cyclically to the slaves for data to display - transmit to the slaves the parameter values programmed by operator through the keypad of the programming unit (in case of inverter, the values will be stored into the EEPROM memory of the control card R03.0). In particular it is thus possible to setup a drive during commissioning, to change some parameters when necessary, to make effective the different operating modes foreseen by the drive, to restore the old parameter values in case of replacement of a fault control card. It has to underline that presence and working of a programming unit are not necessary for the drive running but just to it setting. Optionally, a programming unit can be connected to a Host Computer for plant control, by means of another serial line RS 485 and proper interface and software. Host Computer allows for example to collect production and efficiency data from several machines, statistical processing of production data and failure events, report printing, etc. To a Host Computer is then possible to connect a MODEM for telediagnosis and teleservice.

4-2


4.2

MPE1 8VIIIIII

PORTABLE PROGRAMMING UNIT

The portable programming unit designed by EEI is contained in a very small enclosure (96x96x29 mm) provided with a 5-digit + sign display for numerical values displaying, a 1-digit display for operating mode visualization, and a 4-key touch-pad. Thanking to it compactness and essentiality, the portable programming unit is an economical and useful mean to set parameters in a drive. After setup, it may become also a convenient measuring instrument, on-panel mountable, for main operating quantities visualization. The communication with an EEI converter is possible by directly connecting the programming unit with the serial line socket present on the converter control card.

figure 4.1

4.3

PC-COMPATIBLE PROGRAMMING SOFTWARE

For each application, EEI offer at request a program runable on an AT-compatible PC for setup and communication with a single converter. The communication between computer and drive is realised by a RS-232/RS-485 interface supplied with the kit. This solution is suggested in case of drives which do not require, after commissioning, a programming unit permanently connected, except for servicing or inspection.

4-3


MPE1 8VIIIIII

4.4

EEI VIDEOKEYBOARD

The EEI videokeyboard is a microprocessor system especially dedicated to multidrive machine programming and monitoring. It allows to setup the drives connected and to report actual data and alarms from drives and machine. The videokeyboard, contained into a self-extinguishing plastic enclosure and designed for panel mounting, is mainly composed by: a LCD graphic display (240x128 pixels), back-lighted and provided with cursor for • lighting setting. • a 20-key touch-pad, including key 'Enter', 2 function keys, 6 cursor movement keys, and number keys. Key pression is signalised by LED and buzzer. a 16 bit microcontroller card, with a RAM memory completed of buffer battery for • data conservation when unit is off, an EPROM memory containing application software, an EEPROM memory for storage of the parameter values of all the drives connected.

figure 4.2 Figure 4.2 shows the videokeyboard front (265x132.5 mm).

4.5

LOCAL SUPERVISOR WITH PC

The same functions of a videokeyboard can be carried out by a Personal Computer with colour monitor, equipped with proper EEI software. The PC should be connected to serial line with a RS232/RS485 interface (EEI card C06.0). The advantage of a PC as regards a videokeyboard lies in a more powerful and clear visualization of the various pages.

4-4


4.6

MPE1 8VIIIIII

REMOTE SUPERVISOR WITH PC

A remote PC equipped with EEI special software, may become a remote supervisor (Host Computer) for a plant composed by several machines. The remote supervisor should be connected to the machine supervisors through a RS232/RS485 interface (EEI card C06.0) and an external RS 485 serial line. The machine supervisors (videokeyboards or PCs) should be connected to the external serial line through EEI interfaces (cards type 450.0 or C06.0, respectively). With the special software supplied by EEI, a remote supervisor carries out the following functions: − − − −

collection, storage, statistical analysis, and visualization of operating and production data product quality certification by monitorship of the main features of the product automatic programming of operating modes of the machines real time displaying of data from the machines.

A remote supervisor is user friendly since equipped with graphic man-machine interface and on-line guide. It may be also provided with optional accessories as printer (for quality, production, operating data printing), modem (for telediagnosis and teleservices), etc. MACHINE 1

MACHINE 2

MACHINE N

DRIVE

DRIVE

DRIVE

DRIVE

DRIVE

DRIVE

DRIVE

DRIVE

DRIVE

RS485 DRIVE

RS485

RS485

DRIVE

DRIVE

450.C

450.C

C06.0

RS485 External Serial Line

MODEM

Phone Line

C06.0

figure 4.3

4-5


MPE1 8VIIIIII

chapter 5 PROTECTIONS

5.1 PROGRAMMABLE PROTECTIONS .................................................................5-2 5.2 NON-PROGRAMMABLE PROTECTIONS ........................................................5-3

5-1


MPE1 8VIIIIII

In the following paragraphs they are explained the general protections foreseen in an inverter series 8V, by distinguishing those programmable by the user through software parameters from those non-programmable. Intervention of each of the protections described causes a converter consent output commutation. The protection occurred is signalised by the display DG0 of the control card, by means of a hexadecimal code. A table with the alarm codes is reported in the manual of application in use.

5.1

1

Motor thermal overload

2

Minimum DC link voltage Maximum DC link voltage Speed feedback failure

3 4

NOTE: Protection valid only for drive with vector control.

5-2

PROGRAMMABLE PROTECTIONS

When motor rated current is exceeded, the control system starts to calculate the integral of the squared overcurrent. Protection trips if the calculated value reaches the maximum programmed threshold Protection trips when the DC link voltage becomes lower than the value programmed in Volts. Protection trips when the DC link voltage exceeds the value programmed in Volts. Speed transducer integrity is checked by two different protections. Alarm trips when one or both the following conditions happens: 1) the motor speed detected by encoder exceeds the set value or the frequency exceeds the set value + 5% (slip margin). Such protection is always enabled. 2) the speed error, that is the difference between reference and feedback, exceeds the set value. Such protection is enabled by a configuration bit.


5.2

1

MPE1 8VIIIIII

NON-PROGRAMMABLE PROTECTIONS

Tests at switching-on

At a control card switching-on, after a reset command (key 'CPU Reset'), or at a 'watch-dog' alarm trip, the microcontroller performs an internal functionality test, a CRC test of data stored into EEPROM, a RAM read-write test, and a test of control card supply voltages. 2 Microcontroller 'watch- The microcontroller checks the correct execution of the dog' protection program loaded inside. 'Watch-dog' test lies in zero setting, at every program cycle, of a hardware counter inside the microcontroller. Protection trips if such a zero setting does not occur within a fixed time. Trip causes an automatic reset of the control system of the converter. 3 EEPROM failure Protection trips if, during setting of a parameter, the value is not correctly stored into EEPROM. 4 EEPROM error Protection trips if the microcontroller, with a CRC test, detects corruption of data stores into EEPROM. The test is made at every switching on or reset of the control card. 5 RAM error Protection trips if the microcontroller is not able to read or write the RAM memory. RAM read-write test is done at a control card switching-on and after a reset command (key 'CPU Reset'). 6 Supply voltages out of Protection trips if values of control card supply voltages tolerance +12V (VDD) and -12V (VEE) are out of tolerance range. 7 IGBT module Protection trips if a failure is detected in the IGBT power protection modules (overload, minimum driver supply voltage, overtemperature). 8 Inverter Protection trips if the thermal sensor (klixon) placed on the overtemperature heat-sink of the inverter signals 'maximum temperature reached'. 9 External motor Protection trips on input Z6 turning off. This optoinsulated protections input receives consent signal from the external motor protections (overtemperature, fan failure, etc.) 10 DC link overvoltage Protection trips if the DC link voltage exceeds a maximum (HardWare) threshold fixed by an analog circuitry.

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chapter 6 SERVICING

6.1 INSTALLATION OF NEW APPLICATIONS .......................................................6-2 6.2 CONTROL CARD REPLACEMENT................................................................... 6-4 6.3 MAINTENANCE.................................................................................................6-5

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MPE1 8VIIIIII

INSTALLATION OF NEW APPLICATIONS

As already mentioned in this manual, the most important feature of EEI converters is the possibility to obtain customised software versions. Therefore it may occur that a customer needs to install a new application software version. The software is installed into a memory of the control board. The kind of memory employed depends on the control card mounted: in the traditional card R03 the memory is and EPROM, while in the new card R06 it is a FLASH. The EPROM memory is marked with a lable reporting the number of the application, checksum number, and date. The FLASH memory reports only the number of the application. In case of EPROM, the updating of the program requires the substitution of the component, while, in case of FLASH it is possible re-programming the memory via serial line RS485 connected with a PC with proper software. Here they are listed in detail the instructions to follow:

EPROM (card R03): − De-energise the control card R03 by disconnecting the wire from faston terminal +24 or removing the fuse present on the card − Remove with the aid of a screwdriver the pre-existent EPROM (component no. 22) by keeping attention to not damage the pins. − Install the new EPROM in the socket by respecting the correct displacement of the component and checking that all pins are inserted − Energise again the control card. ATTENTION EPROM memory replacement may cause partial or total reset of parameter values previously memorised. Moreover, a new software version may contain new parameters, therefore a general verify of the parameter values is recommended.

FLASH (card R06): − Energise the control card (+24 Vdc between the terminals +24 and 0P). - Connect the PC to terminal RS485 of the control card through a serial cable and the proper RS232/RS485 interface. - Push at the same time the push-buttons CPU-RESET and PRO located on the right center of the control card. - Release only the CPU-RESET push-button and check that the display DG0 show digit '1' and the red Led PRG is on. Then release also the push-button PRO. - Start the proper program in the PC (e.g. C:\LOADER.EXE). On the screen it will appear a menu bar. - Chose the function 'LOAD' of the menu 'UTILITY' and answer to the questions as they will be put, by confirming the answers with the key Enter (e.g.: serial port used, baud-rate of serial transmission between master and slave, name of the program *.HEX to load into FLASH).

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- When answered to all the questions, chek that the display DG0 show before the digit '2' (FLASH data deleting) an then the digit '3' (FLASH data writing). In this phase, on the screen of the PC they will scroll numbers indicating the percentage of data transferring into FLASH memory. - At the end, exit from the program and disconnect the computer from the control card of the inverter. NOTE: If you have available a new FLASH memory in which is already installed the new application program, it is possible to replace the old FLASH by the new one by following the same instructions given for an EPROM replacement. The only differences are that in this case the component is the no. 19 instead of no. 22 and the replacement requires a proper extractor instead of a simple screwdriver. ATTENTION EPROM memory replacement may cause partial or total reset of parameter values previously memorised. Moreover, a new software version may contain new parameters, therefore a general verify of the parameter values is recommended.

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6.2

MPE1 8VIIIIII

CONTROL CARD REPLACEMENT

In order to replace a damaged control card R03 or R06 with a new one, make sure that the drive is de-energised and follow strictly these instructions: •

Disconnect the connections of the card

•

Unscrew the four clamping screws on the angles and take out the card, paying attention to the connector on the bottom

•

With the aid of a screwdriver, remove from the damaged card the EEPROM memory (component no. 28 mounted on socket, on the centre) and install it on the new card.

•

In the new card, set the same address of the damaged card by acting on the proper dip-switches. With card R03, they are on the center (on the left of the EEPROM memory) and are marked as SW0, SW1, SW2, SW3, SW4. With card R06, they are on the right (below the two displays) and are marked as SW1, SW2, SW3, SW4, SW5.

•

In case of card R03, check that the EPROM memory of the new card has the same application number, checksum number, and date of the old card (refer to the lable on the component no. 22). In case of card R06, check that the FLASH memory of the new card has the same numebr of the old one (refere to the lable on the component no. 19).

•

Check that the trimmers 'I MAX ECC' and 'I MAX COPPIA' (on card R03) or 'I MAX' (on card R06) placed on the top right are completely clockwise rotated (trimmer at maximum).

•

Clamp the new card on the module by screwing the four screws on the angles

•

Reconnect the wires to the card

•

Energise the drive

•

Check on the programming unit that 'master' and 'slave' values of the parameters related with the drive are equal. If not, copy the value 'master' into the value 'slave'.

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MPE1 8VIIIIII

6.3

MAINTENANCE

ATTENTION DE-ENERGISE THE DRIVE BEFORE DOING ANY REPAIR OR MAINTENANCE ACTIONS

In order to keep the electric equipment in the best conditions and to preserve its performance, we recommend to do an inspection every 6 months, by following these instructions: •

Remove dust and dirt from the inverter unit

•

Check for any colour changes or deformations of cable sheaths and components

•

Check for loosening of termination screws and slack between connectors and wires.

•

Check for loosening of screws clamping different parts of the module.

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MPE1 8VIIIIII

Appendix A CONNECTION AND WIRING SCHEMES

FIG. A1: EXTERNAL WIRING AND BLOCK DIAGRAM .................................. A-2 FIG. A2: INTERNAL CONNECTIONS MOD. 8V003021.................................. A-3 FIG. A3: INTERNAL CONNECTIONS MOD. 8V003051.................................. A-4 FIG. A4: INTERNAL CONNECTIONS MOD. 8V203360-8V203500................. A-5 FIG. A5: INTERNAL CONNECTIONS MOD. 8V313750-8V313100................. A-6 FIG. A6: INTERNAL CONNECTIONS MOD. 8V403120-8V513150-8V513200A-7 FIG. A7: INTERNAL CONNECTIONS MOD. 8V613300 .................................. A-8 FIG. A8: INTERNAL CONNECTIONS MOD. 8V703600 .................................. A-9

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A-5


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Série 8v - Manual Inglês

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