PREMESSA GENERALE
Contents
1. Exit menu Press ENTER to exit the system parameters or from any position press twice ENTER quickly Press PARAM to continue POWER UNIT PARAMETERS For each POWER module of the WAVES system the set parameters can be optimized according to the user s specific application The parameters for each POWER unit are divided into groups GROUP to 6 having different configurations they can be scrolled with keys PARAM e PARAM Once the concerned POWER unit is identified see chapter Power unit programming by using keys WAVE and WAVE press o SET to enter the group parameters digit the POWER related password 1099 confirm with ENTER and select the parameter group with SET or SET Select the parameter with PARAM and PARAM Increase o r decrease its value with 5 e SET Press ENTER twice to exit the POWER unit parameter programming and go back to the main menu The parameter groups are described in the following pages The respective control mode is indicated on the chart s right side under Q according to the setting SVC Space Vector Control Voltage vector control FVC Flux Vector Control Vector control SFT Stator Flux Torque 7 Direct Torque Control SB Sinusoidal Brushless Sinusoidal brushless control NOTE stresses that the parameter can be set OFF LINE only Drive not running shows the control mode in which the parameter is active Telephone 390444730003 Fax2. stes TES 17 gt ACCESS TO THE MODULES eicere ito rin vto Eee SERE EET HERE PEE ERE DERE ERES CHENEY 18 gt WAVE3 OPTION BOARDS riti iet ee I E e TE eee TY 20 gt gt COMMISSIONING neret citet n ee eie Eve e EUER RE 21 gt PROGRAMMING WAVE EH ER EUER REEF WERE RAE AE EE NUR ETENEE ERENS E 22 gt SYSTEM PARAMETERS rrt ertet pae eb ye Erat bra ege epe med 25 gt POWER UNIT PARAMPBTERS eerte tenter tr etat o e o Po cree vtr tun 33 gt MAINTENANCE AND SERVICING eese eene eene Innen entren enteras enter ener nnne 41 gt DIAGNOSTICS ea A R 42 gt LIST OF ALARMS DISPLAYED E E E AR ERER 43 gt SERVICE CHECK LIST WAVE SYSTEM eene enne innen 44 gt CHECK LIST FOR MECHANICAL REPLACEMENT OF A WAVE 3 45 EM Pag REEL Se Release 05 04 03 2003 W3 System Instruction and Servicing Manual CONFORMITY DECLARATION REEL S r l Via Riviera Berica 42 36024 Ponte di Nanto VI Declares upon own responsibility that the following items WAVES Supply Unit WAVE 3 Capacitor WAVES Power Unit WAVE 3 Fan satisfy the standards listed below CEI EN 61800 3 Product standard for adjustable speed electrical power drive systems 1000 3 5 1994 Limitations of voltage fluctuations and flicker TEC 1000 4 2 1995 Electrostatic
3. ELECTRICAL INSTALLATION The information below regard the installing dimensioning connecting as well as the wiring outside the drives Please see attachments for EU regulations on the EMC directive CAUTION The following operations are subject to electrical risks described in the initial part of the manual Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual Power mains supply and drive motor decoupling cables must be increased of 15 compared to section needed for the nominal current value and anyway not below 1 5mm Place three ultra quick fuses before the supply unit dimensioned according to the unit itself as per chart below see chapter Dimensioning of the ultra quick fuses Shielded cables are needed for references and feedback minimum conductor section 0 5mm Carry out the ground connection by keeping the conductor length as short as possible it is recommended to use separate grounding bars for power and signals as indicated under chapter Ground connections In order to reduce the harmonic distortion of the mains current and reduce the input Ai At a choke is needed be tween mains supply and drives A EMI RFI filter might be necessary according to the related regulations see also chapter Application of the EEC regulation on the EMC norm it is also recommended to install a Philips ferrite ring type CST26 13 29 452
4. GROUP 3 Drive Config GROUP 4 I O Config GROUP 5 PID Config GROUP 6 User Config With keys tWAVE ENTER SET VERSION EXIT Telephone 390444730003 Fax 39 0444 638213 POWER unit selection parameter selection password selection enters the parameters password confirmation edits values set of the password figures REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual back Programming with PC Serial communication through RS 232 or RS485 option Reel supplies a communication software for the own drives easy to load on any IBM or WINDOWS 9x or NT compatible PC Download from www reel it The communication is activated by clicking on the related window on the DESKTOP The program communicates at one time with up to 31 drives connected to a single serial knot The OFF LINE mode al lows reading a previously ON LINE configured system See software program manual for further reference SYSTEM PARAMETERS The system parameters refer to the whole tunnel and must therefore be set by the user basing on the kind of installation for instance T O configuration voltage etc Mains Failure Control Menu ID PARAMETER RANGE DEFAULT AVAILABLE SELECTION 59 HOLD 0 5 1 Kind of Mains Failure handling 20 1 0 100 100 Inert
5. 84 Source DO3 0 0 31 0 All 1531 Drive 1 31 Determines the source activating DO4 85 Source DO4 0 0 31 0 AII 1 31 Drive 1 31 Analog input R1 i 0000 User 80 Analog input 0000 0 R1 0001 Kappa 0002 Destinat Analog input R1 R1 destina 92 0 0331 0 broadcast tion 1 31 drive 1 31 Configuration ANA output 0 10V 0000 User 0001 DC Link voltage of display not depending on ANA 0 Analog out source ut a P PIRE 0002 Drive Frequency 0004 Drive Speed 0008 Drive Current Determines the source activating output ANA 0 90 ANAO 1 1331 1 31 Drive 1 31 Source Filter analog OUT ANA 0 91 T ANAO 10ms 0 1000 0 1 sec Alarm memory menu N NAME DEFAULT KEYS SELECTIONS Displays the latest 32 alarms in their occurring order 1 1 last one occurred Allows deleting the alarm memory NO SETt do not delete mory YES dolete Telephone 390444730003 Fax 39 0444 638213 REEL S r l 3 W3 System Instruction and Servicing Manual Release 05 04 03 2003 Parameter backup menu N NAME DEFAULT KEYS SELECTIONS Enables the backup of all system parameters on data key BE wo SETt NO Not allowed ckup YES Start Back up Parameter restore menu N NAME DEFAULT KEYS SELECTIONS Allows restoring al system parameters from back up key E
6. No SETt NO Not allowed YES Restore Key label menu N NAME DEFAULT KEYS SELECTIONS il Key label SET Assigns the key a 16 character identification string chosen by the user Communication board menu N NAME DEFAULT KEYS SELECTION 1 Depends on _ SET Detects the communication board used rs485 Can etc and allows entering the OPT parameters if available User program menu N NAME DEFAULT KEYS SELECTIONS 1 Exe enable NO SET Enables the user program execution YES or NO 8 Cycle time 10 ms SET Cycle time set of the user program Range 1 50ms Debug aba SET Enables or disables the debug mode mode D 3 Save pro NO SET Saves the user program YES or gram 4 Delete prg NO SET Deletes the user program YES or NO Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual User parameters menu N NAME DEFAULT KEYS SELECTIONS 1 0 127 User parameters 2 FFFF User parameters value VERSION MENU Displays the Fimware version both for the Main Program and the logic FPGA ex WAVE3 MASTER Program dd mm yy Where RR program version dd mm yy creation date FIRMWARE FPGA Logic RR dd mm yy
7. 39 0444 638213 REEL S r l emn W3 System Instruction and Servicing Manual Group 1 Motor Configuration Release 05 04 03 2003 No NAME DEFAULT UNIT gt gt E m ill IaN 2 00 Amp Nominal motor current 2 IMAX 4 00 Amp Allowed overload current oo Q 3 ULN 400 Volt Nominal voltage applied to the motor 4 FLN 50 Hz Nominal motor frequency 5 FMAX 50 0 Hz Max working frequency 6 Nn 1450 rpm Nominal motor rpm 7 nMAX 1500 rpm Max working speed 8 Cos phi 0 85 Power factor e 9 Poles 4 Determines the number of pole pairs Qe 11 515 0 mH _ Stator inductance 12 Tau R 0 ns Time constant of the stator circuit Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual Group 2 Run Configuration E e m N NAME DEFAULT UNIT 2 13 Fmin 0 Hz Processing start frequency 14 V1 0 Volt Voltage applied to the motor at fre quency F1 Reference frequency for the processing us f He of a linear V F ration change 2 Voltage given to the motor for RI com 16 vo 10 Volt pensation torque optimization at low rpm 17 FO 30 Frequency value at the end of VO link to V F
8. POWER UNIT The control board of the POWER module has the following connectors Connector for 2 X Connectors for OPT 3 X Connector for OPT 1 X mm for OPT 4x P1 Back up voltage Reel serial bus 1 24 24Vdc from ext back up 2 0D from ext back up 3 In s s Reel serial bus input 4 In s s Reel serial bus input 5 5 s Reel serial bus output 6 Out s s Reel serial bus output WAVE 3 OPTION BOARDS Options for control board SUPPLY unit S485 with standard WAVE3 protocol or WAVE 2 c
9. Release 05 ms 04 03 2003 W3 System Instruction and Servicing Manual m 3 back Electronic Power Drives INSTRUCTION AND SERVICING MANUAL Telephone 390444730003 Fax 39 0444 638213 Pag 1 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual CONTENTS gt CONFORMITY DECLARATION ccccsccccsssceceesseeecssaeeeceseeeceesseeecsessececssesececauseeeneaaeeeensnteeeesas 3 PRELIMINARY REMARKS innere ev wee v o eu a aries RD DRE ev ee v v ER 4 X CAUTION 5 gt QLOBSARY iuiciudueane n n hoes a desea ads e Ee o reli er P b rd trei 6 gt GENERAL SAFTY MEASURES FOR THE USER 1 4 eese nnne entente tenni 7 gt GENERAL RECOMMENDATION ABOUT THE 8 WARRANTY edente tap EO e RH HT EHE 9 gt PRODUCTEIIDENTIFIGATIGON citerior tati tee tette o REPE e EE E e Ie Ya SEE EET 9 gt WAVESYSTEM COMPOSITION EE RU Ce V THREE NETT 12 gt MECHANICAL INSTALLATION W000 cccceeccccssccesssecssecesssceececssecsaecesssecseseesecaecessseeeseceseeenaeensnes 13 gt ELECTRICAL INSTALLATION ccccccccccceccccssscesssccssecessecssesecseecssscessecaeceseecsssseesesesseceseeenaeessnes 13 gt GROUND CONNECTIONS 15 gt POWER CONNECTION STANDARD TUNNCU GL eene eren nennen enne 16 gt WIRING A STANDARD TUNN BL 1 1 e
10. Notes on servicing gt Cleaning of metal parts with compressed air 10bar max 135psi gt The cleaning of the boards if necessary must be carried out by skilled personnel that will use specific solvents for electronic components after check their suitability for plastic parts as well NOTE __ itis recommended to contact a REEL Service Center Do not replace electronic components on the boards even when they look seriously damaged Always contact a Service Center instead gt The replacement of fan or capacitor modules having failed shall be carried out according to the instructions con tained in the check list available on the manual s CD ROM Exploitation factor 100 machine used at full load during every working shift Telephone 390444730003 Fax 39 0444 638213 REEL S r l 3 W3 System Instruction and Servicing Manual Release 05 04 03 2003 back DIAGNOSTICS The modular drive system by REEL communicates with the outside world through the supply module Any status or alarm of a single power module is signalled to the supply unit which takes the info to RS 485 and disables in case of alarm a hardware enabling output when programmed for such purpose When the SUPPLY module is provided with a programming keypad a message identifying the alarm appears on the dis play Every single drive informs the supply unit on the own alarm and displays the own status through LEDs The number of blinking identi
11. 0444 638213 Release 05 ms 04 03 2003 W3 System Instruction and Servicing Manual m 3 WIRING A STANDARD TUNNEL MAINS SUPPLY 220Vac or 24Vdc x x T 24 24V 3 5 i53 Mu VV vil 14 AAI V2 W 5 F A A EN 410 10 L lA C DDI Ts W3 SUPPLY 10 9 i OA 1 on SWITC OA 8 P S MA SWITCH E 424 6 SUGGESTED EE DAD PRIE EN 4 REACTANCE j RST DINA 3 _ 2 IL nb H JIN2 FILTER d i DIN FC 9 24V L 3 gt 0073 7 4 6 T T CEDIA R 4 TO EXTERNAL SERIAL lt scheda seriale opt N R1135 oUm 2 si TO PE 4 RS 232 OA 4 KAS AS A1 N gt E96 0A KAA AS KA2 KA O n OP o W3 POWER AE EM d according to the sizes as per attachment Telephone 390444730003 Fax 39 0444 638213 REEL Srl 3 W3 System Instruction and Servicing Manual 04 03 2003 back ACCESS TO THE MODULES In order to operate on the control boards of the WAVE 3 SYSTEM loose the central screw or the screws according t
12. 39 0444 638213 REEL S r l
13. running 44 Hold 1 1 Standard Reel control Energy Recovery o 2 Controlled stop 3 Not controlled stop 45 Off AN1 0 Analog input offset OPT1 o 46 Off AN2 0 Analog input offset OPT2 o 47 R1 memo 0 Digital speed reference saving Selects the available macros 48 Select 0 0 none 1 Electronic Traverse SVC type selection 49 Tab_VHz 0 0 open speed loop 1 closed speed loop Group Group belonging of the drive during mains 90 Hold failure control 0 4 0 none Under development Telephone 390444730003 Fax 39 0444 638213 REEL S r l 3 W3 System Instruction and Servicing Manual Release 05 04 03 2003 Group 4 I O configuration parameters U U N NAME DEFAULT UNIT gt gt E wn m Functions of the programmable digital input for DIN1 functions assignment 0 Disabled 8 TUNE RESOLVER 1 ON 9 el Traverse set 2 En 10 therm motor pro tection E CU ds dl d oed 11 7 Encoder CHA 4 2 ENT4CW Encoder DUIS CHBxDIN2 EN1 CCW S ENAC 12 unid Encoder 6 EN2 input Possible for 7 ALARM RESET DIN2 only 13 enable motor catch 52 Din24 11 1 Functions of the programmable digital input e le le le for DIN2 functions assignment 53 Din3 0 _ Functions of the programmable digital input e le la le for DIN3 functions assignment 54 Dina 1 Fun
14. selection SET a Once the parameter to be modified is chosen the value can be increased or decreased ENTER Access to the programming page RESET Keypad reset communication with the drives is stopped and automatically restarted after a few sec onds The reset key acts on all drives connected in the system it is deactivated when the system is running Parameter input with keypad After connecting the unit to the drive and feeding after a few seconds the display shows the menu page There are two parameter groups for W3 1 SYSTEM PARAMETERS 2 POWERUNIT PARAMETERS Access to the Parameters from keypad by pressing SET or SET and digiting password 1098 for system pa rameters 1099 for the power unit parameters Telephone 390444730003 Fax 39 0444 638213 REEL Srl emn Release 05 W3 System Instruction and Servicing Manual 04 03 2003 System Programming Password 1098 MAINS FAILURE SETTING BAUD RATE RS232 LANGUAGE IGNORE DRIVE ALARM KILLER ALARM WARNING Vnom DC LINK I O CONFIG ALARM MEMORY BACK PARAM RESTORE PARAM KEY LABEL COMUNIC BOARD USER PROGRAM USER PARAMETERS Power Programming 1099 Password GROUP 1 Motor Configuration GROUP 2 Run Config
15. 0 076 Machine speed percentage to start dc braking on ac motors 35 KM 0 300 5 0 Average slip of the motors driven the system 36 PNDm 0 10 000 2 M acceleration gradient limit calculated by the 37 KG 0 01 50 00 1 00 PID Multipl factor according to the instant line speed 38 KL 0 1999 50 PID gain adaptor depending on inertia load according to the line speed 39 10 0 100 30 Average of the motor current values without load basing on the nominal plate values 40 VO mr 0 201 5 Voltage BOOST optimisation during mains failure control 41 T_mr 500 2000 500ms Minimum time mains failure loop 47 Smk 0 0 100 0 0 Minimum speed threshold below which speed does not go back to the previous value during a mains failure 48 TauD 0 1000 Ding eg time constant on the derived mains Failure control 49 Mains failure control selection 0 No control 1 Standard energy recovery 50 Hold 1 2 Energy recovery with differential stop 3 Supply from DC bus m f not controlled 4 Control through a master drive 5 Control through several independent drive groups Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual m 3 Baud Rate menu RS232 N PARAMETER DEFAULT UNIT SELECTIONS Baud rate selection for RS 232 4 Baud Rate RS 232 19200 b p s 9600 38400 19200 57600 0 CRC CCITT 5 Error check 0 x 1 CKS XOR Langu
16. 0003 Fax 39 0444 638213 REEL S r l 3 W3 System Instruction and Servicing Manual Release 05 04 03 2003 back PRELIMINARY REMARKS The WAVE 3 system consists of multi function vector drives able to control asynchronous and brushless motors Through just one supply unit the system feeds several drive units controlling different kinds of motor thus otimizing the space needed inside the cabinet and allowing remarkable energy saving This instruction and service manual was written for specialized operating personnel in charge of installation assem bling commissioning as wellasservicing the mentioned multi drive system Such operators are supposed to e Have attended a training course on installation commissioning and servicing of electrical devices and anyway be experienced as regards possible risks and dangers e Have attended courses according to the regulations in force for use and servicing on safety devices e Know the main physical and electrical system features e Know the symbol system used for electrical schemes e Know all cabling and wiring procedures as well any detail regarding the use of electrical components Itis not necessary for such persons to be experienced in the field of frequency converters Please read the manual carefully before using any product belonging to the WAVE 3 system for further technical detail please contact REEL S r l by fax or e mail reel reel it The information provided in
17. 05 04 03 2003 N NAME DEFAULT RANGE SELECTIONS Polarity outputs DOUT1 DOUT2 DOUT3 DOUT4 0 F SET boum DOUT DOUT3 DOUT4 0 H H H H 1 L H H 2 H L H H 3 L L H H 4 H H L H 5 E H L H 6 H L L H EE Output po 1 0 7 L L L H larita 8 H H H L 9 L H H L A H L H L B L L H L C H H L L D L H L L E H L L L F L L L L H USCITA ATTIVA ALTA L USCITA ATTIVA BASSA Output DO1 configuration 0000 User Available for user progr 0001 Alarm OR with source 0 0002 mSR AND with source 0 76 DO1 config 0001 0 0004 Power failure OR with source 0 0008 Rotation direction OR with source 0 0010 Set point reached AND with source 0 0020 Brake OR with source 0 0040 Thermal alarm OR with source 0 77 DO2 config 0002 0 Config Output DO2 like DO1 78 DOS config 0000 0 Config like DO1 79 DO4 config 0000 O FFFF Config DO4 like DO1 Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual N NAME DEFAULT RANGE SELECTIONS Determines the source activating 82 Source DO1 0 0 31 0 All 131 Drive 1 31 Determines the source activating DO2 83 Source DO2 0 0 31 0 All 1 31 Drive 1 31 Determines the source activating
18. 18 ACC 10 00 sec Acceleration time at start Qa 19 DEC 10 00 sec Deceleration time at stop Qa 20 Ramp 10 00 sec Time variation on speed set Qa 21 Timax 1 0 Sec Overload limit time Pt for the motor 20 Tbrake 0 0 Sec Brake handling time if programmed e o 23 msr Hz 0 3 Hz Minimum speed relay threshold in Hz 24 msr rpm 5 Rpm Minimum speed relay in rpm o Qe 25 T cong 0 0 Sec Limit duration time for congruence error e 26 S cong 0 Rpm Window in revolutions for congruence error ee le handling 27 1 0 De injection at 0 speed parameter for mains failure control handling 28 Tw_fil 0 ms Filter time constant on the speed detecting Nominal current percentage used to search for 28 Pouch 30 s motor speed in the motor catch handling x 30 Search 5 Search time for motor speed in the motor catch handling Telephone 390444730003 Fax 39 0444 638213 REEL S r l W3 System Instruction and Servicing Manual Group 3 Drive configuration Release 05 04 03 2003 N NAME DEFAULT UNIT SVC FVC SFT SB 31 Defines the control mode 0 SVC Space Vector Control V Hz 1 FVC Flux Vector Control 2 SB Sinusoidal Brushless 3 SFT Stator Flux Torque 32 Size 19 0 Module size see size chart 33 PWM 2 00 KHz Modulat
19. 2 DIN3 DIN4 0 H H H H 1 L H H 2 H L H H 3 L L H H 4 H H L H 5 L H L H 6 H L L H 70 d 0 0 F polarity 8 H H H L 9 L H H L A H L H L B L L H L C H H L L D L H L L E H L L L F L L L L H ACTIVE INPUT HIGH L ACTIVE INPUT LOW Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual m 3 N NAME DEFAULT RANGE SELECTIONS DIN1 configuration 0000 USER available for user program 0001 Drive ON 0002 RUN CW 0004 RUN CCW 71 Config 0000 0 FFFF 0008 EN1 0010 EN2 0020 RESET can be executed in Broadcast only 0040 STROBE 0080 MOTOR CATCH 72 DIN2 Config 0008 0 FFFF DIN2 configuration like DIN1 78 DINS config 0001 0 FFFF DING configuration like DIN1 74 DIN4 config 0000 0 FFFF DIN4 configuration like DIN1 Destination DIN1 on Drive n EN o 0 0 31 0 alll broadcast nation 1431 Drive 1 31 Destination DIN2 on Drive 87 DINA 2 i 0 0 31 0 all Broadcast nation 1431 Drive 1 31 Destination DIN3 on Drive n EE DNS desti 0 0 31 0 all BROADCAST nation 1431 gt Drive 1 31 Destination DIN4 on Drive n BENE DINGS desti 0 0 31 0 all BROADCAST nation 1431 Drive 1 31 Telephone 390444730003 Fax 39 0444 638213 REEL S r l 3 W3 System Instruction and Servicing Manual Release
20. CE AND SERVICING Caution measures Servicing on the tunnel may be carried out by qualified personnel only since some parts of it are under high volt age while running Careless behaviour may cause death or heavy injuries to persons or damage things Before starting any operation on the drive disconnect it from the mains and wait at least 10 minutes before touching parts under voltage as there might still be dangerous voltage on the capacitors of the intermediate cir cuit maintenance personnel must have read this manual thoroughly See attached diagrams to identify the different drive parts Periodical servicing The WAVE 3 system scheduled servicing on the FAN and CAPACITOR modules only The other modules just need a clean and dust free environment especially free from conductive dusts Periodical servicing also depends on the kind of environment in which the DRIVES work as well as ventilation To ensure correct servicing follow the check list to be found at the end of this manual Part replacement Due to the ageing of mechanical and electronic components we suggest replacing gt FANT O01 modules every 27500 hours FAN T 02 modules every 40000 hours FAN T 03 modules every 40000 hours Capacitor modules every 5 years after inspection if exploited for 50 2 years in case of 100 exploitation The capacitor boards inside the system every 5 years after inspection VV ON ON ON Fuses every 10 years
21. NAME DEFAULT RANGE 85 106 Usr0 21 0 65 535 User parameter depending on selected mode and macro Mains failure control parameters Active if the power unit acts as mains failure master N NAME DEFAULT RANGE S E E A 72 m wn 65 Ramp_V 0 50 030000 Raising time for the DC BUS at the catching dc in case of mains failure Master configuration Proportional constant of the voltage loop 66 Kp Vdc 700 0330000 Slave configuration Compensation level of the DC LINK voltage SVC control mode during mains failure control 67 500 0 30000 Integral constant of the voltage loop oo QG o 68 Vdc 500ms 0 30000 Derivative constant of the voltage loop 69 Td Vdc 500ms 0 1000 Filter band width the feedback for the Vdc constant Internal Communication N NAME DEFAULT e m o 110 CLSI out 8C01 For expert users only og 111 52 8C01 For expert users only o og 0000 For expert users only 119 51 in 8022 For expert users only 120 51 in 8064 For expert users only e ao eG 000 For expert users only Telephone 390444730003 39 0444 638213 REEL S r l Release 05 ms 04 03 2003 W3 System Instruction and Servicing Manual mut3 MAINTENAN
22. S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual 1 Back up voltage Reel serial bus P2 RS232 1 24 24Vdc from ext Back up 1 5 2 OP OVdc Ext Back up 2 Tx 3 In s s input reel serial bus 3 Rx 4 In s sinput reel serial bus 4 n c 5 Out s s output reel serial bus 5 0D 6 Out s s output reel serial bus 6 5 7 CTS 8 RTS 9 0D P5 User Terminal Board 1 P6 User Terminal Board 2 1 DIN2 Programmable user input 1 0 Analog Zero 2 DIN3 Programmable user input 2 OUT1 Programmable analog output 3 DIN4 Programmable user input 3 R1 differential input for reference 4 EN Ref Enable Progr Input 4 R1 differential for reference 5 OP Zero 5 DOUT1 Programmable user output 6 24 24V supply 1 5 A max 6 DOUT2 Programmable user output 7 Common for programm Inputs 7 DOUTS3 Programmable user output 8 0A Analog Zero 8 DOUT4 Programmable user output 9 10 10Vdc supply for references 9 C Common for programmable outputs 10 10 10Vdc supply for references 10 DIN1 Programmable user input NOTE The setting of the programmable user inputs and outputs is described under chapter SYSTEM PARAMETERS Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 emn W3 System Instruction and Servicing Manual 04 03 2003
23. age menu N PARAMETER DEFAULT UNIT SELECTIONS 7 LANGUAGE ENGLISH Italian English German French Ignore drive alarm N PARAMETER DEFAULT UNIT SELECTIONS DISABLED handles all alarms 1 Ignore drive DISABLED p alarm ENABLED ignores all alarms Killer menu N NAME DEFAULT UNIT SELECTIONS Max activation time dynamic brake 62 KILLER 0 000 5 0 000 10 000 0 000 Killer disabled Thermal warning menu N NAME DEFAULT UNIT SELECTIONS Thermal warning alarm selection0 0 20 0 s 60 PREWARNING 0 0 5 0 0 warning disabled Vnom dc link menu N NAME DEFAULT UNIT AVAILABLE SELECTION Tensione nominale di rete che alimenta il sistema 65 Vnom 400 Vac da 380 500Vac Telephone 390444730003 Fax 39 0444 638213 REEL S r l 3 W3 System Instruction and Servicing Manual Release 05 04 03 2003 Tunning Parameter Reading parameters configuration reserved N NAME DEFAULT RANGE SELECTIONS e Setting value for OFFSET compensation 2 _ Setting value for OFFSET compensation Vmax DC 800 400 900 Max voltage alarm value on DC link OFF SET ntc Ambient temperature error adjustment set Config menu N NAME DEFAULT RANGE SELECTIONS Polarity inputs DIN1 DIN2 DIN3 DIN4 0 F SET DIN1 DIN
24. an be modifies by the user according to the own needs and applications Voltage Frequency controlor Volt Herz control or scale control mode Space Vector Control For the optimal control of one or more standard motors Flux Vector Control Pure highly dynamic vector control with encoder or resolver feedback Stator Flux Torque Direct torque control of the new generation Highest performances in torque control mode also sensorless Sinusoidal Brushless Control for permanent magnet brushless motors Component able to receive and forward data POWER remote I O etc REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual m3 back GENERAL SAFTY MEASURES FOR THE USER This charter contains all info regarding the safety measures to be taken by personnel operating with WAVE 3 These are general indications regarding possible risks and the maintenance and servicing on the drives Operators and technicians in charge of service must be aware of the dangers related to high voltage and frequency values and must know all related safety measures and procedures CAUTION e Any service or installation operation on the tunnel or the single modules must be carried out by qualified personnel e The tunnel and connected devices must be grounded properly e Do not act on the tunnel while under voltage After cutting off the power and auxiliary supply wait for time indicated i
25. ctions of the programmable digital input e le la le for DIN4 functions assignment 55 Din5 2 _ Functions of the programmable digital input e je le Je for DIN5 functions assignment 56 Din6 3 _ Functions of the programmable digital input e le la le for DIN6 functions assignment Functions of the programmable digital output for the DO1n functions assignment 0 Disabled 1 msr 571 DO1 5 2 BRAKE 3 SPEED REACHED 4 ROTATION SENSE 5 ALARM Start release Functions of the programmable digital output Es i for the DO2 functions assignment s 2 2 Functions of the programmable analog output for the OUT1 functions assignment 0 disabled 59 Outl 1 1 SPEED OUTPUT 10V 2 CURRENT OUTPUT 10V 3 DC LINK VOLTAGE OUTPUT 0 10V 10 1000Vdc Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual m 3 m N NAME DEFAULT UNIT 2 e E Functions of the programmable analog out 60 Out2 2 put for the OUT2 functions assignment like 61 Offout1 0 Offset for analog outputs Outl e 62 Offout2 0 Offset for analog outputs Out2 63 tw outil 10 ms Time constant PB filter on analog output o Outl 64 tw out2 10 ms Time consta
26. discharge immunity TEC 1000 4 3 1995 Electromagnetic field immunity 1000 4 4 1995 Electrical fast transient burst immunity 1000 4 5 Surge immunity According to the contents of European Directives 89 336 EEC on EMC and 73 23 CEE on Low Voltage Ponte di Nanto 2001 Ezio Bertotto Giancarlo Verlato Product Manager Tecnico CE Remarks on electromagnetic compatibility According to EEC 89 336 WAVE 3 drives are considered as components and must therefore satisfy the requirements of the specific product regulation For semiconductor power converters for adjustable speed electrical drive systems the regulation is CEI EN 61800 3 Adjustable speed electrical drive systems According to directive 89 336 EEC on EMC and 73 23 EEC on Low Voltage the product developped and manufactured by REEL S r L is to be considered a BDM Basic Drive Module The BDM along with electromechanical and auxiliary electronic parts compose the CDM Complete Drive Module The CDM along with the motors and sensors inside the machine compose the PDS Power Drive System The PDS only is a complete item that can be certified the assembling person will take care of the CE marking for the whole machine bas ing on the documentation on all components The manuals delivered along with the REEL products contain all information to obtain results according to standard CEI EN 61800 3 Ad justable speed electric drives Telephone 39044473
27. e drives need some parameters in order to get adequate protection for the specific use The standard configuration parameters for the drive are already installed and can be changed or re installed for example for adjustment toward the mains or the connected motor by following the indications below The programming is carried out with the built in keypad option or through RS 232 Programming devices 1 Programming keypad Keypad alphanumeric display with two lines and 16 letters A remote keypad version is also available to be connected with a shielded 9 pole cable to RS232 useful when the machine control system is far away 2 PCSoftware Communication with the Reel drive from any PC having RS232 free download from www reel it Programming keypad Acts as interface with the WAVE 3 system Take off the protecting cover connect the flat cable place the new cover bear ingthe keypad and fix it The keypad informs on the status motor revolutions absorbed current etc or in case of fault on the alarm type occur ring 4 languages are available Italian English German French Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual Programming keys WAVE In case of several drives controlled by the unit the display shows the serial code of the selected drive PARAM During programming they scroll the parameters for
28. e the system beyond its nominal capacity otherwise the tunnel could be damaged irreversibly e Handle the device with care to avoid damaging of any part e Protect the device against not admitted exceeding such as temperature humidity blows shocks etc e Voltage may not be applied on the power module output It is neither allowed to connect more inverters in parallel on the output nor the direct connection of the in put to the inverter output Bypass e No capacity load may be connected to the inverter output terminals U2 V2 e W2 for instance phasing capacitors e Ground connections have always to be carried out PE by using the ground termi nal or the grounding bar e Use insulated instruments having an adequate scale end For voltage measuring e Ensure the system protection against aggressive environments such as o Powder content o Dust Air saturated with oil or corrosive agents o Volatile coarse grained dusts obstructing even partially the ventilation ducts o Chemical or organic agents that lay on surface and thus damage the internal insulations o Gas vapors Even poorly conductive material that may affect parameters of the high impedance circuits Warm and humid environments supporting water condensing the part being cooled 2 WARNING e In case of installation inside conditioned cabinets cut off supply and wait for the temperature to reach a normal level before opening the cabine
29. ent labels show the product family Power Modules VERSION BARCODE The barcode identifies product typology and order SIZE Module size according to the nominal current value MODEL VERSION The version number is assigned by REEL to distinguish the different op tions of the same series to be considered in case of order or spare part de mand CONSIDER THE EVIDENCED SIZE ONLY V MAX OUT IN MAX f OUT Limit value for the product if used exploiting the maximum features Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 W3 System Instruction and Servicing Manual 04 03 2003 Supply modules barcode BARCODE The barcode identifies product typology and order no V Indicates the minimum maximum input voltage values The programming section contains all necessary indications for the voltage selection kVA kVA maximum power absorbed by the supply module at the given min max voltage values SIZE Module size MODEL The version number is assigned by REEL to distinguish the different options of the same series to be considered in case of order or spare part demand 2 WARNING The version must be looked up in case of spare part demand to determine the perfect compatibility Should the spare part s version number be different from the installed drive then the compatibility must be checked by looking up the
30. fies the kind of alarm or the enable status Have the modules no programming keypad the occurring alarm or the enable status can be identified through the three LEDs on the control board Every LED signals 0 OFF 1 ON 2L blinking twice pause 3L blinking three times pause 4L blinking 4 times pause IL LED 3 differentiates the running from the alarm status L3 0 gt alarm L3 1 gt run L3 2L gt ready to start stand by Is LEDS off then LED1 and LED2 identify the alarm LED1 LED2 ALARM 0 0 NULL 0 1 Motor protection 1 0 Power section protection 1 1 Overload 0 2L Low 24V 2L 0 Max Voltage 2L 2L Feedback 0 3L Overspeed 3L 0 Not encoded 3L 3L Congruence 0 4L Thermal switch 4L 0 Communication 4L 4L Not encoded Is LED3 on LED1 and LED2 signal the following functions LED1 LED2 STATUS 0 0 Not enabled 0 1 EN1 1 0 EN2 1 1 EN2 EN1 2L 2L CCW 2L 1 CCW EN1 1 2L CCW EN2 3L 3L CCW EN1 EN2 Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual n LIST OF ALARMS DISPLAYED MESSAGE ON DISPLAY Comm Comm slave Bus open Comm M gt Prec Download param Bus not config Frame error Eeprom not found Invalid conf Conf mismatch Mains failure Slave in alarm Min voltage Max voltage Killer Brake OFF Brake Thermal probe Charge failed T
31. hermal prealarm Low 24 Volt Card temperature Boot error FPGA Overload Thermal switch Encoder Power section protection Motor protection Min voltage Max voltage Overcurrent Congruence Feedback Telephone 390444730003 Fax 39 0444 638213 DESCRIPTION Communication between masters Communication between two indicated slaves Communication bus is not properly connected between the indicated points Communication between master and previous slave The master cannot send parameters to the slaves Configuration error of one slave at the start up Frame error System memory not working properly Memory data configuration on supply unit not correct The tunnel configuration does not correspond to the previously saved one Mains Failure on one phase already given at start up Alarm on one slave press ENTER for further details Min supply voltage Max voltage on the DC bus Excessive use of the dynamic brake Dynamic brake out of service Short circuit on the brake output Thermal probe of the supply unit Capacitor charge failure Thermal warning Stabilized voltage not sufficient or in overload Env temperature 250 C Configuration error PLD at start up Overload on the indicated slave Thermal protection on the indicated slave Encoder error on ind Slave Power section protection on ind Slave Motor protection on ind Slave Minima tensione dello slave indicato Max voltage on Dc bus Overcurrent on the ind Slave Congruence er
32. ia from motor n 1 21 M2 0 100 0 Inertia from motor n 2 p M3 0 100 0 Inertia from motor n 3 23 MA 0 100 0 Inertia from motor n 4 24 M5 0 100 0 Inertia from motor n 5 25 M6 0 100 0 Inertia from motor n 6 26 M7 0 100 0 Inertia from motor n 7 27 M8 0 100 0 Inertia from motor n 8 28 M9 0 100 0 Inertia from motor n 9 29 M10 0 100 0 Inertia from motor n 10 30 KP_mr 0 1000 500 proportional setting of the Mains Failure function 31 KI mr 0 1000 500 Constant linear setting of the Mains Failure function PID 32 KD_mr 0 1000 500 derivative setting of the Mains Failure function Telephone 390444730003 Fax 39 0444 638213 REEL S r l W3 System Instruction and Servicing Manual Release 05 04 03 2003 ID PARAMETER RANGE DEFAULT AVAILABLE SELECTION 48 TauD 0 1000 Oras di time constant on the derived Mains Failure Control 42 KP sus 021000 500 Constant proportional setting of the Mains Failure function auxiliary PID 43 Ri 0 1000 500 Constant integral setting of the Mains Failure function aux iliary PID 44 ieee 0 1000 500 Constant derivative setting of the Mains Failure function auxiliary PID 45 TauD 0 1000 Oms Filter time constant on the derived Mains Failure Control auxiliary PID 46 33 DI 0 1000 30 05 Deceleration coefficient for the start of Mains Failure han dling 34 RmK 0 20 0
33. ion frequency 2 0 2kHz 21 2 1 random 2 kHz 500 Hz 4 0 4kHz 41 41 random 4 KHz 500 Hz 80 8kHz 81 8 1 random 8 KHz 500 Hz 12 0 12 kHz 16 0 16 kHz Setup 0 Assignment of the drive commands the serial port 0 all Hardware commands 35 R1 Configuration 15 reference 0000 User 0001 Analog from OPT1 0002 Analog from OPT2 0004 from serial bus 1 0008 from serial bus 2 0010 4 20 mA from OPT2 36 R2 Configuration 2 reference 0000 User 0001 Analog from OPT1 0002 Analog from OPT2 0004 from serial bus 1 0008 from serial bus 2 0010 4 20 mA from OPT2 37 1 100 Rpm Pulse speed 1 38 Jog2 1000 Rpm Pulse speed 2 39 Enc Out 1024 ppR Pulse rev of the encoder simulation output Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual m 3 N NAME DEFAULT UNIT S S gt zm 40 Enc_in 1024 P p R Nominal pulse rev of the encoder Q Encoder type 0 Svc id 41 Type Enc 1 FVO 0 Unidirectional standard on SVC 1 Bidirectional standard FVC 42 Bit Ress 14 BpR Resolver conversion resolution 43 Off res 8181 Resolver offset Tuning Configuration for mains failure control 0 No control drive keeps
34. m part under voltage can endanger the operator s safety as wellas cause the drive s failure e Should it be necessary to have access to the device wait at least 10 minutes after cutting the mains supply before going on with any other operation gt e This manual refers to product versions with default configuration The setting of special functions or commands may need logics different from the standard to be implemented CAUTION e Please take special care whenever you see a WARNING on the WAVE 3 SYSTEM and the accessoire parts used their text illustrates source and what to do e The warning messages used are shown below WARNING HOT SURFACE Telephone 390444730003 REEL S r l Fax 39 0444 638213 Release 05 W3 System Instruction and Servicing Manual 04 03 2003 GLOSSARY TUNNEL IGBT PRECHARGE PWM DEFAULT VALUES V F SVC DEVICE Telephone 390444730003 Fax 39 0444 638213 System consisting of a group of inverters called POWER modules connected through a power dc bus to a supply unit called SUPPLY All modules are assembled to build up the TUNNEL Insulated Gate Bipolar Transistor Stepwise voltage increase on the capacitor bank on the dc current side of the POWER modules or connected to the tunnel Pulse Width Modulation Values of the software parameters programmed ex factory To each parameter a default values is assigned during the test phase such value c
35. module 160mm Du SE Power module 160mm Power module 240mm Power module 320mm Motor connec tion FAN supply xing round cable erminal board motors Terminal boards option boards Motor cable protection Fan module T03 Telephone 390444730003 Fax 39 0444 638213 Pag 12 REEL S r l Release 05 ms 04 03 2003 W3 System Instruction and Servicing Manual MECHANICAL INSTALLATION A few general rules should be followed during installation of WAVE 3 e The tunnel has to be placed away from heat sources and in well ventilated environments e Although the tunnel was made to be installed in vertical position it can be placed horizontally as well since it is cooled externally forced ventilation gt e The system has to be assembled so to be protected against aggressive environments Read para graph General Safety Measures carefully e Provide at least 100mm space both on the upper and lower side as well as around the fan mod ule to grant good cooling It is recommended to leave 60mm air gap laterally for wiring N E FAN 5 T02 TI 1 1 LJ i SIZE opt T power LI Eze Karran power LJ b Sue pasas 6042 N d
36. n the Installation and service manual before touching the power sections e The power modules output terminals motor connection have dangerous volt age when the inverter is supplied apart from the motor running or not e Even when the tunnel is not under voltage mains supply open and capacitors not charged there might be voltage inside the tunnel coming from the auxiliary circuits as well as from the external control When acting on the system utmost caution is needed all connections have to be cut off otherwise the persons safety and life can be endangered e 15 the motor stopped but the tunnel not cut off from the mains and the capaci tors have not been discharged there might be an accidental motor shaft move ment in case of failure or bad working e tis forbidden to change the insulation distances or remove insulation materials as well as coverings CAUTION e During commissioning and while the tunnel is working operators must follow all detailed safety prescriptions contained in this manual Telephone 390444730003 Fax 39 0444 638213 REEL S r l 3 W3 System Instruction and Servicing Manual Release 05 04 03 2003 back GENERAL RECOMMENDATION ABOUT THE PRODUCT gt WARNING e All insulation tests on motor and or connection cables must be carried out after disconnecting the power modules from the cables Dielectric stiffness tests must not be carried out on inverter parts e Do not try and us
37. necting the tunnel check the following make sure that Anunwanted motor movement does not cause damages to the machine or persons Thesupply voltage corresponds to the supply unit s nominal features The power and control connections are carried out correctly All connecting and setting operations have to be carried out by qualified personnel Before enabling the start check the following Programmable in and outputs must be adequately configured The motor s setting parameters must correspond to the motor itself The function parameters correspond to the drive application Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 W3 System Instruction and Servicing Manual 04 03 2003 Connection After checking the above mentioned follow the steps below 1 Disconnect the extractable connectors on the optional parts 2 Feed the SUPPLY module 3 Check for the supply module to be ready to start as well as all stabilized voltage supplies to be present 4 Plug the extractable connectors again 5 Check for every module to be failure alarm free 6 check all specific setting parameters for the POWER module and the motor 7 Run every POWER module singularly and check for the related motor to turn in the correct sense OoOoOoooo 8 Set the system PID s according to the indications contained in the manual PROGRAMMING WAVE 3 General Notes At the moment of installation th
38. nt PB filter on analog output o Out2 Group 5 PID configuration N NAME DEFAULT RANGE S S gt n zm vili KpI 300 0 30000 Proportional constant of the current control 72 Kil 300 0 30000 Integral constant of the current control 73 Kpw 300 0 30000 Proportional constant of the speed control e Qe 74 Kiw 20 0 30000 Integral constant of the speed control 75 Kdw 0 0 30000 Derivative constant of the speed control Qe 76 tdw 15 0 1000 Filter band width on feedback for con stant 77 Kpflx 40 0 30000 Proportional constant of the flux control 78 Kiflx 1 0 30000 Integral constant of the flux control 79 R2a 0 0 100 0 Absolute constant auxiliary PID control 80 R2p 0 0 100 0 Proportional constant auxiliary PID control o o 81 R2i 0 0 32000 Integral constant auxiliary PID control 82 R2d 0 0 32000 Derivative constant auxiliary PID control o 83 R2td 0 0 32000 Filter Band width setting for the derivative 9 constant of the auxiliary PID control Telephone 390444730003 Fax 39 0444 638213 REEL S r l 3 W3 System Instruction and Servicing Manual Release 05 04 03 2003 Group 6 User configuration The parameters below are available depending on the control mode and the selected macros The values taken by the parameters are shown in the annex according to the selected macro N
39. o the size with a screwdriver take off the side supports and remove the cover To avoid mixing up the covers look at the label fixed on them informing on the DRIVE SETTING and possible APPLICATIONS Side supports Side supports Setting label see chapter on product identification Central screw Please follow the indication in order not to damage the system SUPPLY UNIT The control board of the supply unit has the following connectors 77 Ww t t ra jum P1 eo See ae 56 2 EG E C EL DB B LI SEQ 02 mm li E akeen d co aoe S BS BBB B D BEES o ca 28 2 25 Ser of a Seo IC tinii iS CI Seqces coo 1258 Sceala m OGA co Os v orr Ed LIE u 1 rl i oO oo oo Lc rt se om er 777 RESET Cd coos JL H SOF uA Connector for data back up Connector for option boards Telephone 390444730003 Fax 39 0444 638213 REEL
40. ompatible RS485 with MODBUS CANBUS with DEVICENET 1Mb s PROFIBUS DP 1 5Mb s Keypad for parameter display Ooocoo Data back up key Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual m 3 Control board POWER unit Placement of the options ex OPT 1 X Power unit 1 OPT1 1 analog reference frequency inputs 60kHz max for open collector or Push pull encoder configur able as standard I O as well 2 digital outputs OPT 2 x OPT2 1 14 bit analog input 2 10bit analog outputs digital inputs OPT2 2 PC connection for P L C applications to be used as debug only OPISx OPT3 1 Resolver input with line driver or open collector encoder simulation output OPT3 2 Line receiver encoder input line driver or open collector encoder output OPT33 Sine cos input line driver or open collector encoder output OPT4x OPT4 1 Standard Sercos communication port OPT4 2 Proprietary Shift register AMbaud UNDER DEVELOPMENT COMMISSIONING General notes The WAVE 3 system is supplied with factory settings except for the size which is configured according to the construction hardware when specified installer in charge shall configure the WAVE 3 system according to the motor features as well as the specific automation field Safety CAUTION Before con
41. or compatible on the serial connection terminal boards near the drives The power cables toward the motor must be shielded in case the same raceway of another conductor should be used or in case of devices sensible to emissions do not shield the ground cable between drive and motor Adequate filters have to be used for connections where the drives are subject to electrostatic discharges The mains switch has to be chosen according to chart AC1 by adding up the motors nominal currents and in creasing the resulting value of 15 20 CAUTION Do not place any contactor between motor and drive If this should be necessary for gt safety reasons ensure that the contactor is touched only while the drive is off disabled for at least for 1 second Keep about 100mm free space around the tunnel in order to make thermal dissipation easier The drive must be connected to a regular ground Do not ground the supply 0 point of the control electronics 0 0A OP In case the application requires more motors connected to one inverter adequate thermal protection must be pro vided in series to each single motor disabling the drive when necessary do not cut the power connection di rectly If the application requires a dynamic braking resistor a overload protection device in series is needed Do not install the drive on panels subject to strong vibrations directly All parts assembled in side the cabinet relays switches solenoid valves
42. or fed by common sources must be pro vided with RC groups or recycling diodes in case of dc supply For tunnels having fan modules WAVES sizes 02 03 the installer has to place adequate mains protections accord ing to the plaque data The drive controls the current to the motor by modifying a direct voltage with variable duty cycle This system is typical for all PWM drives and has steep switching fronts producing electromagnetic emissions that can create noise and interference on other sensible devices The problem grows in case of long power cables WARNING Long or high capacity cables can cause the drive block for reasons of protection Under such conditions either special cables have to be used described in the user manual or chokes or decoupling filters Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 W3 System Instruction and Servicing Manual 3 04 03 2003 back GROUND CONNECTIONS In order to make ground connecting easier REEL has shaped the metal heat sink bearing part in a way allowing good grounding of every single module It is recommended to install two copper bars one of them for the power round connections motor cables EMC cables shield etc and one for the signal ground shielded signal cables metal frame of the W3 modules etc next to the tun nel as showed on the picture below The bars are provided with holes and must be mechanically held by insulators Connec
43. ror on the ind Slave Feedback error on the ind Slave REEL S r l Release 05 W3 System Instruction and Servicing Manual 04 03 2003 SERVICE CHECK LIST WAVE 3 SYSTEM In order to prepare the system for servicing Stop the system Cut off the mains Wait for the system to be fully unloaded LEDs must all be off Wait 5 minutes after the last LED has gone off before removing the protecting covers Use handshoes made of rubber or other insulating material Use shoes having an insulating sole Oooooodo Use tools with insulating grip Start checking Check for the slits on the Power modules to be clean Check for the slits on the Supply module to be clean Check for the ventilation part of the system to be clean in order to avoid duct obstruction Check also other ducts and slits ensuring the correct air circulating within the system Check for the ventilation inside the FAN module to avoid possible trouble due to bearings Check for the power terminal boards of the mains or motor to be fixed properly Check for the screws to be properly tightened Check for humidity inside the cabinet housing the system Check for darkened or burnt or faded wires especially near the clampings of the power part Check for the capacitors not to show any swelling on their upper part Check for liquids smell coming from the system especially from the capacitor modules Check the fixing of the metal bearings Replace detective pa
44. rts when needed Close the cabinet s door and start the system by following the indications contained in charter starting the sys tem Person in charge esee eene date esee Telephone 390444730003 Fax 39 0444 638213 REEL Sr Release 05 l 04 03 2003 W3 System Instruction and Servicing Manual CHECK LIST FOR MECHANICAL REPLACEMENT OF A WAVE 3 MODULE How to disassemble the unit Disconnect the supply voltage After disconnecting wait atleast 10 minutes before working on the tunnel NOTE REEL SRL is not responsible for any damage to persons or things in case the rule should not have been respected The warning is printed on the unit in English WARNING After switching off the mains voltage wait for at least 10 minutes before open ing the protection Disconnect the module s output connections with a screwdriver for modules with screw terminals In case of modules with screw bolts disconnect the motor connections as follows Remove the protection on the module s right side Disconnect using a wrench size 10 Remove the protecting cover by unscrewing the central screw with a screwdriver Remove the connectors to the other modules and the external electromechanical parts Remove the left protection of the dc bus Unscrew the dc bus screws with a wrench size 10 Oooocoo Unscrew the fixing screws between the modules using a screwdriver Un
45. screw the tunnel fixing screws on the panel or other supporting structure with a spanner size 10 Take out the module slowly gently turning it toward the right Pack the module properly in order to protect is against bumps or dropping NOTE do not use melt polystyrene or other small size material which could obstruct the cooling ducts or the fans How to re assemble the unit Mount the new module gently taking care that the boards are not damaged during the operation NOTE Should it be difficult to assemble the new module inside the tunnel more space can be gained by acting as follows Loosen all bolts on the dc bus from the top to the bottom Loosen all panel fixing bolts of the other modules Tighten the screws between the modules with a screwdriver Tighten the dc bus bolts with a wrench size 10 having a 8 Nm load limit Tighten the fixing bolts of the tunnel on the back panel Oooo Re assemble the dc bus left side protection carefully Re connect the module s output cables by using a proper screwdriver For modules with bolt connections act as follows Remove the protection on the module s right side Connect the cables using a wrench size 10 with 8 Nm load limit Re assemble the protection carefully Re assemble the connectors Fix the protection cover again and tighten the central screw Person in charge sese Date eere Telephone 390444730003 Fax
46. specific sections under product version Follow the instructions contained there or in the documentation re lated to the module in order to make the part compatible Fan modules Fan modules 02 03 have a label indicating the technical installation data T barcode FREQUENCY CURRENT C SIZE VOLTAGE FREQUENCY CURRENT Telephone 390444730003 Fax 39 0444 638213 The barcode identifies product typology and order no Nominal supply voltage Supply Frequency Current absorbed at the different available supply frequency values REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual Setting label The label must be filled in by the installer and indicates drive configuration and application REEL Application TYPE mark the selected control mode SVC Space Vector Control V Hz FVC Flux Vector Control SB Sinusoidal Brushless SFT Stator Flux Torque kW mark the kW size of the DRIVE OPT mark the installed option opt 1 1 2 1 3 1 SIZE mark the set DRIVE size APPLICATION TYPE Mark product application spindle 1st shaft 3rd draw pitch NO serial address number assigned to the DRIVE Telephone 390444730003 Fax 39 0444 638213 REEL Srl g 2 Release 05 W3 System Instruction and Servicing Manual 04 03 2003 WAVE SYSTEM COMPOSITION Supply
47. t s door e Carry out periodic service operations according to the indications under paragraph Regular Servicing of chapter SERVICING MAINTENANCE Telephone 390444730003 Fax 39 0444 638213 REEL S r l Release 05 04 03 2003 W3 System Instruction and Servicing Manual m 3 back WARRANTY fo The warranty granted by REEL regarding the perfect working of the devices means that REEL will repair or replace free of charge at the own premises within the shortest possible time those parts that should fail due to production or defective material during a warranty period of 24 months from delivery date The freight costs for the devices repaired at the Reel premises or the Reel Service Centers are on Customer s charge The warranty period for replaced and or repaired components have a warranty is 6 months from the date of the product sent back to the Customer can be laid on REEL for damages occurred during transportation or unpacking REEL is not responsible for damages from not correct use of the product or wrong installation or not taking care of the needed measures The warranty declines in case of not correct product use or non observance of chapter GENERAL CAUTION MEASURES as well as chapter MAINTENANCE AND SERVICING PRODUCT IDENTIFICATION Refer to the label on the side of every single module in order to identify construction and working features of the device Three differ
48. t then the bars to the PE input of the electrical cabinet Power cable Ground bars III v NOTE The terminal board for the signal cables is made for connection of the related shields as well shield terminals Telephone 390444730003 REEL S r l Fax 39 0444 638213 wmi3 2 Release 05 W3 System Instruction and Servicing Manual 04 03 2003 POWER CONNECTION STANDARD TUNNEL R S T N FU 220Vac or 24Vdc KM FU FACA 33 L M Q M r b Y FA T02 AFL m supply oooc bd Lad l J SIZE opt 2 2 power l J SIZE I power Lod bad SIZE FU Ultra quick fuses 5 Pom ES KM Mains switch N N L Mains choke recommended V Y FL EMI filter for EMC recommended X d J No 7 i Sensor fuses for FAN protection E E see attachments for FAN module data M M CAUTION FAN T01 needs 24V dc supply FAN T02 and 03 need 220 V dc supply Telephone 390444730003 REEL S r l Fax 39
49. this manual can be changed without notice REEL s r l is not responsible for any mistake contained in the manual or for damages deriving from such mistakes REEL s r l is not reliable for any damage deriving from improper or negligent use of the device It is forbidden to copy or duplicate parts of this manual without previous written authorization by REEL s r l that re serves all rights The manual contains three different kinds of indication CAUTION Indicates not correct actions or behaviors that can generate situations dangerous for the operator It can also indicate dangers occurring during service operations WARNING Indicates a procedure to be followed or avoided in order to carry out installation repair or replacement correctly without any damage to the device NOTE Is used to make further clarify an instruction repair or any other item The indications are provided with the following symbols Indicating situations that can generate high danger for the operator It is always marked with CAUTION Indicating circumstances under which the voltage given can generate high danger for the operator It is always marked with CAUTION 2 Underlines a WARNING Y Means a NOTE Telephone 390444730003 REEL S r l Fax 39 0444 638213 Release 05 ms 04 03 2003 W3 System Instruction and Servicing Manual mu3 CAUTION CAUTION e Some devices inside the system are under high voltage e The access to any syste
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