Home

K4000 - USER MANUAL

1. 2 25 V to X2 73 X2 74 Pre set speed 3 Page 24 48 User Manual K4000 476 gb 0348 Connecting the dynamic braking resistor The dynamic braking resistor is a potential free stainless steel heating resistor The 2 terminals of the resistor connect to the 2 power terminals X1 B The kit shown on the picture consists of the resistance with a 200 C temperature sensor opening contact a protection grid and mounting accessories It is mandatory to connect the temperature sensor to the external interlocks to avoid overheating of the resistance risk of fire in case of breakdown of the braking chopper short circuit c 2 il i ka o o E z N connect to terminals X2 39 and X2 40 The 2 wires have to be protected against accidental contact with the braking resistor as the temperature of the resistor could damage the insulation of the wires Temperature sensor Contact opens at 200 C Resistor terminals Dynamic braking resistor Thermal 5 D c o 2 pus A insulating washers Dimensions in mm OPTIONS Temperature sensor rated at lower level than 200 C The required temperature must clearly be specified on order The unit will get a specific part number User Manual K4000 Page 25 48 S476 gb 0348 Programming the K4000 The Menus e MenuA Menu B Menu C Me
2. The shield of the cables must be grounded at both ends Power connections and control connection must be placed in separated canals A line filter must be installed The machine manufacturer has the option to use a single filter for all of his equipment In this case the correct definition and sizing of the filter is his responsibility If the option of a separate filter is selected this filter will have to match the following specification Fietype iA 8 Kanto FMACO0321610 16 kos 16 FMACO0322500 25 FMACONH2i0 180 Supplier Timonta Mendrisio Switzerland S476 gb 0348 User Manual K4000 Page 47 48 Page 48 48 User Manual K4000 476 gb 0348
3. 2ndF F will allow to change the speed of the motor but only if 0 has been programmed in the corresponding step of the Menu B part 1 Following messages can be displayed Display Description New frequency If frequency has been selected as unit in Menu B Part 1 Hz See Speed display units rpm See Speed display units T Block See Freq ctrl source To enter the new frequency or speed just type in the desired value of the frequency in Hz or the speed in RPM and confirm with ENTER Menu G Selection of the display bloc Allow to select between 3 blocs of information to be displayed Any time you enter 2ndF G you will switch to the next display bloc P Partition number U Mains voltage Motor current in A Ug DC bus voltage Fc Output frequency reference Pw Active power W F Output frequency actual lw Active current A U Output voltage V IREF Motor reference current A Bloc 2 is displayed only in START Bloc 4 is described hereafter Page 38 48 User Manual K4000 476 gb 0348 Display of the digital I O status With the display bloc 4 you can visualize using the 2 lines of 20 characters the status of the digital Inputs and Outputs available on TERMINAL BLOC X2 Each assigned character show a 0 if the corresponding input is not activated or low respectively a 1 if activated or high Regarding the assignment of the analogue outputs SAN1 and SAN2 characters 18 and 19 of the second
4. K4000 USER MANUAL OTION 25 11 03 476 gb 0348 Empty page Page 2 48 User Manual K4000 476 gb 0348 TABLE OF CONTENT Safety instructions Information on the Operating Manual The Basic Safety Rules Working instruction Overspeed protection Proper installation Responsibility A comprehensive range of product Product basics Main technical data Current and Power ratings Dissipation and Dynamic Braking Resistors ratings Type Part Numbering Overload protection Connecting the K4000 to a transformer The 19 rack versions KL4000 Current and Power ratings Type Part Numbering The dimensions of the KL4000 K4000 Drive overview The KT4005 KT4010 KT4015 KT4020 and KT4030 The KT4040 and KT4060 The KT4090 and KT4120 The 19 rack version KL4000 The 19 rack version KL4000 K4000 Terminals descriptions Input circuit breaker The power terminals Terminal bloc X1 of the KT4005 to KT4030 Terminal bloc X1 of the KT4040 and the KT4060 Terminal bloc X1 of the KT4090 and the KT4120 View of the control terminal bloc X2 View of the control terminal bloc X2 The 25 VDC Auxiliary Power Supply The 25 VDC Auxiliary Power Supply The control terminals description Compulsory Connections The START STOP functions The Speed Reference Input The digital and analog programmable outputs and Inputs Selection of the MCM reference Selection of the speed control source The Sample Hold of the MCM function Current parametric
5. Partition No 2 terminal 35 Partition No 3 terminals 34 35 Partition No 4 terminal 36 and so on until Partition No 63 all terminals 34 35 36 37 38 and 67 connected to 25 VDC terminal 33 In TERMINAL BLoc mode if no selection is applied to terminals 34 to 67 the error message Partition selection missing will be displayed at START Number of poles This is the number of poles and not the number of pairs It must be an even number This value is shown on the motor plate and or in the motor data sheet Maximum number of poles 24 Motor power Input here the power of the motor which will correspond to a P kW 10 V signal when Py is allocated to the analog output SAN lref source Motor current reference source This function can be allocated 0 PC560 1 Rtrip to the KEYPAD or to a resistor connected to TERMINAL BLoc Enter e 0 for KEYPAD e 1 for R rip to TERMINAL BLOC is connected to terminals X2 15 and X2 16 For the setting of the current see page 18 Motor nom Current Value in A This input is use to check the setting of current Inom A related parameters as follow IREF lt 150 of IFCC lt 100 of IFCP lt 20 of Current accel decel Set here the maximum allowed current during acceleration lacc A deceleration The limit value is 200 of Inom The function If Im gt Inge is inhibited during acceleration and deceleration 476 gb 0348 User Manual K4000 Page 31 48
6. This is the comparison value for Time delay Delay to trigger the output when the above comparison s level has been exceeded Delay 0 5 Menu D The parameters accessible in START mode Access allowed in START mode The following parameters have been described in the menu B For complete information please refer to Menu B Display 1 to 10 0 PC560 1 T BI MCM 0 Abs 1 SH The current monitoring function Only value Courant A current lt ler Courant Ish A A sensitivity value Courant A dynamic factor between 0 and 300 In START a will be IDTO displayed on pos 18 second line when the condition is true i e the allocated relay pulls A current lt Inom of the motor IFCC A A current lt 20 of Inom of the motor IFCP A Low freq smoothing Asmoothing factor between 0 and 250 Slip compensation A compensation factor between 0 and 254 476 gb 0348 User Manual K4000 Page 37 48 Menu E reversing from KEYPAD 2ndF E will reverse the rotation direction of the motor but only if 0 has been programmed in the corresponding step of the Menu B part 1 If reversing from the TERMINAL BLoc X2 has been selected the following message will be displayed Reversing assigned to T Bloc If in the menu B within the active partition the reversing has been prohibited the message Reversing prohibited will be displayed Menu F Setting a new speed using the KEYPAD
7. for cabinet with air conditioning Overload protection UL requires an external overload protection Connecting the K4000 to a transformer The K4000 can be connected to any input voltage from 3 x 200 V to 3 x 480 V 50 60 Hz without a line transformer Nevertheless if the input voltage is higher than 480 V or the installation requires a galvanic insulation in front of the drive following rules must be respected eDon t use an auto tranformer but only a transformer with separated windings eThe output voltage of the transformer should not be higher than 460 V Page 8 48 User Manual K4000 476 gb 0348 The dimensions of the KT4000 FPR E RET 87 87 07 57 7 Brant 7 evi EZ B o tfi Model Overall Dimensions Mounting Dimensions Weight A B C D E F Screws KT4005 KT4010 223 557 265 199 537 7 4x M6 29 kg KT4015 KT4020 KT4030 KT4040 KT4060 484 820 350 450 800 11 4 x M10 71 kg KT4090 KT4120 91 kg All dimensions are in mm Cabinet enclosure 1 The cabinet size and or cabinet fan cooling heat exchanger air conditioning must be sized according the power dissipation shown on the table page 7 2 The minimum distances between cabinet walls and the
8. Onthe left side they are ventilation opening to allow a correct cooling of the chopper inductance Those opening must not be covered Unit height 6U 265 9 mm Weight 29 kg All units have the same dimensions Page 10 48 User Manual K4000 476 gb 0348 K4000 Drive overview The KT4005 KT4010 KT4015 KT4020 and KT4030 Display 2 lines of 20 Characters Serial link RS485 to control board Terminal bloc removable cover Control board with signal control terminals X2 61 to X2 80 CN4 RS232 RS422 D Sub 9 pins switchable for direct programming and controlling of the drive using a PC in terminal mode Serial link connectors CN2 and CN3 display or PC connection X2 control terminal block X2 01 to X2 60 DC bus capacitors IGBT drivers Power connecting board current sensina and drive protection Chopper inductance Input capacitor Heat sink with input rectifier and integrated IGBT modules including brakina chonner Input circuit breaker Input Output power terminal block X1 Connecting cables and shielding grounding clamps with strenght relief 476 gb 0348 User Manual K4000 Page 11 48 The KT4040 and KT4060 The control board Switching power supply board and control signal connecting board IGBT drivers Chopper Power terminal driver bloc X1 Driver braking chopper Input circuit breaker Page 12 48 User Manual K4000 S476 gb 0348 The KT4090 and KT412
9. e According to IEC364 DIN VDE0100 the qualified personnel must be familiar with the User Manual e Have knowledge of national standards and accident prevention regulations O BE Working instruction During installation observe the following instructions e Always comply with the connection conditions and technical specifications e Comply with the standards for electrical installations such as regarding wire gauges grounding lead and ground connections S476 gb 0348 User Manual K4000 Page 5 48 The converter control board uses a large number of MOS Metal Oxide Semiconductor which are highly sensitive to electrostatic charge To avoid any damages to the control board e wear an earthing strap and always handle the board by the extractors e make sure you are working on an earthen anti static floor e use anti static packing material only Overspeed protection If an overspeed protection is required it must be provided by the motor manufacturer as this function is not integrated in the drive Proper installation Inverter drives are components that are intended for installation within electrical systems or machines The inverter may not be commissioned or put into operation until it has been established that the machine as a unit complies with the provisions of the EC Machinery Directive 89 392 EEC as well with the standard EN 60204 Safety of machines If the frequency inverter is used for special applications the specific standa
10. which is 616 Page 30 48 User Manual K4000 476 gb 0348 Menu B Part 2 Motor related parameters This section of the menu B related to parameters that are linked to a specific partition 32 partitions can be entered and recorded They can be different motors or specific values for the same motor for example if you want to limit the maximum speed at a lower value for reverse operation you enter a new partition and specify the speed you want For the reverse operation you select then this specific partition The following parameter group of the menu B can be entered 32 times Partition No During the programming process you have to Enter now the Partition No to which the following parameters are related During the operating process you will select at this step the active partition e Having selected KEYPAD control for the partition selection by entering 0 at the previous step you can now input the partition No by just entering its numerical value 1 to 32 The first partition is No 1 the last one No 32 e Having selected TERMINAL BLOC control for the partition selection by entering 1 at the previous step the selection will be done by applying 25 V to the terminals 34 35 36 37 and 38 of the TERMINAL BLOC X2 As source for the 25V you can use any of the 25V terminals the closest one is on terminal 33 The sequence of the partition selection using the TERMINAL BLOC X2 is the following Partition No 1 terminal 34
11. 2ndF J Enter the minimum allowed operating frequency in Hz Input in RPM is here not allowed and will lead to a mis setting Any reference input lower than this value will be ignored This low limit is active when the Freq ctrl source has been selected either from the TERMINAL BLOC from the KEYPAD Possible values 0 to Fmax User Manual K4000 476 gb 0348 Menu B Section 2 Motor related parameters cont Pre set Frequency 1 If you have selected the Freq ctrl source from the TERMINAL BLock in the Menu B Part 1 you have the possibility to define up to 3 pre set speeds The selection of one of those pre set speeds will be done applying 24V to the terminals 73 and 74 of the TERMINAL BLOCK X2 If this feature has been activated and no selection made through terminals the analog reference input will be active Here again the input must be in Hz input in RPM is not allowed and will lead to a wrong setting e Enter pre set frequency 1 e n operating mode the selection is made applying 25V to terminal X2 73 of TERMINAL BLOCK X2 e Enter pre set frequency 2 e n operating mode the selection is made applying 25V to terminal X2 74 of TERMINAL BLOCK X2 e Enter pre set frequency 3 e n operating mode the selection is made applying 25V to terminals X2 73 and X2 74 of TERMINAL BLOCK X2 Proh Frequency 1 With the K4000 it is possible to define up to three prohibited Hz operating frequency fields This feature can be used to avoid
12. Permanent current IF Low freq smoothing Slip compensation Low freq smoothing Slipcompensation Us Fs Pt 2 Us Fs Us Fs Pt 3 Us Fs Us Fs Pt 4 Us Fs Men Display Rel Rel Failure ReLlNo 5 SAN1 1 Fs 2 Im 3 N4 Pw 5 Iw 6 Us SAN2 1 Fs 2 Im 3 N4 Pw 5 lw 6 Us Comp level Timedelay sj u C Inputs Outputs FS Factory setting CS Customer setting 476 gb 0348 12 NAHER MOTION DECLARATION OF CONFORMITY We Danaher Motion declare under our sole responsibility that the products of the family K4000 are exclusively designed for incorporation in an other machine The operation of the product is submitted to the conformity of the complete equipment following the provisions of the directive 89 392 EEC The conformity of the above specified products with the provisions of the Directive 73 23 EEC is supported by the respect of the standards CEI IEC 1010 1 If the mounting and connecting instructions of the installation s manual have been respected this product will be conform to the standards EN50081 1 and EN50082 1 relating to the EMC directive 89 336 EEC Mounting instructions related to the EMC directive 89 336 EEC The frequency converter must be mounted in a closed metal cabinet The power connection between converter and motor must be MADE using shield cable The control connection must utilize shielded cables
13. drive left right top and bottom as well between drives mounted side by side in the same cabinet are 100 mm 476 gb 0348 User Manual K4000 Page 9 48 The 19 rack versions KL4000 Current and Power ratings Model Output Current Typical motor power kW 3x 400 V 014051 5 6 10 X 25 J k KL4010 10 12 15 5 Input current All units are rated for maximal input current of 32 Arms Input terminals 10 mm Input cables Minimum section 6 mm resp 10 AWG Use copper conductors 75 C only Type Part Numbering Connection from front KL40xx 00F Without PC560 and external dynamic braking resistor KL40xx 01F Without PC560 with external dynamic braking resistor KL40xx 10F With PC560 and without external dynamic braking resistor KL40xx 11F With PC560 and with external dynamic braking resistor Connection from rear KL40xx 00R Without PC560 and external dynamic braking resistor KL40xx 01R Without PC560 with external dynamic braking resistor KL40xx 10R With PC560 and without external dynamic braking resistor KL40xx 11R With PC560 and with external dynamic braking resistor The dimensions of the KL4000 Mounting Instructions 1 The area on top of the 3 fans whole width and 112 mm depth must remain free for correct cooling of the heat sink At least 50 mm must be available on bottom and top of this area 2
14. gb 0348 User Manual K4000 Page 45 48 Overview of Menu A B and C Menu A Converter parameters Please copy Menu A data Running timer Time power applied Menu B Operation Motors Display cs 0 F1 GB2 D3 I4 E 1 Menu locking O B C o Start Stop choice O PC560 0 Speed display units 1 rpm 1 Motor reversing 0 NO 0 Motor reversing O PC560 0 Frequence ctrl 1 0 to 10V Partition selection 0 560 Delay time S Motor nom Current Inom A Current accel decel lacc A Motor current A H H H H H H H H Nbre pulses revolution o Slipin lol 2 2 2 2 2 2 2 2 2 2 mi 400 i 4 If Im gt lref O tip 0 i 10 i 10 m 46 48 User Manual 4000 FS 3 none 3 Current__labs1 Current Ilsh1 A Curent IDTO1 Alo Curent labs2 A o Current Ish2 A o Current IDTO2 Curent labs3 A o Current Ish3 Curent IDTO3 Af o Curent labs3 A o Current Ish 3 A Current _ 3 FCC duration FCC current IFCC Permanent current IECP A 0 0 0
15. having the system running at speeds where a vibration resonance area exist or may exist Any speed reference inside of the prohibited area will run at the closest lowest or highest limit of the area Here again the input must be in Hz input in RPM is not allowed and will lead to a mis setting The overlap of prohibited frequencies is not allowed Prohibited area 1 based frequency e Enter first prohibited frequency in Hz This value is the middle of the bandwidth set in the next step Hz e Enter bandwidth in Hz Prohibited area 2 based frequency Hz e Enter first prohibited frequency in Hz This value is the middle of the bandwidth set in the next step Prohibited area 2 frequency bandwidth e Enter bandwidth in Hz Prohibited area 3 based frequency Hz e Enter first prohibited frequency in Hz This value is the middle of the bandwidth set in the next step Proh Band 3 Prohibited area 3 frequency bandwidth Hz e Enter bandwidth in Hz Measure speed If the frequency converter is equipped with the option Speed 0 no 1 yes Sense enter here a 1 in other case enter 0 This is only a speed measurement and not a speed closed loop Nbre pulses revol If the motor is fit with a speed feedback the speed measurement option installed and the function 1 selected above you have to enter here the number of pulses per revolution Value 1 to 256 Slip in Using the speed feedback is it possible to monitor the slip of t
16. set the displayed units for the speed e Enter 0 for Hz e 1 for RPM the number of poles of the motor will be taken into consideration automatically User Manual K4000 Page 29 48 Menu B Part 1 Operation related parameters continued Motor reversing If you want to lock any reversing of the rotating direction of the OzNO 1 YES motor you can do it here Enter 0 Reversing forbidden 1 Reversing according assignment either from KEYPAD or TERMINAL BLoc X2 Motor reversing Motor reversing means changing the direction of the rotation 0 PC560 1 T BI This function can be allocated to the KEYPAD or to the TERMINAL BLoc Enter e 0 for KEYPAD e 1 for TERMINAL BLOC The reversing function is now allocated to terminal 31 and 32 of the terminal bloc X2 Closing this contact will reverse the direction of the rotation For safety reason the factory setting is 1 to avoid KEYPAD reversing by mistake pushing key E instead of F after 2ndF Filter freq ctrl Input here a filter value for the analog speed reference input 1 10 This factor need to smooth speed variations due to signal noise Value 1 to 10 Freq ctrl 0 10 10V Define here if your analog speed input reference is unipolar or 1 0 to 10V bipolar Enter e for bipolar 10V 10V e 1 for unipolar O 10 V Mains voltage Enter here the nominal value in V of the voltage of your power Ur V supply This value is used to detect a mains anomaly Input value betwee
17. the drive if open 9 12 COMC Return the control of the speed to Apply 25 VDC the KEYPAD External resistor to set the motor current reference Digital pulses train as frequency digital output pulse sensor Available for input activation Contact will close When relay is energized Contact will open Contact will close When relay is energized Contact will open Contact will close When relay is energized Contact will open 36 38 2 Partiionselection value 16 Apply 25VDC 60 Page 18 48 User Manual K4000 476 gb 0348 Term Short No Name Description How to activate Internal programmable parameter 0 10 VDC Internal programmable 44 Analog ground To activate apply 25 VDC Must be connected to AGND connected to AGND 38 parameter 0 10 VDC 25VDC__ 25 VDC auxiliary power supply Available for input activation 25VDC 25 VDC auxiliary power supply Available for input activation RE3 NO Output relay contact NO RE3 COM Output relay 3 common Contact will close When relay is energized 53 Contact will open Contact will close When relay is energized Contact will open Activated when motor temperature too high INO MUSED Sr 40 61 Analog input 1 Analog input O 10 V na Comparator level and time delay to be programmed in KENN menu C 62 A
18. 0 The Twin Chopper drivers The 3 input fuses S476 gb 0348 User Manual K4000 Page 13 48 The 19 rack version KL4000 The terminal blocks connection for front access terminals power terminals X1 The terminal blocks connection for access from the back CN2 CN3 X2 control terminals X1 power terminals 14 48 User Manual K4000 S476 gb 0348 K4000 Terminals descriptions Input circuit breaker This is not a power switch The converter is protected against ground short circuit by a fast circuit breaker Resetting is performed manually by pushing a lever during this operation tripping is disabled so that the converter is no longer protected It is therefore important to disconnect the converter from the power line prior to resetting the circuit breaker The power terminals Motor output terminals U V W In STOP mode the drive remains active and the motor terminals are at a potential of 300 VDC against the ground Before any intervention on the drive make sure that the power supply has been removed DC bus voltage Large capacitors are installed on the intermediate DC bus voltage Please wait at least 5 min before to remove the cover of the terminal bloc and to access to the internal part of the drive Please check of voltage free intermediate DC bus Terminal bloc X1 of the KT4005 to KT4030 PE Principal earth terminals L1 L2 L3 Line input phases 200 V to 4
19. 0 180A Softwareversion Release number of the installed software V In case of programming problems please indicate this number when calling our customer support left our manufacturing plant in Switzerland com number Specific to each unit The first 4 digits xxxx are Kxxxx yyyyy zz related to the power rating of the units The 22 are related to our internal codification h Time power Cumulated time input voltage ON applied h The Menu A is a read only No information can be modified by the customer Menu B Part 1 Operation related parameters Access in STOP mode only Display 0 1 GB 2 D 3 1 4 Menu locking 0 B C 1 B9F J Start Stop choice 0 PC560 1 T BI Speed display units 0 Hz 1 rpm S476 gb 0348 Selection of the user language Enter e Ofor French e 1 for English e 2 for German e for Spanish 4 for Italian For the time being only English German and French manuals are available Locking the acces to menus using terminals X2 47 48 0 Locking acces to menus B and C 1 Locking access to menus B C D E F J Only menus G Display H faults list and Reset remain accessible CAUTION The STOP key of the keypad is always active The START STOP function can be assigned to 0 KEYPAD PC560 1 TERMINAL BLOC X2 This allocation is an OR function for the START but an AND function for the STOP the STOP key on the KEYPAD being always active Here you pre
20. 29 30 relay No 2 Terminals 52 53 54 relay No 3 Terminals 55 56 57 relay No 4 Terminals 22 23 24 relay No 5 Reversing from the terminal block X2 4 25 External motor reversing contact This function must be set for terminal block mode ISR Partition selection from terminal block The selection of the partition is made using BCD coding The sequence of the partition selection using the TERMINAL BLoc X2 is shown here Partition No 0 doesn t exist in TERMINAL BLoc mode If no voltage is applied to terminals 34 to 38 the error message Partition selection missing will be displayed Partition No 1 terminal 34 Partition No 2 terminal 35 Partition No 3 terminals 344 35 Partition No 4 terminal 36 Partition No 5 terminals 34 36 Partition No 6 terminals 35436 and so long until Partition No 63 terminals 34 35 36 37 38 and 67 We have represented here the selection using relays or jumpers integrated in a connecting plug The partition selection can be done too using signals coming from the CNC control External Interlocks X2 When this circuit is open a converter error condition is generated This e 25 failure is considered as non destructive see programming section This interlock is used for monitoring external functions such as spindle EXT lubrication safety door etc Page 22 48 User Manual K4000 476 gb 0348 The programmable analog output SAN1 and SAN2 X2 SAN1 The out
21. 80 V 10 15 U V W Motor output MAX 460 V B B Terminals for dynamic braking resistor 476 gb 0348 User Manual K4000 Page 15 48 Terminal bloc X1 of the KT4040 and the KT4060 3 Fuses 160 A Super quick acting Use only original model Page 16 48 User Manual K4000 S476 gb 0348 View of the control terminal bloc X2 The Power switching board with terminals X2 1 60 and the D sub connectors CN2 and CN3 Reference P N HB7451 CN3 9 pins D Sub connector for remote display DD550 only A PC560 must be Connected to CN2 CN2 9 pins D Sub connector for RS485 serial link to be used for KEYPAD PC560 2 s je je 9 to tt 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 ee m serm The control Board with terminals X2 61 80 and the D sub connector 4 Reference part number HB7701 Switch RS232 422 Factory setting RS232 61 62 63 64 65 66 67 68 69 70 1 72 73 74 zs ze 77 78 79 80 Ep spp qe ees qe CN4 5232 RS422 D Sub RS232 9 pins PIN2 Transmit from K4000 to PC For direct programming and PIN3 Receive from PC to K4000 controlling the drive through a PINS Ground PC in termi
22. GND jAnadoggound 63 INHA Inhibition of the analogue speed Apply 25VDC 27 C E 64 AGND Analog ground NOT USED NENNEN USED Partition selection value 32 NOTUSD parameter 0 10 VDC 476 gb 0348 User Manual K4000 Page 19 48 Compulsory Connections Some of the connections are optional depending on what functions are required and whether these functions are to be accessed in digital mode from KEYPAD or from the TERMINAL BLOC X2 For further information refer to the bloc diagram Even to control the drive through the user interface PC560 the following connections are compulsory e Mains input terminals L1 L2 L3 and PE e Converter outputs X1 U V W and PE e STOP terminals X2 8 X2 9 must be strapped together In case of KEYPAD PC560 control opening this contact will stop the motor e External interlocks terminals X2 39 X2 40 must be strapped together if the external interlocks are not used e The access key terminals must be strapped terminals X2 47 X2 48 e Motor temperature probe PTC terminals X2 58 X2 59 must be strapped together if the motor has no temperature probe UL requires an External Motor Overload Protection The START STOP functions START command with impulse contact The START remains active until the STOP circuit between terminals 8 and 9 is interrupted When the drive is READY 24VDC is avai
23. Menu B Section 2 Motor related parameters cont Display Motor current A Im gt lref 0 trip 1 dec 2 ignore Rl compensation Acceleration time s Deceleration time s Freq ctrl source 0 PC560 1 T BI Default frequency Hz Minimum frequency Hz Page 32 48 Enter here the reference current of the motor Normally a value of maximum 150 of the nominal current of the motor is used Any lower value can be set Set here the reaction of the drive when the motor current Im exceed the set reference value lrer Set 0 if you want to trip the drive e 1 if you want to reduce the output frequency Fs to keep the motor current lower than the reference current e 2 if you want to ignore the information In this case the maximum current of the inverter will be available for the motor The information that the current Im gt lage can be allocated to one of the output relay see menu C The resistance R of the motor winding is source of a voltage drop proportional to the motor current I The RI voltage will be added to the output voltage Us to obtain the nominal torque over the entire frequency range This function is mainly used when operating at the lower part of the range The value can be set between 0 and 38 V The acceleration time is set in seconds between 1 to 255 This is the acceleration time needed to reach the full speed of the motor If the set speed is t
24. anual K4000 Page 35 48 Menu C Allocation of the relay outputs Access in STOP mode only The digital outputs are relay RE1 output No 1 terminals 25 26 27 relay RE2 output No 2 terminals 28 29 30 relay RE3 output No 3 terminals 52 53 54 relay RE4 output No 4 terminals 55 56 57 relay RE5 output No 5 terminals 22 23 24 The digital outputs are located on the TERMINAL BLOC X2 To allocate one or more of the available functions just input the corresponding relay Nr Functions to allocate Comments on the allocated function Reached frequency The allocated relay contact will switch as soon the Relay nr output frequency of the converter is higher than 95 of the set value Reached speed The allocated relay contact will switch as soon the Relay nr measured motor speed 95 of the set value This function need the option Speed Sense Zero frequency The allocated relay contact will switch as soon the Relay nr output frequency of the converter is under 0 5 Hz This function is only active in STOP mode Zero speed The allocated relay contact will switch as soon the Relay nr measured output speed is lower than 2 pulses sec This function is active only in STOP status Start stop The allocated relay contact will switch as soon the Relay nr converter is in START mode Motor overload The allocated relay contact will switch as soon the motor Relay nr current is higher than the reference current Im g
25. automatically activated To leave the step and confirm the value just key in Enter During the setting of the Ipro of MCM a sign will be displayed at the position 18 of the second line of the display Page 40 48 User Manual K4000 476 gb 0348 The Tachobox Option EE TACHOBOX 1 Senso I Senso 3 JM on Signal 4 12 a 211 _ UL i 5 edit 19 O Digital speed signal cuts 8 cD 20 0 5 Digital speed X 6 n Sp O c S 8 L25v 50 oO 9v x AGND 48 8 AGND 106 nc 11 0 nc E ED S476 gb 0348 User Manual K4000 Page 41 48 Galvanic insulation of the power circuitry Function This option includes a EMC input line filter and the galvanic interruption of the power connections in front of the filter when the drive is in STOP mode the control part of the inverter remains powered Principle F gt 0 START Control relay 24 VDC OV Transformer 3 PHASES POWER SWITCH 30Aor80A EMC Input Filter Part Numbers e HPSF30 for input current up to 30 A i e up to K4030 e HPSF80 for input current up to 80 A i e up to K4060 e design for the K4090 and K4120 is not yet completed Order instruction The Power Switch Option will be an additional line on the order exemple 1 HKU4030 20 1 PSF30 Page 42 48 User Manual K4000 476 gb 0348 K4000 List
26. current lrer to the KEYPAD PC560 ENTER Enter the nominal current of the motor Inom A Will be used to check other current inputs ENTER Input the nominal motor current A A Acceleration time ENTER Set the acceleration time to 10 s Deceleration time ENTER Set the deceleration time to 10 s SENE NEUE Locis Us Fs Pt 1 V Hz ENTER Enter the U F characteristic Start point The content of the partition inputs must be confirmed by entering 2ndF ENTER Current accel decel ENTER Input the acceleration current in A lacc A 6 The START Display show bloc G1 Open the menu to input a speed New frequency 1000 ENTER Input a speed We suggest 25 of the rpm maximum motor speed but maximum 1000 rpm START The motor wil run atthe inputted speed THE QUICK START IS NOW COMPLETED AND YOU CAN PROCEED TO THE FINAL AND COMPLETE PROGRAMMING Page 28 48 User Manual K4000 476 gb 0348 The programmable parameters Menu A Inverter Related Parameters Access in STOP mode only by entering 2ndF A Max current Display the maximum output current of the 4005 10A inverter This parameter is related to the drive K4010 15 rating and is used to protect the drive in overload K4015 23 conditions as well short circuit between phases K4020 30 and phase to ground K4030 2 45A K4040 60A K4060 90 K4090 135 K412
27. diode In case of overvoltage on this input the Zener diode will blow and must be replaced for proper operation The analog input AI1 x2 Input for an analog voltage comparator Input value 0 10 VDC The activation level of the comparator and the time delay and the output 61 relay to be triggered are programmed in menu C 70 AGND Inhibit the analog speed reference input x2 The analog speed reference input voltage can be affected by inducted disturbances To reduce or eliminate the impact of those signal noises the 63 mounting instructions specified at the end of this manual must be 25V respected Such speed variations during the machining process are often not welcome The K4000 frequency inverter offers a great solution to this problem A digital signal coming from the CNC controller can be used to inhibit the analog speed reference signal during machining Closing a contact between terminals X2 11 and X2 63 will inhibit the processing of the analog speed reference signal and the speed will be hold constant at the last registered value To activate again the analog speed reference input just open the contact Selecting one of the pre set speeds x2 The selection of one of the 3 pre set speeds is made by applying 25V to the 2 terminals X2 73 and or X2 74 using a BCD coding 2 No 25 V applied Analog speed reference active 25 V to X2 73 Pre set speed 1 25 25 V to X2 74
28. ed reference display the sign of the input 0 or 1 Line 2 01 ISR Reversing signal on TERMINAL BLOC 32 02 MC MCM selection 2 06 03 MC MCM selection 2 07 04 INHA Inhibit of the analogue speed 63 reference 05 Not used 06 OUTPUTS Not used 07 Not used 08 Not used 09 STP Input signal for STOP 09 10 STR Input signal for START 10 11 12 RE1 Relay 1 Status of the NO contact 31 13 RE2 Relay 2 Status of the NO contact 34 14 RE3 Relay 3 Status of the NO contact 37 15 RE4 Relay 4 Status of the NO contact 41 16 RE5 Relay 5 Status of the NO contact 22 17 18 SAN1 Display the number of the assigned 41 19 SAN2 functions to analogue outputs 69 20 Not used S476 gb 0348 User Manual K4000 Page 39 48 Menu H Display of the last 8 failures Allow to display the last 8 failures recorded in a FIFO table Menu 1 RESET 2ndF I will RESET the drive and allow to start again if the cause of the failure has been removed Menu J Save the last speed reference as default In the KEYPAD operation this instruction allows a fast save of the last inputted speed reference value without to go through the all Menu B Setting a value using the Arrow UP and Arrow DOWN Two parameters can be set using the Arrow UP and Arrow DOWN of the KEYPAD e The speed reference 2ndF e The value of the when accessed from menu D Once you arrived to the corresponding menu step the function is
29. ed to start using the TERMINAL BLoc X2 Not allowed in STOP You tried to reverse direction in STOP Access forbidden During WORK The drive is in START mode and you try to access to Menu B or C using the KEYPAD No errors recorded Displayed after 2ndF H if the memory of failure is empty S476 gb 0348 User Manual K4000 Page 43 48 Part Number HB7701 HB7451 HPC560DX0 H9000099 LL HPC560DX1 H9000103 LL HFRR4015 200 NG HFRR4015 080 NG HFRR4030 200 NG HFRR4030 080 NG HFRR4060 200 NG HFRR4060 080 NG HFRR4120 200 NG HFRR4120 080 NG HTACHOBOX 1 HPC600DX0 H9000099 LL HPC600DX1 H9000103 LL HPSF30 HPSF80 HKIT K3030 K4030 HKIT K4030 K3030 Page 44 48 Part numbers for spares options and accessories Spare Control board Power supply board KEYPAD for mounting in cabinet door without cable Cable for PC560DXO LL is the length in meter Keypad with housing for remote control without cable Cable for PC560DX1 LL is the length in meter Braking resistors without protective grid For K4005 4010 4015 temperature sensor 200 C As above temperature sensor 80 C For K4020 and 4030 temperature sensor 200 C As above temperature sensor 80 C For K4040 and 4060 temperature sensor 200 C As above temperature sensor 80 C For K4090 and 4120 temperature sensor 200 C As above temperature sensor 80 C Options Tachobox KEYPAD for mounting in cabinet doo
30. he motor and issue a signal when the slip exceed a pre set value Input of the maximum slip 0 1 to 10 0 476 gb 0348 User Manual K4000 Page 33 48 Menu B Section 2 Motor related parameters cont 0 Abs Motor Current Monitoring functions 1 and 2 can be allocated to 1 SH2 DTO one of the relay output 3 e 0 are working Absolute value The motor current is compared to the value entered in the next step 1 Sample amp Hold the motor current is compared to a reference value recorded by closing a contact between terminals X2 13 and X2 14 The current reference is the motor current at closing of the contact 2 Dynamic Tool tOuch The dynamic variation of the motor current is compared to a factor set in the next step e 3 No current monitoring is active This is our standard factory setting For each partition up to 4 sensitivity level can be programmed Selection is made using the terminals X2 6 and X2 7 Depending on the selection of the MCM type ABS SH or DTO we have to input now for MCMf the required sensitivity is selected when no 25 V is applied to terminals X2 6 and X2 7 Current Set here the absolute reference value to which the motor current labs 1 A must be compared to trigger the allocated output Current The value to set here is the sensitivity of the SH monitoring The Ish 1 A value set is the current increase A versus the recorded one which will trigger the co
31. he half of the full speed the time to reach this speed will be the half of the acceleration set time This value is a minimum and can t be reduced in menu D The deceleration time is set in seconds between 1 to 255 This is the deceleration time needed to reach zero speed from the full speed of the motor If the set speed is the half of the full speed the time to stop will be the half of the deceleration set time This value is a minimum and can t be reduced in menu D At this step you can set if you want to control the output frequency of the drive respectively the motor speed using the KEYPAD or the TERMINAL BLOC X2 e Enter 0 for the KEYPAD control You will here set the speed using the function 2ndF F followed by the value of the frequency in Hz or the speed in RPM depending on your setting of the displayed unit see Speed display units above Enter 1 for the TERMINAL BLoc control The connections are described in paragraph The Speed Reference Input page 17 In case of selection of the Freq ctrl source selection from the KEYPAD frequency control the value entered or shown here will be taken as speed reference input when the inverter is being turned ON In programming mode you can change the value just by entering a new one Here again the input must be in Hz input in RPM is not allowed and will lead to a mis setting In operating mode you can record here the last input made by 2ndF F using the quick recording process
32. lable on terminal COM X2 START STOP command using permanent contact x 10 START Caution If the permanent start contact is closed when the o STOP inverter is powered up the motor will start automatically if a com RESET is performed The Speed Reference Input Note Any input reference voltage 100 mV is considered as speed reference 0 i e speed range 1 to 100 Input 0 10 V Reversing through terminal bloc X2 32 or user interface PC560 depending on the programming Input 10 V Reversing of direction when crossing 0 V The reversing from the terminal bloc X2 32 must be open Differential input from outside source eae 4 01 CanbeO 100r 10V from CNC CMD1 Reversing from terminal bloc or crossing 0 V Page 20 48 User Manual K4000 476 gb 0348 The digital and analog programmable outputs and Inputs Selection of the MCM reference The selection of one of the 4 MCM sensitivity level is made by applying 2 25V to the 2 terminals 2 6 and or X2 7 using a BCD coding 2 Sensitivity 1 no 25 V applied 2 25 V to X2 6 25V 3 25 V to X2 7 4 25 V to X2 6 and X2 7 Selection of the speed control source Using an external information you can return the control of the speed to comc the KEYPAD even if it has been assign to the TERMINAL BLOC X2 in the 425y Menu B Just close the contact and you will be able to control the speed from your KEYPAD The Sample Hold of the MCM function Sa
33. line a number between 1 and 6 will be displayed according the number of the parameter assigned by program see page 28 Pos 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 N1 INPUTS G G G 6 FF FF EXT RST COMC M RS 2 TERM BLoc 2 34 35 36 37 38 67 14 73 74 47 40 49 12 N2 ISR MC MC INHA OUTPUTS STP STR RE4 RE5 SAN1 SAN2 x2 32 06 07 63 TERMINAL BLoc X2 9 10 22 41 37 34 51 17 69 Character Short name Description X2 term No Line 1 01 INPUTS Not used 02 Not used 03 Not used 04 G Partition selection 2 34 05 G Partition selection 2 35 06 6 Partition selection 2 36 07 G Partition selection 2 37 08 Partition selection 2 38 09 6 Partition selection 2 67 10 SH Sample Hold sampling signal 14 11 FF Pre set frequency selection 2 73 12 FF Pre set frequency selection 2 74 13 KEY Program access key 47 14 NTC Heatsink temperature sensor 15 Not used 16 EXT External interlocks 40 17 RST Reset on TERMINAL BLOC X2 49 18 COMC Selection of drive control source 12 19 M Drive in Start mode 20 RS By 10 V spe
34. mple command for motor current monitor in Sample amp Hold mode 25 measure and store motor current under no load conditions Used mainly for gap elimination SH y tor gap Current parametric resistor This parametric resistor set the current limit level lage when function is selected from the terminal block Tolerance of the current limit is 10 15 This resistor is often integrated into the spindle connector to provide automatic current limitation setting for different spindles Resistance value 3000 Iper A Digital Output SDIG X2 Digital output from converter clock The number of motor poles as set in ER Menu B max 24 poles is taken into consideration so that the signal 8 lspic SDIG is a true indication of the set speed respectively the motor speed in RPM if the speed measurement option is integrated Output frequency time 10 equal speed in RPM Signal level 24 VDC 20 mA Digital speed input Input for rotor incremental encoder Signal level 24 VDC 20 mA CDI Ifthe signal is supplied by a magneto resistive sensor use the TACHO cpi PRINT option to shape the signal 476 gb 0348 User Manual K4000 Page 21 48 The relay contact outputs Digital outputs No 1 2 3 4and 5 Contact rating 25 VDC 100 mA NO Output relay 1 contact normally open COM Outputrelay 1 middle point NC Output relay 1 contact normally close Terminals 25 26 27 relay No 1 Terminals 28
35. n 200 and 480 V All mains voltages between 170 VAC and 530 VAC are considered being inside of the tolerances Partition selection At this step you decide the way you want to select the active 0 PC560 1 T BI partition using either the KEYPAD or the TERMINAL BLOC X2 e Enter 0 for KEYPAD control At the next step you will have to enter the partition No you want to be active The first partition is No 1 e Enter 1 for TERMINAL BLoc X2 The selection of the active partition will be made using the terminals 34 35 36 37 and 38 of the TERMINAL BLOC X2 Stop by default For all non destructive failure where the STOP can be 0 Coast 1 Stop monitored like Converter temperature External Interlocks We can choice between 2 ways of stopping the motor 0 Coast to rest 1 Braking down using the deceleration s ramp Delay time For all non destructive failure where the turn off can be delayed s like Converter temperature External Interlocks Motor temperature a delay time of 0 to 5 s can be input here This function is to allow the CNC to monitor the machine motion before the converter trips Catch spinning mot When this function is activated it is possible to catch a spinning 0 1 YES motor and to accelerate it back to the set speed Enter e 0 to lock this function e 1 to activate it PASSWORD To be able to read and or modify the content of the available 32 partition you have to enter here the correct access password
36. n of the power circuitry Galvanic insulation of the power circuitry K4000 List of Error messages Part numbers for spares options and accessories Assistance and Trouble shooting Overview of Menu A B and C DECLARATION OF CONFORMITY Page 4 48 Valid from Software Version V15 dated January 2002 or later User Manual K4000 41 42 43 44 45 46 47 S476 gb 0348 Safety instructions Information on the Operating Manual This operating manual applies to the K4000 frequency inverter family It describes the connections and basic functions of the standard models CAUTION Danger of death by electrocution CAUTION Absolutely essential FORBIDDEN Incorrect operation may lead to damage The Basic Safety Rules First read the user manual Before installing and commissioning it is important for such personal to read carefully the operating instructions and safety warnings Electric drives are potentially dangerous e Electrical voltages gt 230 V 460 V High voltages may still be present up to 5 minutes after the power has been cut off Therefore you must always check for presence of power and voltages In STOP mode the drive remains active and the motor terminals are at a potential of 300 VDC against the ground e Rotating parts e Hot surfaces Your qualification e In order to prevent personal injury and damage to property only personnel with electrical engineering qualifications may work on the device
37. nal mode All other PIN are not used for this connection For additional information see inal Mode P RS422 erminal Mode Programming PIN5 Ground Manual PIN6 Transmit from K4000 to PC PIN7 Transmit from K4000 to PC PIN8 Receive from PC to K4000 PIN9 Receive from PC to K4000 All other PIN are not used for this connection S476 gb 0348 User Manual K4000 Page 17 48 The 25 VDC Auxiliary Power Supply On the control terminal bloc X2 they are a number of terminals where the 25 VDC internal power supply is available This power supply is only available for the inputs and outputs of the K4000 no other device must be connected The total load must not exceed 400 mA The control terminals description Our digital inputs are not galvanic insulated You must take care that no external potential 24 VDC is applied to those inputs before our own internal auxiliary power supply 25 VDC has been built up Non respect of this process could lead to major damages to the motor and or the drive No Description How to activate X2 Ref 7 4 connect external pot 7 2 Pot 10VDC for speed reference input 4 3 AGND Analog Ground 1 Use to connect the 0 10V 6 5 CMD1 speed reference analog input Janalog reference from CNC 6 2 MOMselecion value 1 Appy 25VDC NA 8 Common terminal to Start Stop Show 25 VDC if no failure 8 9 STOP Stop input stop
38. nction current is used when the motor needs to be braked holding torque at IFCP A standstill for example to keep air bearing spindle from rotating at stop We suggest setting this current not higher than 20 of the motor nominal current Low freq Low frequency smoothing Some standard motors may show smoothing stability problems at low frequency particularly around 30 Hz The stability can be improved by setting here a smoothing factor value between 0 and 250 Slip The torque of a synchronous motor is generated by the slip i e the compensation speed difference between the rotor and the rotating field in the stator This slip increase with the load consequently the speed will drop The correct setting of this factor a value between 0 and 254 will compensate the speed reduction due to the load and keep the speed close to constant The correct factor will be found by measuring the speed under load and increasing the factor until the speed remains constant Factor 254 correspond to 10 compensation for Im Irer if 0 5 lgge the compensation will be 5 Fs Pt 1 V Hz Enter the U F characteristic Start point OV OHz is already stored Us Fs For input information see page 27 To complete and close the input of one partition or group of parameters you must after having confirmed the last point of the Us Fs key in 2ndF followed by ENTER If not your last input will be lost 476 gb 0348 User M
39. nu D Menu E Menu F Menu G Menu H Menu I Menu J Inverter parameters Part 1 Operation related parameter Part 2 Motor related parameter Allocation of the digital and analog outputs The parameters accessible in START mode Reversing from KEYPAD PC560 Speed reference input Display bloc selection Display of the last 8 failures FIFO RESET Memorized the last speed reference as default speed To access to the desired Menu press 2ndF followed by the corresponding letter Example 2ndF B for menu B The User Interface PC560 Page 26 48 User Manual K4000 S476 gb 0348 QUICK START OR THE MINIMUM INPUTS TO RUN YOUR MOTOR WITH KEYPAD CONTROL 3 Compulsory connections Check that all compulsory connections according page 20 have been done 4 The characteristic Voltage Frequency or Power Frequency For optimal performances of the motor and its frequency inverter it is important that u uh 1 Us Fs pt1 Us Fs pt1 Us Fs pt2 this characteristic has been correctly inputted This operation is done at the last step of the menu B Left a typical linear characteristic In this case the maximum operating frequency of the motor Fmax is identical to Fy Right a typical characteristic with a break point In this case the base speed Fy is lower than the maximum operating frequency of the motor Fmax We have to input here the maximum ope
40. of Error messages Messages Explanation No communication Fatal error No communication between the KEYPAD PC580 and the drive Check connecting cable Freq ctrl assigned on T Block The speed control function has been assigned to TERMINAL BLOC X2 in menu B and you try to change the speed from the KEYPAD Partition coding is missing You selected the partition coding via the terminal block and no selection is made This message is displayed only after a START command has been issued to the drive Partition coding through T Block Partition selection is allocated to TERMINAL BLOC X2 and you want to select it using the KEYPAD Reversing assigned on T Block The direction reversing function has been assigned to TERMINAL BLoc X2 in menu B and you try to reverse direction from the KEYPAD Access locked The is locked by the KEY function on TERMINAL BLOC X2 47 AND X2 48 Motor overload Im gt lref The converter tripped because the motor current was higher than the programmed reference current This function is programmed in menu C and a relay will be allocated to it A time delay can be allocated too Please wait before resetting again Display when trying to do a RESET when the intermediate DC bus voltage is still higher than 30 VDC Just wait for a while and perform a new reset Converter temp The temperature of the heatsink exceed 75 C to high Motor temperat
41. only Model Current Arms Typical motor power Nomina Continuous Peak kWQ3x400V KT4040 40 50 60 2 J KT4000 60 5 3 4330 Input cables Minimum section 25 mm resp AWG 4 Use copper conductors 75 C onl Model 1 Output Current Arms Typical motor power Nomina Continuous Peak KkWQ3x400V KT4000 90 110 15 45 KT4120 120 145 180 oO Input terminals 70 mm Input cables Minimum section 50 resp AWG 1 Use copper conductors 75 C only 476 gb 0348 User Manual K4000 Page 7 48 Dissipation and Dynamic Braking Resistors ratings Model Dissipation Braking resistors Watts external KT4005 220 400W KT4010 220 400W 220 400W KT4020 150 1200W KT4030 900 150 200 Type Part Numbering Standalone IP20 units KT40xx 00 Without PC560 and external dynamic braking resistor KT40xx 01 Without PC560 with external dynamic braking resistor KT40xx 10 With PC560 and without external dynamic braking resistor 40 11 With PC560 and with external dynamic braking resistor IP54 cabinet unit KU40xx KV40xx KW40xx KQ40xx for cabinet with convection cooling up to KU4015 for cabinet with fan cooling for larger power ratings for cabinet with heat exchanger air air for cabinet with heat exchanger air water
42. put is O 10 V FXE Maximal load 10 mA 42 AGND The load must be 24 7 kQ respectively lt 10 kQ Use one of the 0 V electronic ground on the terminal bloc X2 for the return m SAN connects to terminals X2 41 and the ground X2 42 44 AGND SAN2 connects to terminals X2 43 and the ground X2 44 Catch a spinning motor 25VDC When this function is activated it is possible to catch a spinning motor and to accelerate it back to the set speed The access key X2 The access to the programming menus can be locked using the 47 terminal X2 47 The access is only possible when the connection to ground is closed The menus to lock i e B and C or B C D E F and J 48 AGND are selected in the beginning of the menu B The RESET X2 In case of failure the drive can be reset by applying 25 VDC to the terminal X2 49 A RESET is only possible when the intermediate DC 49 RST pus voltage is 40 VDC if higher just wait before to redo RESET 50 25 Connecting a NTC temperature sensor Instead of a PTC the motor can be fit with a true temperature sensor In X2 pr this case the connection of the sensor will be made between terminals X 71 and X 72 NTC 476 gb 0348 User Manual K4000 Page 23 48 Connecting the PTC motor temperature protection The PTC motor temperature protection sensor will be connected between terminal X2 58 and X2 59 This input is protected against overvoltage by a Zener
43. r without cable High luminosity display Cable for PC600DXO LL is the length in meter Keypad with housing for remote control without cable High luminosity display Cable for PC600DX1 LL is the length in meter Galvanic insulation of the power circuitry For K4005 4010 4015 4020 4030 Galvanic insulation of the power circuitry For K4040 and 4090 Accessories Converting kit to replace a KT3030 drive with a KT4030 The kit includes mounting plate cable Screws nuts bolts instructions Converting kit to replace a KT4030 drive with a KT3030 kit content as above User Manual K4000 S476 gb 0348 Assistance and Trouble shooting All our products are manufactured in accordance with an accurate quality process Before delivery they are checked for many hours under power The quality system and production process guarantee that all products are shipped free of default The respect of the installation procedure describes in this manual and a correct definition of the application should avoid any commissioning problems Should you meet some problems during installation or commissioning of the frequency inverter our technical staff are available for assistance Please contact your local supplier or the local DANAHER MOTION subsidiary Please includes following information Description of the application Default or problem you met Copy of the programmed parameters Menu B and C Wiring diagram RON 476
44. rating frequency Fmax as well as the base frequency This U F or V Hz characteristic can have up to 32 point the next higher point must show V and Hz values equal or higher than the last one Caution A wrong setting of the U F characteristic can lead to destructive damages of the motor 5 The input of the parameters This is done using the keys of the KEYPAD PC560 The drive is delivered which pre programmed default values selecting operation with the user interface PC560 acceleration and deceleration of 10 s etc Only few parameters have to be entered in the menu B before to be able to start your motor using the KEYPAD The actions to be done are in bold Use the V and to progress inside of the menu and press the ENTER key to confirm an input 476 gb 0348 User Manual K4000 Page 27 48 In the column Display is represented the text shown on the display press pee srt o 0 F 1 GB 2 D 3 1 4 ENTER Selection of the English language Menu locking 0 B C 0 ENTER Access locking through X2 47 48 0 PC560 1 T BI KEYPAD PC560 0 Hz 1 rpm AA RM LL eee NN Ur Partition selection ENTER Assign the partition selection to the PASSWORD ENTER Give you access to the motor partitions Partition No ENTER Open partition 1 Number of poles ENTER The number of poles not of pairs ramen P kW including overload 0 560 1 Rtrip
45. rds and regulations for this environment must always be observed Repairs may only be carried out by authorized repair workshops Unauthorized opening and incorrect intervention could lead to physical injury or material damage The warranty provided by DANAHER MOTION would thereby be void Responsibility Electronic devices are fundamentally not fail safe The company setting up and or operating the machine or plant is itself responsible for ensuring that the drive is rendered safe if the device fails The standard EN 60204 1 DIN VDE 0113 Safety of machines in the section on Electrical equipment of machines stipulates safety requirements for electrical controls The requirements to comply with are intended to protect the integrity of personnel and machines and to maintain the function capability of the machine or plant The function of an emergency off system does not necessarily have to cut the power supply to the drive To protect against risk of injury it may be more beneficial to maintain individual drives in operation or to initiate specific safety sequences The emergency stop process may be assessed by means of a risk analysis of the machine or plant including the electrical equipment to EN 1050 Part of this analysis is determined by the selection of the circuit category in accordance with prEN 954 Safety of machines Safety related parts of controls Page 6 48 User Manual K4000 S476 gb 0348 A comprehensive range of prod
46. resistor Digital Output SDIG Digital speed input The relay contact outputs Reversing from the terminal block Partition selection from terminal block External Interlocks The programmable analog output SAN1 and SAN2 Catch a spinning motor The access key The RESET Connecting a NTC temperature sensor S476 gb 0348 User Manual K4000 Page 3 48 Connecting the PTC motor temperature protection The analog input Inhibit the analog speed reference input Selecting one of the pre set speeds Connecting the dynamic braking resistor Programming the K4000 The Menus The User Interface PC560 QUICK START 3 Compulsory connections 4 The characteristic Voltage Frequency or Power Frequency 5 The input of the parameters 6 The START The programmable parameters Menu A Inverter Related Parameters Menu B Part 1 Operation related parameters Menu B Part 2 Motor related parameters Menu C Allocation of the relay outputs Menu C Allocation of the analog output Menu D The parameters accessible in START mode Menu E reversing from KEYPAD Menu F Setting a new speed using the KEYPAD Menu G Selection of the display bloc Display of the digital I O status Menu H Display of the last 8 failures Menu RESET Menu J Save the last speed reference as default Setting a value using the Arrow UP and Arrow DOWN The Tachobox Option Galvanic insulatio
47. rresponding output At the opening of the contact between X2 13 and X2 14 the instant value of Im is recorded As soon the motor current exceed the recorded m Is the allocated output will be triggered Current Enter here the dynamic sensitivity factor value between 0 to 300 1 Higher is the factor lower is the sensitivity The allocated relay will switch for approximately 200 ms Depending on the selection of the MCM type ABS SH or DTO we have to input now for 2 the required sensitivity 2 is selected when 25 V is applied to terminals X2 6 labs 2 A Ish 2 A 2 Depending on the selection of the MCM type ABS SH or DTO we have to input now for the required sensitivity is selected when 25 V is applied to terminals X2 7 labs 3 A Ish 3 A 3 Depending on the selection of the MCM type ABS SH or DTO we have to input now for MCM4 the required sensitivity MCM4 is selected when 25 V is applied to terminals X2 6 and X2 7 labs 4 A Ish 4 A IDTO 4 Page 34 48 User Manual K4000 476 gb 0348 Menu B Section 2 Motor related parameters cont FCC duration DC braking current duration This function when activated is s automatically initiated after a STOP command when the DC bus reaches 10 x 35 V IFCC A higher than the nominal current of the motor Permanent Value of the permanent injected DC braking current This fu
48. t lrer This choice is only possible if the condition 2 None has been programmed in menu B Relay nr condition set in menu B is true Slip Output The allocated relay contact will switch as soon as the Relay nr SLIP is higher than the programmed value Need SpeedSense option Alarm output The allocated relay contact will switch as soon as an Relay nr alarm has been triggered This function is used in combination with the delayed trip by non destructive failure see programming in the menu B Comp output The allocated relay contact will switch after the Relay nr programmed delay when the analog input exceed the programmed level Failure This function is an inverted one Relay nr In failure free status the allocated relay is powered on The relay will fall down for any failure Never combine this function with an other one Ext interlocks The allocated relay contact will switch as soon the Relay nr external interlock circuitry is open Terminals 39 40 of the TERMINAL BLOC X2 If this function is not used a strap must be placed between terminals 39 and 40 Converter overload The allocated relay contact will switch if the output Relay nr current exceeds the maximum current of the converter This current value is shown in the Menu A Def aux supply In failure free status the allocated relay is powered off Relay nr The relay will pull in case of auxiliary power supply failure and an outpu
49. t signal will be triggered Motor temp PTC The allocated relay contact will switch if the motor Relay nr temperature is to high respectively is the resistance of the circuitry between terminals 58 59 of the TERMINAL BLoc X2 exceed 3000 If this function is not used a strap must be placed between terminal X2 58 and X2 59 Page 36 48 User Manual K4000 476 gb 0348 Menu C Allocation of the analog output Access in STOP mode only Functions to allocate to Comments on the allocated function one of the digital outputs Converter temp NTC The allocated relay switches if the heatsink temperature Mains anomaly The mains voltage is compared to the value entered in Relay nr Menu B part 1 and the allocated relay will switch if the mains voltage is out of the tolerance of 480 V 10 respectively 200 V 15 SAN1 1 Fs 2 Im Set here the parameter you want to allocate to the 3 N4 Pw 5 lIw 6 Us analog output SAN1 TERMINAL BLOC X2 41 X2 42 e 1 forthe output frequency 10 V Fmax 2 for the motor current 10 V Inom 3 speed of the motor 10 V Nmax need the option Speed Sense 4 active output power 10 V Pmax of motor 5 active output current 10 V Pmax 1 28 Us 6 for output voltage 10 V last Us 5 Pt SAN2 1 Fs 2 Im Set here the parameter you want to allocate to the 3 N4 Pw 5 6 Us analog output SAN2 TERMINAL BLOC X2 69 X2 70 Comp level Enter here you comparison level between 0 10 VDC 0 10 V
50. uct Product basics The K4000 is a high frequency inverter designed for application up to 4000 Hz The K4000 family consists of several models with output ratings from 5 to 120 kVA the selective harmonic suppression SHS developed by DANAHER MOTION is aimed at reducing motor losses and winding stresses without output filter e The KEYPAD PC560 control unit can be integrated on the front panel or supplied as a separate remote control unit e The drive is equipped with a RS232 422 serial link A communication protocol in terminal mode for PC is available on request e The UL certification of the KT4000 is in process e The 19 rack version KL4000 will not be UL certified Main technical data e Input voltage all units 3 x 200 V to 3 x 480 V auto ranging no line transformer e Output voltage Vrms 0 max 460 V e Output frequency range 0 4000 Hz e Ambient temperature 40 C e Continuous current overload 120 without time limitation e Max current overload 150 for 1 min every 10 min e Short circuit protection suitable for use on a circuit capable of delivery not more than 5000 Arms symmetrical Amperes 480 V maximum Current and Power ratings Output Current Arms Typical motor power Nomina Continuous Peak KWQ 3x400V KT4005 5 6 10 X 25 KT4010 10 12 15 5 KT4015 15 18 23 7 5 Input cables Minimum section 6 resp 10 AWG Use copper conductors 75 C
51. ure Overheating of the motor detected by the PTC to high PTC Motor temperature Overheating of the motor detected by the NTC to high NTC External External interlock circuitry open Interlocks See TERMINAL BLoc X2 39 X2 40 Converter Displayed in case of short circuit at the output or high current overloaded peak exceeding the capacity of the drive Defect auxiliary In case of problem with the auxiliary supply power supply 24 15 or 5 VDC Mains out of Displayed if your mains voltage is lower than 170 VAC tolerance respectively higher than 530 VAC Any value in between is considered being within the tolerances Failure on module No 1 The output power IGBT No1 is broken Failure on module No 2 The output power IGBT No2 is broken Failure on module No 3 The output power IGBT No3 is broken Failure on Chopper module The IGBT of the chopper is broken Failure on Brake module The IGBT of the braking chopper is broken Stop circuit open When you try to START Check connection X2 8 X2 9 on terminal block This circuitry must be closed to START Switch to catch a spinning motor OPEN To catch a spinning motor Check the circuitry X2 45 and X2 46 Start Stop assigned to Terminal Block START function is allocated to TERMINAL BLOC X2 and you tried to start using the KEYPAD Start Stop assigned to keypad START function is allocated to KEYPAD and you tri

K4000 - USER MANUAL

Contents

Download Pdf Manuals

Related Search

Related Contents