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1. 406 E 378 298 EM I V RE o o o E 3 3 5 _ O 733 711 A _ E cf olli j j x JA o o o d E 12 ATT D L T gt el PUOUOUOUUUUURP Figure 2 2 8 30 10 97 Operating manual 01 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 2 3 Input AC Line Requirements ATTENTION 22 The allowable AC line voltage fluctuation is 10 to 20 of nominal line voltage 400 V A supply voltage above or below these limits could cause the inverter to trip out with either an overvoltage or an undervoltage fault Adaptation to rated line voltages outside the permissible range is possible by means of autotransformers Calculation according to the formula below is recommend P Pol 1 U2 Pr Equivalent two winding kVA rating kVA Fe TA Pp Continuous output KVA Po U2 Xx lz Xx 3 U Rated line voltage V Us Rated voltage frequency inverter V l gt Input current A as per table 1 5 NOTE Exercise caution when using the ACP 6000 under the conditions of a low voltage network An in
2. VUUUUU o AANNAN VUUUUU o NANNAN o A U A U V d d U al Figure 2 2 6 30 10 97 Operating manual 19 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ACP 6000 37 55 kW 37 kW IP 21 or IP 54 45 55 kW only IP 21 417 378 306 42 Z 1 9 1 f PD RN EA D 733 711 D N 4 Ue E Nen II Y 4 l 9 35 HG 09 220 be 9 a Figure 2 2 7 20 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ACP 6000 37 55 KW IP 00
3. Figure 2 2 2 30 10 97 Operating manual 15 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ACP 6000 5 5 15 0 kW IP 21 IP 54 229 Las 200 La 210 BY tele T SE 449 419 9 utu A LJ BERGES d Figure 2 2 3 16 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ACP 6000 5 5 15 0 kW IP 00 La 229 e 200 203 n TUS X C O SI Loi T 9 5 d 1 90 o 9 ii H E 441 419 6 ot db 7 9 OY 29 Figure 2 2 4 30 10 97 Operating manual 17 05 GB AC
4. NUMBER MESSAGE EXPLANATION FO1 COMPUTER ERROR CPU Malfunction F02 MEMORY ERROR EEPROM Data Destroyed F03 CURR SENSE ERROR Wrong Bus Current Measurement F04 PWR SUPPLY ERROR Power Supply Voltage Low F05 NO DC BUS VOLTS Low DC Bus Voltage Detected F06 OUTPUT SHORT CKT Short Sensed During Power up F07 MOL CONTACT OPEN Motor Overload Terminal Fault F08 OPTION BD FAULT Error in an Option Card F10 RESTART LOCKOUT Auto Restart Number Exceeded F11 GROUND FAULT Ground Fault Detected F12 EXT INTERFERENCE External Interference F13 OVERVOLTAGE DC Bus Voltage Too High F14 UNDERVOLTAGE DC Bus Voltage Too Low F15 DYN BRAKE OVLD DB Duty Cycle above Limits F16 ACCEL OVERCURR Overcurrent During Acceleration F17 DECEL OVERCURR Overcurrent During Deceleration F18 RUN OVERCURRENT Overcurrent While at Speed F19 OVERTEMP TRIP Heat sink Temperature Too High F20 TIMED OVERLOAD Electronic Overload Exceeded Table 7 1 NOTES 1 Faults F01 F08 are checked during the power up sequence F02 is also checked during programming F04 is also checked in the run and stop modes 2 Faults F11 F20 will be reset and the inverter restarted if the Auto Restart function is selected A fault reset for all faults FO1 F20 can be effected by mains ON and OFF or by pushing the STOP key 30 10 97 Operating manual 77 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheid
5. X 115 V AC 1 A PRESET j SPEED SELECTIONS mer cou CIN conj VIN REF LIM con FWD REV 24 R J PS1 PS2 PS3 ART 24 MOL cts RST sT1 ST2 sta ers COM SIO SIO 28 29 30 cf rms S AUXILIARY m lt __1__1_____ D Age 122262 Waat et SE E ue i e RELAY wu OUTPUTS 2g IDE E QE SAN il 5 Eu T cl COAST Eg 35 FORWARD ALTERNATE TO STOP 8888 990 E IE RAMP TIME SELECTOR DIGITAI 2 w che gu oe SELECTOR y T FREQUENCY 5 9s 1185 SE REVERSE REMOTE METER oa Y ra RESET L1 OE Lo de Tt PUSHBUTTON N STOP ww i NOTE 1 A K2 NOTE 6 no 22 RUN JOG SIO F4 SERIAL INPUT OUTPUT RS 485 A OFF 13 PE Li L2 L3 PE ON Ki 14 m NOTES Es F1 F4 FUSES a d LPS _ TWISTET WIRE Ka A2 m OPTION IF TERMINAL MOL IS NOT USED 2 woll A 5 OUTPUT CHOKE A JUMPER WIRE BETWEEN MOL ra AND 24 HAS TO BE CONNECTED e Z F1 F2 F3 E E did dim 5 P e P1 A1 EA K2 Li L2 183 PTC P2 A2 _ The total resistance connected between terminals REF and COM shall not be less than 1000 Ohms 2 Do not connect a potentiometer if inputs such as 4 20 mA or 0 10 VDC are used 3 All control board connections should use twisted and shielded wire with the shield connected to terminal COM see also page 26 Interference suppression measures EMC electromagnetic compatibility and page 28 W
6. group B2 B1 B1 B1 Motor connection 1 5 1 5 1 5 15115115125 4 6 10 16 25 35 50 group B2 B1 B1 B1 Table 2 5 NOTE Observe general RFI suppression measures refer to the Chapter Interference suppression measures EMC electromagnetic compatibility Chapter 2 3 5 Page 26 Control Wiring Interface All interfaces or control inputs and outputs possess only basic insulation by the mains and must be incorporated in a further protective measure Control wiring is wiring connected during installation to the control terminal strip 30 terminals Control wiring must be selected as follows 1 Screened wire is recommended to prevent electrical noise interference from causing improper operation or nuisance tripping 2 Use only VDE UL or CUL recognized wire 3 Wire voltage rating must be a minimum of 600 V for 400 V systems 4 Connect shield to inverter COM terminal only NOTE Observe general RFI suppression measures refer to the Chapter Interference suppression measures EMC electromagnetic compatibility Chapter 2 3 5 Page 26 2 6 Reducing Current Surges and Voltage Transients 30 10 97 05 GB Inrush currents to the coils of the magnetic contactors relays and solenoids associated with or in close proximity to the inverter can induce high current spikes in the power and control wiring causing faulty inverter operation If this condition occurs a snubber network c
7. PARAMETER DESCRIPTION DATA RANGE FACTORY ACCESS SEE CUSTOMER NUMBER NAME SETTING LEVEL PAGE SETTING 01 MODEL Model Number 0 65000 1 1 47 02 RVLVL Software Revision 0 640 W 2 47 03 IRAT Rated Current 2 200 A Wi 2 47 05 SERNO Serial Number 0 65000 2 47 06 REP Repair Date 0 65000 2 47 07 FLT3 Last Fault 1 48 08 FLT2 2nd Fault 2 48 09 FLT1 1st Fault 2 48 12 FOUT Output Frequency 0 400 Hz 1 48 13 VOUT Output Voltage 0 100 1 48 14 IOUT Output Current 0 650 A 1 48 15 LOAD Drive Load 0 200 1 48 16 TORQ Load Torque 0 200 1 48 17 TEMP Inverter Temperature 2 105 C 1 48 18 TIME1 Total Run Time 0 65000 h 2 48 19 TIME2 Power On Hours 0 65000 h 2 48 1B FLUX Magnetizing Current 0 100 2 48 21 MODE Input Mode 0 36 13 1 49 24 FSEL Reference Select 0 19 0 2 49 27 TLSEL Torque Limit Select 0 6 0 2 51 31 FMIN Minimum Frequency 0 01 400 00 Hz 0 00 Hz 1 51 32 FMAX Maximum Frequency 20 00 400 00 Hz 50 00 Hz 1 51 33 F2 Preset Frequency 2 Jog 0 00 400 00 Hz 5 00 Hz d 51 34 F3 Preset Frequency 3 0 00 400 00 Hz 20 00 Hz 2 51 35 F4 Preset Frequency 4 0 00 400 00 Hz 40 00 Hz 2 51 36 F5 Preset Frequency 5 0 00 400 00 Hz 60 00 Hz 2 2 51 37 F6 Preset Frequency 6 0 00 400 00 Hz 0 00 Hz 2 2 51 38 F7 Preset Frequency 7 0 00 400 00 Hz 0 00 Hz 2 2 51 39 FTL Minimum Frequency in Torque Limit 0 00 400 00 Hz 10 00 Hz 2 52 41 RSEL Ramp Selector 0 7 0 2 52 42 ACC1 Acceleration Ramp 1 0 10 600 00 s 3 00 s 1 52 43 DEC1 Deceleration Ram
8. 3 The customer supplied soeed command may be A 0 2 10 VDC B 0 1 10 kHz Pulse train C The 6FS output of another ACP 60008 series inverter 4 The relay combinations K1 K2 and K3 may select 1 of 8 preset speeds See section 2 7 for further Details Relays K4 K6 shall be selected such that their maximum coil current doesn t exceed 50 mA 6 External overloads are optional when using single motors see parameter 67 TOL The function of the MOL input normally closed or normally open contact has to be set via parameter 77 MOL al Frequency inverters must not be connected via a residual current op erated circuit breaker as the sole protective measure see chapter 2 3 1 page 23 30 10 97 Operating manual 73 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 6 2 Options and Accessories WPC Plug In Option Boards WPC Plug In Option Boards are specifically designed to work with BERGES ACP Inverters They install inside any ACP model inverter above the control board in the J7 connector WPC01 Isolated Output Board The WPCO1 Isolated Output Board has two functions One section is used to convert the three open collector transistor outputs ST1 ST2 and ST3 to Form C contacts rated 115 VACA Amp for customer use Each relay can be individually programmed to indicate one of eleven 11 inverter states The other section provides two isolated 4 20 m
9. Mains filter connection with a second Mains filter connection with at least parallel PE conductor 10 mm PE conductor cross section Interference suppression measures EMC electromagnetic compatibility Electrical electronic devices are capable of influencing or disturbing each other through connect ing cables or other metallic connections Electromagnetic compatibility consists of the factors interference resistance and interference emission Correct installation of the inverter in conjunction with any possible local interference suppression measures has a crucial effect on minimizing or suppressing mutual interference The following notes refer to a mains power supply that is not contaminated by high frequency interference Other measures may be necessary to reduce or suppress interfer ence if the mains voltage is contaminated No generally valid recommendations can be given in such cases Please consult BERGES if all recommended interference suppression measures should not produce the desired result Basically it is not the cross section of the conductor that is important for radio frequency interference suppression but the surface area Since the high frequency interference does not flow through the entire cross section but mainly on the outer surface of the conductor skin effect braided copper tapes of corresponding cross section should be used All conductive housing parts must be interconn
10. 30 ae Sea CE RON D s _ SE en NT ___ l i CC 2L LL ske FEE C TII i F AUXILIARY KI A 2222 2 GE ER E a T LE ld ev P RELAY T OUTPUTS 28 30 K4 i START STOP Ki RELAY KS SEE RECOMMENDATION e I T i K6 CUSTOMER KS l SUPPLIED NOTE 4 NOTE 5 z d SPEED COMMAND ki E Ga N h An SEE NOTE 3 ls l PE L1 L2 L3 B B Mi M2 M3 PE l j RECOMMENDATION III ON CONTROL VOLTAGES gt 115 V N N n See DISCOUPLE WITH EXTERNAL 24 V RELAY d PT ATTENTION D I I OPTION CURRENT SUM OF 24 V SUPPLY 200 mA 5 ep ca A 1 OUTPUT CHOKE E T te 4 6 E rL m Fi F2 F3 bett T 5 a L1 gn 1 12 L3 m NOTES F4 F1 F4 FUSES _ d LL F5 MOTOR THERMAL OVERLOAD H i ll el E K1 K3 PRESET SPEED SELECTIONS SERON 1 1 i li MOTOR K4 K6 OPEN COLLECTOR OUTPUT I 1 I Le EXTERNAL FL T t WII THERMAL R IF TERMINAL MOL IS NOT USED BRAKING I ppp sl pa TE OFF A JUMPER WIRE BETWEEN MOL CHOPPER PDB ji NOTE AND 24 HAS TO BE CONNECTED H 13 iaa a 1 el ON Ko M d 14 9 3 AL KO A2 NOTES Do not connect a potentiometer if inputs such as 4 20 mA or 0 10 VDC are used 2 All control board connections should use twisted and shielded wire with the shield connected to terminal COM see also page 26 Interference suppression measures EMC electromagnetic compatibility and page 28 Wiring Practices
11. BERGES Operating manual FIG FIFI MF ACP BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 Program Code Summary Level 1 and 2 Level 1 accesses only basic operator parameters e Level 2 accesses all parameters in Level 1 and Level 2 Level 3 accesses all parameters in Level 1 Level 2 and Level 3 For more information consult Section 5 and publication ACP 6000 Option PARAMETER DESCRIPTION DATA RANGE FACTORY ACCESS SEE CUSTOMER NUMBER NAME SETTING LEVEL PAGE SETTING 01 MODEL Model Number 0 65000 1 1 47 02 RVLVL Software Revision 0 640 W 2 47 03 IRAT Rated Current 2 200 A Wi 2 47 05 SERNO Serial Number 0 65000 2 47 06 REP Repair Date 0 65000 2 47 07 FLT3 Last Fault 1 48 08 FLT2 2nd Fault 2 48 09 FLT1 1st Fault 2 48 12 FOUT Output Frequency 0 400 Hz 1 48 13 VOUT Output Voltage 0 100 1 48 14 IOUT Output Current 0 650 A i 48 15 LOAD Drive Load 0 200 1 48 16 TORQ Load Torque 0 200 1 48 17 TEMP Inverter Temp 2 105 C 1 48 18 TIME1 Total Run Time 0 65000 h 2 48 19 TIME2 Power On Hours 0 65000 h 2 48 1B FLUX Magnetizing Current 0 100 2 48 21 MODE Input Mode 0 36 18 1 49 24 FSEL Reference Select 0 19 0 2 49 27 TLSEL Torque Limit Select 0 6 0 2 51 31 FMIN Minimum Frequency 0 01 400 00
12. Bussmann FRS R are recommended For currents between 15 and 200 amps the typical disconnection times are 150 250 sec for 2 times the overcurrent and 180 1500 msec for 10 times the overcurrent 2 5 Wiring Practices ATTENTION 28 Care should be taken to ensure that field wiring is installed in accordance with the National standard Where local codes exceed these requirements they must be followed Power Wiring Power wiring are those wires which are connected during installation to the power circuit terminals L1 L2 L3 M1 M2 and M3 Power wiring must be selected as follows 1 Use only VDE UL or CUL recognized wire 2 Wire voltage rating must be a minimum of 600 V for 400 V systems 3 Refer to table 2 5 for details of the wire cross sections for mains motor connection DIN VDE 0298 Part 4 The cables must posses copper conductors and must be designed for an insulation class up to 60 C or 75 C Refer to table 1 5 Maximum motor ratings Continuous A 4 Grounding must be in accordance with VDE NEC and CEC Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ATTENTION CROSS SECTION FOR CONNECTION mm Inverter type 0 75 1 5 2 2 3 0 4 0 5 5 7 5 11 15 22 30 37 45 55 Mains supply 15 15 15 1 511 511 512 5 4 6 10 16 25 35 50
13. The standard display shows the inverter operating frequency in Hertz This can be custom tailored to any engineering or machine units by the setting of parameters 84 DISP and 85 UNITS LOAD The last four characters in line 2 display the percentage of maximum continuous inverter output current that is being delivered If a custom display is programmed on this line this information is not displayed but is still viewable at parameter 15 LOAD When the programming mode is accessed by pressing the PROG key for LEVEL 1 or SHIFT and PROG keys for LEVEL 2 or 3 the above display will appear for one second PROGRAMMING ACCESS PARAMETERS PROGRAM LEVEL 1 Rights Access Operating manual ACP 60003 0 75 55 39 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 RIGHTS This section explains the operator s access rights after the program mode has been entered PROGRAM This indicates that while in the programming mode parameter data can be changed VIEW If the inverter is in the run mode forward or reverse when the PROG keys was pressed parameters may viewed but not changed ACCESS This denotes the access level that is being entered It may show Level 1 or Level 2 Section 4 or Level 3 Section 5 Once the program mode has been accessed the above display will provide information on each parameter PROGRAMMING DISPLAYS Desc
14. Installation of a mains filter or a mains filter and a motor choke in accordance with the table below mains filter and motor choke are not included in the scope of delivery Laying the motor cable in a shielded configuration Laying the control cable in a shielded configuration Observe general RFI suppression measures refer to the Chapter Interference suppres sion measures EMC electromagnetic compatibility As compliance with the limit values depends to a great extent on the installation and combination with other units and on the specific application a conclusive statement about compliance with the limit values is possible only after measurement when the installation has been completely installed and is ready for operation Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ACP 6000 DEVICE TYPE FILTER TYPE ARTICLE NO INPUT PHASES VOLTAGE V WEIGHT kg ACP 6000 7 BE V 3012 32501746 3 380 480 1 80 ACP 6001 5 BE V 3012 32501746 3 380 480 1 80 ACP 6002 2 BE V 3012 32501746 3 380 480 1 80 ACP 6003 0 BE V 3012 32501746 3 380 480 1 80 ACP 6004 0 BE V 3012 32501746 3 380 480 1 80 ACP 6005 5 BE VI 3040 32501747 3 380 480 2 70 ACP 6007 5 BE VI 3040 32501747 3 380 480 2 70 ACP 601
15. between the fault occurrance and the resetting of it Parameter 07 FLT3 contains the most recent occurrance 08 FLT2 the one prior to that and 09 FLT1 the first fault on record The elapsed time since the last restart power up or fault reset is the last digit and indicates up to 0 9 Hr The remainder of the code represents the reason for the trip Consult Section 7 Troubleshooting for a list of fault codes and their potential causes 12 FOUT Inverter Output Frequency Hz LIV This display indicates the output frequency at which the inverter is operating 13 VOUT Motor Output Voltage L2V This display indicates the percent of input voltage that is being delivered by the inverter to the motor It is useful when operating motors with non standard Volts Hertz V Hz ratios by means of 53 FKNEE and 32 FMAX 14 IOUT Motor Output Current A LIN This display indicates computed output current in amperes The accuracy is 10 of inverter rating 03 IRAT 15 LOAD Drive Load LIV The display indicates the real part of the motor current by multiplying the computed output current by motor power factor and comparing it to the inverter s capacity The indication is positive in the motoring mode negative in the regenerative mode of operation The accuracy is 10 of full scale 16 TORQ Load Torque 96 LIV This display shows the torque reduction experienced when operating in the constant power or field weakened condition when opera
16. the unit you must ensure that a heat buildup is prevented In certain circumstances the internal air circulation does not suffice when installing the unit in a control cabinet with a small volume Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ATTENTION 30 10 97 05 GB H J The units should never be installed in the proximity of corrosive or flammable gases conductive dust or large magnetic and electric fields Pay close attention during installation to ensuring that no objects such as drilling swarf wire or anything else fall into the unit Otherwise a device fault cannot be excluded even after longer periods of operation Do not use wire end ferrules for the control terminals The terminals are designed so that the wires can be inserted in the terminals after twisting the individual wires Line starting ACP is designed to provide controlled starting and stopping of AC motors by use of the keypad or external contacts connected to the control terminal strip ACP may also be started by applying AC power to terminals L1 L2 and L3 The inverter has line start lock out as a standard feature to prevent automatic starting when line power is applied This provision can be defeated by appropriate programming The inverter may be started once every two minutes in this mode The safety of the operating personnel must be guara
17. 0 Inverter Duty Trip time is at 150 of 67 TOL setting Trip time is at 110 of 67 TOL setting If 67 TOLC is selected 0 3 then the overload trip limit is linearly dropped to 63 of TOL setting from 44 Hz to O Hz in order to compensate for reduced motor ventilation at lower speeds If 67 TOLC is selected 4 7 then the function is set for 10 1 motors without progressively lower limits at speeds below 44 Hz Thus the trip curve for gt 40 Hz will always apply 70 MCAL Analog Meter Output Calibration L2P This parameter adjusts the meter output value at terminal MET The full scale output is programmable from 0 to 255 which corresponds to approximately 0 to 16 5 VDC Factory default is for 10 VDC at terminal MET at nominal full scale output 70 MCAL can be programmed while the inverter is running 71 METER Analog Meter Output Selector L1P 71 METER defines what the analog meter output terminal MET will indicate The data codes are defined as 58 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 DATA CODE DESCRIPTION 0 Output inactive 1 Output proportional to output frequency 12 FOUT with full scale at 32 FMAX 2 Output proportional to output voltage 13 VOUT with full scale at 100 3 Output proportional to output current 14 JOUT with full scale at 200 of drive rating 4 Outpu
18. 00 C IP 21 IP 54 Example Control Identification Number 30 10 97 Operating manual 5 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 The different power ratings available and code for each rating are as follows CODE KW PS 3 x 400 V 6000 7 0 75 1 0 X 6001 5 1 5 2 0 X 6002 2 2 2 3 0 X 6003 0 3 0 4 0 X 6004 0 4 0 5 0 X 6005 5 5 5 7 5 X 6007 5 7 5 10 0 X 6011 0 11 0 15 0 X 6015 0 15 0 20 0 X 6022 0 22 0 30 0 X 6030 0 30 0 40 0 X 6037 0 37 0 50 0 X 6045 0 45 0 60 0 X 6055 0 55 0 75 0 X Table 1 3 1 4 ACP Series Control Specifications MODEL SERIES ACP 6000 SEE PAGE Applicable Horsepower PS 1 75 Motor Output Kilowatt KW 0 75 55 10 Inverter Output Capacity kVA 1 5 135 0 10 Ratings Continuous Amps A 2 421 10 Output Voltage 3 x 7 0 460 VAC Source limited Frequency Range Programmable 0 1 400 Hz 51 62 Overload Capacity at 150 for 60 Seconds 57 58 40 C Ambient 120 for 90 Seconds Running Torque More than 100 Programmable autoboost 54 Efficiency at Rated Greater than 9596 Outputs Inverter Input Input Voltage 10 at 400 460 V 10 22 Ratings 3 inputs all 3 wire Input Current at 2 2 152 8 A 10 Maximum Rated Output AC amperes KVA at 50 60 Hz 1 8 122 0 10 Input
19. Display Units 6 digit RPM 1 2 63 86 LANG Display Language 0 3 0 2 64 87 ACODE Security Access Code 0 999 0 2 64 88 FRO Frequency Reference Output 0 1 0 2 65 A2 RATIO Master Slave Speed Ratio 0 00 200 00 100 00 2 2 65 B1 OPTNO Option Board Number 0 6 0 2 65 Cx CNTLx Event Control 1 9 Binary 8 0 3 2 Ex ECNTx Event Counts 1 9 0 65535 0 3 2 NOTES Level 1 Parameters shown shaded See Section 5 for parameters accessible in Level 3 SIO control 1 Default value is model dependant 2 Parameter adjustable while the drive is in the run mode 3 Consult BERGES for specific implementation instructions Operating manual 30 10 97 05_GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 30 10 97 Operating manual 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 Table of contents Page General information 000 cc tetas 2 1 0 Safety and operating instructions for drive converters 2 1 1 LEE MTM 5 1 2 Inspection RC TT 5 1 3 Control Identification Number 5 1 4 ACP Series Control Specifications 6 1 5 ACP Inverter Input Output Ratings 10 1 6 AC Inverter Fundamentals c c 10 1 7 Description of Operation 11
20. Frequency 50 60 Hz 10 Phase Imbalance 2 maximum 22 Control Control System Sine weighted Pulse Width Modulation with Specifications Application Specific Integrated Circuit Frequency Range 4000 1 0 1 400 Hz Programmable 51 62 6 Operating manual 30 10 97 ACP 6000 LVY 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 MODEL SERIES ACP 6000 SEE PAGE Conirol Frequency Command 0 10 VDC or 0 2 VDC 100 kQ 30 49 Specifications Selections 4 20 mA 237 0 1 kHz or 0 10 kHz pulse train Ext Potentiometer Digital Keypad RS 485 Serial Communication Link Frequency Resolution 0 01 Hz Frequency Stability Analog 40 296 0 1 kHz pulse train 0 4 0 10 kHz pulse train 0 1 Keypad 0 1 RS 485 Port 0 1 V Hz Ratio Programmable using FKNEE function 54 0 01 Hz resolution 400 VAG output models 0 72 to 17 69 Acceleration Deceleration Programmable 0 1 to 600 seconds to maximum 52 Ramps frequency primary and alternate available Minimum Frequency Programmable 0 5 to 400 Hz 0 01 Hz increments 51 Maximum Frequency Programmable 20 to 400 Hz 0 01 Hz increments 51 Torque Limit Four Quadrant Programmable 51 56 5 to 200 torque motoring mode 5 to 110 torque regenerative mode Individual program settings for FWD run FWD regen REV run and REV
21. Hz 0 00 Hz 1 51 32 FMAX Maximum Frequency 20 00 400 00 Hz 50 00 Hz 1 51 33 F2 Preset Frequency 2 Jog 0 00 400 00 Hz 5 00 Hz 1 51 34 F3 Preset Frequency 3 0 00 400 00 Hz 20 00 Hz 2 51 35 F4 Preset Frequency 4 0 00 400 00 Hz 40 00 Hz 2 51 36 F5 Preset Frequency 5 0 00 400 00 Hz 60 00 Hz 2 2 51 37 F6 Preset Frequency 6 0 00 400 00 Hz 0 00 Hz 2 2 51 38 F7 Preset Frequency 7 0 00 400 00 Hz 0 00 Hz 2 2 51 39 FTL Minimum Frequency in Torque Limit 0 00 400 00 Hz 10 00 Hz 2 52 41 RSEL Ramp Selector 0 7 0 2 52 42 ACC1 Acceleration Ramp 1 0 10 600 00 s 3 00 s 1 52 43 DEC1 Deceleration Ramp 1 0 10 600 00 s 3 00 s 1 52 44 ACC2 Acceleration Ramp 2 0 10 600 00 s 1 00 s 2 52 45 DEC2 Deceleration Ramp 2 0 10 600 00 s 1 00 s 2 52 46 DECTL Torque Limit Response Time 0 10 30 00 s 1 00s 2 53 47 DCBRK DC Brake Time 0 00 5 00 s 0 20 s 2 53 48 DCVLT DC Brake Voltage 0 00 15 00 W 2 53 1 Default value is model dependant 2 Parameter adjustable while the drive is in the run mode 30 10 97 Operating manual 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ACP 60005 0 75 55 PARAMETER DESCRIPTION DATA RANGE FACTORY ACCESS SEE CUSTOMER NUMBER NAME SETTING LEVEL PAGE SETTING 51 VSEL V Hz Characteristic Selector
22. Torque Limit FWD 5 110 80 2 56 64 RTLR Regenerative Torque Limit REV 5 110 80 2 56 65 SLIP Slip Compensation 0 00 10 00 0 00 1 56 66 STAB Current Stability 0 6 2 2 56 67 TOL Timed Overload Trip Point 0 100 0 1 57 68 NRST Restart Number 0 8 0 2 57 69 DRST Restart Delay 0 00 60 00 s 0 00 s 2 58 6A TOLC Timed Overload Characteristic 0 7 0 2 58 70 MCAL Meter Calibration 0 255 Set to 1 58 10 VDC 2 71 METER Analog Meter Output 0 8 1 1 58 72 ST1 Auxiliary Output 1 0 11 6 2 59 73 ST2 Auxiliary Output 2 0 11 3 2 59 74 ST3 Auxiliary Output 3 0 11 7 2 59 75 STR Auxiliary Relay Fault 0 11 1 1 59 77 MOL Motor Overload Input Function 0 1 0 2 60 81 PRGNO Special Program Number 0 65000 0 2 61 82 START Inverter Start Options 0 7 0 2 62 83 PWM Carrier Frequency Selector 0 8 1 2 62 84 DISP Display Option Full Setting 0 65000 0 2 63 85 UNITS Display Units 6 digit RPM 1 2 63 86 LANG Display Language 0 3 0 2 64 87 ACODE Security Access Code 0 999 0 2 64 88 FRO Frequency Reference Output 0 1 0 2 65 A2 RATIO Master Slave Speed Ratio 0 00 200 00 100 00 2 2 65 B1 OPTNO Option Board Number 0 6 0 2 65 Cx CNTLx Event Control 1 9 Binary 8 0 3 2 Ex ECNTx Event Counts 1 9 0 65535 0 3 2 NOTES Level 1 Parameters shown shaded See Section 5 for parameters accessible in Level 3 SIO control 1 Default value is model dependant 2 Parameter adjustable while the drive is in the run mode 3 Consult BERGES for specific implementation instruct
23. een een 66 5 1 Program Code Summary Level 2 66 5 2 Programming EE 66 5 3 Parameter Descriptions liliis 67 Applications mac i m r mad bes RE eel ADS deg d M Rh x Rex A Seed ei ds 72 6 1 Connection Diagrams 72 6 2 Options and Accessories s suua aeaaea 74 6 3 Application Hints RP 75 Troubleshooting varen nennen TT 7 1 Eault God8s EE 77 7 2 Troubleshooting og iua EE i Be 78 7 3 Maintenance and Inspection liiis 80 Operating manual 1 ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 1 General information A ATTENTION Explanation of symbols and notes Work safety symbol You will find this symbol next to all work safety notes in this operating manual if there is a risk of injury or death for persons involved Pay attention to these notes and observe particular caution in such cases Also pass on all work safety instructions to other users Voltage warning This symbol is shown wherever particular caution is necessary owing to occurring or applied voltages e g DC voltages up to 650 V and where special precautionary measures have to be taken The inverter must always be isolated from the mains when working on it Caution note This note is shown in all parts of this operating manual to which particular attention must be paid to ensure that the guidelines specifications notes and the correct sequence of work will be obeyed and to preve
24. four 4 parameters set the center frequency of the skip bands over which normal operation will not be allowed The inverter will ramp through these frequencies but not settle on them Each is adjustable in 0 01 Hz increments from 0 00 to 400 00 Hz 59 MVOLT Rated Motor Voltage V L2P 59 MVOLT is a parameter active in the 5 5 55 kW models that allows the user to precisely calibrate inverter to the motor being operated by it This parameter sets the voltage that the inverter delivers to the motor terminals at the setting of 53 FKNEE Therefore it is possible to power the ACP series from 460 VAC and deliver 400 VAC to the motor at 50 Hz precisely matching the motor s design limits The entry specifies the voltage output to the motor by the inverter when 53 FKNEE is reached It is thus possible to supply the inverter with a mains voltage of 460 V however the motor would receive a voltage of 59 MVOLT at the frequency of 53 FKNEE The permissible setting range lies between 370 and 480 Volts Should a number outside of the valid range be selected a F02 fault could be registered This will not be resettable until 59 MVOLT is returned to a number in the valid range Simply re program the drive as you would under normal circumstances 5B IMAG Magnetisierungsstromregelung L2P This parameter tunes the Vector Control scheme to match motor design By adjusting this parameter the inverter motor combination can be optimized for ideal performanc
25. setting of parameter 65 SLIP EXAMPLE Assume the use of a 1440 RPM motor with a nameplate current Im rating of 9 6 amperes From Section 1 5 or parameter 03 IRAT we determine that the drive is rated at 15 2 amperes From Section 1 6 we can determine that the synchronous unloaded speed of the motor to be 1500 RPM Using the formula we find RPMs RPM Im 1500 1440 9 6 65 SLIP x x 100 x X 100 2 5 RPMs IRAT 1500 15 2 65 SLIP is programmable in 0 01 increments from 0 00 to 10 00 66 STAB Current Stability Adjustment L2P Lightly loaded motors tend to oscillate and become unstable due to electro mechanical relationships in the motor This may be more prevalent when the inverter capacity is larger than the motor This adjustment will stabilize the motor current in these conditions The range of adjustment O through 6 with the default being 2 0 no compensation 1 minimum compensation 6 maximum compensation Some 2 pole motors 3000 RPM synchronous Speed have proven to require alteration of this parameter to assure stable operation 56 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ATTENTION 68 NRST Timed Overload Trip Point 67 TOL is the timed overload trip point This parameter defines the load point beyond which a timed electronic overload trip can o
26. settling in at the value programmed at 39 FTL Each is adjustable in 196 increments from 5 to 150 of drive rating If 39 FTL is set to a value greater than 32 FMAX torque limiting will be disabled 63 RTLF Preset Regenerative Torque Limit Forward 96 L2P 64 RTLR Preset Regenerative Torque Limit Reverse L2P These parameters work in conjunction with 27 TLSEL to set the level at which the inverter goes into torque limit in the forward and reverse regenerative modes When these limits are exceeded the motor is accelerated at a rate determined by 46 DECTL toward 32 FMAX Each is adjustable in 196 increments from 5 to 110 of drive rating If 39 FTL is set to a value greater than 32 FMAX torque limiting will be disabled 65 SLIP Slip Compensation LIP Slip compensation is used to provide a more constant output speed as motor loading changes This parameter is used in both the Volts Hertz and High Torque modes of operation Too much slip compensation may result in unstable motor operation It is not intended for use with a synchronous motor In Volts Hertz mode the inverter s output frequency is increased as the motor loading increases In HT mode Vector Control the setting of 65 SLIP is the nominal full load speed compensation for the motor This setting is required for optimum performance at low speeds 65 SLIP is programmable in 0 01 increments from 0 00 to 10 00 See the following formula and example to determine the proper
27. 0 6 0 2 53 52 BOOST Torque Boost 0 00 20 00 Wi 1 54 53 FKNEE V Hz Knee Frequency 26 00 640 00 Hz 50 00 Hz 2 54 54 SKBND Skip Frequency Hysteresis Band 0 20 20 00 Hz 1 00 Hz 2 54 55 SK1 Skip Frequency 1 0 00 400 00 Hz 0 00 Hz 2 54 56 SK2 Skip Frequency 2 0 00 400 00 Hz 0 00 Hz 2 54 57 SK3 Skip Frequency 3 0 00 400 00 Hz 0 00 Hz 2 54 58 SK4 Skip Frequency 4 0 00 400 00 Hz 0 00 Hz 2 54 59 MVOLT Rated Motor Voltage 370 480 V 400 V 2 55 5B IMAG Rated Magnetizing Current 15 00 80 00 0 00 2 55 61 LTLF Load Torque Limit FWD 5 200 150 2 56 62 LTLR Load Torque Limit REV 5 200 150 2 56 63 RTLF Regenerative Torque Limit FWD 5 110 80 2 56 64 RTLR Regenerative Torque Limit REV 5 110 80 2 56 65 SLIP Slip Compensation 0 00 10 00 0 00 1 56 66 STAB Current Stability 0 6 2 2 56 67 TOL Timed Overload Trip Point 0 100 0 1 57 68 NRST Restart Number 0 8 0 2 57 69 DRST Restart Delay 0 00 60 00 s 0 00 s 2 58 6A TOLC Timed Overload Characteristic 0 7 0 2 58 70 MCAL Meter Calibration 0 255 Set to 1 58 10 VDC 2 71 METER Analog Meter Output 0 8 1 1 58 72 ST1 Auxiliary Output 1 0 11 6 2 59 73 ST2 Auxiliary Output 2 0 11 3 2 59 74 ST3 Auxiliary Output 3 0 11 7 2 59 75 STR Auxiliary Relay Fault 0 11 1 1 59 77 MOL Motor Overload Input Function 0 1 0 2 60 81 PRGNO Special Program Number 0 65000 0 2 61 82 START Inverter Start Options 0 7 0 2 62 83 PWM Carrier Frequency Selector 0 8 1 2 62 84 DISP Display Option Full Setting 0 65000 0 2 63 85 UNITS
28. 00 LV series inverters in serial communication applications 66 To change the default programming for a given parameter from 5 1 Program Code Summary Level 3 NAME DESCRIPTION DATA RANGE FACTORY ACCESS SEE CUSTOMER SETTING LEVEL PAGE SETTING 04 TMAX Maximum Heat sink Temperature 60 100 C 85 C 3 67 OA CFLT Current Fault 3 67 11 STAT Inverter Status Byte Binary 8 3 67 22 FNCT Inverter Operating Function 0 4 3 68 23 CNTL Control Information Byte Binary 8 3 68 25 FEXT1 External Speed 1 0 00 400 00 Hz 0 00 Hz 3 69 26 FEXT2 External Speed 2 0 00 400 00 Hz 0 00 Hz 3 69 28 TLEXT External Torque Limit Reference 0 150 0 3 69 29 COUT Control Output Status Binary 8 3 69 7A CIN Control Board Terminal Status Binary 8 3 69 7B CIN2 Option Board Terminal Status Binary 8 3 69 7C FIN Control Board Analog Input Status 0 32768 0 3 70 7D FAUX Option Board Analog Input Status 0 32768 0 3 70 7E LIM Analog Torque Limit Input Status 0 15000 15000 3 70 91 SIOG SIO Communication BAUD Rate 0 7 0 3 70 92 SIOA SIO Slave Address 1 94 1 3 70 93 SIOT SIO Watchdog Timer 0 00 60 00 s 0 00 s 3 70 94 SIOF SIO Fault Byte Binary 8 3 70 95 SIOP SIO Protocol 0 3 0 3 70 5 2 Programming SIO SLAVE ADDR he K er PROG 92 1 A Press the STO
29. 1 0 BE VI 3040 32501747 3 380 480 2 70 ACP 6015 0 BE VI 3040 32501747 3 380 480 2 70 ACP 6022 0 BE 3060 32501665 3 380 480 4 15 ACP 6030 0 BE 3080 32501689 3 380 480 7 95 ACP 6037 0 BE 3100 32501621 3 380 480 7 95 ACP 6045 0 BE 3120 32501736 3 380 480 14 20 ACP 6055 0 BE 3150 32501737 3 380 480 15 40 DEVICE TYPE OUTPUT CHOKE ARTICLE NO INPUT PHASES VOLTAGE V WEIGHT kg ACP 6000 7 BV 20394 307 32501345 440 0 25 ACP 6001 5 BV 20394 307 32501345 440 0 25 ACP 6002 2 BV 20394 307 32501345 E 440 0 25 ACP 6003 0 BV 20394 307 32501345 E 440 0 25 ACP 6004 0 BV 20394 313 32501346 440 0 70 ACP 6005 5 BV 20394 313 32501346 440 0 70 ACP 6007 5 BV 20394 325 32501347 440 1 10 ACP 6011 0 BV 20394 325 32501347 E 440 1 10 ACP 6015 0 BV 20394 330 32501348 E 440 1 15 ACP 6022 0 BV 20394 345 32501350 440 1 65 ACP 6030 0 DRDKkes 80 0 32501783 Z 440 14 60 In 60 A 3 x 0 48 mH ACP 6037 0 DRDKkes 125 0 32501784 a 440 19 85 In 100 A 3 x 0 29 mH ACP 6045 0 DRDKkes 125 0 32501784 440 19 85 In 100 A 3 x 0 29 mH ACP 6055 0 DRDKkes 200 0 32501785 440 32 10 In 130 A 3 x 0 22 mH ACP 6000 IP 54 DEVICE TYPE FILTER TYPE ARTICLE NO INPUT PHASES VOLTAGE V WEIGHT kg ACP 6000 7 BE V 3012 IP 54 32501775 3 380 480 4 65 ACP 6001 5 BE V 3012 IP 54 32501775 3 380 480 4 65 ACP 6002 2 BE V 3012 IP 54 32501775 3 380 480 4 65 ACP 6003 0 BE V 3012 IP 54 32501775 3 380 480 4 65 ACP 6004 0 BE V 3012 IP 54 32501775 3 380 480 4 65 ACP 600
30. 2 52 Input ramps can be selected by connecting this terminal to 24 These ramps Terminals are programmed by parameters 41 44 and 45 See 21 MODE for more information on when this function is active MOL Motor Overload input terminal Requires N C contact for operation refe 10 60 72 renced to 24 Connected to 24 by a jumper wire at the factory 73 CTS Coast to Stop Connecting this terminal to 24 VDC turns the drive output 52 72 73 OFF allowing the motor to coast to a stop The inverter s output is cut off not ramped to a stop When the terminal is set to 0 V open the drive output is reinstated and the output will ramp to the programmed frequency This function may be used when electro mechanical brakes are required This feature can also be accessed in programming by the 41 RSEL parameter to automatically coast to a stop on a stop command RST External Fault Reset input terminal After a fault connecting this terminal 72 to 24 VDC will reset any fault Digital ST1 Open collector NPN transistor output connections Each output can be 59 72 73 Output ST2 individually programmed to respond to any one of eleven conditions See Terminals ST3 parameters 72 ST1 73 ST2 and 74 ST3 Each output can sink up to 50 mA from a 24 VDC source 6FS This terminal provides a 24 VDC pulse train output which is 6 times or 48 65 73 times the output frequency of the inverter Selected by parameter 88 FRO Serial COM Control circuit common electric
31. 44 0 51 0 30 10 97 05_GB ACP 60008LV 0 75 55 Operating manual BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 1 5 ACP Inverter Input Output Ratings AC RATINGS BY MODEL NUMBERS Input ratings Maximum motor ratings Continuous Continuous 1 min at 40 C 2 Inverter type KW KVA 5 A KVA A 1 KVA A 6000 7 0 75 1 8 2 2 1 6 2 0 2 4 3 0 6001 5 1 5 3 4 4 3 2 9 3 7 4 4 5 6 6002 2 2 2 4 9 6 2 4 4 5 5 6 6 8 3 6003 0 3 0 5 5 7 0 4 9 7 0 7 4 10 5 6004 0 4 0 8 6 10 8 7 2 9 0 10 8 13 5 6005 5 5 5 12 8 16 0 10 4 13 0 15 5 19 5 6007 5 7 5 17 7 22 2 14 3 18 0 21 5 27 0 6011 0 11 0 24 7 31 0 19 1 24 0 28 7 36 0 6015 0 15 0 30 2 37 9 23 9 30 0 35 9 45 0 6022 0 22 0 45 3 56 8 35 9 45 0 53 8 67 5 6030 0 30 0 61 4 77 1 48 6 61 0 72 9 91 5 6037 0 37 0 75 5 94 7 59 8 75 0 89 6 112 5 6045 0 45 0 90 0 112 0 71 0 90 0 106 4 133 5 6055 0 55 0 111 0 134 0 88 0 110 0 131 5 165 0 Table 1 5 NOTES 1 Value stored in parameter 03 IRAT Wire size must be selected based upon 60 75 C copper wire insulation rating 2 For chassis models IP 00 ratings are for 1 minute at 50 C 40 C external ambient when enclosed 3 Control rated for 110 of motor rating Continuous 4 Motor thermal overload relay rating 1 1 x continuous motor nameplate amps neces sary only in multimotor applica
32. 5 5 BE VI 3040 IP 54 32501776 3 380 480 6 10 ACP 6007 5 BE VI 3040 IP 54 32501776 3 380 480 6 10 ACP 6011 0 BE VI 3040 IP 54 32501776 3 380 480 6 10 ACP 6015 0 BE VI 3040 IP 54 32501776 3 380 480 6 10 30 10 97 Operating manual 05 GB ACP 6000 Y 0 75 55 25 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 2 3 4 Using mains filters ATTENTION ATTENTION 2 3 5 26 Special protective measures must be observed when using mains filters Owing to the leakage current involved 3 5 mA attention must be paid to EN 50178 when using BERGES mains filters One of the following protective measures must be taken Themains filter must be connected separately by laying a second cable thatis electrically parallel with the PE conductor this conductor must meet the requirements of IEC 364 5 543 on its own The PE conductor must have a cross section of at least 10 mm refer to the following diagrams The PE conductor must be monitored by a facility that isolates the inverter from the mains in the event of a fault PE conductor monitoring The inverter must always be connected permanently EN 50178 when using mains filters leakage current gt 3 5 mA Inverter Mains filter Inverter Mains filter Mains 1 Mains EE L3 PE L1 L2 13 PE PE voll L1 12 L3 PE u u s PE PE L L2 L3 I T I l L I L t I I I L l I l I 10 mm
33. A output signals for customer use One output varies proportionally to the output load and the other is programmable to follow either frequency volts current load or torque WPC02 115 Volt Input Interface Board This option card is used to allow the inverter to be controlled by 115 VAC signals instead of the normal 24 VDC logic It provides isolated control of FWD REV R J PS1 PS2 PS3 ART MOL CTS and RST Additionally two relays are provided with one Form C contact each rated 115 VAC 1 Amp These are controlled by the settings of ST1 and ST3 A Triac output is also supplied which is controlled by the setting of ST2 WPC03 Relay Line Transfer Board This option board provides three relays to convert the three open collector transistor outputs ST1 ST2 and ST3 to Form C contacts rated at 115 VAC 1 Amp for customer use It also allows for synchronous transfer of a motor from inverter power to AC line power and back when used with external contactors not supplied WPC04 Encoder Interface Board The WPC04 option allows the user to interface the ACP 60005 Inverter to a shaft mounted encoder or magnetic pickup It permits such advanced control functions as Closed loop speed control Master Slave operation and Event counting WPC05 Process Control Board The WPCO5 board adds two additional functions to the ACP 6000 LV A bipolar speed reference input with trim and an interface with process signals for speed regulation T
34. Fault refer to parameter 68 NRST for further information 3 Motor running FWD or REV 4 Motor running REV 5 Motor running FWD 6 Motor speed 0 Hz 7 Motor at speed 8 Motor speed greater than value programmed at parameter 36 F5 9 Drive operating in torque limit 10 Drive operating near overtemperature limit 11 Drive operating in LOCal Mode 75 STR becomes active whenever a fault occurs but not in Auto Restart fault conditions where 68 NRST is set different from O The output actions basically follow the individual bits in variable 11 STAT and are subject to the same rules 30 10 97 Operating manual 5 05 GB ACP 60005 0 75 55 co BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 77 MOL Motor Overload Input Function L2P The purpose of this parameter is to specify the input for the MOL input on the connection terminals of the frequency converters and the option boards WPC02 and WPCO6 The following tables show the different settings that are possible DATA TERMINAL BLOCK TRUTH TABLE ACP 6000 LY CODE 0 Normally Closed Contact 24 VDC applied to MOL contact Default 1 Normally Open Contact 0 VDC applied to MOL contact DATA TERMINAL BLOCK TRUTH TABLE OPTION CARD CODE 0 Normally Open Contact 0 VDC applied to MOL contact 1 Normally Closed Contact 24 VDC applied to MOL contact JUMPER J1 DATA CODE DESCRIPTIO
35. Fault L3P This parameter is accessible serially in the event of a default to determine the cause of a fault Itis stored as an integer value with fault code See section 7 and elapsed time available to the host computer Refer to Section 4 for a more thorough discussion of fault codes 07 FLT3 08 FLT2 and 09 FLT1 11 STAT _ Inverter Status Byte L3P This parameter is accessible to determine the present conditions in which the inverter is operating The data is stored as an integer but represents a binary word Bit 47 the most significant bit when active indicates that the drive is operating within the 8 C limit of 04 TMAX Bit 46 when active indicates that the drive is operating in torque limit When bit 5 is active the drive is operating at an output frequency in excess of that programmed at parameter 36 F5 Bit 4 being active indicates that the drive is AT SPEED The remaining bits 3 through 0 combine to indicate multiple conditions as outlined in the following table BIT NUMBER DESCRIPTION 3 2 a 0 O O O Power applied to the inverter and it is IDLE awaiting either an operation or programming instruction 0 0 1 The inverter has faulted O 0 1 O The inverter is in the STOP condition 0 0 O The FORWARD direction has been selected 1 0 O O The REVERSE direction has been selected 1 1 1 0 DC voltage is presently applied to the moto
36. In all other cases the drive obeys the setting of parameter 27 directly 2 Enables or disables the REV key on the keypad 3 When Terminals specified as a speed reference the programming of parameter 24 FSEL actually controls the active speed reference 4 In REM operation terminals PS1 PS2 PS3 and ART are active All will except PS3 in modes greater than 20 perform their previously defined function see Section 2 7 22 FNCT Inverter Operating Function L3P This RAM parameter represented by the integer values 0 thru 4 defines whether the inverter is expecting to receive a programming change or an operational command The host computer either sets 22 FNCT to code 4 to enable a program parameter change or code 9 to enable an operational command 23 CNTL Control Information Byte L3P This RAM parameter is the mechanism thru which actual SIO control of the inverter is achieved It is represented by a binary word The activation of each binary bit is read by the inverter as if the respective terminal were activated at the terminal strip The breakdown is as follows BIT FUNCTIONAL RESPONSE 7 A forward command is initiated as though the FWD terminal is activated from the terminal strip 6 A reverse command is initiated as though the REV terminal is activated from the terminal strip 5 Once this command is initiated either directional command will be maintained until the inverter is commanded to stop or change d
37. Installation and enclosure dimensions 12 2 1 General Rules for Installation 12 2 2 Dimensional Data 14 2 3 Input AC Line RequirementS c ccc 22 2 3 1 Mains power connechon 0000 23 2 3 2 Motor connection llle m MC 0 24 2 3 3 EMC Ordinance EMC Directive O0o 1226EEC rann vnr raner 24 2 34 Using mains filters occ em ee SEN E nex eee EE ER RR kem en 26 2 3 5 Interference suppression measures EMC electromagnetic compatibility 26 2 4 Line FuseorCircuitBreakerSiZing c c eese 28 2 5 Wiring Practices ore ee ebene Een 28 2 6 Reducing Current Surges and Voltage Transients 29 2 7 Function and Use of Terminals 0 cee nenn 30 2 8 Environmental Considerations 33 Control Functions and Operation 35 3 1 General Information liliis 35 3 2 Digital Keypad anne annen tees 35 3 3 Operation Mode STOP and RUN modes 36 3 4 Program Mode u ee en nn 37 3 5 Status LED Indicators 0 nennen rn nenn 37 3 6 Description of Displays Operating Display 38 3 7 eurn 41 3 8 Quick Start Running the Motor 42 3 9 Programming Flowchart 44 Level 1 and 2 Parameters c c 2 2 2 22224 45 4 1 Program Code Summary Level 1 and 321 45 4 2 Programming s e kr x eei ed E um ER Ren d mod E Roca e RR ewe 47 4 3 Parameter Descriptions l l 47 Level 3 parameter rune navn
38. N OPTION CARD 77 MOL WPC02 WPC06 0 Option Card Terminals High input 24 VDC or external signal max 24 VDC referenced to COM will generate an F07 Fault N O operation See also 1 2 Connection Diagrams Page 72 73 See note 1 1 Option Card Terminals Removal of high input 24 VDC or external signal will generate an F07 Fault NC operation See also Connection Diagrams Page 72 73 0 Control Board Terminal Removal of high input 24 VDC or external signal will generate an F07 Fault N C operation See also Connection Diagrams 2 3 Page 72 73 See note 2 1 Control Board Terminal High input 24 VDC or external signal max 24 VDC referenced to COM will generate an F07 Fault N O operation See also Connection Diagrams Page 72 73 NOTES 1 Jumper J1 maintains its function selection of the MOL input exactly as specified in the instructions for installing setting the option board If the option board MOL input is used the MOL input of the option board must be connected to the 24 volt DC connection This prevents overdriving of the buffer gate on the option board If there are zero volts on the MOL terminal of the control board when the option board is selected the operation amplifier of the control board sets the output of the buffer to earth while the operation amplifier changes the signal 2 If the option board has not been installed the MOL input of the cont
39. Operating manual ACP 6000 LV 0 75 55 Two decimal places 63 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 64 Retention Time Example Assume the following program settings The display versus output frequency would be 32 FMAX 50 Hz Motor Frequency Display 31 FMIN 10Hz 50 10 00 MIN 84 DISP 1000 40 15 00 MIN 85 UNITS MIN 9 30 20 00 MIN 20 30 00 MIN 10 60 00 MIN To program 85 UNITS DISPLAY UNITS PROG 85 RPM 1 1 Press the STOP key if the inverter is running Hold the SHIFT key while pressing the PROGram key to enter level 2 Press the SHIFT key The cursor will appear under the leftmost character in the data field Use the UP DOWN arrow keys to scroll through the available choices Press the SHIFT key to move the cursor one place to the right Repeat steps 4 and 5 to complete the character selections N Oo oO fF O N The sixth position requires a number from 0 9 and either determines the number of decimal places in the display or whether the retention time function is activated 8 Press the ENTER key to store the engineering units display in memory or the SHIFT key to move the cursor back to the first position After 84 DISP and 85 UNITS have been set the inverter output will be set and displayed in the engineering units format Display Language L2P This parameter sets the language for the display readout Th
40. P 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ACP 6000 22 30 kW IP 21 IP 54 365 9 gt 327 1 lt Ve RN i r 306 Y 619 600 BERN SCH A ae Ne L L 35 Ao o o o o 2 2 C HE A C DIC 2 Y o o ANNANA VUUVUU r 178 Figure 2 2 5 18 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic e D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ACP 6000 22 30 KW IP 00 356 327 298 9 14 TRA N E O L i a 619 600 gt al 200 i gt C 39 j 00 CH l C 5 sone 210 z LIT TT T lo oLUUUUUUU UR
41. P key to stop the inverter if running Some parameters see the individual parameter description can be changed while the inverter is operating B To enter Level 1 programming press the PROGram key To enter Level 3 hold the SHIFT key and press the PROGram key C Use the UP DOWN arrow keys to select the program parameter for change D Press the SHIFT key The program number will blink indicating that the data value may be changed E Use the UP DOWN arrow keys to select the new data code F Press the ENTER key The display will indicate STORED for one second then revert to the normal parameter display G Press the PROGram key to exit the programming mode or the UP DOWN arrow keys to select a new parameter for change 30 10 97 05 GB Operating manual ACP 60005 0 75 55 BERGES Berges electronic e D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 5 3 Parameter Descriptions This section provides a functional description of all ACP 60005 V programming parameters at Level 3 A V means that this parameter only has a view function while P stands for programmable PARAMETER DESCRIPTION UNITS LEVEL 04 TMAX Maximum Heat sink Temperature C LIV This parameter is factory set to the maximum heat sink temperature that the processor will allow continuous operation of the drive The inverter s display will indicate HI TEMP at TMAX 8 C The data type for 04 TMAX is a real number OA CFLT Current
42. The input logic will accommodate either 12 or 24 VDC logic signals Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 C Input Terminal Usage HINT All ACP inverters are set at the factory so that control is possible both via the terminals and via the keypad Refer to pages 49 and 72 for details of adaptation to customer specific control methods 21 MODE 24 FSEL Applications On delivery the default language of the display messages is English If necessary change parameter 86 LANG in order to set the country specific language J7 Option connector J6 E Control terminals K Power terminals CPU activity LED Charge indicator Figure 2 7 30 10 97 Operating manual 31 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 Analog Terminals MET DESCRIPTION OF TERMINALS This analog output is adjustable from 0 VDC to 15 VDC full scale and is referenced to COM It may be programmed via parameter 71 METER to read output frequency output voltage output current output load in percent of inverter capacity and output motor torque In the constant torque range torque follows load In the constant power range torque will decrea
43. al isolated from the AC line terminals 66 72 Communi SIO Positive connection for the Serial Input Output Operation communication cation link Responds to RS 485 protocol see Section 5 A SIO Negative connection for the Serial Input Output Operation communication link Responds to RS 485 protocol see Section 5 Normally open contact for the Auxiliary Relay Will close when the relay is 59 Auxiliary activated Rating is 115 VAC at 1 Amp Relay Auxiliary Relay Common terminal May release by appropriate adjustment Terminals at one of eleven preset conditions see parameter 75 STR BEY Normally Closed contact for the Auxiliary Relay Will open when the relay is activated Rating is 115 VAC at 1 Amp Table 2 7 2 8 Environmental Considerations The BERGES ACP 6000 Inverter is rated IP 54 through 37 kW indoor or outdoor use This is a sealed unit providing a degree of protection against falling rain splashing water and hose directed water If your inverter will be subjected to high pressure wash down or atmospheric contaminants such as acid or caustic vapours or carbon metallic or corrosive dust contact BERGES for specific instructions In order to maintain the IP 54 NEMA 4 integrity of the ACP inverter enclosure some care must be exercised when the cover is installed With the smaller chassis configurations ACP 6000 thru 15 kW the following cover installation procedure shall be employed 1 Snug each of t
44. al of SIO generated fault Options codes Parameter Block A0 Speed Ratio and various parameters relative to the Option Parameters calibration of option cards WPC Parameter Block BO Option Board Identification and various parameters Option Parameters relative to the calibration of option cards WPC Parameter Block CO Used with program sequencer to control drive Event Control Bytes operation Parameter Block EO Used with program sequencer to control drive Event Count Bytes operation Construction IP 00 IP 21 IP 54 IP 54 standard thru 37 kW Mounting IP 00 and IP 21 In separate enclosure free from dust liquids and 12 Location corrosive fumes IP 54 Indoor or Outdoor protected from direct sunlight 12 33 Ambient Operating Temperature IP 00 0 C to 50 C Conditions IP 21 IP 54 0 C to 40 C Storage Temperature 20 C to 60 C Humidity 90 RH or less noncondensing Vibration 0 6 G Maximum Elevation Below 1000 m without derating Table 1 4 DIMENSIONS WEIGHT N LO CN e e LO LO e e e e e e e o e a ei Te N L a e n LO L a e e e e e e e r r N co co T LO gt e e e e e e e e e e e e e e r e o o Dimensions IP 00 mm 221 x 301 x 135 229 x 441 x 203 356 x 406 x733 x298 W x H x D 619 x 298 Weight IP 00 kg 5 5 11 5 35 0 39 0 Dimensions IP 54 mm 227 x 307 x 142 229 x 449 x 210 365 x 417 x W x H x D 619 x 306 733 x 306 Weight IP 54 kg 6 0 12 5
45. al speed pot current monitored If any of the three connections are broken the drive will stop Not for use with any external supplied voltage or current references 3 VIN Terminal Input follows the 6FS 6x output of another ACP series 1 3 inverter 4 FPT1 Pulse train input at VIN 0 1 kHz 6 10 VDC peak minimum 4 5 FPT2 Pulse train input at VIN 0 10 kHz 6 10 VDC peak minimum 6 FKPAD Keypad Speed Reference 2 7 FEXT2 External speed reference 2 programmed via 26 FEXT2 default 0 Hz 8 FEXT1 External speed reference 1 programmed via 25 FEXT1 default 0 Hz 9 F2 Programmable via 33 F2 default 5 Hz 10 F3 Programmable via 34 F3 default 20 Hz 11 F4 Programmable via 35 F4 default 40 Hz E 12 F5 Programmable via 36 F5 default 60 Hz 13 F6 Programmable via 37 F6 default 0 Hz 14 F7 Programmable via 38 F7 default 2 O Hz 15 FMAX Programmable via 32 FMAX default 50 Hz 19 VIN Terminal Input follows the 6FS 48x output of another ACP series 13 inverter NOTES 1 Data codes 0 through 5 define the type and response characteristic of input speed signal connected to the terminal strip of the inverter 2 If speed control is programmed from the keypad at parameter 21 MODE the selection at parameter 24 is ignored oo Frequency of input signal determined by parameter 88 FRO If parameter 24 FSEL is set data code 19 adjust the J2 jumper see page 31 figure 2 7 to the 0 2 V position for better resolu
46. ameter values This section will give a brief description of the various display formats that may be seen during start up operation and programming On delivery the default language of the display messages is English If necessary change parameter 86 LANG Page 64 in order to set the country specific language POWER UP AND FAULT RESET MODES RESTART The restart display is present whenever power is applied to the inverter or a fault condition is reset It will be displayed for about one second during which time the computer is checking various functions within the inverter OPERATING DISPLAY Control Status LOG STOP SET 0 00 Hz 0 96 Mode Frequency Load During normal operation this display will provide important information about the inverter and load CONTROL The first three characters of the top line denote the source of control for the inverter LOC Local control via the Keypad REM Remote control from the terminal strip SIO Remote control via the RS 485 Serial SIO Link SEQx Control via the Program Sequencer ADJ Auto tune mode for Parameter 5B IMAG STATUS 38 Twelve characters are dedicated to the current status of the inverter output This includes normal operating conditions and warning messages STOP The inverter is in the STOP mode ACCELERATE The motor is increasing in speed DECELERATE The Motor is decreasing in speed AT SPEED Motor spe
47. arameter 44 ACC2 defines the secondary inverter response to an increase in speed command It is adjustable in 0 01 second increments from 0 1 to 600 seconds from zero to maximum frequency The factory setting is one 1 second Deceleration Ramp 2 s L2P Parameter 45 DEC2 defines the secondary inverter response to a decrease in speed command It is adjustable in 0 01 second increments from 0 1 to 600 seconds from maximum to zero frequency The factory setting is one 1 second Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ATTENTION ATTENTION 30 10 97 05 GB 46 DECTL Torque Limit Response Time When the drive senses that the torque limit threshold has been exceeded it takes immediate action If operating in the motoring mode it begins to decelerate toward the value of 39 FTL If operating in the regenerative mode it begins to accelerate toward the rational speed to which it is being driven In either case 46 DECTL governs the drive s response time 47 DCBRK DC Brake Time s L2P In the keypad or terminal input mode after issuing a STOP command the inverter ramps down to zero speed and provides a holding DC current in the motor windings for the period set by 47 DCBRK This function is not available with zero 0 seconds set at 47 DCBHK or if the stopping performance is set for coast If DCBRK set to 5 0 seconds and bo
48. at are active from the Keypad the Terminal Strip and the SIO Serial Link in both the LOCal and REMote operating modes Also the mode transfer mechanism is defined by your selection at this parameter Proper setting of this parameter is the first step in customising the inverter to your application The following table defines all the combinations available Other selections for 21 MODE are discussed in Section 5 DATA CODE LOCal 1 REMote 1 LOC REM SEE FWD only FWD REV Speed 3 Start Stop Speed 3 Start Stop TRANSFER VIA NOTE 2 2 Keypad Control Only 0 20 10 30 Keypad Disabled N A Terminal Strip Control Only 4 24 14 34 Disabled Terminals N A 4 Combination Keypad Terminal Strip Control 1 11 Keypad Terminals Keypad LOC REM key 4 5 12 Keypad Keypad Terminals LOC REM key 4 13 Keypad Terminals LOC REM key 4 21 31 Keypad Terminals Keypad PS3 4 5 22 32 Keypad Keypad Terminals PS3 4 23 33 Keypad Terminals PS3 4 NOTES 1 Under LOCal operation when control is specified as keypad the active torque limit reference is the preset values at parameters 61 thru 64 as if parameter 27 TLSEL were set to a code 3 In all other cases the drive obeys the setting of parameter 27 directly 2 Enables or disables the REV key on the keypad 3 When Terminals specified as a speed reference the programming of parameter 24 FSEL actually controls the active speed reference 4 In REM operation terminals PS1 PS2 PS3 and ART a
49. be answered is What numeric indication do we want the display to indicate at if we re operating at maximum frequency parameter 32 FMAX This value may be modified to compensate for the number of decimal places programmed at parameters 85 UNITS For example to indicate 1500 0 RPM on the display at FMAX 50 Hz enter 15000 at parameter 84 DISP Entries must be within the range of 10 65000 85 UNITS Display Units Setting The programming for 85 UNITS is different from most parameters in that the keypad keys operate differently The UNITS identifier has up to a six character format with each of the first five characters having the ability to display characters from the following list Blank O through 9 lt gt and A through Z L2P The last character is a number between 0 and 9 If this value is set between 0 and 5 it will assign the position of the decimal place in the engineering units display The factory setting 1 which will display the value programmed at 84 DISP with one decimal place is RPM If the last character is selected to be 9 the retention time function is invoked This is rather than a frequency speed proportional output a reciprocal function The maximum display is 655 34 dependent on the value programmed at 84 DISP at output frequencies less than that or less than 3 2 Hz the display will indicate are maintained in this mode of operation and cannot be changed
50. binations with RC elements or with free wheel diodes Use shielded cables for external control and measuring cables Lay disturbing cables e g power and contactor control circuits separately and at a distance from the control cables 30 10 97 Operating manual 27 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 2 4 Line Fuse or Circuit Breaker Sizing ATTENTION The user must provide either a circuit breaker or a fused disconnect switch in accordance with the local codes The following rules should be used to select the correct size of the input line fuses or circuit breaker Sizing The ACP inverter is able to withstand a 15096 overload for 60 seconds Minimum voltage rating for the protection device should be 500 VAC for ACP 6000 models Fuse Type To guarantee a maximum protection of the inverter fuses should be used for current Limitation These fuses should have a breaking capacity of 200 000 Aen Table 2 4 shows the recommended values in amps for all ACP inverters For 400 V mains supplies we recommend time lag type NEOZED fuses ACP 6000 KW 0 75 1 5 2 2 3 0 4 0 5 5 7 5 11 15 22 30 37 45 55 Rating A 2 4 6 6 10 16 16 25 32 50 63 80 100 125 Table 2 4 For mains supplies with rated voltage exceeding 400 V the semi lag fuses type
51. ccur The trip time depends on the amount of overload and is 1 minute for 150 of the setting longer for lesser degrees of overload A 10 overload will not cause the drive to trip Parameter 67 TOL is adjustable in 1 increments from 0 to 100 of drive capacity The factory setting is 0 inactive The action of 67 TOL is presented graphically in the Trip Time chart to the follow See also parameter 6A TOLC for information on setting timed overload appropriately for your motor The proper setting of parameter 67 TOL is calculated by using the value stored at 03 IRAT and the motor nameplate current lm according to the following formula Im 67 TOL x100 IRAT V EE 36 180 360 30 150 300 0 20 gt 40Hz G 24 120 240 D L 18 90 180 E o 2 12 60 120 kr 6 30 60 o 0 Y 0 50 100 150 Percent load When using multiple motors on a single inverter use separate external protection on each motor and set 67 TOL to 0 disabled This parameter is not active when 67 TOL 0 30 10 97 05 GB Trip Restart Number Providing the inverter is operated from a maintained run command this parameter will allow the drive to be automatically restarted after fault up to a programmed number of attempts This limit is from zero 0 up to a maximum of eight 8 tries within a 10 minute time frame In each case the drive will wait fo
52. control for most applica tions This may be prohibitive in some cases If a remote station is to have exclusive control of speed and direction commands set 21 MODE to code 4 or 14 The keypad stop key will remain active as both an EMERGENCY STOP button and a fault RESET mechanism To defeat the E STOP function set parameter 82 START to a value greater than 3 being careful to observe the other ramifications of the selection ability to start a rotating motor and line start lockout An access code may be assigned to prohibit unauthorized program revision See parameter 87 ACODE for more information Finally if absoluted necessary the entire keypad may be removed for total isolation of the control Install a WBPO1 in place of the keypad on enclosed models to maintain the IP 54 integrity Operating manual ACP 60005 0 75 55 75 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 76 Fixed Ratio Master Slave Control of Multiple Inverters A series of master and slave controls is quite common in industrial processes Most are uni directional applications Frequently it is necessary that they not all run at exactly the same speed With the ACP 6000 LV series the kind of control is possible even while maintaining the use of one standard keypad for system control This scheme requires control reprogramming to reset the speed ratio of the followers however To accomplish full system control from the
53. d controls all operations of the inverter The ten input keys allow Press and Run operation of the motor and straightforward programming of the parameters To simplify the programming further the parameters are separated into pro gramming levels Level 1 Easily accessed by pressing the PROG key at anytime Limits access to the most commonly used parameters for operator convenience Level 2 This is used when the more advanced features of ACP are needed It is accessed by pressing the SHIFT and PROG keys simultaneously All parame ters can be either viewed or programmed except those associated with the SIO Serial Communication Link Level 3 This level is automatically added to Level 2 when the SIO Serial Input Output link is selected parameter 21 MODE 3 2 Digital Keypad Figure 3 1 A detailed description of all the keys and displays follows 30 10 97 Operating manual 35 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 3 3 Operation Mode STOP and RUN modes KEY FUNCTION Initiates forward run when pressed momentarily If the drive is running in reverse when FWD is pressed it will decelerate to zero speed change direction and accelerate to the set speed N Initiates reverse run when pressed momentarily If the drive is running in forward when REV is pressed it will decelerate to zero speed change
54. direction and accelerate to the set speed May be disabled by the setting of 21 MODE Note If both keys are pressed and held at the same time the drive follows the first key pressed 9 Press to enter the JOG mode when stopped When in the JOG mode the drive will ramp in the forward direction to a programmable JOG speed 33 F2 while the FWD key is held The drive will ramp to a stop when the FWD key is released Pressing the REV key causes a similar operation The ramp will be at a rate set for normal acceleration and deceleration To leave the JOG mode press STOP or the JOG key a second time Causes a Ramp to Stop when pressed This function can be programmed to cause a Coast To Stop when pressed 41 RSEL If the drive has stopped due to a Fault condition pressing the STOP key will reset the fault Also functions as an emergency stop when the drive is remotely controlled In the Stop mode pressing this key increases the desired running speed of the drive That is the speed to which the drive will accelerate when a Run is initiated In the Run mode pressing this key dynamically adjusts the running speed of the drive Setting resolution is 0 01 Hz If the key is pressed and held for five 5 seconds the setting frequency will scroll automatically at an increased rate Also see SHIFT description below In the Stop mode pressing this key decreases the desired running speed of the drive That is the speed to which the
55. drive will accelerate when a Run is initiated In the Run mode pressing this key dynamically adjusts the running speed of the drive Setting resolution is 0 01 Hz If the key is pressed and held for five 5 seconds the setting frequency will scroll automatically at an increased rate Also see SHIFT description below In the Stop or Run modes pressing this key will Lock in the frequency selected by the UP and DOWN arrow keys so that if power is removed and re applied that frequency will be the initial default speed setting The display will show STORED for 1 second when the command is completed RIP Shifts drive control between the LOCal and REMote control modes as selected by the 21 MODE Page 49 parameter Can be programmed to shift 1 The Run Stop command either FWD or REV or 2 The speed reference signal or 3 Both or 4 Disabled Will operate either in the Stop mode or while the drive is running If power is removed and re applied the memory will retain the last selected function In the Run mode pressing this key will access the parameters at Level 1 for viewing only Pressing the SHIFT and PROG keys simultaneously will access Level 2 for viewing only The UP and DOWN arrow keys will work as described in the Programming section of this document Operation of the motor will not be affected while viewing the information in these parameters and parameter changes cannot be made Pr
56. e This parameter becomes active when parameter 51 VSEL is set to a Data Code of 6 The ACP 60008 V has an Auto tune function that will measure the no load currents and automatically set 5B IMAG See High Torque Set Up Procedure for Auto tune procedure Although normally not required fine tune adjustments can be made to the parameter after the Auto tune procedure is completed The value of 5B IMAG is adjustable in 0 0196 increments in a range of 15 80 with a model dependant factory setting The factory setting is 0 Adjustments to the setting can be made using the following formula measured no load current B IMAG x 1009 5 G IRAT 00 High Torque Set Up Procedure The following procedure allows the ACP 60008 V series AC inverter to be set up for low speed high torque operation 1 Program Parameter 51 VSEL to Data Code 6 see page 53 2 Program Parameter 65 SLIP per the formula on page 56 3 Run the drive at 15 Hz setpoint and minimal loading free shaft operation if possible Enter Level 2 programming and scroll to parameter 5B IMAG ADJ should appear in the lower left corner of display Press the ENTER key on keypad to have the drive Auto tune the 5B IMAG value The drive will measure the magnetising currents and place a value into parameter 5B IMAG Although not required repeating the process to verify consistent results is recommended Check the system for performance For most applications the abov
57. e Rodt Tel 02264 17 0 Fax 02264 17126 7 2 Troubleshooting FAULT CAUSE REMEDY NUMBER F01 Noise on Power Line Reset the drive using the stop key or remote reset 2 Remove power wait for the BUS CHG indicator to extinguish and re establish power 3 If the problem persists install a line noise filter F02 Excessive Ambient Electrical Noise 1 Verify the proper use of shielded wire for remote signal or an Invalid 59 MVOLT Setting connections 2 Remove power wait for the BUS CHG indicator to ex tinguish and re establish power 3 Verify the setting of 59 MVOLT and reset to a valid number F03 Excessive DC BUS Current Verify the proper sizing of the inverter for the driven load Determine the reason for the overload Check for reduce excessive load on the 24 VDC supply Remove power 10 15 min then reapply F04 Logic Power Supply Overload F05 No DC Bus Voltage Check for proper source voltage Check for DB component or output transistor failure Check for shorted DC bus Check motor wiring Extend the acceleration time Consult BERGES Reduce 52 BOOST value Increase 53 FKNEE value Isolate line and load wires F06 Output Short Circuit or Ground Fault F07 External Fault Mechanism i e Motor Overload Relay MOL Tripped F08 Option Board Fault Check motor temperature Verify the sizing of MOL Verify the proper connection and usage of applicable opti
58. e factory can supply a complete listing in all languages The options include DATA CODE LANGUAGE 0 English 1 Spanish 2 French 3 German 87 ACODE Security Access Code L2P This parameter allows the user to control access to the programmable functions of the inverter The initial value of 87 ACODE is 000 that results in no access code being necessary Any number between 001 and 999 may be used for an access code but is not necessary To enter a access code simply re program parameter 87 as though you would any other parameter After you have stored this new value you will have ten minutes of free access If you remove power and re establish it you will need to enter the access code to change any program parameter If you enter an incorrect access code the inverter will display WRONG CODE and allow only VIEWing rights to the various parameters Once the correct code is entered you again have 10 minutes of free access unless power is removed and re applied To disable the access code requirement set 87 ACODE back to 000 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 88 FRO Frequency Reference Output L2P This parameter determines the frequency pulse train output from the 6FS terminal Each of the frequency outputs can be used as a speed reference input to another ACP 60008 series inverte
59. e inverter output terminals M1 M2 or M3 Never use power factor correction capacitors on the motor terminals M1 M2 and M3 or damage to the semi conductors will result If interrupting contacts e g contactors or motor protection switches etc have to be installed between the motor and inverter the circuit must be configured so as to ensure that the Enable signal terminals 24V CTS is activated before separation of the inverter motor connection A relay switching time of approx 30 ms suffices 2 3 3 EMC Ordinance EMC Directive 89 336 EEC HINT 24 The frequency inverters were tested in the form of a practical test set up in a switchgear cabinet in accordance with our interference suppression measures in these operating instructions Interference suppression measures EMC electromagnetic compatibility The limit values of the standards below were fulfilled under these conditions EMA Electromagnetic emission EN 50081 1 Basic specification Emitted interference Limit value class A or EN 50081 2 Basic specification Emitted interference Limit value class B EN 55011 Emitted interference EMB Electromagnetic interference EN 50082 2 Basic specification Interference immunity EN 50140 Electromagnetic fields EN 60801 Static discharge ESD IEC 801 4 Burst on mains lead data line At least the following conditions must be fulfilled for compliance with the limit values of the aforementioned standards
60. e is exited the display will indicate INIT PARAMETERS then RESTART 3 Data code 2 allows storage of the current set of program parameters Data code 3 allows a previously stored set of program parameters to be retrieved Data code 4 allows the current and stored set of program parameters to be exchanged 4 Parameter 21 MODE must be set to a code that permits MODE 2 REMote operation Also the drive must be operated in REMote mode 5 Data codes 32 and 33 select the ACP EMOP control programs With code 32 selected commanded output frequency returns to 31 FMIN when the drive is stopped With code 33 selected commanded output frequency remains at the previous setpoint See follow ing table for proper usage FUNCTIONAL EMOP2 EMOP3 DATA CODE 32 33 DESCRIPTION TERMINALS FWD REV PS1 PS2 Off 0 0 X X Speed 0 1 1 X X FWD Decrease Speed 1 0 1 X FWD Hold Speed 1 0 0 0 FWD Increase Speed 1 0 0 1 REV Decrease Speed 0 1 1 X REV Hold Speed 0 1 0 0 REV Increase Speed 0 1 0 1 0 Inactive 1 2 Active X Ignored 30 10 97 Operating manual 05 GB ACP 60005 0 75 55 61 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 82 START Inverter Start Options L2P This parameter selects options such as line start lockout line starting or starting a rotating motor 82 START also allows the keypad STOP key for function as an emergency stop wh
61. e procedure is sufficient for ideal drive motor performance For additional fine tune adjustments see the following steps 1 Run the motor in the 2 6 Hz range If the drive appears to draw excessive currents at low speeds with no load decrease the setting of 5B IMAG Too much 5B IMAG can result in unstable motor operation 30 10 97 Operating manual 55 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 2 Run the motor in the 2 6 Hz range under full load conditions If the drive draws greater than motor nameplate current reduce the value of 52 BOOST If it appears the motor is not developing sufficient torque increase the value to 52 BOOST For proper performance at frequencies below 6 Hz inverter duty motors are recommended 52 BOOST is set at a value predetermined for premium efficiency motors When using inverter and vector duty motors the value of 52 BOOST may need to be adjusted HINT Application support is available from BERGES by calling the telephone numbers 02264 17 160 02264 17 102 and 02264 17 109 61 LTLF Preset Load Torque Limit Forward 96 L2P 62 LTLR Preset Load Torque Limit Reverse 96 L2P These parameters work in conjunction with 27 TLSEL to set the level at which the inverter goes into torque limit in the forward and reverse motoring modes When these limits are exceeded the motor is decelerated at a rate determined by 46 DECTL
62. e purpose of continuously variable speed control of three phase motors Drive converters are components designed for inclusion in electrical installations or machin ery The drive converters are designed for installation in a switchgear cabinet applies only to units of protection class IP 00 IP 21 and for permanent connection The operator of the system is solely liable for damage resulting from improper use of the drive converter Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic e D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 30 10 97 05 GB Only items expressly approved by BERGES e g mains filter choke external braking choppers and braking resistors etc may be used as accessories The installer of the system is liable for any damage resulting from the use of accessories that have not been approved expressly by BERGES Please consult us in case of doubt In case of installation in machinery commissioning of the drive converters i e the starting of normal operation is prohibited until the machinery has been proved to conform to the provisions of the directive 89 392 EEC Machinery Safety Directive MSD Account is to be taken of EN 60204 Commissioning i e the starting of normal operation is admissible only where conformity with the EMC directive 89 336 EEC has been established The drive converters meet the requirements of the low voltage directive 73 23 EEC They a
63. ected using corresponding lines Minimum cross sections are prescribed for a fault case at 50 Hz referred to the range of the safety regulations which must be observed under all circumstances The inverter and all other components used for interference suppression especially also the shield of the motor cable should be contacted over as large an area as possible when connected to metal control panels switchgear cabinets and similar skin effect Remove the paint at the respective areas to ensure good contacting over a large area Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 A central earthing point should be used for interference suppression e g equipotential Housing wall earth bonding strip or centrally at an interference suppression filter The earthing lines are routed to the respective terminals radially from this point Conductor loops of the earthing lines are ETEN impermissible and can lead to unnecessary interference paint or varnish e S A The shield cross section must not be reduced when the shield is connected to continuing lines This would give rise to RF resistance at a cross section reduction and the resulting RF energy would consequently not be discharged but radiated Shields particularly shields Large area x contacting of of control lines must not be contacted via pin contacts of plug con
64. ed Frequency inverters must not be connected via a residual current operated circuit breaker as the sole protective measure The single exception below permits connection of a frequency inverter via a residual cur rent operated circuit breaker as the sole protective measure Installation of a residual current operated circuit breaker of the newest design for fre quency inverters up to 4 kVA input voltage 1 x 230 V with MOBILE connection This residual current operated circuit breaker must be suitable for alternating and pulsating DC leakage current Residual current operated circuit breakers of this type bear the symbol X Reliable tripping of the residual current operated circuit breaker is not ensured in the case of frequency inverters up to 4 kVA input voltage 3 x 400 V with MOBILE connection an additional protective measure must be used for this reason Also see the diagram below In the case of frequency inverters with PERMANENT connection input voltage 1 x 230 V and 3 x 400 V another protective measure must always be used in addition to the residual current operated protective device Also see the diagram below The protective function of the residual current operated circuit breaker is no longer ensured due to leakage currents from interference suppression capacitors in the inverter and DC components in the fault current All devices connected to this residual current operated circuit b
65. ed and will always be 0 If bits 4 thru O active the representation is as follows BIT FUNCTIONAL INDICATION 4 Will indicate the activity of ST5 used only on option boards 3 Will indicate the activity of STR the auxiliary relay mounted on the control board 2 Will indicate the activity of ST3 one of the open collector outputs on the control board or the option card mounted relay following its active state 1 Will indicate the activity of ST2 one of the open collector outputs on the control board or the option card mounted relay following its active state 0 Will indicate the activity of ST1 one of the open collector outputs on the control board or the option card mounted relay following its active state 7A CIN Control Board Terminal Status L3P 7B CIN2 Option Board Terminal Status L3P The binary word represented by this integer value can be used to determine the status of the input terminal function Parameter 7A CIN relates to the control board inputs parameter 7B relates to the option board inputs The functions detected by this parameter are represented as active bits according to the following BIT FUNCTIONAL INDICATION 7 Will indicate that Reverse is active Will indicate that Forward is active Will indicate that R J is active Will indicate that CTS function is active Will indicate that the ART input is active Will indicate that terminal PS3 is ac
66. ed by input terminal ART To use ART 21 MODE must be set for terminal start stop control First set of ramps in the forward direction second set of ramps in the reverse direction Terminal ART is inactive Dual slope linear ramp Primary set of ramps control acceleration deceleration when 12 FOUT less than the value programmed at 37 F6 Secondary set of ramps control when 12 FOUT greater than 37 F6 Terminal Art is inactive S curve acceleration and deceleration Terminal Art is inactive Performance same as code 0 except Coast to stop when STOP is commanded Performance same as code 1 except Coast to stop when STOP is commanded Performance same as code 2 except Coast to stop when STOP is commanded Performance same as code 3 except Coast to stop when STOP is commanded 42 ACC1 Acceleration Ramp 1 s LiP Parameter 42 ACC1 defines the primary inverter response to an increase in speed com mand It is adjustable in 0 01 second increments from 0 1 to 600 seconds from zero to maximum frequency The factory setting is three 3 seconds 43 DEC1 45 DEC2 Deceleration Ramp 1 s L1P Parameter 43 DEC1 defines the primary inverter response to a decrease in speed command It is adjustable in 0 01 second increments from 0 1 to 600 seconds from maximum to zero frequency The factory setting is three 3 seconds 44 ACC2 Acceleration Ramp 2 s L2P P
67. ed is at the desired point ZERO SPEED The inverter is in the RUN mode but the motor is not turning Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 30 10 97 05 GB JOG Motor turns only while the FWD or REV keys are pressed Displayed only while JOGGING TORQ LIMIT The output torque of the inverter has reached it s programmed limit level DYN BRAKE The Dynamic Brake circuits are helping to decelerate the motor and load HI TEMP The temperature of the drive is near the maximum limit point HI CURRENT _ The output current is near the overcurrent cutoff point HI VOLTAGE The voltage on the DC bus is near the high voltage cutoff point LO VOLTAGE The voltage on the DC bus is near the low voltage cutoff point SPD SEARCH Autostart has been programmed to 82 START and the inverter is attempting to synchronize its output with the motor speed IDLEZxx SIO mode of operation only The drive is programmed to SIO address 92 SIOA xx It is awaiting either a program or run command LS LOCKOUT Line Start Lockout A run command was detected when power was applied MODE The first three characters on the second line denote the present operating mode of the inverter FWD A Forward run command has been given REV A Reverse run command has been given SET The inverter is waiting to have or is having the running frequency set FREQUENCY
68. en operating the inverter from the terminal strip Various options for 82 START include DATA CODE 0 Line Start Lockout When the inverter is configured for terminal strip operation with a maintained run command present it will not start upon the application of line power The direction command must be removed and re established to start the drive The keypad STOP functions as an EMERGENCY STOP when controlling the inverter from the terminal strip Recovery from an EMERGENCY STOP will require that the STOP key be pressed a second time and then the direction command re established DESCRIPTION 1 Line Start Autostart With this setting the inverter will turn on when line power is applied and a direction command is present The STOP key is configured as an EMERGENCY STOP when operating from the terminal strip 2 This setting allows the drive to successfully start a rotating motor Line start Lockout is active The STOP key functions as an EMERGENCY STOP when operating from the terminal strip 3 Start into a rotating motor with Autostart STOP key enabled 4 7 Same start functions as 0 through 3 but STOP key is disabled totally in terminals mode NOTE When data codes 2 3 6 or 7 are selected the display will indicate SPD SEARCH upon the initiation of a run command INSURE THAT AUTOMATIC RESTARTING WILL NOT CAUSE DAMAGE TO EQUIP MENT OR INJURY TO PERSONNEL 83 PWM _ PWM Carrier Freque
69. er trapped within the fan motor 80 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES BERGES electronic GmbH IndustriestraBe 13 D 51709 Marienheide Rodt Postfach 1140 D 51703 Marienheide Tel 0 22 64 17 0 Fax 0 22 64 I 71 26
70. eration Parameter Block 20 Definition of the LOCal REMote keypad button in Control reference to the keypad terminal strip and the SIO link Also various speed and torque references are contained within this block Parameter Block 30 Various speed setpoints of the inverter Frequencies Parameter Block 40 Ramp time selections the time from start to Ramps maximum frequency FMAX or from FMAX to stop Parameter Block 50 V Hz curves boost minimum frequency at full Voltage Frequency voltage and skip frequencies Characteristics Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 MODEL SERIES ACP 6000 SEE PAGE Programming Parameter Block 60 Torque limit setpoints slip compensation overload Torque Limit trip point and auto restart parameters Parameter Block 70 METer output open collector output and fault relay 1 0 Definition definitions Parameter Block 80 Storage and Retrieval of standard or custom Program Options programs complete reset to factory settings auto restart line start lockout PWM selection display of engineering units alternate display languages and customer access code storage Parameter Block 90 BAUD or communication rate slave address RS 485 Serial Link watchdog timer and retriev
71. essing SHIFT momentarily while holding either the UP or DOWN arrows will initiate the fast scroll without waiting for the five second delay Pressing it a second time will start the fastest scroll rate 36 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 3 4 Program Mode FUNCTION When in the STOP mode pressing this key will enter the PROGRAM mode at Level 1 Pressing this key at any time while in the PROGRAM mode will return the unit to he OPERATION mode Pressing the SHIFT and PROG keys simultaneously will enter Level 2 If an Access Code has been entered re entry is required to change program data In the PROGRAM mode pressing this key will move forward through the successive Parameter Addresses When changing Data in a Parameter this key will increment the data value The ENTER key must be pressed to store the new value In the PROGRAM mode pressing this key will move backward through the successive Parameter Addresses Then changing Data in a Parameter this key will decrement the data value The ENTER key must be pressed to store the new value JD NOTE All parameters except 85 UNITS momentarily pressing both the UP arrow and DOWN arrow keys simultaneously will return the parameter setting to factory defaults Pressing this key while a Parameter is displayed will allow that Parameter to have it
72. esulting phase imbalance exceeds 2 consult your local power company or plant maintenance personnel and ask them to investigate this problem and recommend methods of correcting this condition Phase imbalance can also cause damage to motors running direct on line A 2 imbalance requires a 596 derating factor on the motor 3 imbalance requires a 10 derating 496 requires an 18 derating NEVER USE POWER FACTOR IMPROVEMENT CAPACITORS ON THE ACP MOTOR TERMINALS M1 M2 AND M3 OR DAMAGE TO THE INVERTER S SEMICONDUC TORS WILL RESULT Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 2 3 1 Mains power connection The frequency inverters are designed for installation in a switchgear cabinet applies only to units of protection class IP 00 IP 21 and for permanent connection To guarantee lasting operating safety and reliability the inverter must be connected expertly in accordance with the valid electrical standards Attention must be paid to good insulation from earth potential on the power terminals An three phase system with a nominal voltage of 400 V 50 60 Hz must be connected to mains terminals L1 L2 L3 and PE pay attention to rating plate The neutral point must be earthed TN C system Ensure a voltage balanced to earth or phase to phase when feeding in the mains power through an isolating transformer star point must be earth
73. g the setpoint whereby the drive converter and motor may remain live If inadvertent startup of the motor must be excluded to protect operating personnel electronic interlocking by disabling the motor or by deactivating the setpoint is inadequate This is why the drive converter must be isolated from the mains voltage During operation all covers and doors shall be kept closed Measuring instruments must be connected and disconnected only in de energized condition Unauthorized conversions or modifications on or in the drive converter and its components and accessories will render all warranty claims void When installing an option board observe the installation specification valid for this board Please contact BERGES if conversions or modifications are necessary particularly if electrical components are involved 7 Maintenance and servicing The manufacturer s documentation shall be followed KEEP SAFETY INSTRUCTIONS IN A SAFE PLACE Before you read on please check whether technical changes are attached in the annex to this operating manual 4 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 1 1 Preface This manual contains the specifications installation instructions description of operation and troubleshooting procedure for the ACP 6000 AC inverter Before installing the drive read this manual carefully to ens
74. he bi polar speed reference allows a 10 VDC signal or potentiometer to be used to control both the speed and direction of the motor The process control function permits set point with proportional and integral gain adjustment of pumps fans winders etc using standard analogue feedback signals WPC06 Logic Interface Board This option board has similar features and functions as WPCO2 115 VDC Input Interface Board but is scaled for use with 24 volts AC or DC control signals It also permits the ACP 60005 to be controlled by open collector pull down transistor circuits if required The Triac output used on the WPC02 is not provided 74 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 WKMO1 Keypad Mounting Kit The WKM01 option is intended for use when the standard ACP is mounted inside another enclosure and it is desired to have the standard keypad remotely mounted from the control The kit includes a mounting bezel instructions a 3 m cable for installation and a terminal fan out strip When used with WBP01 see below the keypad can be mounted more than 30 m from the control If properly installed the keypad will retain its IP 54 rating WKM02 Keypad Remote Control Kit The WKMO2 option is intended for use when it is desired to have the standard keypad remotely mounted from the IP 54 inverter unit It allows the key
75. he four 4 cover screws into place 2 Sequentially tighten each screw until the gasket is compressed evenly Tighten first one corner then the opposing corner to minimize the chance of pinching the gasket 30 10 97 05_GB Operating manual ACP 6000 LY 0 75 55 33 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 3 Do not exceed 2 Nm of torque on these screws With the larger chassis configurations the cover should be installed according to the following procedure 1 Swing the hinged door closed making sure that the gasket is not pinched 2 Sequentially tighten each screw until the gasket is compress Alternate sides of the enclosure when tightening to assure even compression 3 Do not exceed 1 1 Nm of torque on these screws If the conduit entries are not used utilize the hole plugs supplied with the IP 54 models and the WCKO01 thru WCK04 Chassis mounting Kits to close the unused holes This will assure the enclosure s environmental integrity 34 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 3 Control Functions and Operation 3 1 General Information All ACP inverters come with a digital keypad as standard equipment Your ACP Inverter is pre programmed to run a standard AC induction motor in many cases no additional programming is required ACP s advanced digital keypa
76. ically Some 2 pole 3600 RPM synchronous speed have proven to require less than the default value of 52 BOOST 53 FKNEE Volts Hertz Knee Frequency Hz L2P This parameter is used to set the frequency at which full voltage is delivered to the motor Thereby the output volts hertz ratio of the inverter is adjusted It is adjustable in 0 01 Hz increments from 26 00 to 640 00 Hz It is factory set to the base frequency of the motor which is 50 Hz for most European made induction motors 53 FKNEE sets the point at which the motor goes from constant torque to constant power operation 32 FMAX determines the maximum operating frequency of the drive Almost any V Hz profile can be generated using the ACP 60009 Y inverter Consult BERGES with your special requirements 54 SKBND Skip Frequency Hysteresis Band Hz L2P This parameter sets the range of frequencies above and below associated with each of the skip frequencies Skip bands are used to avoid mechanical resonances in a drive system The deviation is adjustable in 0 01 Hz increments from 0 20 Hz to 20 00 Hz The factory setting is 1 00 Hz equating to an overall 2 Hz band 55 SK1 Skip Frequency 1 Hz L2P 56 SK2 Skip Frequency 2 Hz L2P 57 SK3 Skip Frequency 3 Hz L2P Skip Frequency 4 58 SK4 Operating manual ACP 60005 0 75 55 Hz L2P 30 10 97 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 These
77. ing Data Codes 1 2 7 or 8 Adjustments are as follows 62 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 30 10 97 05 GB DATA MAXIMUM CARRIER CARRIER CARRIER CODE MOTOR FREQUENCY FREQUENCY FREQUENCY FREQUENCY HZ KHZ KHZ 12 VOUT KHZ 6 VOUT 0 400 Autoselect Autoselect Autoselect EST 260 3 3 3 2 350 4 4 4 3 400 6 6 6 4 400 8 8 8 5 400 12 6 6 6 400 16 8 8 7 400 12 6 3 8 400 16 8 4 Factory setting 84 DISP Display Option Full Setting L2P Parameter 84 DISP along with parameter 85 UNITS allows the bottom line of the keypad display to be programmed in engineering units such as RPM Bottles per hour BPH or any desired unit up to five characters long With factory default setting of 0 the display will present the command output frequency being delivered to the motor As long as the speed command does not change the display will not change With data code 1 selected the operating display will change as the inverter makes changes in the output frequency to maintain commanded performance stator frequency For example slip compensation and regenerative current limit make changes in the stator frequency see parameter 14 FOUT 2 an option parameter For more information on option parameters see parameter 87 PRGNO The basic question that must
78. ions Operating manual 30 10 97 46 ACP 60008LY 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 4 2 Programming To change the default programming for a given parameter INPUT MODE PROG 21 0 A Press the STOP key to stop the inverter if running Some parameters see the individual parameter description can be changed while the inverter is operating B Toenter Level 1 programming press the PROGram key To enter Level 2 hold the SHIFT key and press the PROGram key C Use the UP DOWN arrow keys to select the program parameter for change D Press the SHIFT key The program number will blink indicating that the data value may be changed E Use the UP DOWN arrow keys to select the new data code F Press the ENTER key The display will indicate STORED for one second then revert to the normal parameter display G Press the PROGram key to exit the programming mode or the UP DOWN arrow keys to select a new parameter for change 4 3 Parameter Descriptions The following section contains functional descriptions of all programming parameters at Level 1 and Level 2 The number in the Level column indicates the programming level in which access to the parameter in question is possible Access to all parameters is possible in Level 2 also too parameter in Level 1 A V means that this parameter only has a view function while P
79. irection just as if the R J terminal were activated Activating this bit will put the inverter in a coast to stop mode Activating this bit is functionally the same as engaging the ART terminal Activating this bit is functionally the same as engaging terminal PS3 Activating this bit is functionally the same as engaging terminal PS2 o n w Activating this bit is functionally the same as engaging terminal PS1 30 10 97 05 GB Operating manual ACP 60005 0 75 55 68 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 25 FEXT1 External Speed 1 Hz L3P 26 FEXT2 External Speed 2 Hz L3P Both 25 FEXT1 and 26 FEXT2 are RAM parameters that allow the host computer to write real values for output frequency in storage registers Parameter 24 FSEL then can be used to have the inverter to look at these values as the active speed reference The range is 0 00 to 400 Hz 28 TLEXT External Torque Limit Reference L3P Like 25 FEXT1 and 26 FEXT2 28 TLEXT is a RAM parameter that works as a storage register Real number values between 5 and 150 or drive rating can be stored here Based on the value of 27 TLSEL 28 TLEXT can become the activate torque limit reference 29 COUT Control Output Status L3P The binary word that is represented by this integer value can be used to deduce the status of the drive s digital outputs Bits 5 thru 7 are not us
80. iring Practices 4 The factory setting for the customer meter is 10 VDC full scale indicating output frequency See 71 METER for further information 5 External overloads are optional when using single motors see parameter 67 TOL 6 The function of the MOL input normally closed or normally open contact has to be set via parameter 77 MOL Frequency inverters must not be connected via a residual current op erated circuit breaker as the sole protective measure see chapter 2 3 1 page 23 72 Operating manual 30 10 97 ACP 6000 LV 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 The following diagram shows a two wire starting control along with the implementation of preset speeds and open collector outputs In addition it shows the connection of various customer supplied speed command signals 115 V AC 1 A H L PRESET A SPEED SELECTIONS lt J NL MET com CIN com VIN REF LIM E FWD REV 24 RJ PS1 PS2 PS3 ART 24 MOL CTS RST sT1 ST2 sta 6FS cov se SIO 28 29
81. l optional external DB package F18 Running Overcurrent 1 Locate the cause of a mechanical overload on the motor F19 Heat Sink Overtemperature 1 Check for excessive load on the motor 2 Verify the proper sizing of the ACP for the application 3 Locate the ACP in a cooler location out of direct sunlight F20 Timed Overload 1 Check for ACP sizing for the application 2 Reduce the loading on the motor 3 Check for DB component or output transistor failure 4 Check for shorted DC bus Table 7 2 PROBLEM CHECK POINT CORRECTIVE ACTION Motor is not running Incorrect wiring 1 Check all power and control wiring External frequency command Verify that the external frequency control signal is if used properly connected 2 Verify the integrity of the frequency control po tentiometer if used Programming selections 1 Verify that the proper programming selections have been made for the application Fault 1 Verify that the inverter has not shutdown due to a fault condition 2 Consult Table 7 2 Motor stall 1 Release any overload on the motor 2 Verify that adequate torque boost is available Motor Speed Loose terminal connection 1 Stop the inverter turn off power and tighten all Fluctuation terminal screws 2 Check for tightness of all connections within the drive Frequency control pot erratic 1 Replace frequency control potentiometer Motor Speed Too High Frequency profile 1 Verify tha
82. lectronics necessary to provide variable speed control of the motor in a very friendly fashion Signals can be introduced to the terminal strip for full or partial control of the inverter The powerful serial input output SIO link is available for total communication and programming The keypad provides total control of programming and drive operation LINE INPUTS PRE CHARGE DC BUS 7 T d MOTOR Eg i OUTPUTS RECTIFIER DC QO 1 T BRAKE 3 INVERTER BRIDGE p Oh I 0 iR iA ol kA 4 TEMPERATURE POWER SUPPLY VOLTAGE CURRENT MEASUREMENT AND MONITOR MEASUREMENT MEASUREMENT DRIVER ELECTRONICS Mas CH ees c EL I I l I l RAMP CURRENT PWM I N GENERATOR CONTROL GENERATOR O I I 0 l oo 1 1 i CONTROL i O SIGNAL 1 FUNCTIONS i CONDITIONING i I SC i I O CONTROL AND PARAMETER OT BLOCK l l l 0 SERIAL LINK SIO KEYPAD AND DISPLAY OPTION BOARD o oO Figure 1 7 30 10 97 Operating manual 11 05_GB ACP 6000SLY 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 2 12 Installation and enclosure dimensions 2 1 General Rules for Installation Improper installation of the inverter will greatly effect its life Be
83. master s keypad the following program changes must be made Master 75 STR 5 88 FRO 0 Slave s 21 MODE 4 24 FSEL 3 75 STR 1 Parameter A2 RATIO on each other drive will be used to set the speed ratio of each follower to the master s speed To get the speed to follow each other in a ratio sequence connect Terminal 6FS on the master to each of the follower s VIN terminals and Terminal COM on all the drives together To achieve common direction command connect the FWD terminals on all slaves together with the normally open auxiliary relay on the master and connect the common connection of the master s auxiliary relay to its Terminal 24 To achieve fault interlocking for all the drives connect the normally closed auxiliary relay contacts on all the follower drives in series back to Terminals 24 and MOL on the master This will cause the fault on any slave to shut down the master and the entire system Conclusion Refer to the description of the individual parameters in this manual for the effects of the individual program changes You can consult BERGES if you should have any questions See the contact information on the back of the manual Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 7 Troubleshooting POTENTIAL DANGER Disconnect electrical supply before servicing the electrical system 7 1 Fault Codes
84. meter allows an individual slave address to be assigned to each slave inverter in a multi drive application Integer values between 1 and 94 are available 93 SIOT SIO Watchdog Timer L3P This parameter is the storage location for a real number of seconds With 93 SIOT set to a value greater than zero SIO activity must be logged at least once in that timeframe It is used to monitor communication integrity primarily 94 SIOF SIO Fault Byte L3P The integer value stored at this location may be decoded to a binary word detect faults associated with SIO communication When various bits become active they represent various faults that are SIO communication related The significant bits and their indication are as follows BIT FUNCTIONAL INDICATION 7 The value written in the last communication was outside the range of acceptable values 6 The last communication was to a write protected parameter 5 The last communication was to an unknown parameter 1 The value in seconds programmed at 93 SIOT has been exceeded without a valid SIO communication 0 The restart procedure of drive re initialisation is in process 95 SIOP SIO Fault Byte L3P The integer value stored at this parameter defines the communication protocol selecting various ISO 1745 and OPTO22 options The selections are outlined as follows Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges elect
85. ncy Selector L2P This parameter sets the carrier frequency of the Pulse Width Modulation wave form supplied to the motor Low carrier frequencies provide better low end torque but produce audible noise from the motor Higher carrier frequencies produce less audible noise but cause more heating in the inverter The ACP 6000 Y is rated to produce continuous full load current at rated ambient temperatures when parameter 83 PWM is set to carrier frequencies 3 4 6 or 8 kHz At higher carrier frequencies 12 and 16 kHz the inverter will automatically switch to a lower carrier frequency when load conditions exceed the derating levels Consult Factory for derating by models When the load is reduced the carrier frequency will return to its previous setting Data Code 0 Autoselect autornatically selects the highest carrier frequency permitted without overheating the inverter HINT Autoselect will also adjust the carrier frequency to 8 kHz at 75 C and to 4 kHz at 90 C When using Data Codes 5 amp 6 the carrier frequency will shift to 1 2 of the selected carrier frequency when the output voltage is less than 696 of nominal rating When using Data Codes 7 and 8 the carrier frequency will shift to 1 2 of the selected carrier frequency when the output voltage is less than 12 of nominal rating and to 1 4 of the selected carrier at 6 of nominal output voltage For low speed high torque applications the best performance can be achieved by select
86. nectors In these cases the cable shield the metallic hand guard of the plug connector should be used for large area connection of Motor cable the shield with braided shield Use a shielded motor cable earthed over a large area at both sides The shield should be routed uninterrupted from the PE terminal of the inverter to the PE terminal of the motor see also Connection Diagrams Page 72 If a shielded motor line cannot be used the unshielded motor line should be laid in a metal duct The metal duct must be uninterrupted and adequately earthed The following points are prescribed if radio interference suppression is to be realized in accordance with EN 55011 EN 55014 and EN 50081 1 Installation of a mains filter or a mains filter and a motor choke in accordance with the table on page 25 mains filter and motor choke are not included in the scope of delivery Laying the motor cable in a shielded configuration Laying the control cable in a shielded configuration Observe general RFI suppression measures refer to the Chapter Interference suppres sion measures EMC electromagnetic compatibility Lay motor mains power and signal cables as far away from each other as possible and separately If a mains filter is used the smallest possible spatial distance from the frequency inverter must be selected so that both units can be connected by short connection leads If an output choke is used option it must be fi
87. nt damage or destruction of the inverter and or systems 1 0 Safety and operating instructions for drive converters N 1 General In operation drive converters depending on their degree of protection may have live unisolated and possibly also moving or rotating parts as well as hot surfaces In case of inadmissible removal of the required covers of improper use wrong installation or maloperation there is the danger of serious personal injury and damage to property For further information see documentation All operations serving transport installation and commissioning as well as maintenance are to be carried out by skilled technical personnel Observe IEC 364 or CENELEC HD 384 or DIN VDE 0100 and IEC 664 or DIN VDE 0110 and national accident prevention rules For the purposes of these basic safety instructions skilled technical personnel means persons who are familiar with the installation mounting commissioning and operation of the product and have the qualifications needed for the performance of their functions We draw attention to the fact that no liability can be assumed for damage and malfunctions resulting from failure to observe the operating manual Technical amendments of illustrations and data given in this operating manual are reserved in the interest of improving the unit and its functions 2 Intended use The application of the drive converter described in this operating manual exclusively serves th
88. ntained or three wire momentary operation 72 73 24V Reference Voltage for Digital inouts FWD REV R J Run Jog PS1 PS2 PS3 MOL and ART rated 200 mA Overloading this terminal will result in fault F04 May be used to power relays tied to open collector outputs ST1 ST2 and ST3 72 73 R J Run Jog Selector When this terminal is connected to 24 momentarily connecting either FWD or REV to 24 results in a latched run mode 3 wire operation 72 73 PS1 PS2 PS3 Preset Speed 1 input Preset Speed 2 input Preset Speed 3 input Eight preset speeds are attainable one from the main speed setter six programmed speeds and FMAX Preset speeds can be programmed from 0 to 400 Hz but FMAX sets the actual operating range 1 is closed to 24 0 is open All may be obtained from the following switching matrix PS1 PS2 PS3 Effective speed reference Basic speed setpoint 24 FSEL 33 F2 34 F3 35 F4 36 F5 37 F6 38 F7 QOD Q0 0O 0O 4 0 0 a 0 0o aa O l ololo 32 FMAX 51 72 73 32 Operating manual ACP 60005 0 75 55 30 10 97 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 DESCRIPTION OF TERMINALS SEE PAGE Digital ART Alternate Ramp Time Selector Separate acceleration and deceleration 49 5
89. nteed in all oper ating states Please refer to the safety instructions in chapter 1 0 page 2 The mains voltage must be switched off before opening or working on the device Dangerous voltages are present as long as the charge indicator lamp is still lit Operating manual ACP 60005 0 75 55 13 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 2 2 Dimensional Data The following pages show the dimensional data for the IP 00 IP 21 and IP 54 ACP inverters ACP 6000 0 75 4 0 kW IP 21 IP 54 Ka 200 142 ge IT i ie 307 280 noe nw A BERGES A U Figure 2 2 1 Operating manual 30 10 97 14 ACP GO003LV 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 ACP 6000 0 75 4 0 kW IP 00 221 200 135 id 79 ER Ei i 301 280 0002 Cg DODO t J lesesosos Q D
90. o the inverter DC intermediate circuit is possible via the terminals B and B An additional dynamic braking unit additional support capacitors or a DC emergency power supply system can for example be connected to these terminals Another possibility is to connect the inverter intermediate circuits in parallel regenerative braking in the case of group drives in which motor operation and power generation take place at the same time Please contact BERGES if you would like further information PE is located in the lower left hand internal corner of the control casting It is a green screw with brass cup washer Finely strandet conductors should be used in order to ensure the effectiveness of the earthing connection at high frequencies skin effect Observe the respectively valid national regulations and standards VDE NEC CEC when selecting the conductor cross section Control Terminals The control terminals are located on the bottom edge of the inverter s control board see Figure 2 7 These terminals are available for use with external control devices if remote operation is desired All control terminals are isolated from earth ground bases isolated Do not exceed 50 VAC potential between any terminal and GND Technical data about the control inputs 1 Control terminal impedance a VIN terminal 100 kQ b CIN terminal 237 Q C All Logic Terminals 4 5 kQ 2 Logic input levels a ACTIVE 10 30 VDC b INACTIVE 0 5 VDC
91. odt Tel 02264 17 0 Fax 02264 17126 42 e f the SHIFT key is momentarily pressed while holding one of the arrow keys the five second delay will be bypassed e f the SHIFT key is pressed a second time while holding an arrow key the display will scroll at the fastest rate This is useful for entering very large numbers as in parameter 84 DISP Restoring Factory Settings e Whenever a parameter s data is being changed noted by the Parameter number blinking the original factory setting for that parameter can be restored by pressing both the UP and DOWN arrows simultaneously and pressing the ENTER key Torestore all parameters to their factory settings see section 4 3 page 61 81 PRGNO Help For Application Assistance call BERGES electronic at 02264 17 160 02264 17 102 and 02264 17 109 3 8 Quick Start Running the Motor This section is for operators who would like to get up and running quickly and with a minimum amount of research through the manual Be sure to read sections 3 1 through 3 7 before proceeding In many cases your ACP Inverter will perform perfectly without making any changes to the factory settings A Perform all procedures for installation as specified in Section 2 Installation Instructions RE VERIFY THAT THE PROPER VOLTAGE IS AVAILABLE FOR THE INVERTER BEFORE APPLYING POWER FAILURE TO DO THIS CAN BE RESULT IN EQUIP MENT FAILURE AND PERSONAL INJURY B Apply AC power to the input terminals For ab
92. on board Check the fault log 07 FLT3 08 FLT2 and 09 FLT1 Institute corrective action for those faults SINSIDARARONAS JONAINAIN F10 Auto Restart 68 NRST Number Exceeded F11 Ground Fault Check motor wiring Extend the acceleration time Check for and remove any capacitive load Reduce 52 BOOST value Increase 53 FKNEE value Isolate line and load wires F12 External Interference Verify line voltage Look for electrical noise sources in proximity to the drive see Section 2 3 5 Install line reactor or isolation transformer Consult BERGES Motor is decelerating too quickly Increase deceleration time or add optional external DB package Check input line voltage N DURON ID F13 Overvoltage on DC Bus N RO Co F14 Undervoltage on DC Bus 1 Verify applied line voltage 2 Check for possible DB failure 78 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 FAULT CAUSE REMEDY NUMBER F15 DB Overload 1 Reduce the braking duty cycle 2 Install optional external DB package 3 Verify line voltage F16 Acceleration Overcurrent 1 Increase acceleration ramp time 2 Check motor wiring for short circuit F17 Deceleration Overcurrent 1 Increase deceleration ramp time 2 Instal
93. onsisting of a series resistor and capacitor for AC loads or a free wheeling or flyback diode for DC loads should be placed across the relay coil to prevent the occurrence The following component values should be used for 230 VAC relays or solenoids Main Circuit Contactors and Solenoids C 0 2 MFD 500 VDC R 500 Q 5 Watts e Auxiliary Control Circuit Relays C 2 0 1 MFD 500 VDC R 200 Q 2 Watts For magnetic contactors relays and solenoids which are energized from a DC source a free wheeling diode should be used The diode should be a high speed fast recovery type Connect the diode across the coil as shown above The diode current and voltage should be selected by the following formulae Coil Capacity VA Rated Voltage of Coil V Diode Current Rating A gt Diode Voltage Rating V 2 Rated Voltage of Coil V x 2 Operating manual ACP 60005 0 75 55 29 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 Connection Diagram for AC and DC Relay Coils and Solenoids AC S DC gt R P RC type v Freewheeling snubber diode C Figure 2 6 2 7 Function and Use of Terminals ATTENTION 30 A Power Circuit Terminals The power terminals are located on the ACP Power Board and are labelled L1 L2 L3 and PE for incoming three phases AC line power and M1 M2 and M3 for the motor connections Direct access t
94. operation Parameter 21 MODE can override this selection when it dictates that the drive operates under keypad control The proper usage of this parameter is dependent on the selection made at 21 MODE Typically no changes are necessary at this parameter DATA REVERSE FORWARD CODE Regenerative Motoring Regenerative Motoring 0 LIMit input LIMit input LIMit input LIMit input 1 64 RTLR LIMit input 63 RTLF LIMit input 2 64 RTLR 62 LTLR 63 RTLF LIMit input 3 64 RTLR 62 LTLR 63 RTLF 61 LTLF 4 28 TLEXT 28 TLEXT 28 TLEXT 28 TLEXT 5 64 RTLR 28 TLEXT 63 RTLF 28 TLEXT 6 64 RTLR 62 LTLR 63 RTLF 28 TLEXT See Section 5 for more information on parameter 28 TLEXT 31 FMIN _ Minimum Frequency Hz LIP 31 FMIN defines the minimum frequency that the inverter will deliver to the motor in the run mode It is adjustable in 0 01 Hz increments from 0 to 400 Hz The factory setting is 0 Hz 32 FMAX Maximum Frequency Hz LIP 32 FMAX defines the maximum frequency that the inverter will deliver to the motor in the run mode It is adjustable in 0 01 Hz increments from 20 to 400 Hz The factory setting is 50 Hz FOR OPERATION ABOVE 50 HZ ENSURE THAT THE MOTOR IS CAPABLE OF EXTENDED SPEED OPERATION SEE THE INSTRUCTIONS FOR PARAMETER 53 FKNEE FOR MORE INFORMATION PARAMETER 83 PWM WILL ADDITIONALLY INFLUENCE THE ACTUAL MAXIMUM FREQUENCY CAPABILITY OF THE DRIVE Hz L1P Hz L2P Hz L2P Hz L2P Hz L2P H
95. ost setting Quadratic V Hz characteristic with AUTOBOOST This characteristic is typical of fan applications Same as 4 but with a fixed boost setting Vector Control NOTE When selecting the HT mode Vector Control parameters 5B IMAG and 65 SLIP must be activated for high torque low speed operation Fine tune can be made for optimum performance Refer parameter 5B IMAG Operating manual ACP 60005 0 75 55 53 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 Standard Linear Pumps Mixed Linear Quadratic Fans Quadratic 52 BOOST Torque Boost 52 BOOST may be programmed to provide additional starting torque to the motor if required It is adjustable in 0 0196 increments from 0 to 25 Factory set BOOST values are model ATTENTION 54 dependent 100 Y v SITE 51 VSEL 0 FKNEE o v M 51 VSEL 4 FKNEE Auto Boost 100 V BOOST 0 100 100 BOOST 0 FKNEE 51 VSEL 1 FKNEE 51 VSEL 3 Fixed Boost Typical curves for auto boost and fixed boost FKNEE 51 VSEL 5 LIP Care must be exercised with this adjustment Too much boost may cause excessive motor currents and motor heating Use only as much boost as is necessary to start the motor AUTOBOOST may be selected at parameter 51 VSEL to provide the optimum value of boost to suit the load automat
96. ous constant torque operating speed range With these data codes the degree of overload permitted by the drive depends on the output frequency Lesser degrees of overload are permitted at lower speeds Data codes 4 through 7 provide for the use of an inverter duty motor that has a more extensive continuous constant torque operating speed range With these data codes the overload performance follows the curve designated gt 40 Hz regardless of operating frequency As you adjust between 0 amp 3 and 4 amp 7 you get various inverse time characteristics Data codes 0 and 4 give you the characteristic depicted by the scale designated C Data codes 1 and 5 work on scale B and codes 2 and 6 on scale A With data codes 3 and 7 the parameter 67 TOL works as an adjustable electronic shear pin with no inverse time characteristic DATA TRIPPING CHARACTERISTIC TRIP TIME SCALE MOTOR TYPE CODE SECONDS 0 Normal Reduced threshold below 40 Hz 60 C Standard Induction 1 Medium Reduced threshold below 40 Hz 30 B Standard Induction 2 Fast Reduced threshold below 40 Hz 10 A Standard Induction 3 Shear Pin Reduced threshold below 40 Hz 0 Standard Induction 4 Normal Constant torque 60 C Inverter Duty 5 Medium Constant torque 30 B Inverter Duty 6 Fast Constant torque 10 A Inverter Duty 7 Shear Pin Constant torque
97. out one second all the LED indicators will illuminate and the display will show RESTART After one second the STOP LED will stay on and the display will change to LOC STOP SET 0 00 Hz 0 C The ACP is programmed at the works for control via the keypad of the control panel via the terminals and for operation in both directions of rotation The keys REV and LOC REM are therefore activated Press the FWD key the display will change to LOC ZERO SPEED SET 0 00 Hz 0 D Press the UP Arrow to increase the desired running frequency When the motor starts to turn note the direction of rotation If the motor is turning in the wrong direction STOP THE DRIVE REMOVE AC POWER AND WAIT FOR THE BUS CHARGE INDICATOR TO GO OUT After the Charge indicator is extinguished reverse any two of the motor leads at M1 M2 or M3 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 E The length of time that the UP Arrow is depressed determines the scroll rate of the display After itis held for five seconds the rate of change will increase The five second time can be circumvented by momentarily pressing the SHIFT key while holding the UP or DOWN Arrow F The inverter is preset to run a typical induction motor to a maximum speed of 50 Hz with both Acceleration and Deceleration time
98. p 1 0 10 600 00 s 3 00 s 1 52 44 ACC2 Acceleration Ramp 2 0 10 600 00 s 1 00 s 2 52 45 DEC2 Deceleration Ramp 2 0 10 600 00 s 1 00 s 2 52 46 DECTL Torque Limit Response Time 0 10 30 00 s 1 00 s 2 53 47 DCBRK DC Brake Time 0 00 5 00 s 0 20 s 2 53 48 DCVLT DC Brake Voltage 0 00 15 00 W 2 53 1 Default value is model dependant 2 Parameter adjustable while the drive is in the run mode 30 10 97 Operating manual 05 GB ACP 60003 V 0 75 55 45 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 PARAMETER DESCRIPTION DATA RANGE FACTORY ACCESS SEE CUSTOMER NUMBER NAME SETTING LEVEL PAGE SETTING 51 VSEL V Hz Characteristic Selector 0 6 0 2 53 52 BOOST Torque Boost 0 00 20 00 Wi 1 54 53 FKNEE V Hz Knee Frequency 26 00 640 00 Hz 50 00 Hz 2 54 54 SKBND Skip Frequency Hysteresis Band 0 20 20 00 Hz 1 00 Hz 2 54 55 SK1 Skip Frequency 1 0 00 400 00 Hz 0 00 Hz 2 54 56 SK2 Skip Frequency 2 0 00 400 00 Hz 0 00 Hz 2 54 57 SK3 Skip Frequency 3 0 00 400 00 Hz 0 00 Hz 2 54 58 SK4 Skip Frequency 4 0 00 400 00 Hz 0 00 Hz 2 54 59 MVOLT Rated Motor Voltage 370 480 V 400 V 2 55 5B IMAG Rated Magnetizing Current 15 00 80 00 0 00 2 55 61 LTLF Load Torque Limit FWD 5 200 150 2 56 62 LTLR Load Torque Limit REV 5 200 150 2 56 63 RTLF Regenerative
99. pad to be mounted in its own enclosure up to 30 m from the control The kit includes the mounting enclosure 135 9 x 172 2 x 63 5 mm H x W x D keypad connector fan out board WBPO1 Keypad Blank Plate Option and instructions for installation When properly installed the keypad and unit will retain their IP 54 ratings WBP01 Keypad Blank Plate Option This option is used to replaced the digital keypad in IP 54 models when the keypad has been remotely mounted When properly installed the ACP 60008 will retains its IP 54 rating BC6000 External Dynamic Brake Assembly The BC6000 assemblies are designed to increase the capacity of the ACP 6000 to absorb the regenerated energy from a motor during rapid deceleration or overhauling loads The BC6000 is designed to connected to any 400 Volt ACP Inverter and provide 13 6 kW of braking capacity at a 1096 duty cycle For capacities greater than 13 6 kW units can be connected in parallel SIOCO1 Serial Interface Converter This is a stand alone converter module which will translate the RS 232 communications protocol used in many personal computers to the industrial RS 485 protocol used in the ACP 60009 Inverter 6 3 Application Hints 30 10 97 05 GB A number of typical applications have proven to require further explanation Several typical applications are summarized in the following paragraphs Defeating the Keypad The inverter s standard keypad is designed to give full functional
100. r 1 11 1 1 Writing this value into 11 STAT can be used to reset all faults 21 MODE Input Mode L1P L3P 21 MODE defines the operating functions that are active from the Keypad the Terminal Strip and the SIO Serial Link in both the LOCal and REMote operating modes Also the mode transfer mechanism is defined by your selection at this parameter Proper setting of this parameter is the first step in customising the inverter to your application The following table defines the combinations available to the SIO user 30 10 97 Operating manual 6 05 GB ACP 60005 0 75 55 N BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 DATA CODE LOCal 1 REMote LOC REM FWD only FWD REV Speed 3 Start Stop Speed 3 Start Stop TRANSFER VIA SEE NOTE 2 2 SIO Control Only 7 17 Disabled 24 FSEL 23 CNTL N A Combination Keypad SIO Control 6 16 Keypad 24 FSEL 23 CNTL LOC REM key 26 36 Keypad 24 FSEL 23 CNTL PS3 Combination Terminal Strip SIO Control 8 18 24 FSEL 23 CNTL Terminals PS3 Combination Keypad Terminal Strip SIO Control 5 15 Keypad 25 FEXT1 Terminals LOC REM key 4 25 35 Keypad 25 FEXT1 Terminals PS3 4 NOTES 1 Under LOCal operation when control is specified as keypad the active torque limit reference is the preset values at parameters 61 through 64 as if parameter 27 TLSEL were set to a code 3
101. r See parameter 24 FSEL for additional information Note that the pulse train from the 6F6 terminal is rated at approximately a 30 duty cycle DATA DESCRIPTION CODE 0 6 times operating frequency 1 48 times operating frequency A2 RATIO Master Slave Speed Ratio L2P A2 RATIO allows the 6FS output of one ACP series inverter master to be used to control the speed of up to eight 8 other slave inverters The output of each slave unit can be individually programmed or trimmed ON THE FLY with A2 RATIO The range of adjust ment is 50 200 of the master NOTE Parameter adjustable while the drive is in run mode See Section 6 3 Application Hints for further information B1 OPTNO Option Board Number L2V This parameter serves as an excellent diagnostic tool It indicates which if any of the WPC style option cards have been installed in the ACP 60003 inverter For instance if the WPC01 Isolated Analog and Digital Output Card has been installed in the drive B1 would indicate 1 If no card is in the drive or if the card is not recognized by the drive B1 would indicate 0 30 10 97 Operating manual 6 05 GB ACP 60005 0 75 55 OT BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 5 Level 3 parameter The following is a summary of the parameters associated with SIO communication Consult BERGES for more information on the use of ACP 60
102. r the delay programmed at 69 DRST Only fault codes F11 thru F20 are effected by this process Once the programmed value of 68 NRST has been exceeded the drive will display a F10 fault and wait for a manual reset When 68 NRST is active the function of parameters 72 ST1 73 ST2 74 ST3 and 75 STH is altered Data code 2 for each parameter will not activate the respective output for every fault only for fault codes 1 10 To maintain a similar yet inverse function with 68 NRST active use data code 1 INSURE THAT AUTOMATIC RESTARTING WILL NOT CAUSE DAMAGE TO EQUIPMENT OR INJURY TO PERSONNEL This function is disabled when it is programmed to zero Operating manual ACP 60005 0 75 55 57 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 69 DRST Trip Restart Time Delay s L2P If 68 NRST greater than 0 the inverter will wait the programmed time value after a fault before re starting Restart performance will be governed by parameter 82 START DRST is programmable in 0 01 sec Increments from 0 00 to 60 00 seconds 6A TOLC Timed Overload Characteristic 6A TOLG works in conjunction with 67 TOL to customize the overload characteristics of the inverter to the driven motor Refer to the graphic presented with parameter 67 for a more in depth understanding of this parameter Data codes 0 through 3 provide for the use of a standard motor that typically has a limited continu
103. re subject to the harmonized standards of the series prEN 50178 DIN VDE 0160 in conjunction with EN 60439 1 DIN VDE 0660 part 500 and EN 60146 DIN VDE 0558 The technical data as well as information concerning the supply conditions shall be taken from the rating plate and from the documentation and shall be strictly observed 3 Transport storage The instructions for transport storage and proper use shall be complied with Damage established after delivery must be notified to the transport company immediately Where necessary the supplier must also be notified before the damaged drive converter is put into operation The climatic conditions shall be in conformity with prEN 50178 4 Installation The installation and cooling of the appliances shall be in accordance with the specifications in the pertinent documentation The drive converters shall be protected against excessive strains In particular no compo nents must be bent or isolating distances altered in the course of transportation or handling No contact shall be made with electronic components and contacts Drive converters contain electrostatic sensitive components which are liable to damage through improper use Electric components must not be mechanically damaged or destroyed potential health risks 5 Electrical connection When working on live drive converters the applicable national accident prevention rules e g VBG 4 must be complied with The electrical in
104. re active All will except PS3 in modes greater than 20 perform their previously defined function see Section 2 7 5 Entering the JOG mode from the keypad will override any active presets In any questions arise please don t hesitate to contact BERGES for clarify before proceed ing See Section 6 for terminal strip connection details 24 FSEL Speed Reference Selector L2P NOTE Reference 21 MODE and parameter 32 FMAX through 38 F7 for a thorough under standing of this parameter setting This parameter is used to define the frequency command signal source when operating from other than the inverter s keypad That generally means the definition of signal types applied to either the VIN or CIN terminals This parameter can also be used to re define terminal strip speed control referenced in 21 MODE as keypad operation The proper usage of this parameter is dependent on the selection made at 21 MODE Typically no changes are necessary at this parameter 30 10 97 Operating manual 05 GB ACP 60005 0 75 55 49 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 CODE bios DESCRIPTION SEE NOTE 0 VIN CIN Terminal input speed pot or external 0 2 VDC 0 10 VDC or 4 20 mA Potentiometer for speed regulation or an external input unit 1 VIN CIN Terminal input inverse speed control 1 2 VIN Same as Code 0 but extern
105. reaker and persons touching them are no longer protected in the event of a fault Compatibility of electrical equipment and residual current operated protective device Plugged in Connection of the electrical Permanent connection equipment to the mains lt 4 KVA gt 4 KVA Rated power The compatibility of the electrical Additional protection besides equipment with the residual current residual current operated operated protective device must protective device is always be checked necessary Flow diagram of the requirements relating to the combination of frequency inverter and residual current operated protective device The inverter will be destroyed if the mains feeder is confused with the motor cable 30 10 97 Operating manual 23 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 The DC link capacitors must be reformed if the inverter you wish to connect has been out of operation for more than a year To do this connect the inverter to voltage for approx 30 minutes The inverter should not be loaded by connected motors during forming 2 3 2 Motor connection ATTENTION Connect the motor cable to the M1 M2 M3 and PE terminals The inverter will be deactivated if shorted to the motor terminals M1 M2 M3 The output of the drive will always be three phase Do not connect single phase motors to th
106. regen Torque Limit Deceleration Programmable 0 1 to 30 Seconds 53 Rate Minimum Frequency in Programmable 0 5 to 400 Hz 52 Torque Limit Torque Boost Programmable to suit requirements plus Autoboost 53 54 Dynamic Braking 30 200 of drive rating 10 sec max standard Consult BERGES for model specific data Additional capacity available by adding external DB kits Adjustments Over 100 parameters can be monitored with over 80 user adjustments PWM Frequencies Two settings available 62 Agency Listing Ce UL and CULO Listed Protection Charge Indicator Indicates the presence of potentially lethal bus voltage 31 Features Ground Fault All models fully protected Output Short Circuit All models fully protected Line to Line Electronic Motor Overload Programmable Inverse Time Overload Trip 57 58 Overvoltage Trip Level 763 VDC on DC bus Undervoltage Trip Level 395 VDC on DC bus 30 10 97 Operating manual 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 MODEL SERIES ACP 6000 SEE PAGE Protection Torque Limit 4 Quadrant Independently Programmable 51 56 Features Program Lockout User definable security access code 64 Line Start Lockout Prevents automatic start up when line power is 62 applied defeatable by programming Overtemperat
107. ription MIN FREQUENCY PROG 31 0 0 Hz D war Pa EN Rights Parameter Data DESCRIPTION The top line will give a full 16 character description of the parameter that is being accessed RIGHTS The first four characters of the second line will indicated if the particular parameter can be changed PROG or only examined VIEW If an attempt is made to change data while in the VIEW mode the message NO ACCESS will be displayed for one second PARAMETER This is the actual parameter number being displayed When data is being changed this number will blink on and off A list of all parameters for levels 1 and 2 is given on page 45 in section 4 1 DATA Up to eight characters are used to display the information stored in the parameter Some parameters have a unit designator such as S Seconds h Hours C Degrees centigrade Hz Hertz Percent A Amperes Operating manual 30 10 97 40 a ACP 6000 LV 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 FAULT DISPLAY PAGE 1 Code Next Page FAULT F07 MOL CONTACT OPEN Description When the inverter stops due to a fault trip a unique error message will be displayed along with a flashing STOP LED indicator Two pages of information are available concerning the actual fault and drive status Page 1 is shown above CODE The top line signifies that a fault has occ
108. rol board has the same function 60 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 81 PRGNO Special Program Number L2P This parameter allows the storage retrieval and exchange of customer defined program setups as well as a means of returning all parameters to factory defaults Numerous special programs are also included at this parameter Standard data codes are outlined in the following table DATA SEE CODE DESCRIPTION NOTE 0 Standard Factory Program 1 1 Reset all parameters to factory settings 1 2 2 Store customer parameter settings 1 3 3 Recall customer parameter settings 1 3 4 Exchange current with stored customer parameter settings 1 3 10 Makes option parameters inaccessible 1 11 Makes option parameters accessible for viewing and change 1 32 33 EMOP2 EMOP3 Electronic Motorized Potentiometer speed 4 5 control 60 62 Program Sequencer consult factory for specific implementation instructions 430 BERGES crane option consult factory for specific implementation instructions NOTES 1 When data codes 1 29 are invoked 81 PRGNO will revert to 0 upon exiting the program mode When data codes greater than 29 are used 81 PRGNO will retain the data setting 2 Data code 1 allows all program parameters to be returned to factory defaults When the program mod
109. ronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 DATA CODE 0 ISO 1745 protocol with even parity and seven data bits DESCRIPTION 1 ISO 1745 protocol with no parity and seven data bits 2 8 OPTO protocol with no parity and seven data bits OPTO22 M is a trademark of OPTO 22 Huntingdon Beach CA 30 10 97 Operating manual 71 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 6 Applications The following sections show various typical wiring connections of external controls to the ACP 6000 inverter Section 6 1 contains wiring diagrams for various speed control torque control start stop and direction control as well as options available from the inverter s terminal strip Refer to Section 2 7 Function and Use of Terminals 6 1 Connection Diagrams The following diagram shows typical connections for external speed and torque control as well as external starting and stopping of the inverter Requirements for a job feature and reversing are also included
110. s data g changed by use of the UP and DOWN arrow keys Pressing this key after data has been changed in a Parameter will store that information in non volatile memory SA So 3 5 Status LED Indicators LED INDICATION LOCATION The red Stop LED located in the STOP key illuminates whenever a stop command has been A given If the inverter has stopped due to a fault this LED will flash to call attention to the digital display The green Forward LED located in the FWD key illuminates whenever a forward command has A been given When both the Forward and Reverse LED s are on the DC braking function is active S The green Reverse LED located in the REV key illuminates whenever a reverse command has been given When both the Forward and Reverse LED s are on the DC braking function is active e The green Jog LED located in the JOG key illuminates to signify the inverter is in the JOG mode of operation 3 30 10 97 Operating manual 47 05 GB ACP 60009 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 3 6 Description of Displays Operating Display HINT The ACP inverter has been designed to provide the greatest level of information possible to the operator through an easily readable 2 x 16 character Super Twist LCD alphanumeric display including data on drive and motor status fault information and par
111. s set to 3 0 seconds The Jog frequency is set for 5 0 Hz G Use the Arrow keys to set the proper running speed of the motor and the FWD and STOP keys to control it s operation 30 10 97 Operating manual 43 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 3 9 Programming Flowchart Press STOP STOP drive Reset faults Press PROG for level 1 SHIFT and PROG for level 2 Enter the PROGram mode Access code assigned View last parameters Press A or V Select new parameter Enter the access code gt ul Press SHIFT Enable data change Press A or v Set new data value Press ENTER Store data Change another parameter yes Press PROG Return to operation mode 44 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 4 Level 1 and 2 Parameters Level 1 accesses only basic operator parameters e Level 2 accesses all parameters in Level 1 and Level 2 Level 3 accesses all parameters in Level 1 Level 2 and Level 3 For more information consult Section 5 and publication ACP 6000 Option 4 1 Program Code Summary Level 1 and 2
112. se as frequency increases The output is rated at 5 mA SEE PAGE 58 72 COM Circuit common isolated CIN Speed reference input 4 to 20 mA 237 Q load referenced to COM The current input signal is calibrated by parameters 31 FMIN and 32 FMAX FMIN sets the frequency 4 mA should generate and FMAX sets the frequency 20 mA should produce Operation can be inverted 20 mA min frequency and 4 mA max Frequency see 24 FSEL 49 72 VIN Speed Reference input 0 10 VDC or 0 to 2 VDC selectable by jumper J11 It will also accept pulse train inputs O to 1 kHz or Oto 10 kHz 6 10 V peak min and the 6FS output from another control Operation can be inverted 10 V 2 min frequency and 0 V max frequency see 24 FSEL 49 72 REF This terminal is a 10 VDC power supply with 10 mA capacity and may be used as the Torque Limit Reference supply or the reference for VIN in which case the drive can be programmed to shut down if the common line to the remote speed potentiometer opens see 24 FSEL 49 72 LIM Torque Limit input terminal It will accept 0 to 10 VDC 10 VDC equals 150 output torque Defaults to 10 V with no input connected 51 72 Digital Input Terminals FWD Forward Direction Selection terminal May be connected for two wire maintained or three wire momentary operation 72 73 REV Reverse Direction Selection terminal May be connected for two wire mai
113. stallation shall be carried out in accordance with the relevant requirements e g cross sectional areas of conductors fusing PE connection For further information see documentation Instructions for the installation in accordance with EMC requirements like screening earthing location of filters and wiring are contained in the drive converter documentation They must always be complied with also for drive converters bearing a CE marking Observance of the limit values required by EMC law is the responsibility of the manufacturer of the installation or machine 6 Operation The components of the power section and certain elements of the control section are connected to the voltage mains when the drive converter is connected to the mains voltage Touching these components involves mortal danger Always isolate the drive converter from the mains supply before performing any work on the electrical or mechanical part of the system Operating manual 3 ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 Isolate the drive converter from the mains before removing the terminal cover or the housing e g by removing or deactivating on site fuses or by deactivating a master switch isolating all poles etc After disconnection of the drive converters from the voltage supply live appliance parts and power terminals must not be touched immediately because of possibly energized capaci
114. stands for programmable Parameter PARAMETER DESCRIPTION UNITS LEVEL 01 MODEL Inverter Model Number L1V This display is a code that conveys the input voltage rating and horsepower rating of the control For example a code of 6000 7 would equate to an ACP with 400 460 VAC input and 0 75 kW rating A code of 6007 5 would equate to a 400 460 VAC input and 7 5 kW rating 6045 0 would indicate 400 460 VAC and 45 kW ratings 02 RVLVL Software Revision L2V This display indicates the software revision installed in your inverter 03 IRAT Inverter Rated Current L2V This display indicates the 100 rating of output current for the inverter It is used by the inverter as the basis for all current measurements and output indications Your ACP 6000 inverter can provide 110 of this rating continuously without damage or tripping 05 SERNO Manufacturing Serial Number L2V This is the unique serial number assigned to the inverter 06 REP Repair Date Code L2V If the control has been repaired a specific code will be installed in this location 30 10 97 Operating manual 4 05 GB ACP 60005 0 75 55 NJ BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 07 FLT3 Last Fault L1V 08 FLT2 Second Fault L2V 09 FLT1 First Fault L2V These displays indicate a code that represents both the cause of the last three 3 inverter faults and the elapsed time in 0 1 Hr increments
115. sure to observe the following points when selecting a mounting location A Mount the unit vertically and do not restrict the airflow to the heat sink fins on the back of the controller The fan and fins allow cooling of internal components Any air restriction could greatly reduce the life of the inverter as well as resulting in nuisance overtempera ture trips If the inverter has to be installed in a different position external cooling is required for full capacity utilization The ACP inverter generates heat and therefore there must be a sufficient amount of free space around the unit see Figure 2 1 If the unit is accommodated in a housing together with a different unit the prescribed minimum distances must be observed so that adequate ventilation can be ensured 130 mm 20mm gt 20 mm ACP gt 130 mm Figure 2 1 D Do not install the inverter in a place subjected to high temperature high humidity or excessive vibration consult Table 1 4 for temperature humidity and maximum vibration limits E Do not mount the ACP near heat generating equipment or in direct sunlight F BERGES inverters are generally designed so that they can be operated at ambient temperatures of O C to 50 C IP 00 or 0 C to 40 IP 21 54 and at a relative humidity of up to 90 The occurrence of condensate must be avoided Please contact BERGES if the above values are exceeded Therefore when installing
116. t proportional to drive load Current 15 LOAD with full scale at 20096 load 5 Output proportional to load torque 16 TORQ with full scale at 200 torque 6 Output proportional to stator frequency 14 FOUT 2 with full scale at 32 FMAX 7 Output proportional to feedback encoder frequency A7 OPTA7 with full scale at 32 FMAX Used with WPCOA see section 6 2 8 Output proportional to FSET with full scale at 32 FMAX An additional meter selection 71 METER 8 was added which allows the meter output to follow the speed reference FSET The FSET meter selection is active during both RUN and STOP modes but not during POWER UP FAULT IDLE or STOP These conditions also apply to 71 METER 7 which allows the meter output to follow the encoder speed feedback 72 ST1 Auxiliary Output 1 Open Collector L2P 73 ST2 Auxiliary Output 2 Open Collector L2P 74 ST3 Auxiliary Output 3 Open Collector L2P 75 STR Auxiliary Relay Output L1P Each of these parameters work similarly with the open collector outputs at the terminal strip designated ST1 ST2 and ST3 and the auxiliary relay The data code programmed at these parameters defines the condition that activates that particular output either open collector or relay Each may be programmed as follows to indicate ODE DESCRIPTION 0 Output inactive 1 No fault becomes active when the inverter is ready 2
117. t the setting of 53 FKNEE and 32 FMAX or Too Low are correct for the motor specification and application Frequency control signal Verify the input signal level Motor nameplate specifications 1 Verify that the motor selection is proper for the application Display Blank Keypad connections 1 Verify keypad connections to control board intermittent Logic supply overload 1 Check for excessive load on terminal 24 2 Remove power for 10 15 minutes then reapply Table 7 3 30 10 97 Operating manual 79 05 GB ACP 60009 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 7 3 Maintenance and Inspection The ACP Inverter is essentially maintenance free and should provide years of trouble free operation if proper installation and operation procedures are observed Chassis type controls are designed to be operated in relatively clean and low humidity areas If dust accumulates on the internal printed circuit boards and components remove power and clean with low pressure air or vacuum Remove any dust or lint that accumulates on the outside of the enclosure the fan the fan grille and the heat sink fins to maintain the excellent cooling properties of your ACP Inverter IP 54 models are by design compatible with being washed down by water After this has been done it is suggested that the drive be operated for several minutes to expel any wat
118. th the FWD and REV terminals activated simulta neously or if a zero speed command is issued DC current will be applied to the motor at zero speed until one or both terminals are de activated 48 DCVLT DC Brake Voltage 96 L2P The parameter controls the amount of DC voltage applied to the motor windings by 47 DCBRK Factory setting is of 52 BOOST It is adjustable between 0 and 15 of full voltage If DC braking is used as a holding brake excessive motor heating may result 51 VSEL Volts Hertz Characteristic Selector This parameter selects between the HT mode Vector Control and Volts Hertz operation By selecting Data Code 6 the ACP 6000 LV activates the Vector Control scheme When selecting Data Codes 0 through 5 the Volts Hertz mode is initiated and one of the three Volts Hertz characteristics and one of two Torque Boost modes are enabled The following table defines these selections Their actions are shown graphically below DATA CODE 0 DESCRIPTION Linear V Hz characteristic with AUTOBOOST feature The optimum boost will be selected upon load and motor condition with the limit being the programmed value of 52 BOOST Linear V Hz characteristic with constant boost added to the basic V Hz pattern The amount of boost is programmed by 52 BOOST Mixed linear quadratic V Hz characteristic with AUTOBOOST This cha racteristic is typical of pumping applications Same as 2 but with a fixed bo
119. ting above 53 FKNEE The accuracy is 10 of full scale 17 TEMP _ Inverter Temperature C LIV This display indicates the inverter s operating temperature in C The accuracy is 2 C 18 TIME1 Total Run Time h L2V This display is an indication of the total time the inverter is in the run mode of operation It has a range of 0 65000 hr and is not resettable NOTE Frequent line starting operation of the inverter may result in the recording of erroneous times in this parameter 19 TIME2 Total Operating Time h L2V This display indicates the total time that power has been applied to the inverter up to 65 000 hrs It does not reset when power is removed and re applied 1B FLUX Magnetizing Current 96 L2P This display indicates the amount of magnetizing current that is present to the motor The displayed percentage is a calculated factor based on a pre determined motor model When using Volts Hertz mode the percentage is based on bus current measurements and torque boost settings In Vector mode the percentage is the inverter s regulated magnetizing current levels Parameter 1B can be monitored while the inverter is in operation 48 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 21 MODE Input Mode L1P 21 MODE defines the operating functions th
120. tion The table that follows notes the maximum operating frequency when using this data code and parameter 83 PWM Consult BERGES with any questions The maximum running frequency available when using data code 19 48x pulse train from another ACP 60008 series inverter is limited by the operating carrier frequency When selecting the carrier frequency at parameter 83 PWM and parameter 24 FSEL is set to data code 19 the maximum operating frequency will be limited by the following values ACPSLV 6000 7 6045 0 ACPS 6055 0 83 PWM data code 1 3 kHz 62 Hz max 83 PWM data code 1 2 3 kHz 48 Hz max 83 PWM data code 2 4 kHz 83 Hz max 83 PWM data code 2 2 5 kHz 52 Hz max 83 PWM data code3 6 kHz 125 Hz max 83 PWM data code 3 4 6 kHz 95 Hz max 83 PWM data code 4 8 kHz 166 Hz max 83 PWM data code 4 5 0 kHz 104 Hz max 83 PWM data code 5 12 kHz 250 Hz max 83 PWM data code 5 9 2 kHz 191 Hz max 83 PWM data code 6 16 kHz 332 Hz max 83 PWM data code 6 10 0 kHz 208 Hz max 50 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 27 TLSEL Torque Limit Reference Selector 27 TLSEL selects one of seven combinations of six torque limit setpoints to be effective during driving and regenerative operation Torque limit may be different for forward and reverse
121. tions 5 If the KVA rating of the power source exceeds ten times this value the use of an isolation transformer or a line inductor is recommended 1 6 AC Inverter Fundamentals The principal of operation of the ACP or any AC Inverter is to provide both an adjustable voltage and an adjustable frequency to the AC motor The ACP automatically maintains the required volts hertz ratio allowing the AC motor to run at its optimum efficiency and providing rated torque capability throughout the motor s speed range The basic formula that relates the output frequency to motor speed is 60xf P Ng Synchronous Speed RPM f Frequency Hertz P Number of pairs of poles Ns 10 Operating manual 30 10 97 ACP 60005 0 75 55 05 GB BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 For Induction Motors Motor RPM Synchronous Speed Motor Slip RPM The number of pairs of poles of a particular motor and the amount of slip for a given load torque are set by the motor s design and manufacturer 1 7 Description of Operation The primary functional blocks of the inverter are outlined in Figure 1 7 The ultimate goal of any inverter is to accept fixed voltage and frequency from a power source and convert this power into variable voltage and frequency to control a three phase AC induction motor The ACP 6000 does this and much more It allows the user to interface into the very powerful e
122. tive DM CO R 0 0 Will indicate that terminal PS2 is active 0 Will indicate that terminal PS1 is active 30 10 97 Operating manual 6 05 GB ACP 60005 0 75 55 Wel BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 70 7C FIN Control Board Analog Input Status L3P 7D FAUX Option Board Analog Input Status L3P The integer value found at this parameter represents the real world value of the analog speed input at the control board 7C FIN or from the option board input 7D FAUX It translates to a number in the range of 0 32 767 for 0 to maximum input 7E LIM Analog Torque Limit Input Status L3P The integer value found at this parameter represents the real world value of the analog torque limit input at the control board It translates to a number in the range of 0 15 000 for 0 to 150 of rated torque 91 SIOC SIO Communication BAUD Rate L3P The integer value stored at this parameter determines the communication BAUD rate used between the inverter and the host computer Also communication rights may be selected as either read write or read only Data codes 0 thru 3 provide both read and write capability Codes 4 through 7 are read only The BAUD rates available are DATA CODE BAUD RATE 0 4 9600 1 5 4800 2 6 2400 3 7 1200 92 SIOA SIO Slave Address L3P This para
123. tors In this respect the corresponding signs and markings on the drive converter must be respected After switching off the mains voltage wait for at least 5 minutes before beginning work on or in the drive converter Dangerous voltages are still present as long as the BUS CHG lamp is still lit In the event of malfunctions the discharge time of 5 minutes may be exceeded substantially The drive converter contains protective facilities that deactivate itin the event of malfunctions whereby the motor is de energized and comes to a standstill so called coasting of the motor is possible depending on the rotating mass of the type of drive involved Standstill of the motor can however also be produced by mechanical blockage Voltage fluctuations and particularly mains power failures may also lead to deactivation In certain circumstances the drive may start up automatically once the cause of the fault has been remedied As a result of this certain systems may be damaged or destroyed and there may be a risk for operators working on the system Installations which include drive converters shall be equipped with additional control and protective devices in accordance with the relevant applicable safety requirements e g Act respecting technical equipment accident prevention rules etc Changes to the drive converters by means of the operating software are admissible The motor may be stopped during operation by disabling it or by deactivatin
124. tted in the direct vicinity of the inverter and connected to the inverter via screened cables earthed at both ends Shielded signal cables should be laid at a minimum distance of 10 cm from power cables running parallel A separate earthed metal cable duct is advisable for such signal cables If signal cables intercept with a power cable they should do so at an angle of 90 Control lines longer than 1 m must be laid with a shield and earthed at one side on the frequency inverter see Connection Diagrams Page 72 The screen is earthed via terminal COM If cables have lengths in excess of 10 m use a 0 20 mA control signal because of the possibility of parasitics The inverter can be switched over to this mode of operation See table 2 7 Description of terminals Page 32 33 Other loads connected to the mains may produce voltage spikes that may interfere with functioning of the inverter or may even damage it Chokes or mains filters can be used on the mains side to protect the inverter against voltage spikes resulting from switching large loads to the mains Such chokes and filters are available as accessories see page 25 If inverters are operated in switchgear devices or in their close proximity e g in one common control cabinet in connection with the same power mains we recommend the following precautionary measures to suppress interference in the switchgear Wire the coils of contactors switchgear devices and relay com
125. ure Drive will shutdown if heat sink temperature exceeds rating DB Failure Drive will sense circuit failure and shutdown Error Fault Messages 19 fault codes 6 warning displays 77 Fault Storage Last three 3 faults stored Most recent displayed 48 Line Transient Limit 2 kV Maximum less than 40 microsecond duration External MOL Contact Compatible with NC fault contact 60 Operating Operating Controls 1 Keypad Forward Reverse Jog Stop Program 35 Features Shift Enter Local Remote and Up Down Arrows 2 Terminal strip See typical connection diagrams 32 Page 72 3 RS 485 Serial Input Output SIO Link 66 LED Indicators Forward Reverse Jog Stop Bus Charged and CPU 37 active Display 2 lines of 16 characters Super Twist alphanumeric 38 63 64 for all modes of operation Programmable to display in English French Spanish or German Any engineering units such as RPM FPM and GPM are supported Auxiliary Relay Programmable as Fault Relay or to signal one of 33 59 eleven conditions Programming Programming Levels Level 1 Operator 45 66 Level 2 Engineer Level 3 Engineer with SIO Parameter Block 00 Model software revision rated current heat sink Drive Data temperature trip point mfg serial repair date code and fault log Parameter Block 10 Output frequency voltage motor current motor load Status torque drive temperature elapsed time since power applied and total hours of op
126. ure correct installation and maximum performance The information contained in this manual is current for versions fitted with drive software series 4 43 02 RVL VL Display Language HINT With the parameter 86 LANG you can select the display language see page 64 1 2 Inspection A Upon receipt of the product unpack the AC inverter and carefully inspect for any damage sustained in transit depression in the enclosure damage to parts missing parts B Next remove the AC Inverter cover if supplied and inspect for any loose screws nuts or connectors C Read the technical data plate and verify the correct power size for the application and note the input voltage and current required for the inverter D If the inverter is to be stored for a long period of time repack the inverter and store in a clean dry place free from direct sunlight or corrosive fumes and in a location where the ambient temperature will not be less than 20 C nor more than 60 C 1 3 Control Identification Number A systematic numbering system is used to define all models by input voltage rating power rating and enclosure type This model number appears both on the shipping carton label and the technical data label on the enclosure A model number code is also accessible in the Level 1 programming mode Refer page 47 01 MODEL ACP 6007 5A De 6 007 5 A BERGES inverter type Input volts 6 400 V AC 460 V AC KW 007 5 7 5 kW Housing A IP
127. urred and displays one of 19 fault codes See Section 7 2 page 78 Troubleshooting for a complete list of all codes and explanations of each NEXT PAGE The A symbol indicates that pressing the Up Arrow will shift the display to Page 2 DESCRIPTION The second line provides a full 16 character description of the cause of the fault FAULT DISPLAY PAGE2 AT SPEED FWD 49 60 Hz 80 6 Page 2 of the fault display will show the operating conditions of the inverter at the time of the fault All other operating parameters are frozen until the drive is reset 3 7 Operating Tips Parameter Access When the PROG or SHIFT PROG key is pressed after application of power 21 MODE will always be the first parameter displayed e f a different parameter is accessed and the Program mode is exited that parameter will be the point of entry the next time the programming mode is accessed The ACP will remember different last parameters for levels 1 2 and 3 f no key is pressed for 10 minutes while in the programming mode the ACP will automatically revert back to the operating mode Display Scroll Rate Three scroll rates are used to speed entry of information into the ACP e If either the UP or DOWN arrow is pressed and held for five seconds the rate of change of the display will increase 30 10 97 Operating manual 41 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide R
128. verter from the ACP 6000 series is fully functional when connected to an alternating current of 370 V for example However the maximum output voltage is limited to 370 VAC If the motor is rated for a mains voltage of 400 VAC this can lead to higher motor currents and overheating of the motor It must be ensured that the connected mains voltage corresponds to the rated voltage of the motor If other than 50 Hz output can be tolerated proper volts hertz can be programmed into the inverter by the 53 FKNEE and 32 FMAX parameters If you are unsure about this feature consult Section 4 3 or BERGES Phase voltage imbalance of the input AC source can cause unbalanced currents and excessive heat in the input rectifier diodes and in the DC bus capacitors of the ACP Phase imbalance is calculated by the following method Assume The voltage from L1 to L2 2 La The voltage from L2 to L3 Lb The voltage from L1 to L3 2 Lc The average line voltage Lavg La Lb Lc 395 400 405 3 3 Determine the absolute value of the difference between each of the line voltages La Lb and Lc and Lavg subtract the two values and disregard the sign of the result Consider the results of this calculation to be Laa Lba and Lca Lavg 400 Laa Lba Lca 5 0 5 Phase Imbalance x 100 2 Lavg 2x400 x 100 1 25 Example Measured phase voltages of 395 400 and 405 would result in a calculated phase imbalance of 1 25 If the r
129. z L2P Preset Frequency 2 Jog Speed Preset Frequency 3 Preset Frequency 4 Preset Frequency 5 Preset Frequency 6 Preset Frequency 7 Parameter 33 F2 is preset speed 2 and is used to set the JOG speed reference when in the keypad operating mode All preset values are programmed and operate similarly in conjunction with 24 FSEL Each is adjustable in 0 01 Hz increments from 0 to 400 Hz NOTE Parameter 36 F5 37 F6 and 38 F7 adjustable while the drive is in run mode The fixed frequencies overwrite the analog setpoint value Refer to Table 2 7 and Section 6 for proper selection of preset frequencies 30 10 97 Operating manual 51 05 GB ACP 60005 0 75 55 BERGES Berges electronic D 51709 Marienheide Rodt Tel 02264 17 0 Fax 02264 17126 52 39 FTL 41 RSEL Minimum Frequency in Torque Limit When the drivers output current exceeds the limits defined by 27 TLSEL the motor will be decelerated at a rate determined by 46 DECTL to the frequency programmed at this parameter If this parameter is set to a value greater than 32 FMAX TORQUE LIMITING WILL BE DISABLED Ramp Selector L2P This parameter defines the acceleration and deceleration characteristics of the drive The following table outlines the possibilities DATA CODE 0 DESCRIPTION 42 ACC1 and 43 DEC1 control drive acceleration and deceleration for both forward and reverse operation 44 ACC2 and 45 DEC2 are select

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