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1. Terminal strip for line shielding D BERGES NC Figure 2 4 Connection terminals size VII 2 8 1 Tightening torques of the connection terminals The following torques must be observed for inverter connection sizes VII IX Description en Control terminals of all sizes Phoenix COMBICON 0 22 0 25 Nm Power terminals of size VII insulating stud 10 Nm Power terminals of size VIII and IX rivet bush in rail 35 40 Nm Operating Instructions 04 08 05 1 24 UD 7000 1 5 355 0 07_GB_T1 Control board AAAA CAV u Lad y iad ei S Connection screws power terminals M12 ZK ZK U V W L3 Rb2 L1 L2 optional Figure 2 5 Connection terminals size VIII 04 08 05 Operating Instructions 07_GB_T1 UD 7000 1 5 355 0 1 25 2 8 2 Power Terminals TERMINAL DESCRIPTION Line connection terminals Check that the available line voltage corresponds to the in formation specified on the rating plate ofthe inverter The rating ofthe back up fuses and the cable cross sections are listed in Chapter 2 5 3 If fault current safety switch are used for fusing
2. After disconnection of the drive converters from the voltage supply live appliance parts and power terminals must not be touched immediately because of possibly energized capaci tors In this respect the corresponding signs and markings on the drive converter must be respected After switching off the line voltage wait for at least 5 minutes before beginning work on or in the drive converter Dangerous voltages are still present as long as the BUS CHG lamp is still lit Ensure that no DC injection e g by a DC link coupling is performed Hazardous voltages are still present if lamp BUS CHG is still lit up to 55 kW in the case of inverters On units upwards of 75 kW the DC link voltage at terminals ZK ZK should be measured in order to preclude the possibility of accidents resulting from hazardous volt age In the event of malfunctions the Discharge time of 5 minutes may be exceeded sub stantially The drive converter contains protective facilities that deactivate it in the event of malfunc tions whereby the motor is de energized and comes to a standstill so called coasting of the motor is possible depending on the rotating mass of the type of drive involved Stand still of the motor can however also be produced by mechanical blockage Voltage fluctua tions and particularly line power failures may also lead to deactivation In certain circum stances the drive may start up automatically once the cause of the
3. 1 43 Drive Variants The diagram shows that the V f characteristic is shifted in parallel upwards starting from the no load line as the load increases The increase in motor voltage in the lower area is performed automatically whereby the magnitude of the voltage to be added under no load depends on the motor data i e correct specification of the motor data and conducting a test run are of major significance in this operating mode as well see also Chapter 4 2 The Asynchronous Motor and Speed Control Besides automatic readjustment of the V f ratio in order to maintain the machine s flux con stant the inverter also features slip compensation It can be connected as required as mentioned above and enhances rotational speed stability when subject to load variation The mode of operation of slip compensation is illustrated in the diagram below i Characteristic branch of the motor torque rotational speed iai characteristic Vi M_Nom N M2 M1 Th Nominal rotational speed range Field attenuation range Figure 4 4 Slip compensation Caption to illustration nod Frequency setpoint Field attenuation Working range with decreasing maximum torque resp working range range of constant power Nominal rotational Working range with constant torque resp working range of in speed range creased power n_nom Nominal motor speed speed of rotation at which the voltage lim it w
4. 2 3 2 Filter Components 2 3 3 The following interference suppression components are available for the UD 7000 Series of equipment Inverter type Size Article number zur DL LU Filter type Article number 7001 5 I 365F3502 Device internal See device article number 7002 2 I 365F3511 Device internal See device article number 7003 0 I 365F3521 Device internal See device article number 7004 0 I 365F3531 Device internal See device article number 7005 5 I 365F3541 Device internal See device article number 7007 5 II 365F2550 Device internal See device article number 7011 0 II 365F2560 Device internal See device article number 7015 0 IV 136502570 BE 7322 32501918 7022 0 IV 36502580 BE 7322 32501918 7030 0 V 36501590 BE 7355 32502255 7037 0 V 36501600 BE 7355 32502255 7045 0 V 36502610 BE 7355 32502255 7055 0 VI 36502710 BE 7355 32502255 7075 0 VIT 365x0750 BE 7390 32502277 7090 0 v r 365x0900 BE 7390 32502277 7110 0 vi 365x1100 BE 73132 32502278 7132 0 VT VII 365x1320 BE 73132 32502278 7132 0 CT vin 365x1321 1 BE 73132 32502278 7160 0 CT VII 365x1200 1 BE 73160 32502279 7200 0 CT VIII 365x2000 BE 73250 32502280 7250 0 CT IX 365x2500 1 BE 73250 32502280 7315 0 VT IX 365x3150 BE 73355 32502281 7355 0 VT IX 365x3550 1 BE 73355 32502281 1 An x in the articl
5. sequent DC link capacitor serves as an energy buffer that smoothes the pulsating DC volt age When the line is connected the charging unit ensures smooth charging of the capac itor Figure 1 1 shows a triac for bridging the load resistor Dependent on output the charg ing circuit may vary For instance relays or also half controlled bridge connected rectifiers are also used The charging connection in inverters of 75 kW or greater is located on the minus side of the intermediate circuit This is especially the case with the parallel connec tion of the intermediate circuit DC connections of several inverters The variables used are described in more detail in the following table z i CC in or Size Charging connection CC intermediate Circuit Charging relay braking chopper resistor is used as the II red charging resistor IIred Charging relay a special charging resistor is used Semi controlled rectifier bridge Thyristors between inter IV VI mediate circuit and the single network phases three between and phase VI Charging relay a special charging resistor is used VIT IX Charging relay a special charging resistor is used NOTES For all inverter sizes the intermediate connections are located directly at the intermediate circuit capacitors i e the internal charging connection is not used with a DC feed The complete inverter bridge consisti
6. 0 01 Q 2 118 30 00 F8 Gain I control Current controller gain 0 01 Q 2 119 1 00 F9 TN TA I control Specific current controller reset time 1 2 119 50 FA Dead time comp Dead time compensation 1 2 119 1 FB PWM freq chnge PWM frequency slaving 1 2 120 0 FC Ramp control Ramp acceleration control torque S P 2 120 1 FD Torq limitation Torque limiting S P 2 120 1 FE Excitation Excitation 0 1 2 120 r o GROUP 0 Service data I NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER 01 Outpt frequency Output frequency 0 1 Hz 2 121 r o 02 Output voltage Output voltage 1 V 2 121 r o 03 Output current Output current 0 1 A 2 121 r O 04 Load torque Output torque 0 1 2 121 r o 05 Output power Output power 0 1 2 121 r o 06 Line voltage Line voltage 1 V 2 121 r O 07 DC voltage DC link voltage 1V 2 121 r o 08 Adjust Setpoint Frequency setpoint before the ramps 0 1 Hz 2 121 r o 09 Actual freqncy Actual frequency 0 1 Hz 2 121 r o OA Inverter temp Heat sink temperature 1 C 2 122 r O OB fault 1 Error 1 2 122 r o OC fault 2 Error 2 2 122 r o OD fault 3 Error 3 2 122 r o OE fault 4 Error 4 2 122 r o OF fault 5 Error 5 2 122 r o 1 56 Operating Instructions UD 7000 1 5 355 0 04 08 05 07_GB_T1 Error States Annex 5 4 Error States HINT If the PROG SHIFT or ENTER key is pressed th
7. 355 0 Technical Data WEIGHT DATA SIZE II SIZE III SIZE IV SIZE V SIZE VI SIZE VI SIZE VIII SIZE Ix 1 5 5 5 kW 7 5 11 kW 15 22 kW 30 45kW 55 kW 75 132 kW 132 200 kW 250 355 kW 5 7 8 2 15 4 26 5 31 0 50 0 110 0 120 0 Weight in kg 04 08 05 07_GB_T1 Operating Instructions UD 7000 1 5 355 0 1 40 Drive Variants 4 Drive Variants 4 1 The UD 7000 Series of inverters are general purpose controllers static frequency convert ers which can be used for low loss open loop or closed loop control of the following motor variants 1 Asynchronous motors with squirrel cage rotor 2 Asynchronous motors with squirrel cage rotor and rotational speed feedback encoder for feedback of the rotor speed of rotation 3 Permanent field synchronous servo motors with feedback resolver for feedback of the rotor position The UD Series of inverters features a high performance internal motor control system which controls the connected motor extremely effectively over the entire rotational speed range A precise knowledge of the motor data is required so that the internal motor models used are able to supply as precise an image as possible of the connected motor Since the user will generally be unfamiliar with this data apart from the information on the rating plate the inverter features Autotest functions also referred to as Autotuning which determine
8. 8 1 6 Inverter Control The core of the inverter control is a powerful 16 bit microcontroller with a non volatile pa rameter memory In conjunction with further circuit components it controls all necessary in verter functions In particular the microcontroller generates the pulse width modulated puls es for control of the IGBTs The inverter has the possibility of limiting the emitted motor torque The frequency setpoint is reduced automatically when the limit is reached The data required for this purpose is ob tained from measured values and the rated data of the motor as specified on the motor name plate With the aid of slip compensation it is possible to operate the motor at a constant speed independently of the load The inverters feature a trap circuit that makes it possible to connect the inverter to a still rotating motor and to start it up to the frequency setpoint To suppress drive specific resonance frequencies it is possible to program four different stop frequency bands i e the inverter does not realise these frequencies statically The functional scope if the inverters can be expanded with option cards for FO controller converter with field oriented control for asynchronous motors EC controller converter for permanently excited synchronous motors A detailed description is provided in the application manuals With the LC display of the display and operating unit ABE all operating variables such
9. Annex 5 3 Parameter Overview Parameter Overview GROUP 1 Motor data DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER 11 Nominal voltage Rated voltage 0 1 V 2 40 400 0 12 Nom frequency Rated frequency 0 1 Hz 2 40 50 0 13 Power factor Power factor 0 01 2 40 14 Nominal speed Rated speed min 2 41 15 Nominal power Rated power 0 01 kW 2 41 16 Nominal current Rated current 0 1 A 2 41 GROUP 2 Basic data NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER 21 V Hz knee Knee frequency 0 1 Hz 2 43 50 0 22 Boost Boost 0 1 2 43 100 0 23 Max frequency Maximum frequency 0 1 Hz 2 43 50 0 24 Min frequency Minimum frequency 0 1 Hz 2 43 0 0 25 Acceleration 1 Acceleration time 1 0 1 s 2 44 3 0 26 Deceleration 1 Deceleration time 1 0 1 s 2 44 3 0 27 Acceleration 2 Acceleration time 2 0 1 s 2 44 5 0 28 Deceleration 2 Deceleration time 2 0 1 s 2 44 5 0 29 Control mode Control mode S P 2 44 13 2A Test mode Test mode S P 2 46 101 2C Application Application S P 2 50 0 2D SW Reset Software reset S P 2 56 0 2E U fmin Minimum frequency voltage 0 01 V 2 57 0 00 2F U fmax Maximum frequency voltage 0 01 V 2 57 0 00 GROUP 3 Setpoint selection display Setpoint select DISPLAY DESCRIPTION RESOLUT
10. Dado aa 33 T amp S Key Functions dro eat ee De ee cas ae Ma A AA aces AA ta a 33 TAA A RA RN 33 7 4 2 Control and Parameter Keys Single Operati0M o ooooococococcrcor e eee ae 34 7 4 3 Control and Parameter Keys Combinations with SHIFT oocococcococccococo nennen 36 TAA LED Stat DIS A a nr dh Sig at Mees a Te Ar sw trees naeh 38 8 Parameter Description 4 ars he ai eta date Bea AA aw ae ren ee welehe 39 31 Groupe Motor Data VAN A N BE a AE a E RU ER HS A Ar Nr NER na ES LD O cenit tae 39 8 2 Group 2 Basic Dit r eote ar er Aa en nn ee en Ee 8 hea ihe ne Rn a ew ee he 43 8 3 Ghoup 3 Setpoint Sele CtiO it DR A ee DR er 57 8 4 lt Group 4 Frequencies un deere weed eh seen en ee 68 8 5 Group S TOQUE erecta e Be e Be a geh A iach a ee Dane ne bea 70 86 Group 6 V Hz Characteristic o oooooocoron eet een een 73 8 7 Group Inverter Functions ice oie TA u NIIT Sun ERS 78 8 8 Group 8 Protective FUNCIONS m riiin miera ae ea GA dae ei Sey A ee hee 84 8 9 Group 9 BinaryInputs Qutputs 2 2020 urn ide eee eed ea Pes RR beh eh Pa eee eed lee 90 8 10 Group A Analog Outputs SIO 2 00 amp simio tates 0 wha AA ee ata etna AA ee eee Pe aad eae 102 8 11 Group B Speed Controller 0 en ernennen 106 8 12 Group Stepper Controls ct ae ecg Ria Be ecg ae BR Vee Be ni Veet I ones Bann 110 8 13 Group D OPINAS A A RE Sate EU Rute dee 111 8 14 Group E Semvice Data lis
11. FilterTime Gr 0 Filtering time constant of displayed values in parameter group 0 2 ms 2 104 6 A8 SIO Baudrate Baud rate SIO selection S P 2 104 4 AQ SIO Address Slave address of the inverter for SIO operation 0 31 2 104 0 AA SIO Protocol SIO protocol S P 2 104 1 AB SIO Timeout SIO operation time out 1 s 2 105 0 AC SIO Errors SIO operation error messages Binary 2 105 r o AD SIO Commands Inverter control commands in SIO mode Binary 2 106 0000 GROUP B Speed controller display Speed control DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER P gain Speed controller gain 1 B2 I gain Reset time of speed controller 1 ms 2 106 500 B3 Gain boost Speed controller gain boosting factor 0 1 2 107 1 1 B4 Maxfreq gain b Speed controller gain boosting end frequency 0 1 Hz 2 107 0 0 B5 Holding control Holding control S P 2 107 0 B7 Rel drag dist Specific holding controller following error 0 001 2 107 0 100 B8 TN pos cntrl Specific position control reset time 2 2 108 0 BA Pole pairs Rslv Resolver pole pair number 1 2 109 1 BB Angle mech Motor shaft angle 0 17 2 109 r o BC Off angle senso Angle sensor installation offset 8000 7FFFy 2 109 0000 BD Dir angle senso Angle sensor direction of rotation S P 2 109 0 BE Lines Encoder Num
12. S P 2 70 0 53 Select TLim GFo Torque limit selection right rotation generator operation S P 2 70 0 54 Select TLim GRe Torque limit selection left rotation generator operation S P 2 70 0 55 Torque lim LIM Torque factor LIM input 0 1 2 71 100 0 56 T Offset Acc Additional acceleration torque 0 1 2 71 0 0 57 T Offset Dec Additional deceleration torque 0 1 2 71 0 0 58 TLimit Mot FWD Torque limit right rotation motor operation 0 1 2 71 100 0 59 TLimit Mot REV Torque limit left rotation motor operation 0 1 2 71 100 0 5A TLimit Gen FWD Torque limit right rotation generator operation 0 1 2 71 100 0 5B TLimit Gen REV Torque limit left rotation generator operation 0 1 2 71 100 0 5C SIO Torg limit External torque limit 0 1 2 72 100 0 5E Ref torque VIN Torque setpoint factor 0 1 2 72 100 0 5F Gain TCtrl ramp Gain Vrm acceleration control ramp torque 0 1 2 72 200 0 GROUP 6 V Hz characteristic display V f char NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER 61 Autoboost Autoboost S P 2 73 1 62 V Hz selector V Hz characteristic selection S P 2 74 3 63 Curr DC brake DC brake current 0 1 A 2 75 64 DC brake time DC brake time 0 1 s 2 75 1 0 65 Freq DC On DC brake switch on frequency 0 1 Hz 2 75 0 5 66 Setuptime field Field build up time 0 1 s 2 76 0 5 1 0 67 V f Char VO V Hz characteristic voltage VO 0 1 V 2 76 0 0 68 V f Char V1 V Hz characteristic v
13. These inputs are programmable for further functions selection in parameter group 9 Binary Applicable to all binary outputs outputs Transistor stage with open collector and emitter on COM Transistor forward biased gt Vcg 0 1 VDC Imax 50 mA gt signal level low Transistor reverse biased external voltage VcEmax 30 VDC gt signal level high ST1 ST3 Binary output select function in parameter group 9 ST4 Binary output frequency output Select function in parameter group 9 Relay Relay output select function in parameter group 9 terminals NO Normally open contact 250 VAC 0 2 A 30 VDC 2 A C Mid position contact NC Normally closed contact 250 VAC 0 2 A 30 VDC 2 A Serial SIO A Connection of the RS 485 interface interface SIO B Connection of the RS 485 interface D SUB 5 Earth COM Control 24V 24 V control voltage output Ima 500 mA for binary inputs or binary outputs with and open collector plas REF 10 V reference voltage output Imax 10 mA for external setpoint source REF 10 V reference voltage output Imax 10 mA for external setpoint source COM Reference potential for analog and binary input and output signals GND Aux GND The Aux GND terminal cross head recess M4 screw only with sizes II VI is isolat ed from the housing and can be used as the star point ofthe COM ports for example The securing stud is particularly suitable in
14. Warning R1 measuring out of limit 23 Overcurrent Warning Overcurrent limit would been reached 26 Xs Measuring Warning Xo Measuring is out of limit 27 Set disconn Warning See also parameter 2E Minimum frequency voltage page 2 57 Sensor off Warning The measuring of the mounting offset is fail pulse Warning No zero pulse is found CAN Controller No can controller found Min excitation THE FOLLOWING INTERNAL Ea Watchdog reset III Ext Bus Acc Warning Minimum limit of excitation is reached FAULTS ARE DISPLAYED ONLY AFTER POWER UP Watchdog Fault Unknown trap number Unknown external Bus access lll Instr Access Ill Word Op Acc Unknown instruction access Unknown word access Protection Fault Protection fault Undefined Opcode Undefined op code Stack Underflow Stack underflow Stack Overflow Stack overflow Bes Ill trap number 36 37 38 39 40 41 Nonmaskable Int Nonmaskable interrupt 1 58 04 08 05 07_GB_T1 Operating Instructions UD 7000 1 5 355 0 BERGES BERGES electronic GmbH Industriestra e 13 D 51709 Marienheide Rodt Postfach 1140 D 51703 Marienheide Tel 0 22 64 17 17 Fax 0 22 64 I 71 26 http www bergeselectronic com e mail sales berges de
15. as the frequency current and voltage and all drive parameters can be displayed as absolute or percentage values The inverters can be controlled both through the control terminals the serial RS 485 inter face and also with the keys The required possibility is selected by parameter The same applies to the form of frequency input The control terminal LIM is assigned a double function It serves as a frequency input or as a further analog input Depending on parameter definitions the inverter control processes the analog signal as an additional setpoint or as a torque limit 0 100 The control features six binary inputs FWD REV R J PS1 PS3 which can be pro grammed for various functions for the control of the inverter e g start stop left right rotation or frequency input The inverter features software I t monitoring for thermal protection of the motor For direct thermal motor monitoring the inverter control is capable of evaluating a temperature sensor PTC or normally closed contact A relay output changeover contact and three transistor outputs with an open collector which are switched depending on operating states of the inverter are available for the out put of binary signals The choice is made by a parameter The inverter control possesses a frequency output open collector which is adapted to the frequency input so as to enable master slave control Two analog outputs are available for the connection of indic
16. been developed but none of them have yet reached the actual ob jective of full torque at zero rotational speed Of these variants it is the SLV method above all which has come to the fore owing to its rugged design SLV stands for SensorLess Vector Unlike the above mentioned conventional methods the SLV method does not compute the motor field but presets it in controlled manner The method relies on the fact that the motor generates a correct magnetic field if it receives correct control signals The underly ing idea can be seen particularly well from the transformer model of the asynchronous mo tor APPROACH If the voltage V_L is maintained constant on the basis of the magnetising inductance the magnetising current I is also constant Rotor current l and magnetising current I are naturally perpendicular Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 Drive Variants 04 08 05 07_GB_T1 V_Ln ls Rs i Oe g Rr 3 Lin 2 amp zZ r den Vo 1 5 Im O Ir Im Stator Rotor Where V_Ly Im x xX Lp V_L is proportional to Figure 4 6 Transformer model of the asynchronous motor leakage inductances ignored This provides all preconditions for optimum control of the motor In the above equivalent cir cuit diagram it can be seen that it is of tremendous importance to calculate with the correct motor data Otherwise the ca
17. current lhom Maximum output voltage 3 phase 98 of line voltage Output frequency Hz programmable 0 875 Maximum frequency 0 01 resolution Hz see Chapter 3 3 Resolution Overload factor at 45 C y 7 3 ambient temperature 150 for 1 min with 30 min cycle time Maximum output current A ms 55 7 8 10 2 13 8 17 5 23 4 33 7 45 0 64 0 87 0 107 0 127 0 145 0 Power loss at a carrier frequency of 5 kHz 2 6 a Power loss at a carrier frequency of 10 kHz 3 2 2 6 26 Table 3 1 Inverter model number 7075 0 7090 0 7110 0 7132 0 VT Connectable motor power kW 75 0 90 0 110 0 132 0 132 0 160 0 200 0 250 0 315 0 355 0 Inverter power kVA 104 0 125 0 145 0 173 0 173 0 208 0 256 0 319 0 395 0 423 0 Rate output current A ms 150 0 180 0 210 0 250 0 250 0 300 0 370 0 460 0 570 0 610 0 Continuous output current A 2 100 of the rated output current Inom Maximum output voltage 3 phase 98 of line voltage Output frequency Hz 0 250 3 Maximum frequency resolution Hz 0 01 see Chapter 3 3 Resolution Overload factor at 45 C ambient temperature 120 VT only for pump and fan applications or 150 CT for 1 min with 30 min cycle time Maximum output current Arms 732 0 Power loss at a carrier frequency of 2 kHz
18. disturbing cables e g power and contactor control circuits separately and at a dis tance from the control cables Special case MOL input The MOL input is particularly critical from the point of view of EMC if the input is used to evaluate PTCs or klixons fitted in the motor this will result in high crosstalk on its connection leads owing to the high edge steepness dU dt of the motor voltage This may lead to volt age peaks exceeding 100 V at the MOL input Consequently this lead must be shielded separately The shield should not be connected to the COM terminals but to earth The best result can be achieved by earthing the shield at both ends Motor lead 7 To the MOL terminal 2 3 4 EMC Ordinance EMC Directive 89 336 EEC The frequency inverters were tested in the form of a practical test set up in a switchgear cabinet in accordance with our interference suppression measures in these operating in structions EMC Electromagnetic Compatibility The limit values of the standards below were fulfilled under these conditions EMA Electromagnetic Emission EN 50081 1 Basic specification Emitted interference Limit value class A or EN 50081 2 Basic specification Emitted interference Limit value class B optional EN 55011 Emitted interference 1 In the case of unit classes 1 5 11 0 EMC filters are installed as standard limit class A here interference suppression refers to the AC input ter
19. kW Table 3 2 8 20 NOTES 1 At a set carrier frequency up to 5 kHz At higher carrier frequencies power staggering may be necessary depending on ambient conditions 2 Information required for definition of the motor cable cross sections 1 25 x continuous current on the basis of 400 V line voltage 3 If higher frequencies are required please consult BERGES 1 32 Operating Instructions UD 7000 1 5 355 0 04 08 05 07_GB_T1 Technical Data 3 2 Input Data Inverter model number 7001 5 7002 2 7003 0 7004 0 7005 5 7007 5 7011 0 7015 0 7022 0 7030 0 7037 0 7045 0 7055 0 Line rated current for setting a PKZ A 1 4 3 5 6 6 8 8 4 10 5 14 6 19 4 29 0 38 9 55 0 64 0 76 0 91 0 Installed by default limit class A 3 EMC filter The unit can also be supplied without a filter 3 STANS accessory AC input voltage range 3 x 380 460 VAC 15 size II VI 3 phase Conductor voltage asymmetry less than 2 Maximum line voltage 529 VAC Line frequency 45 65 Hz DC infeed at the terminals 350 VDC to 700 VDC or ZK ZK Please consult BERGES Maximum DC voltage 745 VDC Table 3 3 7132 0 7132 0 7160 0 7200 0 7250 0 7315 0 7355 0 Inverter model number 7075 0 7090 0 7110 0 VT CT CT C
20. only DC AC capable types may be used which have been designed specifical ly for rectifier loads see Chapter 2 5 1 Use of Fault Current Safety Switches CAUTION the number of line Off On cycles is limited owing to the capacitor charging cir cuit Maximum four cycles are permitted per minute A waiting time of min 15 seconds until switching back on must always be complied with If this time is not complied with this may lead to destruction of the inverter Brief line interruptions lasting a few millisec onds causing the DC link voltage to drop below 300 VDC my lead to switch off of the processor In this case the processor reverts to Sleep mode which sets the inputs and outputs to their zero voltage state This error must be acknowledged by one line Off On cycle Sleep mode can be seen from the fact that the display LED s blink simultaneously Motor connection terminals Three phase variable frequency and variable voltage al ternating voltage The rating of the cable cross sections is listed in Chapter 2 5 3 CAUTION switch off of the output stages electronically e g via the MOL control input is not considered as safe isolation The inverter must be disconnected from the line if work is to be conducted on these terminals DC link connection terminals These terminals may be used for several purposes 1 For connection of an external braking chopper The chopper must feature its own con trol circuitry and a power swit
21. the flux The basic physics principle applies here as well M 1x0 x SIN Angle between x ol Since the resultant flux in the machine is now determined not only by the stator end average ampere conductors per unit of length but since the current also flows in the rotor owing to the motor s transformer like design and this current also has a frequency which is not equal to the stator frequency and since this also generates a flux the ratios become very com plex In addition these rotor influences are also load dependent It can be now be easily imagined that the ratios at the rotor end can be computed exactly only if we know the pre cise rotor speed of rotation rotational speed feedback The conditions in the motor can now be grasped with the aid of complex mathematical motor models The data obtained from this can now be transformed to the stator end so that one can construct a precise cur rent phasor diagram To summarise the following measuring sensors are also required e Current transformer in the motor phases Rotational speed feedback on the rotor The simplified phasor diagram in Figure 4 2 has now become a phasor diagram which al lows for influences of the rotor end I 2 Operating Instructions UD 7000 1 5 355 0 1 45 Drive Variants me I_Phase 11_M ana 12 b po 1_9 Magnetic flux Figure 4 5 Extended phasor diagram Here as well itis of major significance that one obtains satisfacto
22. to 60 C Humidity lt 90 relative humidity no condensation Vibration Maximum 0 6 g Altitude level lt 1000 m without performance reduction Table 3 12 1 36 Operating Instructions UD 7000 1 5 355 0 04 08 05 07_GB_T1 Technical Data 3 9 Dimensions Size II VI 1 5 55 0 kW 04 08 05 Operating Instructions 07_GB_T1 UD 7000 1 5 355 0 1 37 Technical Data J BERGES Size VIII 132 200 kW Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 1 38 Technical Data Size IX 250 355 kW DIMENSIONS SIZE II SIZE III SIZE IV SIZE V SIZE VI SIZE VI SIZE VIII SIZE Ix 1 5 5 5 kW 7 5 11 kW 15 22 kW 30 45 kW 55 kW 75 132 kW 132 200 kW 250 355 kW A 100 135 240 345 345 440 518 518 B 395 395 395 510 820 820 Cc 379 379 379 488 488 480 782 782 D 60 95 180 285 285 342 462 462 E 20 20 30 30 30 35 28 28 F 252 252 252 252 252 362 442 442 G 512 H 716 1095 I 3 3 u J 3 K 412 L 322 Dimensions in mm 04 08 05 Operating Instructions 1 39 07_GB_T1 UD 7000 1 5
23. use of expensive hardware Higher performance fu ture microprocessors will be able to solve this disadvantage at less cost Tests have estab lished the following key performance aspects e Rotational speed accuracy fabs lt 1 in the correcting range 1 7 e Torque accuracy fabs lt 1 in the correcting range 1 5 Torque at low rotational speeds 150 at 0 5 Hz at the motor with 50 Hz nominal fre quency 4 3 The EC Drive 04 08 05 07_GB_T1 The EC electronically commutated motor as with the asynchronous motor at the stator end has a three phase winding If a rotor with magnet poles is now fitted in the three phase stator this produces a synchronous motor Here as well as is the case with asynchronous motors the interlinked stator current should be as perpendicular orthogonal as possible on the rotor field in order to maximise the torque developed A knowledge of the rotor position as an absolute magnitude is abso lutely essential in order to guarantee this phase relationship between stator current and magnetic field position In general a resolver mounted on the rotor is used for this This motor type as well features the drive engineering advantages of the field orientated con trolled asynchronous machine It also features other advantages relating to motor physics such as e Lower rotor moment of inertia This predestines the motor for positioning tasks e Lower rotor losses This results in enhanced efficienc
24. 0 1 5 3 ions 55 0 Starting from software version A20 02 appears with parameter 4E in the display U fmin VIN CIN Starting from software version A20 02 appears with parameter 4F in the display U fmax VIN CIN 04 08 05 07_GB_T1 Parameter Overview Annex GROUP 4 Frequencies NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER 41 Preset speed 1 Fixed frequency 1 0 1 Hz 2 68 5 0 42 Preset speed 2 Fixed frequency 2 0 1 Hz 2 68 20 0 43 Preset speed 3 Fixed frequency 3 0 1 Hz 2 68 40 0 44 Preset speed 4 Fixed frequency 4 0 1 Hz 2 68 60 0 45 Preset speed 5 Fixed frequency 5 0 1 Hz 2 68 0 0 46 Preset speed 6 Fixed frequency 6 0 1 Hz 2 68 0 0 47 Skip band Hysteresis band for blocking frequencies 0 1 Hz 2 70 1 0 48 Skip freq 1 Blocking frequency 1 0 1 Hz 2 70 0 0 49 Skip freq 2 Blocking frequency 2 0 1 Hz 2 70 0 0 4A Skip freq 3 Blocking frequency 3 0 1 Hz 2 70 0 0 4B Skip freq 4 Blocking frequency 4 0 1 Hz 2 70 0 0 GROUP 5 Torque NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER 51 Select TLim MFo Torque limit selection right rotation motor operation S P 2 70 0 52 Select TLim MRe Torque limit selection left rotation motor operation
25. 1 phase devices Permissible are pulsed current sensitive Fl safety switches type A or AC DC sensitive safety switches type B 3 phase devices Only AC DC sensitive safety switches type B are allowed Otherwise another safety measure has to be deployed such as the use of double or rein forced isolation to disconnect from the environment network disconnection or similar EN 50178 The release current of the Fl safety switch must be amply dimensioned because capacitive compensating currents cable screens filters can easily lead to accidental re lease Possible reasons why a fault current safety switch is triggered accidentally Capacitive leakage currents of the line shielding occur during operation especially in the case of long shielded motor feed lines e Simultaneous connection of several inverters to the network e Use of additional line filters 2 5 2 Line Conditions The permissible fluctuation in the line voltage is between 15 of the nominal volt age If the voltage exceeds or falls short of the nominal voltage by 25 the inverter is switched off automatically because the voltage is too high or too low Adaptation to rated line voltages outside the permissible range is possible by means of au totransformers Calculation according to the formula below is recommend Vs Pr Equivalent two winding kVA rating kVA Pr Pp 1 lt 2 Pp Continuous output kVA V Rated line voltage V Vo Rated v
26. 1 r o D5 id Id nom Actual value of the field generating current component ig 0 01 2 111 r o D6 iq lq nom Actual value of the torque generating current component iy 0 01 2 111 r o D7 iq set lq nom Setpoint of the torque generating current component ig set 0 01 2 112 r o GROUP E Service data II NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER E1 IxT value Value of Ixt integral 1 2 112 r o E2 IxT DC value Value of Ixt DC integral 1 2 112 r o E3 Ratio frequency Frequency factor 0 01 2 112 r o E4 SoftwareVersion Software version 0 01 2 112 r o E5 Total op time Lifetime 1h 2 112 r 0 E6 Total run time On time 1h 2 112 r 0 E7 Enable time Enabling time 1h 2 112 r o E8 Status Inverter status Binary 2 112 r o E9 Custom para set Customer parameter set S P 2 113 1 EA Reset Parameter Application dependent defaults S P 2 114 0 EB Status 2 Inverter status 2 Binary 2 115 r o EC Standarddisplay Standard display S P 2 116 1 GROUP F Service data III display Service datallI NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER F1 Nom Power Inv Rated inverter power 0 01 kW 2 116 r 0 F2 Filt power fail Power failure filter 0 001 s 2 116 0 040 F3 R1 Stator resistance R1 0 01 Q 2 116 F4 R2 Rotor resistance R2 0 01 Q 2 117 F5 Xsigma Leakage reactance Xo 0 01 Q 2 117 F6 Tr Adaptation Rotor time constant setting 0 1 2 118 100 0 F7 Main reactance Main reactance Xp
27. A industrial networks and B domestic networks In the case of limit class A a line filter 1 must be wired before every frequency inverter In the case of limit class B a filter must also be wired before it The inverters and accessories must be wired as shown in the following schematic If applied consistently the following suggested circuit will successfully render harmless the residual noise voltage on the GND conductor potential for external measurement systems Line filter F or choke BV or measurement output 4 BV or similar 4 i i I Choke H i 4 Isolated against other potential ONS To VDE 0875 To VDE 0875 External measurement systems Limit class A Limit class B NOTES Choke only if required e g owing to motor cable length gt 30 m Please consult BERG For cables shorter than 20 cm an unscreened cable can be used between filter and in verter 1 Inthe case of unit classes 1 5 11 0 EMC filters are installed as standard limit class A The unit can also be supplied without filter See also Tables 3 3 and 3 4 EMC filter 04 08 05 Operating Instructions 07_GB_T1 UD 7000 1 5 355 0 1 11
28. BERGES Operating Instructions Part dada agaaa wke e aaay agav saav U UNIVERSAL Drive 7000 Table of Contents Table of Contents Operating Instructions Part 1 Page 1 General Information 5 5 3375 44 Gales Shs Gye pe eta Sas Rae Be Tara Se Sey Sn tees Sd a ae a ern 3 tA Explanation of Symbols and Not sS ss nannten sa eta ntti wae een A beta ae cas ne a Bu an 3 1 2 Safety and Operating Instructions for Drive Converters 0 ect nennen eenenen 3 Si lo AMA A Mb El ARE SL re A RU EN BE Metered A ae Ele O LEE hs hal ee ae Ae 5 1 4 Description of FUNCTIONS ia ih sei acd get and eae ae en er Een do 6 1 5 7 ROWER SECHON a ee ee A lay a ak ne in ae ee ee ae tee Mawes Gin dessin Oe 7 1 05 Inverter Control iii area er ana nel ee 8 2 Installation 2 2 22 2244 222 ote 2 an a Ese ee ee eo eo Ae nd ae ep 10 2 1 Inspection of Unit after Delivery is sa ci ae ee ee er eee re ee ele 10 2 2 General Installation Instructions 2 2 nehne pdt a Dea nennen e nennen en 10 2 3 EMC Electromagnetic Compatibility 0 rennen een een ernennen 11 23 1 Limit Class Si cnc 2 ke Heer ie ec sen ee Bes nee ee lern 11 2 32 Filter Components se Seas ences hi hind Se re Eee ae ae eae oes eS 12 2 3 3 Interference Suppression Measures 12 2 3 4 EMC Ordinance EMC Directive 89 336 EEC 0 0 eect tenet teen ene 14 ZA ANINO IPFACTICOS ss 18 22 as A ot a Catal zierte Daran Auen nen re al
29. ION PAGE DEFAULT CUSTOMER Reference selec Setpoint selection frequency setpoint S P 2 57 0 Selection LIM Function of the LIM input S P 2 62 1 Ratio frequency Frequency factor 0 01 2 63 100 00 Fact LIM analog Scaling factor A y for analogue LIM input 0 1 2 63 10 0 Calibr LIM digi Calibration digital LIM input with factor Dy m 0 1 Hz kHz 2 64 2 0 Pulse numberLIM Pulse number of LIM input 1 2 64 6 Dir master ref Direction of rotation master setpoint S P 2 66 0 min Ratio freq Low frequency factor limit 0 01 2 66 0 00 max Ratio freq High frequency factor limit 0 01 2 67 105 00 F EXT1 SIO External frequency setpoint 1 0 01 Hz 2 67 0 00 F EXT2 SIO External frequency setpoint 2 0 01 Hz 2 67 80 00 3C Time VIN CIN Filtering time constant VIN CIN input 2 ms 2 67 4 3D Time LIM Filtering time constant LIM input 2 ms 2 67 4 3E Pulse no ST4 Pulse number ST4 output 1 2 67 10 3F Speed Reference Frequency setpoint on the basis of ramp 0 1 Hz 2 68 r o 1 52 NOTES Various parameters are only available as a function of the current mode r o viated to r o Read only parameters are printed in italics and the reference in the tables is abbre S P Selection parameter for adaptation of the inverter functions 0 Value range and default values 1 2 3 In the high frequency application profile unit 0 1 Hz Operating Instruct UD 700
30. L inputs would be destroyed MOL Reference potential for MOL CAUTION the MOL input is not connected to COM The MOL inputs may not be connected either to COM or to the 24 V terminals of the inverter since otherwise the MOL inputs would be destroyed Analog outputs MET1 MET2 Metre 1 output signal for indication purposes 0 10 VDC or 10 VDC Imax 20 mA COM is the reference potential Level and output quantity and its scaling can be selected in parameter group A Metre 2 output signal for indication purposes 0 10 VDC Imax 20 mA or 0 20 mA COM is the reference potential Signal type and output quantity and their scaling can be selected in parameter group Table 2 2 Terminal assignment control terminals 04 08 05 07_GB_T1 Operating Instructions UD 7000 1 5 355 0 1 27 TYPE DESIGNATION DESCRIPTION Binary Applicable to all binary inputs inputs Voltage range 0 30 VDC low 0 0 2 VDC high 2 30 VDC The active level i e high or low can be changed over in parameter group 9 FWD Start or start right rotation REV Change of direction or start left rotation RUN JOG Normal jog mode changeover in the LOCAL mode Jog mode drive runs at the jog frequency fixed frequency 1 for as long as the FWD or REV key is pressed This input is programmable for further functions select in parameter group 9 PS1 PS3 Selection of fixed frequencies
31. RTER INPUT VOLTAGE 3 x 400 V Type of unit 7132 0 VT 7132 0 CT 7160 0 CT 7200 0 CT 7250 0 CT 7315 0 VT 7355 0 VT Inverter power kW 132 0 132 0 160 0 200 0 250 0 315 0 355 0 Line fuse Ferraz 6 6 URD 2 30 D A0400 30 D A0400 31 D A0450 32 D A0550 33 D A0700 33 D A0900 33 D A1100 Cable cross section mains lead mm 185 185 240 2x 120 2x 185 2 x 240 2 x 240 Cable cross section motor line mm 185 185 240 2x 120 2x 185 2x240 2 x 240 NOTES 1 Only l v h b c fuses with gL fusing characteristic VDE 636 Part 1 for example may be connected as line side fuses in the case of devices 7075 0 to 7110 0 2 The specified semiconductor fuses must be connected as line side fuses for the devices listed in the table The medium time delay fuses of type Bussmann FRS R for example are recommended in networks with nominal voltages greater than 415 V The typical operating times are 150 to 250 s for 2x overcurrent and 180 to 1500 ms in the case of 10x overcurrent 2 5 4 Using Line Filters Special protective measures must be observed when using line filters 04 08 05 07_GB_T1 Operating Instructions UD 7000 1 5 355 0 1 19 ATTENTION Owing to the leakage current involved gt 3 5 mA attention must be paid to EN 50178 when using BERGES line filters One of the following protective measures must be taken The line filter must be connected separately by laying
32. T CT VT VT Line rated current for setting a PKZ A 2 131 159 193 244 244 264 302 447 539 596 EMC filter Only externally as an accessory AC input voltage range 3 x 380 460 VAC 10 15 size VII IX 3 phase Conductor voltage asymmetry less than 2 Maximum line voltage 506 VAC Line frequency 45 65 Hz DC infeed at the terminals 350 VDC to 700 VDC or ZK ZK Please consult BERGES Maximum DC voltage 745 VDC Table 3 4 NOTES 04 08 05 07_GB_T1 1 Information required for setting a PKZ switch magnetic circuit breaker line rated cur rent x 1 1 2 Information required for setting a PKZ switch magnetic circuit breaker line rated cur rent x 1 3 The maximum input voltage for EMC filters is 415 VAC 15 Higher voltages on de mand Operating Instructions UD 7000 1 5 355 0 1 33 Technical Data 3 3 Control Data Modulation method Sinusoidal vector modulation subharmonic method trapezoidal control PWM frequency Size II VI 2 00 15 00 kHz in 0 01 kHz steps Size VII IX 2 00 kHz Setpoint input Setpoint source Resolution 0 10 VDC 2 10 VDC 10 VDC 100 kQ 10 bits optionally 12 bits 0 20 mA 4 20 mA 20 mA 50 Q load on request Keypad in the 0 to 99 99 Hz frequency range 0 01 Hz in the 100 0 Hz to Fmax frequency range 0 1 Hz Digital frequency input 0 100 kHz 0 01 Hz Master setpoint phase synchronous fout X 6 Or fout X 10 7 fixed
33. a second cable that is electrically parallel with the GND conductor this conductor must meet the requirements of IEC 364 5 543 on its own The GND conductor must have a cross section of at least 10 mm diagrams 2 refer to the following e The GND conductor must be monitored by a facility that isolates the inverter from the line in the event of a fault GND conductor monitoring The inverter must always be connected permanently EN 50178 when using line fil ters leakage current gt 3 5 mA NOTE For cables shorter than 20 cm an unscreened cable can be used between filter and invert er Inverter Line filter Inverter Line filter Line filter connection with a second Line filter connection with at least parallel GND conductor 10 mm GND conductor cross section 2 5 5 Start Up on the Line The UD 7000 units are designed for controlled starting and stopping of three phase motors by means of the keypad or external contacts latching switches or relays As standard the inverter features a line start up lock to prevent unintentional starting of the motor after a power failure This facility can be cancelled out by programming parameter 71 see Page 2 78 2 5 6 Reducing Current Surges and Voltage Transients 1 20 Voltage spikes caused by coils inductors operated on the same line as the inverter can lead to malfunctions of the inverter In cases of this kind the affected windings of contactors and re
34. all be followed KEEP SAFETY INSTRUCTIONS IN A SAFE PLACE Before you read on please check whether technical changes are attached in the annex to this operating manual The standard documentation covers a set of Operating Instructions Part 1 and the Param eter Description Part 2 A prefix 1 resp 2 corresponding to Part 1 or Part 2 has been added to the page numbers in order to allow cross references to page information in Part 1 and in Part 2 to be distinguished Operating Instructions UD 7000 1 5 355 0 1 5 These Operating Instructions Part 1 cover general information installation technical data a detailed description of the drive variants and the Annex with parameter overview and error states The Parameter Description Part 2 contains commissioning instructions the description of the keys and displays indicators a detailed parameter description the error states and in the Annex the parameter overview Please read through these operating instructions conscientiously before installing the drive in order to guarantee correct installation and maximum performance capabilities The four groups in the converter series are please refer to Chapter 4 for a detailed descrip tion of the drive variants V Hz controller inverter with voltage frequency control for induction motors FO controller servo inverter with field oriented control for induction motors EC controller servo inverter for permanently exc
35. all control components characteristic control does not suffice to achieve a similarly good control and load behaviour on the asynchronous motor as with a DC motor The prin ciple of field orientated control is used for this purpose In this case the field and torque generating current components are computed precisely and controlled highly dynamically If this is possible this provides a control structure which corresponds to that of a DC ma chine control There as well one has one controller for the excitation current and one con troller for the armature current torque controller One talks of magnetisation current and torque generating component on the asynchronous machine A voltage controlled asyn chronous machine becomes a current controlled asynchronous machine The fundamental mode of operation of the asynchronous motor which is able to develop a torque only if there is a rotational speed difference between stator field and rotor slip in dicates a problem which cannot be easily solved As the result of this slip a current is in duced in the motor winding and this current together with the flux in the air gap rotating field results in a torque The flux of the stator must now be linked in the air gap with the flux of the rotor in order to obtain the working flux The fundamental problem is to detect or compute the flux in the machine from easily meas urable variables Only then is it possible to control the torque decoupled from
36. as reached f_Knee M Torque M1 lt M2 s Slip s1 lt s2 synchronous speed of rotation rotor speed of rota tion synchronous speed of rotation It is possible to draw conclusions as regards the load dependent slip of the motor from the torque generating current component I1_M If we know the slip frequency fs1 fs2 this is added to the stator frequency n1 n2 This greatly enhances rotational speed stability The motor is provided with a so called shunt behaviour In generator operation the slip frequen cy is of course subtracted from the stator frequency Starting from the torque rotational speed characteristic of the asynchronous motor in line operation this corresponds to a par allel shift in this characteristic Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 1 44 Drive Variants 04 08 05 07_GB_T1 The essential disadvantage of these open loop controlled methods is the fact that these methods are all based on static models of the motor In dynamic operating cases the op erating data determined differs greatly from the conditions actually obtaining in the motor In order to optimise this it is necessary to use dynamic motor models In addition the pre cise flux obtaining in the motor is computed in these models i e the above mentioned in fluences of the rotor on the stator variables are included in computation 4 2 2 Field Orientated Controlled Mode Vector Control Despite
37. ating instruments The meas ured variables that can be output with them can be programmed by the user Within the scope of status monitoring the control controls important operating variables of the inverter Warnings or error messages are issued if deviations from the specified toler ance range occur In the event of a fault control of the complete IGBT inverter bridge is dis abled to protect the inverter Important operating variables of the inverter are Line voltage e DC link voltage Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 HINT 04 08 05 07_GB_T1 e Output current Heat sink temperature The inverters are resistant to earth faults and short circuits at their motor connection termi nals The ABE indicates the current error or warning message The last five occurring faults are stored in the fault memory parameter memory in chronological order If the PROG SHIFT or ENTER key is pressed the message is reset on the ABE display and operator control unit Acknowledgement of the error message does not cancel the cause of the error Errors may be also still be pending after reset Operating Instructions UD 7000 1 5 355 0 1 9 2 Installation 2 1 Inspection of Unit after Delivery A B Upon receipt unpack and carefully inspect for any damage sustained in transit depres sion in the enclosure damage to parts missing parts Check information on the name plate
38. ber of encoder lines 1 2 110 1024 BF Angle Sensor Resolver measured angle 0 FFFFy 2 110 r 0 GROUP C Stepper control display Step control NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER C2 Step control Enable step by step control application S P 2 110 0 C3 Input step Step number for parameter input 1 2 110 0 C4 Condition Input Input condition 2 110 0 C5 Condition Outpt Output condition 2 110 0 C6 Parameter no 1 Parameter number 1 1 2 110 0 C7 Param value 1 Parameter value 1 1 2 110 0 C8 Parameter no 2 Parameter number 2 1 2 110 0 C9 Param value 2 Parameter value 2 1 2 110 0 CA Parameter no 3 Parameter number 3 1 2 110 0 CB Param value 3 Parameter value 3 1 2 110 0 CC Delay time Waiting time 0 001 s 2 110 0 CD Actual step Current step 1 2 110 0 CE Mask pin Mask for terminal signals 2 110 0 CF Step ctrl input Input for terminal signals 2 110 0 04 08 05 07_GB_T1 Operating Instructions UD 7000 1 5 355 0 1 55 Annex Parameter Overview GROUP D Options NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER D1 Option Option number 1 2 111 r 0 D2 F zero pulse Zero pulse search frequency 0 1 Hz 2 111 0 5 D3 Zero angle Zero angle 0 19 2 111 0 0 D4 sigma Total stray factor o 0 01 2 11
39. ce 4 50 Operating Instructions 04 08 05 u UD 7000 1 5 355 0 07 GB_T1 Parameter Structure Annex 5 2 Parameter Structure UD 7000 Power on display of Start Unit type inverter power and software version Application and application number Power on After approx 2 seconds DEFAULT DISPLAY 1 Status display Permanent storage of the frequency setpoint In LOC mode Set the required Frequency display frequency setpoint Load display Only in REMOTE mode DEFAULT DISPLAY 2 gt S a v 5 p c s YN Display of optional Read Only parameters y Key combination applies when jumping from any parameter group to the default display PARAMETER GROUP 0 PARAMETER GROUP 1 PARAMETER GROUP n Service parameters Motor data Groups are sorted according Read Only to the functions of the subparameters Parameter group NOTES Display of the parameters that deviate from the works settings PARAMETER 1 1 PARAMETER n 1 Permanent storage of all parameters in this group In the case of Read Only parameters the parameter is shown in the first line of default display 2 Depending on the current PARAMETER 1 2 PARAMETER n 2 Parameter list default display q PARAMETER 1 3 PARAMETER n 3 Read Only Figure 5 1 04 08 05 Operating Instructions 1 51 07_GB_T1 UD 7000 1 5 355 0
40. ching transistor Please consult BERGES if necessary 2 For DC powering of the inverter L1 L3 are not connected in this case The DC link capacitors are then pre charged by the external DC power feed module If this is not done this may lead to destruction of the DC link capacitors Please consult BERGES application information 3 For DC link coupling of several inverters Typically one or more inverters is or are powered by one inverter This means that one inverter is connected to the line L1 L3 and all other inverters are powered via these terminals Energy exchange is able to occur between the inverters In applications in which the inverters are operating in braking mode and the rest of the inverters are operating in motor mode this may lead to a substantial energy saving Please consult BERGES application information CAUTION on no account may you design the inverters yourself Incorrect design may lead to destruction of the inverters The maximum voltage measured with respect to earth potential may be up to 400 VDC A voltage of up to 800 VDC may be measured across the terminals risk of lethal injury optionally ZK Connecting terminals of the braking resistor In the standard model of sizes II VI the inverter is provided with a braking resistor that is connected to the terminals BR and BR on the underside of the device If an external resistor is required e g if the dissipation rate of the in
41. clude the relay terminals NO C and NC The terminal Aux GND recessed head screw M4 only with sizes II VI is isolated from the housing and can be used e g as the neutral point of the COM connections TYPE Analog inputs DESIGNATION VIN VIN DESCRIPTION Frequency setpoint difference input for VIN 0 10 VDC 2 10 VDC or 10 VDC input resistance 100 kQ Function selection in parameter group 3 2 Reference level for VIN difference input input resistance 100 kQ Input can be connected to COM level with jumper X57 2 CIN Frequency setpoint current input for CIN 0 20 mA 2 20 mA 20 mA load impedance 50 Function selection in parameter group 3 This setpoint is also added from the VIN input 1 3 CIN Reference level for CIN 1 9 LIM 0 10 VDC COM is the reference potential Input has 100 KQ pull up resistor for the signal REF 10 V Input with double function 1 Analog torque limit or additional setpoint 2 Binary frequency input up to 100 kHz Function selection in parameter group 3 MOL Connection of the normally closed contactor PTC for thermal motor protection or al ternatively as an input for hardware pulse locking Please also refer to what is said in Chapter 2 3 3 Interference Suppression Measures CAUTION the MOL inputs may not be connected either to COM or to the 24 V ter minals of the inverter since otherwise the MO
42. cs coh sea a ri aldea e dts hints 32 3 2 Input Dalaran ra A ii pa RA AA DA AENA ee een een 33 3 3 control DATA A lA hans takes ak Ws Eta LEN En A EN BU E a ek SI he ae ee TE 34 3 4 Protective Function ser eiat fakes Saeed eve Pe es Ge ee E ee De ee ae ee ee ee Be a 34 3 5 Brake Chopper Power Dissipation u ra ee ee er Te GE a we Ba dee bok aT 35 3 6 Display and Operating Uhit Vocal aaa ae charge hed ua rd Bene 35 3 7 Param ter Groups nny dere eet eae eens Ride ede pen eee beds petite aba deed iets 36 3 8 Mechanical Design and Ambient Conditions 0 0 00 ccc tte nt tenets 36 3 9 DIMENSIONS nu ae A ee kena knee A Meena et hie ee O A eae en Berto 37 4 Drive Variants an e n a An le A A gual aan done wala ae oe AA wand a a a eae aba Tees 41 4 1 The Motor Drive Data and How it is Measured 0 000 cette 41 4 2 The Asynchronous Motor and Speed Control 0 6 eet tenet teens 41 4 21 IEC ONE Ora a ee ee ee tee ald nih ne ee een naar 42 4 2 2 Field Orientated Controlled Mode Vector Control 0 00 0 cc cect tent nent tenes 45 4 23 SLV Sensorless Vector Control 2 niassa rankon ene nennen nennen een 46 4 3 ThesEC Drive a ar nannte ny a nee hehe ede i pee o a eh E 49 5 A A ne ds ty ee hee spin ne dnt Prada ge awe Give av ine agin eaten dee aoe nae Sates eee seated 50 51 Abbreviations US6d anciana aw iene ett ah vase eee hay Be a A Dl iw aha lets Beis LS 50 5 2 Parameter Structures coy tice on e
43. e message is reset on the ABE display and operator control unit Acknowledgement of the error message does not cancel the cause of the error Errors may be also still be pending after reset Normal Handling of Error States In certain circumstances the inverter may assume an error state The occurrence of such a State can be reported through relay or transistor outputs parameters 92 96 setting x01 The output is activated if an error occurs When the cause of the error disappears the error signalling output becomes inactive with deactivation of drive enabling the drive is ready for operation 5 4 2 Handling of Error States with the Acknowledge Error State Function When a binary input R J PS1 PS3 is programmed with the Acknowledge error state func tion an error state always continues to exist until the cause of the error has been remedied drive enabling has been cancelled and the binary input Acknowledge error state is acti vated Thus in a system with several inverters it is possible to cancel all drive enabling sig nals in the event of a malfunction occurring and to nevertheless locate the defective inverter through the relay or transistor output In the basic state the binary input must be deactivated as otherwise the inverter cannot be started In the event of an error drive enabling must first be cancelled and only then the input activated The binary input should not be cancelled until the error state is
44. e number means that the inverter is available with braking transistor x is replaced by B or without braking transistor x is replaced by 0 NOTE Additional filters available on request must be used in order to comply with limit curve B Interference Suppression Measures Electrical electronic devices are capable of influencing or disturbing each other through connecting cables or other metallic connections Electromagnetic compatibility consists of the factors interference resistance and interference emission Correct installation of the inverter in conjunction with any possible local interference suppression meas ures has a crucial effect on minimizing or suppressing mutual interference Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 Housing wall earth Remove any paint or varnish Large area contacting of the cable shield Motor cable with braided shield 04 08 05 07_GB_T1 The scope of noise suppression measures depends on the limit value class the local situ ation and the application The following notes refer to a line power supply that is not contaminated by high frequency interference Other measures may be necessary to reduce or suppress interference if the line voltage is contaminated No generally valid recommendations can be given in such cases Please consult BERGES if all recommended interference suppression measures should not
45. e result Consider the results of this calculation to be Laa Lpa and Lea BR Lpa Es a o _5 0 5 2 1 x 100 _ DR o 2x 400 x 100 1 25 Phase Imbalance avg EXAMPLE measured phase voltages of 395 400 and 405 would result in a calculated phase imbalance of 1 25 If the resulting phase imbalance exceeds 2 consult your local power company or plant maintenance personnel and ask them to investigate this problem and recommend methods of correcting this condition Phase imbalance can also cause damage to motors running direct on line A 2 imbalance requires a 5 derating factor on the motor 3 imbalance requires a 10 derating 4 re quires an 18 derating Never use power factor improvement capacitors on the UD 7000 motor terminals U V and W or damage to the inverter s semiconductors will result The number of mains Off On cycles is limited owing to the capacitor charging circuit Max imum three cycles are permitted per minute A waiting time of min 10 seconds until switch ing back on must always be complied with If this time is not complied with this may lead to destruction of the inverter 2 5 3 Line Fusing The user must install either device protection fuses or an overload isolator in the line input line in conformity with the applicable stipulations of the national electric code NEC and all local regulations The following must be observed in relation to the correct design of input fus
46. es or of the overload isolator Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 A Dimensioning The UD 7000 inverters can be operated for 1 minute with 50 overload and the cycle time must be at least 30 minutes If such load cases occur on the drive the fuses or circuit break ers must be dimensioned accordingly higher B Fuse Types To guarantee a maximum protection of the inverter fuses should be used for current Limi tation These fuses should have a breaking capacity of 200 000 Ag The following table shows the recommended values in amps for all UD 7000 inverters For 400 V line supplies we recommend time lag type NEOZED fuses ATTENTION INVERTER INPUT VOLTAGE 3 x 400 V i2 a Q 2 me Q E Q Q 2 E E N N N N N N N N N N N N N Inverter power kW 1 5 2 2 3 0 4 0 5 5 7 5 11 0 15 0 22 0 30 0 37 0 45 0 55 0 Rated current fuse A 6 6 10 10 10 16 25 32 50 80 80 100 125 Cable cross section mains lead mm 1 5 1 5 1 5 1 5 1 5 2 5 4 6 10 16 25 35 50 Cable cross section motor line mm 1 5 1 5 1 5 1 5 1 5 2 5 4 6 10 16 25 35 50 INVERTER INPUT VOLTAGE 3 x 400 V Type of unit 7075 0 7090 0 7110 0 Inverter power kW 75 0 90 0 110 0 Line fuse gL A 160 200 250 Cable cross section mains lead mm 95 120 150 Cable cross section motor line mm 95 120 150 INVE
47. esult We recommend the connection of a PTC resistor or a motor clixon to achieve full protection of the motor The UD 7000 features corresponding connection terminals Adapt to the pro tective element by way of parameter 81 If interrupting contacts e g contactors or motor circuit breakers etc have to be installed between the motor and inverter make sure that the output stages are de energised motor current 0 before the inverter motor connection is interrupted The inverter and motor are adapted by way of parameter groups 1 and 2 2 7 Brake Resistor 04 08 05 07_GB_T1 Model UD 7000 is provided with a standard braking resistor except sizes VII IX The type and size of the mounted brake resistor depends on the Inverter s power Rating For power rating details please see Table 3 7 Page 1 35 Brake Resistor Protection The mounting area can become hot on the inverter s back side The brake resistor is mount ed in such a way that a part of its heat can be transferred to the enclosure The brake re sistor is protected by the inverter in the following ways Operating Instructions UD 7000 1 5 355 0 1 21 1 The inverter computes a thermal model of the resistance The software is matched to the incorporated standard resistor fitted on the rear side of the inverter The default set tings of the parameters ensure that the exterior of the unit does not increase in temper ature to above 70 C A change in these model param
48. eters parameters 7A 7E and 7D may cause higher temperatures 2 Aheat sensor is fitted on the heat sink Temperatures exceeding 70 C at the heat sink generate an error message Error No 02 From case to case temperatures of 90 100 C may be anticipated HINT If the maximum permitted power loss of the default braking resistor is exceeded an external gt braking resistor will be required see also Chapter 3 5 Tables 3 7 and 3 9 Braking resis tors are available as optional packages 2 8 Functions and Use of the Terminals HINT When the unit is delivered the displays are in German Redefine parameter 78 to change a the language Removing the Protective Terminal Cover Switch off the line voltage before opening or working on the frequency converter Also ensure that there is no DC infeed e g by a DC link coupling Hazardous voltages are still present if lamp BUS CHG is still lit up to 55 kW in the case of inverters On units upwards of 75 kW the DC link voltage at terminals ZK ZK should be measured in order to pre clude the possibility of accidents resulting from hazardous voltage Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 1 22 The power and control terminals are covered by one or two covers dependent on size After undoing the securing screws the front panel can be detached by lifting it slightly and swivelling it to the top size II VI In the case of size VII the front pla
49. fault has been reme died As a result of this certain systems may be damaged or destroyed and there may be a risk for operators working on the system Installations which include drive converters shall be equipped with additional control and protective devices in accordance with the relevant applicable safety requirements e g Act respecting technical equipment accident preven tion rules etc Changes to the drive converters by means of the operating software are Ad missible The motor may be stopped during operation by disabling it or by deactivating the setpoint whereby the drive converter and motor may remain live If inadvertent start up of the mo tor must be excluded to protect operating personnel electronic interlocking by dis abling the motor or by deactivating the setpoint is inadequate This is why the drive converter must be isolated from the line voltage During operation all covers and doors shall be kept closed Measuring instruments must be connected and disconnected only in de energized condi tion Unauthorized conversions or modifications on or in the drive converter and its components and accessories will render all warranty claims void When installing an option board observe the installation specification valid for this board Please contact BERGES if conversions or modifications are necessary particularly if elec trical components are involved 7 Maintenance and Servicing The manufacturer s documentation sh
50. frequencies can be selected in binary fashion 0 1 Hz Serial interface RS 485 0 01 Hz V Hz characteristic Programmable characteristic with Autoboost or automatic definition Accel Decel times Two sets which can be switched over 0 1 999 9 s Torque limiting Selective in all 4 quadrants selection from 0 150 Trateg possible Setting possibilities Parameterisation by keypad and RS 485 Field bus Optional Table 3 5 3 4 Protective Function Pilot indication of DC link voltage Incandescent bulb within the range from 80 VDC to Vpc link max only availa ble in inverters up to 55 kW Earth fault Motor connection terminals resistant to earth faults Short circuit Motor connection terminals resistant to short circuits xt monitoring motor temperature sensor optionally normally closed con tactor or PTC Thermal motor protection Thermal protection of inverter Heat sink temperature monitoring integrated temperature monitoring in the IGBT module RFI suppression in accordance Curve A without external filter with DIN VDE 0875 Part 11 Curve B with external filter Voltage in the DC link VDG link min 350 VDC to Vpc link max 750 VDC Torque limiting Independently programmable in 4 quadrants Activation lock Protection against automatic start when power is switched on adjustable Error message Plain text error display and error consequence Error history Storage of the last 5 err
51. g_in 1 lt 10 V ref Analog_in 2 VA Bin_in High Low changeover parameter 9F Selection parameter par 92 Selection parameter par 93 Selection parameter par 94 RS485 SIO Control Z Selection parameter parameter A2 AA NO nn A Error signalling relays parameter 96 a c Idle read FA 250 VAC 0 2 A NG y pa 30 VDC 2 A Dee a Y O N Connection must be laid on site if required 1 Q pe NOTE i Detailed information about the respective parameters O can be found under Functions and Use of the Terminals ch or in the appropriate parameter section in the parameter description Aux GND Figure 2 8 04 08 05 Operating Instructions 4 31 07 GB_T1 UD 7000 1 5 355 0 Technical Data 3 Technical Data 3 1 Output Data Inverter model number 7001 5 7002 2 7003 0 7004 0 7005 5 7007 5 7011 0 7015 0 7022 0 7030 0 7037 0 7045 0 7055 0 Connectable motor power kW 1 5 2 2 3 0 4 0 5 5 7 5 11 0 15 0 22 0 30 0 37 0 45 0 55 0 Inverter power kVA 2 5 3 5 4 6 6 2 7 9 10 6 15 2 20 0 29 0 39 0 46 5 57 0 70 0 Rate output current A ms 3 7 52 68 9 2 11 7 15 6 22 5 30 0 43 0 58 0 71 0 85 0 97 0 Continuous output current A 2 110 of the rated output
52. hed met al cable duct is recommendable for these signal cables If signal cables have to cross a power cable they should cross at an angle of 90 Control lines longer than 1 m must be laid with a screen and one side of the screen must be connected to COM on the frequency inverter 1 In the case of unit classes 1 5 11 0 EMC filters are installed as standard limit class A here interference suppression refers to the AC input terminals L1 L2 L3 and not to the DC input terminals or ZK ZK The unit can also be supplied without filter See also Tables 3 3 and 3 4 EMC filter Operating Instructions UD 7000 1 5 355 0 1 13 Other loads connected to the line can cause voltage spikes which can impair the function of the inverter and can even damage it Chokes or line filters 1 can be additionally used on the line side to protect the inverter against voltage spikes resulting from the switching of large loads on the line These chokes and filters are available as accessories If inverters are operated in switchgear devices or in their close proximity e g in one com mon control cabinet in connection with the same power line we recommend the following precautionary measures to suppress interference in the switchgear e Wire the coils of contactors switchgear devices and relay combinations with RC ele ments or with free wheel diodes e Use shielded cables for external control and measuring cables e Lay
53. his magnetisation current control 1 Characteristic control Vmovfmot with IXR compensation 2 l control reactive power or reactive current control 3 Field orientated control with and without feedback vector control These variants which are all integrated in the UD 7000 are discussed below V f Controlled Operation The UD 7000 Series of inverters features a high performance reactive current control sys tem besides the pure V f control Selection is made with parameter 62 V Hz characteris tic selection In the case of pure V f control setting 2 the various interpolation points are permanently preset by the user in order to define the voltage at the related frequency 5 V f pairs are available see the illustration below Vi Constant voltage range frix a Tis frix 6 fknee f Figure 4 1 Controlled V f characteristic In general presetting points Vo V and Knee will suffice for a standard asynchronous mo tor In the case of special machines such as reluctance motors for instance it is frequently necessary to specify further intermediate values The motor manufacturer must then be consulted for more precise data Note that this preset characteristic is complied with firmly under all load conditions Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 Drive Variants 04 08 05 07_GB_T1 One other version of motor control is as mentioned above l control in combinati
54. inuous transistor current Amps 145 4 177 7 216 2 258 0 258 0 320 0 400 0 500 0 500 0 500 0 Minimum resistance value 5 5 4 5 3 7 3 1 3 1 25 2 0 1 6 1 6 1 6 Table 3 8 HINT When the motor is used as brake or torque application we recommend the following values y p ex for winders and so on SIZE II SIZE IN SIZE IV SIZE V SIZE VI SIZE VIL IX oige lels A A AA e SNS Inverter model number SECAS SSA ES LO g 3 5 o 9 D Q o o o o o o o o o o o o o ov N N N N N N N N N N N N N Nam Inverter power kW 1 5 2 2 3 0 4 0 5 5 7 5 11 0 15 0 22 0 30 0 37 0 45 0 55 0 75 0 355 0 Power dissipation average kW Brake chopper current average A Minimum resistant Q 120 60 30 15 Table 3 9 1 35 1 98 2 70 3 60 4 95 6 75 9 90 13 50 19 80 27 00 33 30 40 50 49 5 1 7 2 5 3 5 4 6 6 3 8 7 12 7 17 3 254 34 6 42 7 51 9 63 0 On request 3 6 Display and Operating Unit Keypad 8 keys FWD REV STOP PROG SHIFT ENTER A Y Display Alphanumeric 2 line super twist LCD display with 16 characters in each line Display languages German or English LED status displays 3 LED s integrated in the FWD REV and STOP keys Control possibilities 1 Keypad 2 Control terminals 3 Serial interface RS 485 Table 3 10 04 08 05 Operating I
55. is ee ee ea A ete Gene N 112 8 15 Group F Service Data Miz 2c drow nie es en ne nn ee me ida A AA ee rd 116 8 16 Group 0 Service Data il nenn Lese ol A bia aig ee nn Ree eee a ately 121 8 17 Error States ican Aust en Na Renee E A ii AA ae waere Sekine 122 8 17 1 Normal Handling of Error States 0 tenn tent t nent eee 122 8 17 2 Handling of Error States with the Acknowledge Error State Function 0 0 0 00 cece eee eee 122 9 ANEX See hanes Pak ee aa Gee Gone dod eng Carne dale HG Me Pane ace re adie eae a 124 9 1 Abbreviations SEA A a bee bee oe ee ee bees De eee nenn 124 9 2 Hexadecimal to Binary Conversion 0 o 124 9 3 Parameter Structures as conc Ao Herne A Nee an A Ar E paula 125 9 4 Parameter Overviews scx er Re Re a Marea ha a en Anetta Tg are ea 126 Operating Instructions 04 08 05 1 2 UD 7000 1 5 355 0 07_GB_T1 1 General Information 1 1 Explanation of Symbols and Notes Work Safety Symbol You will find this symbol next to all work safety notes in this operating manual if there is a risk of injury or death for persons involved Pay attention to these notes and observe par ticular caution in such cases Also pass on all work safety instructions to other users Voltage Warning This symbol is shown wherever particular caution is necessary owing to occurring or ap plied voltages e g DC voltages up to 650 V and where special precautionary measures have to be taken The drive con
56. ited brushless servo machines SLV sensorless control for induction motors 1 4 Description of Functions Analog 3 inputs Binary inputs N Analog outputs Binary 4 outputs Relay 4 output RS 485 1 6 Line voltage measurement The UD 7000 inverter series enables low loss speed control of a three phase motor by in dependent control of the output frequency and output voltage The speed torque response of the motor remains unchanged thanks to automatic control of the V Hz ratio The UD 7000 inverters consist of the two function groups of the power section and inverter control nput ectifier l ri Motor choke Inverter J LYN M 3 3 3 Temperature Output Motor current Trap measurement stage driver measurement circuit Switched mode power supply unit DC link voltage measurement Motor temperature monitoring 1 Voltage i i Current monitoring monitoring Input signal processing Setpoint processing Ramp generator Actual speed Output signal processing processing Torque i Measurement of determination motor parameters J Parameter management Display and operating unit Operating system control Option card Figure 1 1 04 08 05 07_GB_T1 Operating Instructions UD 7000 1 5 355 0 1 5 Power Section The input rectifier converts the three phase line voltage to a pulsating DC voltage The sub
57. lays operated on the 230 VAC line must be damped by fuses in the form of an RC series circuit e Main Circuit Contactors and Solenoids C 0 2 MFD 500 VDC R 500 5 Watts e Auxiliary Control Circuit Relays C 0 1 MFD 500 VDC R 200 Q 2 Watts Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 Connection Diagram for AC and DC Relay Coils and Solenoids R RC type Freewheeling snubber diode C e a 3 Figure 2 2 Free wheeling diodes must be used on contactors relays and solenoid coils operated with direct current The diodes in question should be fast types with short recovery time The diode must be connected in blocking direction in parallel with the winding see Figure 2 2 The rated current and voltage of the diode can be calculated using the formulae below Coil Capacity VA D gt Coil Capacity VA _ aun Reig 2 Rated Voltage of Coil V Diode Voltage Rating V gt Rated Voltage of Coil V x 2 2 6 Motor Connection ATTENTION Connect the motor cable to the U V W and GND terminals The inverter will be deactivated if shorted to the motor terminals The output of the drive will always be three phase Do not connect single phase mo tors to the inverter output terminals U V or W Never use power factor correction capacitors on the motor terminals U V and W or damage to the semi conductors will r
58. lculation of the field voltage V_L leads to incorrect values The model data such as currents voltages and rotor rotational speeds are obtained from the SLV motor model The following block diagram illustrates how this data is obtained from the motor model Motor voltage setpoint V_LH1 V1 l1 Rs V_LH2 V2 l2 Rs V_Lh3 V3 I3 Rs V_LH1 V_LH2 V_LH3 Field coordinates Stator coordinates Figure 4 7 SLV implementation in the inverter Operating Instructions UD 7000 1 5 355 0 1 47 Drive Variants 1 48 Two vector rotators 1 play a central role whereby the upper rotator transforms the motor voltage setpoints from the field coordinate system to the stator coordinate system and the lower rotator performs this transformation in reverse It can be seen that the voltage V_L is calculated for each phase at the stator coordinate end This provides the motor internal actual variable of voltage as a function of magnetising inductance Ly These rotating volt age vectors are transformed back at the field end where they become a DC voltage and are used to compute the angular velocity This is because A ly x Ly and by integration of the angular velocity we obtain the angle of rotation a for controlling the vector rotators We can see the basic principle of SLV for controlling the motor field The field current is preset as a setpoin
59. malfunctions resulting from failure to observe the operating manual We draw attention to the fact that no liability can be assumed for damage and malfunctions resulting from failure to observe the operating manual 2 Intended Use The application of the drive converter described in this operating manual exclusively serves the purpose of continuously variable speed control of three phase motors Drive converters are components designed for inclusion in electrical installations or machin ery The drive converters are designed for installation in a switchgear cabinet and for permanent connection The operator of the system is solely liable for damage resulting from improper use of the drive converter 04 08 05 Operating Instructions 07_GB_T1 UD 7000 1 5 355 0 1 3 1 4 Only items expressly approved by BERGES e g line filter choke external braking chop pers and braking resistors etc may be used as accessories The installer of the system is liable for any damage resulting from the use of accessories that have not been approved expressly by BERGES Please consult us in case of doubt In case of installation in machinery commissioning of the drive converters i e the starting of normal operation is prohibited until the machinery has been proved to conform to the provisions of the directive 89 392 EEC Machinery Safety Directive MSD Account is to be taken of EN 60204 Commissioning i e the starting of normal
60. minals L1 L2 L3 and not to the DC input terminals or ZK ZK The unit can also be supplied without filter See also Tables 3 3 and 3 4 EMC filter Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 HINT EMB Electromagnetic Interference EN 50082 2 Basic specification Interference immunity EN 50140 Electromagnetic fields EN 60801 Static discharge ESD IEC 801 4 Burst on line lead data line At least the following conditions must be fulfilled for compliance with the limit values of the aforementioned standards Preceding the unit by a line filter or a line filter and a output choke line filter 1 and output choke not included in the scope of delivery e Laying the motor cable in a shielded configuration Laying the control cable in a shielded configuration e Observe general RFI suppression measures refer to the Chapter 2 3 EMC Electro magnetic Compatibility As the aforementioned interference immunity tests are based on standardised line condi tions a loss of the inverter function can occur in extreme cases minimum operational qual ity This malfunction generally can be remedied with an inverter RESET See Example 11 Confirmation of an Error Page 2 32 Detailed information and technical data about adapted line filters 2 and chokes can be found in the publication Choke filter application 2 4 Wiring Practices 2 4 1 Applicable Codes Pay conscienti
61. n two lines phases must be exchanged Size VI Size IX Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 2 5 1 Use of Fault Current Safety Switches Owing to leakage currents from anti interference capacitors in the inverter and the motor lines as well as due to d c components in the supply current the protective function of a fault current safety switch can no longer be guaranteed this also applies to Fl safety switch es that are AC DC sensitive All devices connected to such safety switches and the people who come into contact with them are no longer protected in such a situation Consequent ly please note the following Fl safety switches are only to be installed between the supplying network and the inverter Frequency inverters must not be connected through a fault current safety switch as the sole protective measure The following exception permits the connection of a frequency inverter via a fault current safety switch as a single protective measure e Installing the latest model of an Fl safety switch 2300 mA with MOBILE connected fre quency inverters up to 4 kVA input voltage 1 x 230 V which controls alternating and pulsating DC leakage current AC DC sensitive This type of Fl safety switch has this symbol X When using a fault current protective device FI safety switch you should check its com patibility with the frequency inverter Compatibility information for each device type
62. ng of IGBTs insulated gate bipolar transistors is in tegrated in an intelligent power module IPM This converts the DC voltage of the DC link back to a three phase voltage By control of the IGBTs with suitable pulse patterns PWM signals it is possible to control both the output frequency and the output voltage continu ously For regenerative operation of the drive the chopper transistor switches a ballast resistor into the DC link in order to convert the accumulating brake energy to heat The line voltage input filter and the DC link choke serve the purpose of radio frequency in terference suppression The switched mode power supply unit connected to the DC link generates all necessary supply voltages The power supply unit operates provided the DC link voltage does not drop below 310 V The DC link circuits can be electrically connected when operating several inverters in one system In this way regeneratively operating inverters may supply the energy for motive power inverters thus extracting less energy from the line and simultaneously relieving the braking resistor However BERGES should be consulted in this case When it lights up a voltage pilot lamp BUS CHG incandescent bulb present only on units up to 55 kW signals that the DC link voltage is higher than 80 VDC The voltage pilot lamp is visible through a hole above the power terminals 04 08 05 Operating Instructions 07_GB_T1 UD 7000 1 5 355 0 1 7 1
63. no longer indicated by the inverter No MESSAGE DESCRIPTION 0 Local stop Keypad Stop button has been pushed in the remote mode 1 Min net voltage AC Line voltage to low 2 Overtemperature Heat sink temperature to high 3 Overcurrent Over current in the output stage 4 Error PWM PWM Fault 5 MOL open 21 MOL contact open It monitoring of motor is triggered 6 Overvoltage DC L DC Bus voltage to high 7 DC Link failure DC Bus voltage out of limit during power up 8 Speed observer Too many revolutions or excessive control error 9 Dyn brake overld DB duty cycle above limit 10 UndervoltageDC L DC Bus voltage to low 11 Option The option board is not plug in for the selected application 12 Auto Stop The auto stop control has been detect 13 SIO Timeout Series communication is disconnect 14 Position sensor Motor feedback is disconnect 15 Ixt Watch Output stage transistors overloaded 04 08 05 Operating Instructions 07_GB_T1 UD 7000 1 5 355 0 1 57 Annex Error States FAULT NO WARNING MESSAGES MESSAGE DESCRIPTION 16 Overtemperature Warning Heat sink temperature to high 19 Motor synchron Warning Speed synchronization in an running motor doesn t work 20 Motor to small Warning The nominal current of the connected motor is too small 21 121 Warning The electronic motor protection has been exceeded 22 R1 Measuring
64. nstructions 1 35 07_GB_T1 UD 7000 1 5 355 0 Technical Data 3 7 Parameter Groups Parameter block 1 Motor data Parameter block 2 Basic data Parameter block 3 Setpoint selection display Setpoint select Parameter block 4 Frequencies Parameter block 5 Torque Parameter block 6 V Hz characteristic display V f char Parameter block 7 Inverter functions display Inverter funct Parameter block 8 Protective functions display Security funct Parameter block 9 Binary inputs outputs display Binary In Outpt Parameter block A Analog outputs SIO display Analog Out SIO Parameter block B Speed controller display Speed control Parameter block C Stepper control display Step control Parameter block D Options Parameter block E Service data II Parameter block F Service data III display Service datallI Parameter block 0 Service data I Table 3 11 3 8 Mechanical Design and Ambient Conditions Housing design Bookshelf from size IV standard format Degree of protection IP 20 Installation Installation in a separate housing protected against dust and corrosive vapours Vertical assembly Size VII optional lead out assembly external dissipator Operating temperature 0 to 45 C from size VII O C to 40 C Storage temperature range 20 C
65. oltage frequency inverter V Pp VaXlax J3 lo Input current A as per Tables 3 3 and 3 4 Input current for setting a PKZ 04 08 05 Operating Instructions 07_GB_T1 UD 7000 1 5 355 0 ATTENTION ATTENTION NOTE Exercise caution when using the UD 7000 under the conditions of a low voltage network An inverter from the UD 7000 series is fully functional when connected to an alternating cur rent of 370 V for example However the maximum output voltage is limited to 370 VAC If the motor is rated for a line voltage of 400 VAC this can lead to higher motor currents and overheating of the motor If the output frequency is supposed to be higher or lower than 50 Hz the inverter can be programmed for the appropriate relationship between the voltage and frequency by means of the parameters 21 and 23 Further information on these functions is available in Chapter 8 2 Phase voltage imbalance of the input AC source can cause unbalanced currents and ex cessive heat in the input rectifier diodes and in the DC bus capacitors of the UD Phase im balance is calculated by the following method Assume The voltage from L1 to L2 Lg The voltage from L2 to L3 Lp The voltage from L1 to L3 Le The average line voltage Layg _La Lp Lo _ 395 400 405 _ Lava 277 3 400 Determine the absolute value of the difference between each of the line voltages La Lp and Lg and Layg Subtract the two values and disregard the sign of th
66. oltage V1 0 1 V 2 76 100 0 69 V f Char V2 V Hz characteristic voltage V2 0 1 V 2 76 150 0 6A V f Char V3 V Hz characteristic voltage V3 0 1 V 2 76 200 0 6B Max Voltage Cut in point of voltage limitation control 0 1 2 77 98 0 6C Min excitation Minimum excitation 0 1 2 77 33 0 6D Setup fld activ Field build up time activation S P 2 77 1 6E Filt Time FWeak Filter field weakening 1 ms 2 77 100 6F Increments Increment 1 2 78 1 04 08 05 07_GB_T1 Operating Instructions UD 7000 1 5 355 0 1 53 Annex Parameter Overview GROUP 7 Inverter functions display Inverter funct NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER 71 Start Stop opt Start and Stop options S P 2 78 0 72 Ramp selector Ramp function selection S P 2 79 0 73 Ramp smooth Drag time 0 1 s 2 80 0 1 74 Sel power fail Power failure response S P 2 80 2 75 Gain UDC Ctrl DC link voltage control gain Vp link 0 1 2 81 500 0 76 Slip compensat Slip compensation S P 2 81 0 77 Gain slip comp Slip compensation setting 0 1 2 82 100 0 78 Language Sprach Language S P 2 82 0 79 PWM frequency PWM frequency 0 01 kHz 2 82 2 00 4 50 7A Power Chopp R Braking resistor power 0 01 kW 2 83 0 08 7B Sped motpot Inc Increment motor potentiometer speed 0 1 s 2 83 10 0 7C Sped motpot Dec Decrement motor potentiometer speed 0 1 s 2 83 10 0 7D heating time R Pe
67. on with slip compensation parameter 76 Slip compensation This type of V f characteristic con trol can also be selected with parameter 62 V Hz characteristic selection settings 0 3 4 5 The inverter control system detects the instantaneous value of two motor currents The third phase current can be computed from this This allows the phase angle of the currents with respect to the applied voltage to be determined and the currents are then split into active component and reactive component via which it is then possible to conclude the current torque and machine flux The simplified phasor diagram below clearly shows this situation u _Phase MA ee pp 1_9 Magnetic flux Figure 4 2 Simplified phasor diagram It is must be noted that this method makes many simplifications for the complex machine model Influences relating to the rotor are ignored completely for instance However the method has major advantages over purely presetting the V f ratio Thus for instance the theoretical load dependence of the V f ratio is corrected automatically which leads to a major improvement in the drive characteristics and a reduction in thermal motor loading in the part load range This is illustrated in the diagram below V A Constant V_nom Knee voltage range Se 2 4 Sa xs No load I I A Motor load 0 f_Knee f Figure 4 3 Controlled V f characteristic Operating Instructions UD 7000 1 5 355 0
68. operation is admissible only where conformity with the EMC directive 89 336 EEC has been established The drive converters meet the requirements of the low voltage directive 73 23 EEC They are subject to the harmonized standards of the series prEN 50178 DIN VDE 0160 in con junction with EN 60439 1 DIN VDE 0660 part 500 and EN 60146 DIN VDE 0558 The technical data as well as information concerning the supply conditions shall be taken from the name plate and from the documentation and shall be strictly observed 3 Transport Storage The instructions for transport storage and proper use shall be complied with Damage established after delivery must be notified to the transport company immediately Where necessary the supplier must also be notified before the damaged drive converter is put into operation The climatic conditions shall be in conformity with prEN 50178 4 Installation The installation and cooling of the appliances shall be in accordance with the specifications in the pertinent documentation The drive converters shall be protected against excessive strains In particular no compo nents must be bent or isolating distances altered in the course of transportation or handling No contact shall be made with electronic components and contacts Drive converters contain electrostatic sensitive components which are liable to damage through improper use Electric components must not be mechanically damaged or de stroyed po
69. or raceway with power wiring 2 5 Line Power Connection ATTENTION The frequency inverters are designed for installation in a switchgear cabinet and for permanent connection To guarantee lasting operating safety and reliability the inverter must be connected expert ly in accordance with the valid electrical standards Attention must be paid to good insula tion from earth potential on the power terminals An three phase system with a nominal voltage of 400 V 50 60 Hz must be connected to line terminals L1 L2 L3 and GND pay attention to name plate The neutral point must be earthed TN C system Ensure a voltage balanced to earth or phase to phase when feeding in the line power through an isolating transformer star point must be earthed The inverter will be destroyed if the line feeder is confused with the motor cable The DC link capacitors must be reformed if the inverter you wish to connect has been out of operation for more than a year To do this connect the inverter to voltage for approx 30 minutes The inverter should not be loaded by connected motors during forming Inverters of the sizes VI and IX have fans which are supplied by the mains In order to reach a sufficient cooling of the inverters the right rotating direction of the fan is necessary The fan blows the cool air into the inverter Furthermore the direction of rotation is shown on a sticker placed on the fan tunnel In case of wrong direction of rotatio
70. ors error display Table 3 6 NOTE 1 Applicable only to AC voltage connections L1 L2 L3 in the 1 5 11 0 kW power range external filters in excess of the value Operating Instructions 04 08 05 1 34 UD 7000 1 5 355 0 07_GB_T1 Technical Data 3 5 Brake Chopper Power Dissipation SIZE Il SIZE II SIZE IV SIZE V SIZE VI Inverter model number 7001 5 7002 2 7003 0 7004 0 7005 5 7007 5 7011 0 7015 0 7022 0 7030 0 7037 0 7045 0 7055 0 Inverter power kW 1 5 2 2 3 0 4 0 5 5 7 5 11 0 15 0 22 0 30 0 37 0 45 0 55 0 en 10 0 10 0 10 0 125 125 15 0 15 0 50 0 50 0 75 0 75 0 75 0 75 0 Minimum resistance value 0 70 70 70 70 70 50 50 16 16 10 10 10 10 Normal resistance 2 75 735 7 735 75 735 73 20 20 20 20 f 20 20 Average power dissipation Watts 80 80 80 80 80 150 150 275 275 275 275 275 275 Maximum break time with nominal Inverter power sec 7 0 5 0 3 5 2 7 2 0 3 0 2 0 6 0 4 0 3 0 2 5 2 0 1 5 Duty cycle relative to the Inverter power 5 0 3 7 2 7 2 0 1 5 2 0 1 4 2 0 1 25 1 0 0 75 0 6 0 5 Table 3 7 SIZE VII SIZE VIH SIZE IX Inverter model number 7075 0 7090 0 7110 0 7132 0 7132 0 7160 0 7200 0 7250 0 7315 0 7355 0 Inverter power kW 75 0 90 0 110 0 132 0 132 0 160 0 200 0 250 0 315 0 355 0 Maximum cont
71. ous attention to ensuring that the installation wiring is installed at least in con formity with the NEC standards Where local codes exceed these requirements they must be followed 2 4 2 Power Wiring ATTENTION 04 08 05 07_GB_T1 Power wiring are those wires which are connected during installation to the power circuit terminals L1 L2 L3 or ZK ZK BR BR U V and W Power wiring must be selected as follows 1 Use only VDE UL or CUL recognized wire 2 Wire voltage rating must be a minimum of 600 V for 400 VAC systems 3 The core cross section and the associated fuse are given in the tables in Chapter 2 5 3 Page 1 18 The wires must consist of copper and be designed for insulation tempera tures of 60 C or 75 C 4 Grounding must be in accordance with VDE NEC and CEC NOTES Never connect input AC power to the motor output terminals U V and W or damage to the drive will result 1 In the case of unit classes 1 5 11 0 EMC filters are installed as standard limit class A here interference suppression refers to the AC input terminals L1 L2 L3 and not to the DC input terminals or ZK ZK The unit can also be supplied without filter See also Tables 3 3 and 3 4 EMC filter S In the case of unit classes 1 5 11 0 EMC filters are installed as standard limit class A The unit can also be supplied without filter Upon delivery of inverters check whether the unit corresponds to the order in
72. output 1 Output ST1 function selection S P 2 91 3 93 Aux output 2 Output ST2 function selection S P 2 91 102 94 Aux output 3 Output ST3 function selection S P 2 91 10 95 Aux output 4 Output ST4 function selection S P 2 91 115 96 Auxiliary relay Relay output function selection S P 2 91 101 97 Outp SIO Contrl Control of binary outputs through SIO Binary 2 93 0000 98 Input Run Jog Run Jog input function selection S P 2 93 0 99 Input PS1 PS1 input function selection S P 2 94 4 9A Input PS2 PS2 input function selection S P 2 95 1 9B Input PS3 PS3 input function selection S P 2 97 6 9C Status Inputs Status of binary inputs Binary 2 100 r O 9D Status Outputs Status of binary outputs Binary 2 101 r O QF Inpt H L active High Low active binary input selection S P 2 101 1 1 54 Operating Instructions UD 7000 1 5 355 0 04 08 05 07_GB_T1 Parameter Overview Annex GROUP A Analog outputs SIO display Analog Out SIO NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER A1 Meter output 1 Analog output MET1 selection S P 2 102 1 A2 Meter output 2 Analog output MET2 selection S P 2 102 4 A3 Factor Analog1 MET1 factor 0 1 2 102 100 0 A4 Factor Analog2 MET2 factor 0 1 2 103 100 0 A5 Offset Analog2 MET2 offset 0 1 2 103 0 0 A6 Reference MET Reference value for the analog output 1 2 103 500 A7
73. particular for connecting the cable shields using ring cable lugs If interference problems occur on the signal leads it is frequently practical to connect the shield either to COM or to system earth This can be tested very quickly with the aid of the AUX terminal stud PE 3 earthing terminals M6 threaded bolts Table 2 2 Terminal assignment control terminals NOTES 1 The setpoint inputs Vin and Cin The V_in and C_in inputs are additively gated This means that the signals generated from the voltages at the V_in inputs resp the current at the C_in input are processed summed by the microprocessor The two inputs are difference amplifier inputs There is a jumper X57 directly behind the control terminals on the control card and this jumper can used to make a direct connection between the Vin input and COM potential if nec essary This jumper is inserted at the works Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 1 28 Jumper X57 inserted Vin connected to COM Jumper X57 not inserted Vin floating difference amplifier input The required signal type such as unipolar or bipolar setpoints is selected with param eter 31 2 Use of the Vin inputs When should jumper X57 be removed e Inthe case of applications such as simple jockey roller positioning controls in which the rotational speed reference value is applied to the Vin input and the jockey roller po
74. produce the desired result Basically it is not the cross section of the conductor that is important for radio frequency interference suppression but the surface area Since the high frequency interference does not flow through the entire cross section but mainly on the outer surface of the conductor skin effect braided copper tapes of corresponding cross section should be used The inverter and all other components used for interference suppression especially also the shield of the motor cable should be contacted over as large an area as possible when connected to metal control panels switchgear cabinets and similar skin effect Remove the paint at the respective areas to ensure good contacting over a large area A central earthing point should be used for interference suppression e g equipotential bonding strip or centrally at an interference suppression filter The earthing lines are routed to the respective terminals radially from this point Conductor loops of the earthing lines are impermissible and can lead to unnecessary interference The shield cross section must not be reduced when the shield is connected to continuing lines This would give rise to RF resistance at a cross section reduction and the resulting RF energy would consequently not be discharged but radiated Shields particularly shields of control lines must not be contacted through pin contacts of plug connectors In these cases the metallic hand guard of
75. range upwards of 3 kW Today it is a fully fledged alternative to the closed loop controlled DC motor even as of approx 100 Watts in view of the fact that power electronic components are becoming cheaper and cheaper Operating Instructions UD 7000 1 5 355 0 1 41 Drive Variants 4 2 1 1 42 Constant flux operation has become the most successful mode of controlling the asynchro nous motor This is because not least this variant ensures low loss and optimum torque operation over the entire rotational speed range This can be achieved by maintaining the magnetisation of the motor constant over the entire rotational speed range In order to en sure this the ratio of the applied motor voltage to the current motor frequency Vyor TMot must be maintained constantly Theoretically this should result in a linear relationship be tween voltage and frequency However as of the point at which the nominal frequency is reached the motor is operated with rated voltage owing to the limited motor voltage The constant power range starts as of this point However at low frequencies the influence of the ohmic winding resistance resistance of the stator winding comes more and more to the fore so that it is necessary to compensate for this voltage drop which weakens the mag netisation It is therefore necessary to boost the voltage slightly with respect to its ideal characteristic IxR compensation Essentially three methods are used for t
76. rmissible heating time of braking resistor 1 s 2 84 2 7E brake resistor Connected braking resistor 1 Q 2 84 20 75 7F PWM mode Control method S P 2 84 1 GROUP 8 Protective functions display Security funct DISPLAY DESCRIPTION RESOLUTION DEFAULT CUSTOMER Selector MOL MOL input function selection S P 82 MOL Input MOL input display 1 2 85 r o 83 Restart Select Restart after fault definition Binary 2 85 0000 84 Number Restart Number of restarts 1 2 86 0 85 Delay Restart Restart delay 0 1 s 2 86 10 0 86 offset BC Vic offset BC to power supply 1 V 2 86 100 87 Access code Password 1 2 87 0 88 Therm timeconst Thermal motor time constant 1 min 2 87 15 89 1 t Limit Warn 12t warning threshold 0 1 2 87 115 0 8A t Limit 12t error threshold 0 1 2 87 120 0 8B Max Ramp Delay Maximum permissible ramp extension in the event of stop 1 2 87 200 8C T Stop observer Current monitoring time to for stop ramp 0 1 s 2 89 8D Refer ST Outp Reference value for load dependent switching of control outputs 0 1 2 89 0 0 8E Watch Speed Selection speed control 1 2 89 0 GROUP 9 Binary inputs outputs display Binary In Outpt NO DISPLAY DESCRIPTION RESOLUTION PAGE DEFAULT CUSTOMER 91 Inputs FWD REV Function of inputs FWD and REV S P 2 90 1 92 Aux
77. rol board which is now visible Now the control circuit board can be folded carefully to the side and the necessary mod ifications can be made Inverters 132 355 kW sizes VIII IX By unscrewing 4 screws the front panel can be slid upwards and then removed Now all the necessary modifications can be made at the control circuit board see illus tration g g g Flat cabl to display N16 N17 N18 d aR Control board 4 Figure 2 7 Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 2 9 Typical Control Terminal Assignments Inverter control board On site connection X57 Closed COM referred V_in input Screening see also EMC notes in the Open Differential amplifier input V_in operating instructions Part 1 COM D 0 10 V output frequency parameter A1 Analog setpoint input 24 V 0 20 mA 2 20 mA 20 mA par 31 Analog setpoint input 0 10 VDC 2 10 VDC 10 VDC par 31 10 V reference voltage output 0 10 V torque limit parameter 32 or binary frequency input Stop start right rotating field par 91 Stop start left rotating field par 91 24 V control voltage Selection parameter par 98 Selection parameter par 99 Selection parameter par 9A Selection parameter par 9B Motor PTC par 81 A CZ Ba see chapter Interference Suppression Measures Analo
78. ry drive characteristics on ly if the information provided in Chapter 4 1 The Motor Drive Data and How it is Measured is followed precisely What advantages are obtained from the field orientated controlled asynchronous machine Maximum drive dynamics e Full torque at rotational speed 0 Closed loop controlled standstill The torque can be controlled and limited precisely Ramps can be deactivated This means that the drive is ideally suited for applications in conjunction with superimposed positioning controls e Phase synchronous Master Slave operation electronic transmission is possible with out external open loop control systems See also parameter 2C Application e Current controlled operation means that the dead times and switching times of the out put stages have no influence on the sinusoidal waveform of the motor current e More precise current limitation since the current in the motor is preset as a setpoint 4 2 3 SLV Sensorless Vector Control 1 46 The field orientated controlled asynchronous machine represents an optimum control method for the asynchronous motor The method has only one essential disadvantage that attachment of an encoder rotational speed feedback is necessary The sensorless field orientation technology normally attempts to compute the position and amplitude of the mo tor field by suitable motor models from the motor voltages and currents In recent years certain methods have
79. s to be installed in a different position external cooling is required for full capacity utilization In certain circumstances the internal air circulation does not suf fice when installing the unit in a control cabinet with a small volume Therefore when installing the unit you must ensure that a heat buildup is prevented Do not mount the UD 7000 near heat generating equipment or in direct sunlight The UD inverters are generally designed so that they can be operated at ambient tempera tures of O C to 45 C from size VII O C to 40 C and at a relative humidity of up to 90 The occurrence of condensate must be avoided Do not install the inverter in a place subjected to high temperature high humidity or ex cessive vibration see Chapter 3 8 Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 F The units should never be installed in the proximity of corrosive or flammable gases conductive dust or large magnetic and electric fields G Pay close attention during installation to ensuring that no objects such as drilling swarf wire or anything else fall into the unit Otherwise a device fault cannot be excluded even after longer periods of operation 2 3 EMC Electromagnetic Compatibility 2 3 1 Limit Classes With regard to interference suppression of machines or installations in conformity with EN 50081 Parts 1 and 2 or EN 55011 a distinction must be made between the limit classes
80. shing machines Constant rotational speed in the lower speed range Acceleration at the torque limit Unwinders Torque control operation Vector rotator a vector rotator is a mathematical method of for instance converting the rotating phasor of a periodic quantity to sta tionary vectors It is easy to imagine a vector rotator by way of the following example if we could represent the magnetic field of the motor optically by phasors or pointers and if we view what is happening from the outside we can see quickly rotating phasors or pointers which cannot be easily described If we now make it possible to position ourselves on a plate turning at the same speed as the field at its centre we can see a stationary pointer or phasor which can only change its length The vector rotator corresponds precisely to this rotating platform Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 Drive Variants The Limits of SLV SLV is not yet the optimum solution even at zero rotational speed as the inverter does not issue the voltages which it receives as the preset setpoint owing to switching times and dead times of the output stages This contamination effect does of course occur to a par ticularly great extent at low voltages lower frequency range However the cost benefit ra tio would be disproportionate as regards the improved drive behaviour were one to attempt to compensate for these errors by the
81. sition proportional voltage jockey roller potentiometer is applied to Vin The voltage at the Vin input is then subtracted from the voltage level at Vin Ideally the jockey roller potentiometer must be powered with a positive or negative voltage Inthe case of interference problems on the setpoint leads In applications in which the setpoint signal is supplied via long leads laid in parallel to the inverter this fre quently results in a high noise component on the wanted signal This common mode interference can be eliminated by the difference amplifier D1 Frequency setpoint gt Figure 2 6 3 Use of the C_ in inputs This is a current input with a load of 50 Ohm The input is not referred to COM potential This means that several C_in inputs may be connected in series At 20 mA the voltage drop is 1 V The number of inverters which can be connected in series depends on the maximum possible output voltage of the current detector However this voltage should not exceed 50 V ATTENTION If working with a current signal as the setpoint inputs Vin and Vin must be jumpered The setting of jumper X57 is of no significance in this case Jumper X57 Remove either the inverter s right for devices up to 55 kW or left side panel for devices from 75 kW to set the X57 jumper While doing so observe the procedure below e Switch off the line voltage Wait until lamp BUS CHG goes out only available in in
82. t The field voltage is computed from this and is pre set for the motor as a voltage setpoint This voltage is calculated back as an actual value from the variables measurable at the mo tor terminal and on the basis of this the angular velocity is computed and this then con trols the vector rotators after integration The comparison between field voltage setpoint and actual field voltage value is therefore performed indirectly in the vector rotators a is varied until Vi Hact VLHsetpoint A field current controller is not necessary Slip computation In Figure 4 6 Transformer model of the asynchronous motor leakage inductances ig nored we can directly see that the rotor current Ip is proportional to the machine s slip s If I and ly are known and V_L y is indirectly measurable as described above it is possible to compute s We thus know all variables for implementing an optimum field orientated control with indi rect rotational soeed measurement SLV in Practice This mode of operation is particularly suitable for applications such as the following owing to its high dynamic response Application Drive engineering problem e Agitators Heavy starting e Presses Shock loads Winders High torque in the lower frequency range Injection moulding machines High peak torques heavy starting screw conveyors e Inclined lifts Starting torques e Metering facilities Constant rotational speed e Wa
83. te can be slid up wards and then removed by unscrewing one screw in sizes VIII and IX 4 screws must be unscrewed Braking resistor Main switch 0 Fuses rs Line m Shielding O O NOTES The arrangement of the terminals and earthing connections varies depending on the size of the unit Refer to this operating instructions for EMC notes Figure 2 3 Connection terminals size II VI NOTE If it is necessary to comply with the EMC regulations an EMC filter must be connected between the mains circuit fuse and the inverter On sizes II and III these filters are al ready fitted internally These filters are available as options for the other sizes see also Chapter 2 3 and 2 3 2 04 08 05 Operating Instructions 07_GB_T1 UD 7000 1 5 355 0 1 23 NOTE All M8 connector screws Rb2 optionally U V W MET1 A O COM O ZK CIN VIN K S amp Mi EAN ZK LIM COM FWD CIN L2 L3 24V RJ PS1 PS2 PS3 24V MOL MOL ST1 ST2 ST3 ST4 COM SIOA SIOB MET2 REF 24V NO
84. tegrated resistor is not sufficient connect it to the terminal instead of the standard resistor The inverter does not comprise the brake chopper option integrated brake transistor in the standard design of sizes VII IX The connector screw Rb2 is also not included The braking resistor should always be attached externally If the lines are longer than 1 m max 5 m the cables must be twisted Consult the table in Chapter 3 5 Brake Chopper Power Dissipation for the permissible minimum impedance value To ensure protection of the resistor adapt parameters 7A 7D and 7E to the new resistance value NOTE the maximum voltage measured against earth potential can amount to 400 VDC life threatening Table 2 1 Terminal assignment power terminals 1 26 Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 TYPE PE TERMINAL The earth terminals They are also located on the front side of the unit Stud bolts are provided for connection of the earthing connections Ring cable lugs are advisable for reasons relating to EMC DESCRIPTION Table 2 1 Terminal assignment power terminals ATTENTION 2 8 3 Control Terminals The control terminals are located on the front of the unit All control terminals are potential free double isolated Make sure that the potential difference between earth and the control terminals does not exceed a value of 230 VAC This does not in
85. telas outa a ken 15 24 1 Applicable CodeS ru eaa adie ei a ee lose De ne bee een 15 2 4 2 ELON TEAN ATAT aLe Et dt el ca a es acl ett Se SR ER E eit a ae En ee eves 15 24 3 ControlLines Intertace 2 2 22 eee a a en Ne en re Lae we eye wee 16 2 5 ine POWer COnNection u en ened Meee ge ee See nde ee at ne EO teres 16 2 5 1 Use of Fault Current Safety Switches 1 20 0 ccc ernennen een een een nenne 17 2 5 2 gt Eine Conditions awrite aa re ada ee tn br een ee eared 17 2 5 3 ERE le AA A a TE ED te et lat OI NN sista NAOH A A A AIN 18 25 4 Using Eine Rilterse care ana eo wees re ne A ee eo 19 2 5 5 vsta Up onthe Einer Sr en De en nee Shan ee ae re 20 2 5 6 Reducing Current Surges and Voltage Transients 0 0 00 00 t ete nen 20 2 6 7 Motor Connection toto secs ab ee Asean TE ATT eh We ALR BRIO ea ee Aes Bob ARA a 21 2 7 Brake Resistor Yu st aoe eo Bet ed aes E eo eed ae ee ee nae ee ee hele een 21 2 8 Functions and Use of the Terminals 0 cece ee eee ee eee ee renee ee eee nent beeen ene 22 2 8 1 Tightening torques of the connection terminals 0 0 0 tenes 24 2 8 2 Power Terminals ra Be ee tg ace a ea Se drat awe A a Be tobe 26 2 83 Control Terminals u ns ARA aw eee oh AA ae eis Sa eee 27 2 9 Typical Control Terminal Assignments 000 0c ete eet eee eee 31 3 Technical Data tris iien pads Oe hai A ah tear en ee ee A At Bs Reece ye ales 32 Bal OUNDUEDatatics Se
86. tential health risks 5 Electrical connection When working on live drive converters the applicable national accident prevention rules e g VBG 4 must be complied with The electrical installation shall be carried out in accordance with the relevant requirements e g cross sectional areas of conductors fusing GND connection For further information see documentation Instructions for the installation in accordance with EMC requirements like screening earth ing location of filters and wiring are contained in the drive converter documentation They must always be complied with also for drive converters bearing a CE marking Observance of the limit values required by EMC law is the responsibility of the manufacturer of the in stallation or machine 6 Operation The components of the power section and certain elements of the control section are con nected to the line voltage when the drive converter is connected to the line voltage Touch ing these components involves mortal danger Always isolate the drive converter from the line supply before performing any work on the electrical or mechanical part of the system Operating Instructions 04 08 05 UD 7000 1 5 355 0 07_GB_T1 1 3 Preface 04 08 05 07_GB_T1 Disconnect the drive converter from the line voltage before removing the terminal cover or the housing e g by removing or deactivating on site fuses or by deactivating a master switch isolating all poles etc
87. the plug connector should be used for large area connection of the shield Use a shielded motor cable earthed over a large area at both sides The shield should be routed uninterrupted from the GND terminal of the inverter to the GND terminal of the mo tor If a shielded motor line cannot be used the unshielded motor line should be laid in a metal duct The metal duct must be uninterrupted and adequately earthed The following points are prescribed if radio interference suppression is to be realized in accordance with EN 55011 EN 55014 and EN 50081 1 Preceding the unit by a line filter or a line filter and a output choke line filter 1 and output choke not included in the scope of delivery Laying the motor cable in a shielded configuration e Laying the control cable in a shielded configuration e Observe general RFI suppression measures refer to the Chapter 2 3 EMC Electro magnetic Compatibility Lay motor line power and signal cables as far away from each other as possible and sep arately If a line filter is used the smallest possible spatial distance from the frequency inverter must be selected so that both units can be connected by short connection leads If an output choke is used option it must be fitted in the direct vicinity of the inverter and connected to the inverter through screened cables earthed at both ends Screened signal cables should not be routed in parallel with power cables An eart
88. this data automatically This test must run at least once before placing the drive into oper ation Please refer to the Parameter Description parameter 2A Test mode Page 2 46 for further information on this The Motor Drive Data and How it is Measured Only the data of the motor rating plate is entered in the parameters of Group 1 Motor da ta for optimum matching of the inverter to the connected motor Detailed information on commissioning of the inverter as a function of the selected motor variant can be found in Chapter 6 Commissioning and in the section on parameter 2A Test mode On drives with feedback certain other information on the feedback systems used must be entered in Group B Speed controller If all motor and feedback data has been pro grammed correctly other motor feedback data absolutely necessary for optimum control of the selected motor variant is determined during the subsequent test run 4 2 The Asynchronous Motor and Speed Control 04 08 05 07_GB_T1 The asynchronous motor has proven successful in the field of drive engineering owing to its rugged and low cost design When frequency converter technology became cheaper and cheaper and more reliable in the late 70s it took the place of the closed loop controlled DC machine to an ever increasing extent Initially the converter controlled asynchronous motor was a low cost alternative to the closed loop controlled DC motor only in the power
89. this respect if necessary In unit classes 15 355 kW the EMC Directive can be observed only if external filters are used See also Tables 3 3 and 3 4 EMC filter Operating Instructions UD 7000 1 5 355 0 1 15 The output voltage of variable frequency controllers contains high frequency components that might cause disturbances in other installations Therefore avoid laying control cables and line input cables in the same cable duct or conduit together with the output cables from the converter to the motor see also Chapter 2 3 3 Interference Suppression Measures 2 4 3 Control Lines Interface All interfaces and control inputs and outputs are double isolated from the line Control lines include the lines connected with the inverter controller 32 terminals The con trol lines must be designed as described below 1 Shielded wire is recommended to prevent electrical noise interference from causing im proper operation or nuisance tripping Only connect the screen on one end to the GND terminal on the converter s control terminal strip see also Chapter 2 3 3 Interference Suppression Measures 2 Use only VDE UL or CUL recognized wire 3 The rated voltage of the lines must be designed for 50 VDC or 120 VAC These are class 2 lines 4 The lines of the relay terminals NO C NC must be designed for at least 400 V if wired into 230 V line circuits 5 Never run the control wiring in the same conduit
90. to ensure that the rated power and rated voltage of the unit are suitable for the desired application If necessary check whether the unit s EMC filters installed as standard in unit classes 1 5 11 correspond to the order If the inverter is to be stored for a long period of time repack and store in a clean dry place free from direct sunlight or corrosive fumes and in a location where the ambient temperature will not be less then 20 C nor more than 60 C 2 2 General Installation Instructions Improper installation of the inverter will greatly effect its life Be sure to observe the following points when selecting a mounting location Violating the conditions listed below may void the warranty A Install the unit vertically At the same time an unobstructed flow of air through the cool ing slots on the top and bottom must be guaranteed Any restriction in the air flow will reduce the useful life of the inverter and will lead to deactivation as a result of excess temperature The UD inverter generates heat and so there must be adequate space around the unit see Figure 2 1 Only size II VI inverters can be butted end to end If the unit is ac commodated in a housing together with another unit the prescribed minimum clearanc es must be observed in order to guarantee corresponding ventilation UD 7000 UD 7000 1 5 55 0 kW 75 0 355 0 kW 1 5 55 0 kW 75 0 355 0 kW Figure 2 1 If the inverter ha
91. vert ers up to 55 kW or measure the DC link voltage See also Chapter 1 2 Section 6 Op eration Also ensure that there is no DC infeed e g by a DC link coupling 04 08 05 Operating Instructions 07_GB_T1 UD 7000 1 5 355 0 1 29 1 30 Inverters up to 55 kW Turn out the screw right hand thread to loosen the terminal cover Lift the bottom side of the cover and pull it downwards Use a small screw driver to push the small plastic part at the bottom edge of the display cover out of the guideway Push outwards the display cover at its bottom edge and lift it at the same time Then push outwards the upper edge and pull the cover frontwards Undo two resp four cross recessed head screws on the right hand side panel and pull the side panel out of its guide by tilting it and raising it Adjust jumper X57 see illustration Insert the right side plate into the bottom guideway and tighten it with both cross slotted screws Put up the display cover and snap it into place Insert the small plastic part into the bottom edge of the display cover rounded off edge up Lift the terminal cover slightly and slip it into the groove of the display cover Put up the cover and tighten it with plastic screw Inverters 75 132 kW size VII Unscrew the 4 screws and remove the left side panel by lifting it from the recessed mounting holes Then remove the plastic fastening screws from the circuit board on the welded side of the cont
92. verter must always be isolated from the line when working on it ATTENTION Caution Note This note is shown in all parts of this operating manual to which particular attention must be paid to ensure that the guidelines specifications notes and the correct sequence of work will be obeyed and to prevent damage or destruction of the drive converter and or systems gt gt 1 2 Safety and Operating Instructions for Drive Converters 1 General In operation drive converters depending on their degree of protection may have live unisolated and possibly also moving or rotating parts as well as hot surfaces gt In case of inadmissible removal of the required covers of improper use wrong installation or maloperation there is the danger of serious personal injury and damage to property For further information see documentation All operations serving transport installation and commissioning as well as maintenance are to be carried out by skilled technical personnel Observe IEC 364 or CENELEC HD 384 or DIN VDE 0100 and IEC 664 or DIN VDE 0110 and national accident prevention rules For the purposes of these basic safety instructions skilled technical personnel means per sons who are familiar with the installation mounting commissioning and operation of the product and have the qualifications needed for the performance of their functions We draw attention to the fact that no liability can be assumed for damage and
93. y and less rotor heating Very low no load currents The UD 7000 inverter allows operation of an EC motor of any manufacturer whereby the counter EMF of the motor should be sinusoidal This variant achieves best possible true running characteristics Trapezoidal operation is admittedly also possible but is not advis able owing to the aforesaid aspects When the motor is commissioned the motor shaft must be able to turn freely since the mounting angle of the resolver is determined in a test run This involves presetting a sta tionary voltage vector which pulls the rotor to its optimum position If this is not followed the motor is unable to develop its optimum torque and will demand a higher stator current at the same load Operating Instructions UD 7000 1 5 355 0 1 49 Annex Abbreviations Used 5 Annex 5 1 Abbreviations Used The following abbreviations are used in this parameter description OE Parameter can be edited on line SC Parameter can be written in the SIO control mode through the serial interface see description UD 7000 serial interface SL Parameter is of significance in the version consisting of the standard inverter Hz V controlled amplifier FO Parameter is significant in the version consisting of a field oriented controller with feedback SLV Sensorless vector control SLV EC Parameter is significant in the version consisting of a brushless servo amplifier SIO Serial RS 485 interfa
94. ye alee yee ROY A a eee Bahay Sede eae bene E agg aaa eee ee 51 5 3 gt Parameter Overviews ea ee ee olaaa 52 5 4 Eror States a fein tod he eed er a ee er lr Bad aie aaa ae ehe 57 5 4 1 Normal Handling of Error States 2222 cnuenen enn ented een 57 5 4 2 Handling of Error States with the Acknowledge Error State Function 2222 e cece 57 04 08 05 Operating Instructions 07_GB_T1 1 1 UD 7000 1 5 355 0 Table of Contents Table of Contents Parameter Description Part 2 Page 6 COMMISSIONING e is e A ees de AA ad gees Se abba kc rede ade Gta Ss 3 6 1 Prior to Switch ON ten eng ee ara ia Bade Bra et eee pis bade gaye eb ede pid bade pau ea 3 6 2 What Happens on Switch Olty eco aed pee DR en hates ae 5 6 3 Eurthersteps tic tm eh he MN aL FM la e el o ll ot de let lke 6 6 4 Assignment of the Control Terminals 0 02 ccc nn ent t nnn tenet nee 6 6 5 lt Parameter tistel pic ss es e a lofts Nall cabal en SUH nak lesen ee Mela caleta polo fer mua 7 6 6 Commissioning Application O Inverter 2 2 nnn tenet teeta 7 6 6 Preparation sesen aaah ale en Ad dhe de ae een ern oad has eed 7 6 6 2 Parametros peg a eee ea ee eee a 7 6 6 3 Precision AdjUstment srn rer elena tie ran en ee lege ad why Care A dia ee 8 6 6 4 Solution to the Problemiz 0 2 aaron BUG a ari 9 6 7 Commissioning of a Field Orientated Controlled Asynchronous Motor FO or of a Permanent Field S
95. ynchronous Drive EC 9 6 7 1 Hardware Precondition Option Card and Wiring 2 2 6 tenet teen eee 9 6 7 2 Parameterisation of the Speed Controller on Systems with Feedback FO and EC Applications 12 6 7 3 Controller Optimization A Da rin yd ee Be ren eee rege codices 13 ETAS Solution to the Problem 8 u Je Beer rennen Sal ag er Leo Er screen toren ehe 16 6 8 Commissioning an SLV Application ooocoocococoro nen ttn nents 17 6 8 17 INTOGUCTON DRE sk ate dls helt Be Aetna eat Vays A a E vate ah Ba a terete aaa teh Se E E ER 17 6 8 2 Commissioning Application 50 SLV Rotational Speed Control 2 0 2 0 0 02 teens 18 6 9 Note on Commissioning further to Application 51 21 6 ttt ent ene eens 22 6 9 1 Signal Flow Diagramsiz 2 2 22 eee eee le a ee tang whee Lee diel 22 0 10 Stepper Contr l i ataa peran etia na iaaa ont wow dare a 25 7 Keys and Displays Indicators 0 0 0 0 eeaeee aaaeeeaa 26 7 1 Display and Operating Unit ABE gt nerra sin a tte a a e G 26 7 2 Display in the Operating Mode an e irre a a a a a aaae a A pa a ae a aN A 26 7 2 1 Standard Display ori 0 3 dent ban tae eee GRRE Mana RL en anA les A ALAT RARES 26 T22 x Standard Display 22 it Ya Bar es alle E ne DD Rei SA Moe 27 7 2 3 Display inthe Program Mode 2 ei is weve 22 ma u san Ds sh a a E E A 28 7 24 Operating Examples s s u ee Bee ba Aces oe Dre Des cee ne ne Be beans en eh 29 Tas Ohne ela a

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