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Engineering Guide CDA3000

DE
EN
FR

A-55

Appendix D Index

Acceleration behavior as a function of

number of pole pairs

........................

2-33

Acceleration, choice of max.

....................

A-17

Acceptance tests

..................................

3-5

Acceptance tests/Standards

......................

3-5

Ambient conditions

...............................

3-6

Anti-resonant circuit

..............................

6-4

Application data sets

.............................

4-22

Application-specific basic settings

......

4-25

4-59

Areas of application for three-phase

AC motors

...........................

2-25

3-61

Assignment

Line choke/inverter module

..................

6-7

to inverter modules CDA3000

......

6-13

6-15

to the inverter modules

.....................

6-10

Basic physical equations

.........................

A-5

Basic settings, application-specific

.....

4-21

4-22

Basic terms for calculation

.......................

7-2

Belt turning station

...............................

2-20

Bibliography and source reference

..............

C-51

Block diagram of a voltage transformer

........

3-25

Block diagram of an inverter with braking

chopper

......................................

3-83

Braking resistors

.................................

6-12

Break-away and acceleration torques

..........

3-64

Cable type for self-assembly

..............

5-7

5-16

Calculation

.......................................

2-23

Calculation by way of LuDrive

...................

2-22

Calculation of effective inverter capacity

utilization

....................................

3-55

Calculation with LuDrive

.........................

3-85

CAN bus

...........................................

5-4

CAN characteristics

...............................

5-5

CANLust

Control word

.................................

5-11

Status word

..................................

5-11

CANLust control word

...........................

5-11

Characteristic data set switchover

..............

4-30

Characteristic values

of asynchronous servomotors ASx

.........

2-35

of HF motors

.................................

2-47

of machinery

.................................

1-9

of planetary gears

...........................

2-49

of reluctance motors

........................

2-41

of standard gears

...........................

2-49

of standard three-phase AC motors

........

2-26

of synchronous motors

......................

2-44

Circuitry example

................................

3-28

Circumferential backlash

........................

2-50

Communication

via CANLust

..................................

5-8

via CANopen

.................................

5-12

via PROFIBUS-DP

............................

5-18

Communication and user module

................

5-1

Communication module CM-CAN1 or CM-CAN2

5-6

Comparison of motor control methods

..........

4-57

Comparison of solutions

..........................

1-8

Connector with strain relief and cable shield

...

5-17

Connectors, open

.................................

5-8

Control terminal assignments

...................

4-27

Control terminals of user module UM-8I4O

.....

4-37

Cooling methods

..................................

3-8

Cooling methods, for inverter modules

..........

3-8

Current characteristics

..........................

3-37

Cutting forces of various metals

.................

A-9

Data structure

.....................................

4-2

DC network operation

............................

3-79

DC network operation with PTC precharging

circuit

........................................

3-82

Dependency of motor variables / Frequency

...

2-30

Summary of Contents for CDA3000

Page 1: ...C CDA3000 The easy route to your drive solution EN EN FR ES Engineering Guide Inverter drive system to 90 kW With drive engineering formula bank ...

Page 2: ...ANAGER and KEYPAD Application Manual Traction and lifting drives Rotational drives Quick and easy initial commissioning Operation via DRIVEMANAGER and KEYPAD Adaptation of the drive system to the application CANLust Communication Module Manual CANopen Communica tion Module Manual PROFIBUS DP Communi cation Module Manual Project planning installa tion and commissioning of the CDA3000 on the field b...

Page 3: ...t General project planning tasks including Analysis of the task Concept design of the system Design of the system components Selection of the best solution to be implemented How to use this manual 1 Analysis of task 2 Definition of drive Appendix Formula bank Copy templates Bibliography and index Table of contents A 3 Selection of inverter module 4 Selection of user and communication modules 5 Sel...

Page 4: ...n 2 1 2 Calculate drive variables such as power output torque speed etc See sections 2 2 to 2 4 3 Select motor transmission gear and gearing See sections 2 5 to 2 6 4 Select inverter module and software performance See section 3 See section 6 5 Select user and or communication modules See section 4 6 Select supplementary components such as filters line choke etc See section 5 ...

Page 6: ...mple of solution with four pole motor 2 7 2 2 2 Example of solution with six pole motor 2 8 2 3 Drive definition via power rating 2 9 2 3 1 Example 1 Traction drive 2 10 2 3 2 Example 2 Lifting drive 2 12 2 4 Drive definition via LUDRIVE PC PROGRAM 2 13 2 4 1 Example 1 Trolley drive for gantry crane 2 15 2 4 2 Example 2 Belt turning station for truck engine distribution 2 20 2 5 Selection of motor...

Page 7: ...k capacitors 3 25 3 2 8 Direction of rotation and terminal designation 3 27 3 2 9 Switching at the inverter output 3 28 3 2 10 Short circuit and ground fault proofing 3 29 3 2 11 Motor cable length 3 29 3 2 12 Voltage load on the motor winding 3 31 3 2 13 Motor protection possibilities 3 31 3 2 14 Power reduction 3 33 3 2 15 Calculation of effective inverter capacity utilization 3 55 3 2 16 Measur...

Page 8: ...tions 4 20 4 3 1 Traction and lifting drive 4 24 4 3 2 Rotational drive 4 39 4 3 3 Field bus operation 4 49 4 3 4 Master Slave operation 4 56 5 Communication and user modules 5 1 Principle of function 5 2 5 2 User module 5 3 5 3 CAN BUS 5 4 5 3 1 Interconnection of inverter modules on the CAN bus 5 6 5 3 2 Communication via CANLUST 5 8 5 3 3 Communication via CANopen 5 12 5 4 PROFIBUS DP 5 13 5 4 ...

Page 9: ...Assignment to inverter modules CDA3000 6 13 6 4 Radio interference suppression filter 6 14 6 4 1 Technical data of RFI filters EMC34 xxx 6 14 6 4 2 Permissible motor cable length with internal RFI filter 6 15 6 4 3 Permissible motor cable length with internal and external RFI filter 6 16 6 4 4 Permissible motor cable length with external RFI filter 6 16 7 System installation 7 1 Heat discharge fro...

Page 10: ...ective motor torque power output A 15 A 2 7 Choice of max acceleration A 17 A 2 8 Mass moments of inertia A 20 A 2 9 V t diagram A 27 A 2 10 Efficiencies coefficients of friction and density A 30 A 2 11 Motor lists A 34 A 3 Protection A 40 A 3 1 Protection to IEC EN A 40 A 3 2 Protection to EEMAC and Nema A 43 B Practical working aids for the project engineer C Bibliography and source reference D ...

Page 11: ...cteristic values of machinery 1 9 1 3 1 Movement requirement 1 9 1 3 2 Moment of inertia 1 12 1 3 3 Manipulating range and accuracy 1 13 1 3 4 Load torque 1 19 Take your time especially at the beginning Please note The more complex the task the more important is the analy sis A better analysis can identify impending failures in good time Good Better Complexity Complexity Analysis Analysis Intuitio...

Page 12: ...nalysis is to record understand and order the existing inter relationships within a system To this end the sys tem is split down into its subsidiary areas components such that all the individual components are distinct from each other and the relations between them become visible 1 1 1 Inverter system An inverter system comprises the following individual components and modules The chain is only as...

Page 13: ... Interface to the automation process 3 Interface to the surrounding environment and installation conditions 4 Interface to the requirements arising from standards regulations and safety concerns Figure 1 2 System environment This section deals with the interface to the processing process The other interfaces are dealt with in the subsequent sections of the guide Processing process ML f n s Automat...

Page 14: ...analysis Standard screw type extruder An extruder is a machine which takes in solid to liquid synthetic molding compounds and presses them out of an opening for the most part continuously It compresses mixes plasticizes and homogenizes the compound in the process The screw type extruder shown see Figure 1 3 principally comprises a drive unit and a plasticizer unit The plasticizer unit consists of ...

Page 15: ... 4 Load characteristic of the plastics extruder Task for a new drive unit In order to provider a higher degree of machine availability the drive is to be switched from DC to three phase AC The DC drive used to date has a speed manipulating range of 1 1000 and an overload capacity to 200 ML f n P f n 1 DC controller 2 DC motor 3 Tacho 4 Gearing 5 Screw return thrust bearing Figure 1 5 Old solution ...

Page 16: ...ure 1 6 Solution from functional analysis The functional analysis produces a solution with speed feedback See Table 1 1 1 Inverter with field oriented regulation 2 AC motor 3 Encoder 4 Gearing 5 Screw return thrust bearing DC drive Three phase AC drive 1 DC controller 1 Inverter with field oriented regulation 2 DC motor 2 AC motor 3 Tacho 3 Encoder 4 Gearing 4 Gearing 5 Screw return thrust bearing...

Page 17: ...ocess 4 What load torque needs to be overcome Answer the questions in this example 1 Continuous material flow 2 Is of no significance in applications with continuous material flow 3 Speed manipulating range of 1 10 4 No overload necessary because the screw of the extruder would otherwise be damaged When the screw has become clogged it is drawn forward out of the extruder for cleaning The answers s...

Page 18: ...summary Always analyze the processing process Because just because something is known does not necessarily mean it is recognized Solution from functional analysis Solution from process analysis NEW 1 Inverter with field oriented regulation NEW 2 Inverter with VFC Figure 1 8 Comparison of solutions M 3 M 1 M 3 M 1 ...

Page 19: ...g machine referred to the motor shaft 3 the manipulating range and accuracy of the torque speed and posi tion 4 the characteristic over time of the load torque 1 3 1 Movement requirement The movement requirement for processing is roughly divided into three groups Y Movement requirements for processing Continuous Discontinuous Continuous material flow Paper machinery Textile machinery Batch process...

Page 20: ...mechanical function usually generates a non linear movement The processing process coun teracts this movement with a specific load torque Figure 1 9 Movement solution in the processing process Processing material Processing process ML f n s j Product Mechanical function X n2 t n2 n1 n2 n1 M 3 Drive function with frequency inverter Drive function with servocontroller Movement solution X Reference E...

Page 21: ...he startup and shutdown frequency can be determined This repetition rate of the startup and shutdown process determines the For more information on the subject of the v t diagram refer to the formula bank in See Appendix A 2 9 motor rating current load of the inverter module and the braking chopper design y x x y x t t Movement solution Drive function x t Mechanical function y x S S0 ϕ x t start e...

Page 22: ...ssure for technological optimization The moment of inertia of motors is of great significance for the overall drive design in cases of frequent and rapid changes of speed while in rotational drives such as a sugar centrifuge or a continuous winding drive a reduction in the moment of inertia of the motor has little or no effect on the overall drive design For more information on this subject refer ...

Page 23: ...e customer and the drive manu facturer Definition of terms Torque rise time The torque rise time is the time which elapses after a reference step from 0 to MN until the actual value of the torque in the motor has reached 95 of the nominal value The torque rise time is dependent on the control methods applied and on the electrical parameters of the motor used As the speed increases the voltage rese...

Page 24: ... manipulating range is the range in which the motor can always deliver nominal torque Manipulating range fN Rated frequency in Hz fmin Minimum frequency in Hz nN Nominal speed in rpm nmin Minimum speed in rpm Figure 1 12 Speed manipulating range f n M MN fmin nmin fN nN fN fmin nN nmin ...

Page 25: ... startup In operation with speed control a high frequency ripple is superimposed on the actual speed The frequency of the ripple depends on the sampling rate of the speed controller The amplitude of the said ripple is dependent on the encoder system used and on the mass inertia system application and motor 1 Lower limit 2 Upper limit 3 Variation range Figure 1 13 Static speed accuracy t n 1 2 3 ...

Page 26: ...the speed deviation during the startup or braking process of a speed change The greatest deviation very often occurs in the transient response in settling to the desired speed 1 Dynamic variation 2 Reference 3 Actual 1 Dynamic variation 2 Reference 3 Actual Figure 1 14 Dynamic speed accuracy n 1 2 3 t n 2 1 3 t ...

Page 27: ... system of the pickup Gearing used Constant response time of the control Measurement resolution from position transducer etc A precise analysis is only possible in specific cases SF Vmax tRF SF Positioning error in mm Vmax Velocity in mm s tRF Response error terminal scan cycle in s 1 Scan cycle of control terminals on inverter tRF response error 2 Destination position 1 stop signal comes together...

Page 28: ...teristic over time of the reference position Position controller The position controller ensures that the reference position is maintained as closely as possible Speed controller The speed controller in turn ensures that the reference speed of the motor is maintained The speed reference can be specified via 10 V to 10 V or via CAN or PROFIBUS u u uc a b a i b i M 3 Modulator and PWR Encoder G εRS ...

Page 29: ...rive with a specific torque This torque is composed of a static torque which is defined by the technological process and the acceleration or deceleration torque determined by the change of speed and the inert mass The static torque is generally termed load torque and in most cases acts opposing the direction of motion In exceptional cases such as on lifting gear during lowering the load torque als...

Page 30: ...eyor systems piston compressors rolling mills Extruders ML constant P n 1 Break away torque Figure 1 18 Load characteristic Lifting gear conveyor systems piston com pressors rolling mills ML f n P f n Figure 1 19 Load characteristic Extruders n P ML ML P 1 n ML P P ML ...

Page 31: ...sk DE EN 1 2 3 4 5 6 7 A Blowers fans centrifugal pumps Mills ML n P n Figure 1 20 Load characteristic Blowers fans centrifugal pumps ML f n 1 Hammer mill 2 Centrifugal mill 3 Ball mill Figure 1 21 Load characteristics Mills n P ML ML P n 1 2 3 ML P ...

Page 32: ...sis of task Conveyors such as inclined lifts Piston machines eccentric presses metal cutters ML f s Figure 1 22 Load characteristic Conveyors ML f α Figure 1 23 Load characteristic Piston machines eccentric presses metal cutters ML s ML Mm ...

Page 33: ...Engineering Guide CDA3000 1 23 1 Analysis of task DE EN 1 2 3 4 5 6 7 A Machine tools ML f t Figure 1 24 Load characteristic Machine tools ML t ...

Page 34: ... 4 1 Example 1 Trolley drive for gantry crane 2 15 2 4 2 Example 2 Belt turning station for truck engine distribution 2 20 2 5 Selection of motor 2 24 2 5 1 Characteristic values of standard three phase AC motors 2 26 2 5 2 Characteristic values of asynchronous servomotors ASx 2 35 2 5 3 Characteristic values of reluctance motors 2 41 2 5 4 Characteristic values of synchronous motors 2 44 2 5 5 Ch...

Page 35: ... not claim to be generally applicable to all movement tasks It is merely intended to illustrate a pos sible procedure which can be applied with little labor commitment You will find the copy template in the appendix under Practical working aids for the project engineer T The goal must be realistic Key limits must be known Industry Application Goal Special background conditions Author Date Sheet of...

Page 36: ...pendix under Practical working aids for the project engineer Movement requirement Movement requirement for processing Project name Continuous material flow Discontinuous batch process Discontinuous unit process Rotational movement n f t Translational movement v f t Radius of drive shaft by which the movement is generated mm Author Date Sheet of Comments t v 1 T Period ...

Page 37: ...ement requirement Movement requirement for processing Project name Author Date Sheet of Moment kgm Mass kg or of inertia Mode of movement Comments Speed manipulating range Static speed accuracy Dynamic speed accuracy Torque rise time Positioning accuracy rpm rpm ms ms ML 1 n P constant ML constant P n ML f n P f n ML n P n ML f n ML f s ML f ML f t Load torque of processing process ML P MN PN 1 5 ...

Page 38: ... copy template in the appendix under Practical working aids for the project engineer System interface Automate Environment Standards Additional environmental data Project name Author Date Sheet of Automation process Environmental and installation conditions Standards regulations and safety ...

Page 39: ...ted power by a straight line 5 Select your product based on the perfor mance rating data Engine speeds Continuous load characteristic in inverter operation with IEC standard motor 2 2 5 3 4 5 6 7 8 9 10 15 20 25 30 40 50 60 70 80 90 100 PN UR kW 150 200 250 300 2 2 5 3 4 5 6 7 8 9 10 15 20 25 30 40 50 60 70 80 90 100 150 200 250 300 2 2 5 3 4 5 6 7 8 9 10 15 20 25 30 40 50 60 70 80 90 100 150 200 ...

Page 40: ...250 300 2 2 5 3 4 5 6 7 8 9 10 15 20 25 30 40 50 60 70 80 90 100 150 200 250 300 400 4 5 6 7 8 9 10 15 20 25 30 40 50 60 70 80 90 100 150 200 250 300 400 Rated power inverter and motor 0 5 0 6 0 7 0 8 0 9 1 0 M MM UR f Hz 10 20 30 40 50 60 70 80 90 100 750 rpm 8 pole 100 200 300 400 500 600 700 800 750 900 1000 1100 1200 1300 1400 1500 200 400 600 800 1000 1200 1400 1000 rpm 6 pole 1600 1800 2000 ...

Page 41: ...5 3 4 5 6 7 8 9 10 15 20 25 30 40 50 60 70 80 90 100 150 200 250 300 400 4 5 6 7 8 9 10 15 20 25 30 40 50 60 70 80 90 100 150 200 250 300 400 Rated power inverter and motor 0 5 0 6 0 7 0 8 0 9 1 0 M MM UR f Hz 10 20 30 40 50 60 70 80 90 100 750 rpm 8 pole 100 200 300 400 500 600 700 800 750 900 1000 1100 1200 1300 1400 1500 200 400 600 800 1000 1200 1400 1000 rpm 6 pole 1600 1800 2000 1500 rpm 4 p...

Page 42: ...h the design of traction and lifting drives T Packaging machinery Manipulators Conveyor systems General engineering Discharge drive cladding removal vacuum packing sheet feed Metering drive volume metering screw type mete ring Traction lifting axis packers palleti zers Belt drive bucket conveyor product loading belt Labeling machine X Y drive etc Traveling axis X Z axis Lifting axis Y axis Indexin...

Page 43: ... PGross Pa PF PaR 264W 9W 65W 338W For more details on Selection of inverter modules refer to sections 3 3 to 3 6 Example Z axis of a manipulator m 51 5 kg a 3 m s2 v 1 5 m s η 0 88 ta 0 5 µ 0 01 Selected motor Type 71L 4 370W JM 0 00073 kgm The motor is to be run at max 2000 rpm 70 Hz characteristic Pa m a v η 51 5kg 3m s 2 1 5m s 0 88 264W PF m g µ v η 51 5kg 9 8m s s 0 01 1 5m s 0 88 9W PFahr P...

Page 44: ... PH Power to lift the load W m Total mass kg a Acceleration m s v Velocity ms µ Tractive resistance Coefficient of friction η Efficiency of the drive solution g Acceleration due to gravity 9 8m s JM Moment of inertia of the selected motor kgm nM Max speed of the selected motor rpm ta Acceleration time s For a list of standard three phase AC motors See section A 2 11 Motor list Asynchronous motors ...

Page 45: ... 42W 164W 250W For more details on Selection of inverter modules refer to sections 3 3 to 3 6 Example Z axis of a manipulator m 2 5 kg a 10 m s2 v 1 5 m s η 0 88 ta 0 15 µ 0 01 Selected motor Type 71S 4 250W IM 0 00056 kgm2 The motor is to be run at max 2000 rpm 70 Hz characteristic Pa m a v η 2 5kg 10m s 2 1 5m s 0 88 43W PF m g µ v η 2 5kg 9 8m s s 0 01 1 5m s 0 88 1W PH m g v η 2 5kg 9 8m s s 1...

Page 46: ...rives with rise for downward movement Lifting drives without counterweight lifting Lifting drives without counterweight lowering Indexing tables with ball rim Indexing tables with shaft through the center point Spindle drives Rotational drives After calculating the drive LUDRIVE displays a graph on the PC The graph shows the characteristic of the mean torque the speed and the moment over time Base...

Page 47: ... application Please note that the software LUDRIVE is only available in german lan guage Network printing When printing from DOS applications under Windows 95 in network mode the printer must be assigned to the parallel port LTP1 From the Start menu choose Settings Printers select the printer you want to use and click with the right mouse button to open the Pro perties dialog box On the Details ta...

Page 48: ...is a four pole helical gearbox motor with brake Figure 2 2 Standard trolley drive with geared motor Known data Intrinsic weight of the trolley 5 t Lifting weight 10 t Running speed 30 m min Two wheels are driven Wheel diameter 315 mm Journal diameter 80 mm Friction pairing rail wheel Steel steel Transmission gear z1 18 z2 34 Efficiency of the drive 80 Mass moment of inertia of the running wheels a...

Page 49: ...eleration by means of v t diagram program section Calculate longitudinal coefficient of friction between rail and wheel by means of Tractive resistance Fric tion moment program section Calculate drive capacity by means of Drive calcula tion Traction drive program section a for max motor speed 1440 rpm b for max motor speed 2000 rpm 1 2 3 1 ...

Page 50: ...Engineering Guide CDA3000 2 17 2 Drive definition DE EN 1 2 3 4 5 6 7 A Figure 2 4 Tractive frictional resistance 2 ...

Page 51: ...2 18 Engineering Guide CDA3000 2 Drive definition Figure 2 5 Drive capacity Figure 2 6 Motor selection 3 Max motor speed 1440 rpm ...

Page 52: ...Engineering Guide CDA3000 2 19 2 Drive definition DE EN 1 2 3 4 5 6 7 A Figure 2 7 Drive capacity Figure 2 8 Motor selection Max motor speed 2000 rpm 3 ...

Page 53: ...ow center of gravity only one bearing to absorb all forces and moments The size of the bearing support means that correspondingly very high radial and axial forces and moments are absorbed 1 Truck engines Figure 2 9 Belt turning station Known data Mass of indexing table with slewing ring etc 130 kg Indexing table diameter 1600 mm Mass of truck engine 500 kg Distance of truck from pivot point 600 m...

Page 54: ...onal acceleration and rotational deceleration by means of v t dia gram for indexing table program section Calculate drive capacity by means of Drive calcula tion Indexing table with slewing ring program sec tion a Startup factor 1 25 typical values with Voltage Frequency Control VFC b Startup factor 2 typical values with Sensor less Flux Control SFC 1 2 1 ...

Page 55: ...2 22 Engineering Guide CDA3000 2 Drive definition Figure 2 11 Calculation Figure 2 12 Motor selection 2 25 motor overload with VFC Factor for starting tor que 1 25 1 25 MN ...

Page 56: ...Engineering Guide CDA3000 2 23 2 Drive definition DE EN 1 2 3 4 5 6 7 A Figure 2 13 Calculation Figure 2 14 Motor selection 3 100 motor overload with SFC Factor for starting torque 2 2 MN ...

Page 57: ...ting field is created in the motor which drives the rotor The rotation speed is determined by the following variables The motor type is determined by the rotor introduced into the rotating field Overview of three phase AC motors ns synchronous speed P number of pole pairs f stator frequency A ns f 60 P 3 phase AC motor Synchronous motor Asynchronous motor with energized rotor Reluctance motor Stan...

Page 58: ...umps galette drives roller drives etc Further areas of application are in the glass and paper industry as winding drives etc Reluctance motor asynchronous synchronous In the textile industry for Spoolers viscose pumps galette or roller motors etc Further areas of application are in drafting equipment and for synchronous running of two axles High frequency motor asynchronous In the timber processin...

Page 59: ...racteristic in mains operation Figure 2 15 Typical startup characteristic of a standard three phase AC motor in mains operation Operating characteristic Figure 2 16 Typical operating characteristic of a standard three phase AC motor 2 4 2 0 1 6 1 2 0 8 0 4 0 1 0 0 8 0 6 0 4 0 2 0 0 0 2 0 4 0 6 0 8 1 0 1 0 0 8 0 6 0 4 0 2 0 ...

Page 60: ... AC motor Limit speed nmaxLimit speed H Axle height 1 Greased groove ball bearings in two pole motors 2 Greased groove ball bearings in four pole motors and higher 3 Strength of the short circuiting rings of the rotor cage 4 Bend critical speed Figure 2 18 Typical limit speed of a standard three phase AC motor 1 00 0 75 0 50 0 25 0 0 0 25 0 50 0 75 1 00 1 25 1500 rpm n max rpm ...

Page 61: ... of standard three phase AC motor to DIN 57 530 IEC 34 Property Tolerance Efficiency η PN 50 kW 0 15 1 η PN 50 kW 0 1 1 η Power factor ϕ min 0 02 max 0 07 Slip s 20 Break away starting current lA 20 Break away torque MA 15 to 20 Breakdown torque MK 10 Noise LA 3 dB A Voltage deviation u 5 at rated load and 45ºC ambient tem perature Table 2 3 Tolerances to DIN 57530 and IEC 34 1 ϕ cos 6 ...

Page 62: ...Engineering Guide CDA3000 2 29 2 Drive definition DE EN 1 2 3 4 5 6 7 A Notes ...

Page 63: ...2 const Speed n Voltage U Flux Φ Current I Torque M Breakdown torque Mk Mechanical output P2 Slip s Stator copper loss Pcu1 Rotor copper loss Pcu2 Core loss PFe Table 2 4 Dependencies of the motor variables P2 1 n n nN 1 0 f fN f fN f fN 1 1 1 0 f fN 1 1 1 1 1 fN f fN f fG f 0 0 fN f fG f 1 1 0 fN f fN f 1 1 0 f fN fG f 1 1 0 fG f 1 1 0 fN f fG f 1 1 1 0 fG f 1 1 1 0 fN f fN f f fN 3 2 1 0 0 fN fG...

Page 64: ...que MkN Nominal breakdown torque MN Nominal torque n Speed nN Nominal speed Pcu1 Stator copper loss Pcu2 Rotor copper loss Pcu1 N Nominal stator copper loss of fundamental Pcu2 N Nominal rotor copper loss of fundamental PFe Core loss PN Rated power P2 Mechanical output s Slip U Voltage effective value Φ Magnetic flux Achtung Safe inverter operation can only be guaranteed when the max output freque...

Page 65: ...or with inverter 2 Permissible torque characteristic of an internally cooled 3 phase AC motor 3 Permissible torque characteristic of an adequately externally cooled 3 phase AC motor 4 Maximum permissible torque for 120 s to DIN VDE 0530 Part 1 Figure 2 19 Torque characteristic of a standard three phase AC motor in inverter operation 120 0 1 1 0 0 5 100 50 10 1 5 M MN f Hz P 2 2 2 1 3 4 2 0 ...

Page 66: ...ble for dynamic drive tasks In summary As the diagram shows standard three phase AC motors with two pole pairs four pole are particularly well suited to dynamic drive tasks JM Moment of inertia of the motor rotor in kgm tBE Acceleration time in s PMBE Motor acceleration time in W Acceleration from 0 rpm to nominal speed in 100 ms PMBE JM n 2 91 2 tBE 0 500 1000 1500 2000 W 250 W 370 W 550 W 750 W ...

Page 67: ...ts of inertia See Appendix A 2 8 Size Power P in W Idle acceleration time in ms Ired 0 Acceleration time with moment of inertia adaptation in ms Ired IM 63L 4 250 55 110 71L 4 375 49 98 80 S 4 550 57 114 80L 4 750 54 108 90S 4 1100 52 104 90L 4 1500 52 104 90L 4a 2200 35 70 100L 4 2200 50 100 100L 4a 3000 50 100 112M 4 4000 123 246 Table 2 5 Max acceleration times of four pole standard three phase...

Page 68: ... deliver this torque for an unlimited length of time I0 Standstill current Effective value of the motor phase current required to generate the standstill torque MN Nominal torque Thermal limit torque of the motor at nominal speed nN IN Rated current Effective value of the motor phase current required to generate the nominal torque PN Rated power Full load power of the motor at the nominal working ...

Page 69: ...eatherkey way DIN 6885 tolerance band k6 Flange dimension DIN 42948 and IEC 72 Smooth running coaxiality and concen tricity to DIN 42955 Tolerance N normal R reduced on request Vibration severity to ISO 2373 Stage N optionally R Therm motor monitoring PTC thermistor in stator winding Torque load To prevent thermal overloading of the motors the effective load torque must not be greater than the nom...

Page 70: ... i z e l e n g t h V o l t a g e v a r i a n t H o l d i n g b r a k e E n c o d e r s y s t e m N o m i n a l s p e e d T e r m i n a t i o n t e c h n i q u e The order designation must always be quoted in full in the specified order ASM 23 20003 0 No encoder connection Nominal speed 3000 rpm Without encoder Without holding brake Voltage variant 330V Size 2 length 3 Flange self cooling Asynchron...

Page 71: ... 8 8000 ASM H 32 2xxx1 20 17 2 7 8 2 6 8 1500 90 33 8000 ASM H 33 2xxx1 27 5 23 3 6 10 3 8 7 1500 130 41 5 8000 ASM H 34 2xxx1 42 35 5 5 15 1 12 6 1500 209 56 6 8000 ASH 41 2xxx1 47 40 6 3 21 17 9 1500 450 87 8000 ASH 42 2xxx1 70 60 9 4 30 25 5 1500 740 113 8000 ASH 43 2xxx1 85 70 11 37 30 4 1500 960 135 8000 Table 2 7 Technical data self cooling Term Explanation M0 Standstill torque Thermal limit...

Page 72: ...500 70 33 8 8000 ASF V 32 2xxx1 27 5 23 3 6 10 6 8 9 1500 90 37 5 8000 ASF V 33 2xxx1 38 32 5 13 8 11 6 1500 130 46 5 8000 ASF V 34 2xxx1 56 47 7 4 18 4 15 4 1500 209 62 1 8000 ASV 41 2xxx1 83 70 11 33 27 5 1500 450 95 8000 ASV 42 2xx1 140 118 18 5 50 42 1500 740 121 8000 ASV 43 2xxx1 170 143 22 5 61 51 1500 960 145 8000 Table 2 8 Technical data forced cooling Term Explanation M0 Standstill torque...

Page 73: ...elera tion torque Nm Power class kW Idle accele ration time ms Ired 0 Acceleration time ms Ired IM 11 to 15 110x110 3 25 to 11 75 0 4 to 1 5 14 to 12 28 to 24 21 to 25 140x140 8 75 to 32 5 1 1 to 2 7 20 to 19 40 to 38 31 to 34 190x190 32 5 to 87 5 2 1 to 5 5 34 to 38 68 to 76 41 to 43 260x260 100 to 175 6 3 to 11 71 to 87 142 to 174 Precondition Acceleration from 0 to 1500 rpm at 2 5 times nominal...

Page 74: ...Figure 2 22 Typical torque characteristic of a reluctance motor in mains operation Note The motor may only be run to accelerate in asynchronous mode If asynchronous mode is run for longer the motor will be destroyed 1 Pull in to synchronism 2 Pull out of synchronism 0 2 0 4 0 6 0 8 1 1 2 M MN n nN 1 2 Mksy 3 4 MK Msy 1 2 MN Mksy 1 6bis1 8 MN MK 3 5 MN ...

Page 75: ...a fixed magnetic adhesion As the load on the shaft increases the rotor displacement angle load angle increases steadily The speed remains synchronous X Direction of rotation β Load angle Table 2 10 Torque as a function of rotor displacement angle β load angle β referred to the motor shaft Pole pairs βMN typical βMksg 1 20 45 2 10 22 5 3 6 75 15 4 5 11 25 Table 2 11 Internal torque as a function of...

Page 76: ...nce Inquiries for motors for S3 to S6 operation must usually be submitted separately Motor protection only possible via PTC or Klixon High tendency to vibrate especially 25Hz Inverter design In static operation I Inverter 1 2 IN Motor In dynamic operation I Inverter 1 8 IN Motor Shut down the slip compensation load compensation and V F characteristic adaptation software functions V F characteristi...

Page 77: ...age winding and permanent magnets Typical startup characteristic of a permanent magnet excited synchronous motor with cage winding for asynchronous self running Figure 2 24 Typical synchronous motor of a synchronous motor with cage winding and permanent magnets 1 Pull in to synchronism 2 Pull out of synchronism corresponding to VDE 0530 0 2 0 4 0 6 0 8 1 1 2 3 4 M M N n nN Mksy 0 2 0 4 0 6 0 8 1 1...

Page 78: ...otor Loading of the reluctance synchronous motor The stator field Φ1 with the field system of the rotor Φ2 represents a fixed magnetic adhesion As the load on the shaft increases the rotor displacement angle load angle increases steadily The speed remains synchronous X Direction of rotation β Load angle Table 2 13 Torque as a function of rotor displacement angle β load angle N S X I1 I2 N X I1 I2 ...

Page 79: ...ization At low frequencies the no load current may be higher than the load current Motor protection only possible via PTC High tendency to vibrate Inverter design In static operation with manipulating range 1 5 20 100 Hz I Inverter IN Motor In static operation with manipulating range 1 5 5 100 Hz I Inverter 1 2 x IN Motor With group drive Refer to the Multi motor operation project planning notes s...

Page 80: ... 7 A Detailed information can only be provided by the manufacturer of the syn chronous motor however 2 5 5 Characteristic values of high frequency motors Not available at time of going to press At frequencies 1000 Hz special project planning directives must be followed ...

Page 81: ...Max drive speed Max output torque Service factor the standard gears are designed for uniform load Transversal forces axial forces Circumferential backlash Torsional rigidity 2 6 1 Transmission gear Insertion of a transmission gear stage between the geared motor and the output shaft results in different gear output speeds and torques 1 Transmission gear with chain wheels Figure 2 26 Transmission ge...

Page 82: ...pprox 30 to 40 approx 30 to 40 approx 25 to 40 Reduction mathema tically2 precise rating plate no no no no Cost DM Nm low low medium relatively high 1 For explanation See section 2 6 3 2 The cogs of the cogwheel pairing have common dividers so that different cogs always engage with each other Example i Z2 Z1 96 16 5 9375 Catalogue specification 5 94 Table 2 15 Characteristic values of standard gea...

Page 83: ... the gear Figures are always absolute values and in angle minutes Figure is obtained with drive shaft stopped Figure relates to the output and is obtained by means of an alterna ting load of approx 3 to 5 Mmax Torsional rigidity Torsional rigidity is the torsion of a gear relative to the loading Figure always in Nm per angle minute Figure is obtained with drive shaft stopped Figure relates to the ...

Page 84: ...tion of fault current breakers 3 23 3 2 5 Switching at the inverter input 3 24 3 2 6 High voltage test Insulation test 3 24 3 2 7 Forming of the DC link capacitors 3 25 3 2 8 Direction of rotation and terminal designation 3 27 3 2 9 Switching at the inverter output 3 28 3 2 10 Short circuit and ground fault proofing 3 29 3 2 11 Motor cable length 3 29 3 2 12 Voltage load on the motor winding 3 31 ...

Page 85: ...ficiency of the motor control methods 3 62 3 3 3 Standard inverter operation 3 67 3 3 4 70 Hz Characteristic with 25 field weakening 3 69 3 3 5 87 Hz characteristic Expanded manipulating range 3 73 3 3 6 Multi motor operation on one inverter 3 76 3 3 7 DC network operation 3 79 3 3 8 Design of the braking resistor 3 83 3 3 9 Power failure bridging 3 87 ...

Page 86: ...4 3 x 460 V 25 10 Inverter module series C D A 3 x x x x X x x x x Inverter module Rec 4 pole standard motor Rated current Peak current1 Power loss Device output CDA32 003 Cx x 0 375 kW 2 4 A 4 3 A 25 W 0 95 kVA CDA32 004 Cx x 0 75 kW 4 0 A 7 2 A 45 W 1 5 kVA CDA32 006 Cx x 1 1 kW 5 5 A 9 9 A 75 W 2 1 kVA CDA32 008 Cx x 1 5 kW 7 1 A 12 8 A 95 W 2 7 kVA 1 1 8 x IN for 30 s Mains voltage 1 x 230 V 2...

Page 87: ...DA34 024 Wx x 11 kW 24 A 43 A1 390 W 16 6 kVA CDA34 032 Wx x 15 kW 32 A 58 A1 480 W 22 1 kVA CDA34 045 Wx x 22 kW 45 A 81 A2 600 W 31 kVA CDA34 060 Wx x 30 kW 60 A 90 A2 720 W 42 kVA CDA34 072 Wx x 37 kW 72 A 108 A2 840 W 52 kVA CDA34 090 Wx x 45 kW 90 A 135 A2 1080 W 62 kVA CDA34 110 Wx x 55 kW 110 A 165 A2 1300 W 80 kVA CDA34 143 Wx x 75 kW 143 A 214 A2 1680 W 104 kVA CDA34 170 Wx x 90 kW 170 A ...

Page 88: ...011 integrated radio interference suppression level A2 B2 for inverter modules to 7 5 kW For inverter modules 11 to 90 kW a wide range of filters is availa ble to ensure conformance to IEC 55011 All devices conform to the product norm EN618000 3 for speed adjustable electric drives 1 EMC Electromagnetic compatibility 2 Motor cable length See section 6 4 Table 3 3 Acceptance tests Standards Standar...

Page 89: ...h See section 6 4 Standard Test Comments Table 3 4 Explanation of the Acceptance tests and standards table Feature Characteristic data Tempera ture range in operation 10 45 C with derating to 55 C BG1 BG5 0 40 C BG6 BG8 in storage 25 55 C in transit 25 70 C Relative air humidity 15 85 condensation not permitted Mechanical strength to IEC 68 2 6 in stationary operation Vibration 0 075 mm in frequen...

Page 90: ...maintained Clearance above and below There must be a clearance of 100 mm above and below Polluted cooling air dust fluff oil aggressive gases may impair the functioning of the inverter modules Take adequate precautions cold plate separate ventilation installation of filters regular cleaning etc Do not exceed the permissible range of the operational cooling temperature see sections 3 1 2 and 3 2 14...

Page 91: ...2 kW CDA34 00 6 100 W YES YES NO BG3 3 0 kW 4 0 kW CDA34 00 8 CDA34 01 0 120 W 150 W YES YES YES3 BG4 5 5 kW 7 5 kW CDA34 01 4 CDA34 01 7 180 W 225 W YES YES YES3 BG5 11 kW 15 kW CDA34 02 4 CDA34 03 2 330 W 400 W YES YES YES3 BG6 22 kW 30 kW 37 kW CDA34 04 5 CDA34 06 0 CDA34 07 2 500 W 600 W 700 W NO YES YES4 BG7 45 kW 55 kW CDA34 09 0 CDA34 11 0 900 W 1100 W NO YES NO BG8 75 kW 90 kW CDA34 14 3 C...

Page 92: ...W CDA3 Cx x Installation Vertical on mounting plate heat conducting or cooling profile cold plate principle Protection IP20 Cooling air temperature 45 C at 4 kHz switching frequency of power stage Weight 2 8 Kg H height 303 mm W width 100 mm D depth 182 5 mm Table 3 8 Cold plate installation and cooling method start enter stop return W H D CDA3 Cx x ...

Page 93: ...G 4 BG 5 0 37 to 2 2 kW 3 to 4 kW 5 5 to 7 5 kW 11 to 15 kW approx 65 approx 70 approx 75 approx 80 approx 35 approx 30 approx 25 approx 20 Active cooling area Size Power output kW Device basic area mm Active cooling area mm B H a b BG 1 BG 2 BG 3 BG 4 BG 5 0 37 to 0 75 kW 1 1 to 2 2 kW 3 to 4 kW 5 5 to 7 5 kW 11 to 15 kW 70 70 100 150 200 193 218 303 303 303 50 90 120 65 80 165 200 260 215 300 Th...

Page 94: ... the mounting plate active cool ing area and 25 as radiated heat via the housing table 3 9 PMountingplate 180 W x 0 75 135 W 2 Calculate temperature difference between mounting plate and cool ing plate ϑ PMounting plate x Rth 1 135 W x 0 02 K W 2 7 K 1 See table 3 9 3 Maximum temperature at point 2 and on the cooler ϑ Point 2 ϑ Point 1 DJ 85 C 2 7 C 82 3 C 4 Calculation of the cooler At point 2 th...

Page 95: ... Cooling air temperature 45 C at 4 kHz switching frequency of power stage Weight 3 7 Kg H height 330 mm W width 70 mm355 mm D depth 250 5 mm Table 3 10 Wall mounting installation and cooling method CDA3 Dx x Installation Vertical mounting with push through heat sink Protection IP20 units IP54 heat sink side Cooling air temperature 45 C at 4 kHz switching frequency of power stage Weight 3 9 Kg H he...

Page 96: ...Power output kW Cold plate1 W x H x D Wall mounting1 W x H x D Push through heat sink1 W x H x D Clearance above below2 mm BG 1 0 37 to 0 75 70x193x153 70x193x228 no 100 100 BG 2 1 1 to 2 2 70x218x178 70x218x253 no 100 100 BG 3 3 to 4 100x303x183 70x330x251 110x340x171 100 100 BG 4 5 5 to 7 5 150x303x183 120x330x251 160x340x171 100 100 BG 5 11 to 15 200x303x183 170x330x251 210x340x171 100 100 BG 6...

Page 97: ...pproved by the manufacturer Unauthorized opening and unprofessional intervention could lead to physical injury or material damage Intended use Inverters are components that are intended for installation in electrical systems or machines The inverter may not be commissioned i e it may not be put to its intended use until it has been established that the machine complies with the provisions of EC Di...

Page 98: ...t in accordance with the relevant regulations e g cable cross section fuses grounding lead connection Other details are contained in the documentation Electronic devices are fundamentally not fail safe Users are themselves responsible for ensuring that the drive is rendered safe if the device fails If the inverter is used for special applications e g subject to explo sion hazards the required stan...

Page 99: ...ade especially clear how the IT system differs from the TT and TN systems based on the means of ground connection Figure 3 1 IT TN and TT systems First letter Link from the supply system to the ground T Direct connection of a point to the ground I Either all active parts isolated from ground or one point connected to ground via an impedance Grounding lead PEN conductor Neutral conductor ...

Page 100: ... are equally large for every conductor all outer conductors likewise conduct the same voltage against ground High resistance voltmeters connected between the outer conduc tor and ground display the same value In three phase AC systems this is the star voltage in AC systems half the conductor voltage is displayed Insulation monitors should therefore be connected symmetrically If a ground fault occu...

Page 101: ...capacitors of the healthy conductors b Conductor voltage against ground with symmetrical conductor capacity All conductors conduct the star voltage against ground c Conductor voltage against ground in the system System with a ground fault on conductor L3 The healthy conductors conduct the conductor volt age against ground It determines the amount of the ground fault current by way of the conductor...

Page 102: ... in the 3AC N PE system Split symmetrically across the three outer conductors Pay attention to the loading of the common zero conductor increase the cross sec tion as necessary IT with insulated center point Operation of inverter mod ules in this system type is not permitted Radio interference sup pression filters inter nal external may be destroyed in the event of ground fault In the event of a g...

Page 103: ...3 phase input rectifier in the inverter input This non sinusoidal current consumption results in voltage distortions THD Total Harmonic Distortion in the system Depending on local conditions line chokes may need to be inserted to reduce the voltage distortions A line choke reduces the voltage distortion in the system by approx 67 System load Without line choke With line choke Change 4 kW inverter ...

Page 104: ...ambient temperature and the specified rated current of the inverter Current load capacity of multi wire cables and assignment of pro tective devices to VDE 0100 Part 523 Nominal cross section in mm Multi wire cable e g non metallic sheathed cables or moveable cables Rated current of cable Cu in A Protective device rated current in A 0 75 1 0 1 5 12 15 18 6 10 101 2 5 4 6 26 34 44 20 25 35 10 16 25...

Page 105: ...t of the inverter If standard commercially available miniature circuit breakers are used for protection purposes the tripping characteristic C must be configured Insulating material NR SR PVC EPR Permissible operating temperature 60 C 70 C 80 C Ambient temperature C Conversion factors 10 15 20 25 30 35 40 45 50 55 60 65 70 1 29 1 22 1 15 1 08 1 00 0 91 0 82 0 71 0 58 0 41 1 22 1 17 1 12 1 06 1 00 ...

Page 106: ...A Fault current breakers must be used in accordance with local regulations It should however be noted that due to the three phase input rectifier the leakage current contains a DC component and short term pulse shaped leakage currents occur on power up Only all current sensitive fault current breakers suitable for inverter operation may be used The fault current breaker must meet the following con...

Page 107: ...olation inverter from the mains power This is made possible by a special PTC precharge technique 3 2 6 High voltage test Insulation test Every shipped inverter module is tested by means of a high voltage test for insulation resistance between the main circuit and the housing or chassis 1 9 k VDC for 1 s It is therefore not necessary to monitor the insulation resistance of the modules If the insula...

Page 108: ... voltage is rectified The rectified voltage is stored in the so called DC link capacitors The motor side power inverter in the output circuit of the inverter reforms the DC link volt age into a new three phase voltage system with variable frequency f and voltage u Figure 3 3 Block diagram of a voltage transformer Mains Rectifier DC link Pulse controlled inverter PWR PWM Control and monitoring unit...

Page 109: ...h year and month identification Attention If the inverters have been left standing for more than 8 months after shipping see rating plate the DC link capacitors must be reformed This can be avoided if the inverters are connected to the mains for one hour approx every 6 months Of course you can also arrange for our Service department to carry out the forming LUST Service Center Tel 06441 966 136 Ge...

Page 110: ...led such that the alphabetical order of the terminal designation inverter U V W motor U1 V1 W1 corresponds to the phase sequence over time of the mains voltage L1 L2 L3 in clock wise running Clockwise1 Terminals Inverter CDA3000 U V W Motor U1 V1 W1 Anti clockwise2 Terminals Inverter CDA3000 V U W Motor U1 V1 W1 1 Control signal Clockwise 2 Control signal Anti clockwise Table 3 19 Clockwise anti c...

Page 111: ...stepped current changes These switching overvoltage may also lead to fault shutdowns and or error messages from the inverter depending on the drive configuration In such cases a motor choke must be inser ted see section 6 2 Figure 3 6 Circuitry example Switching at the inverter output Multi motor operation Several motors can be run in parallel on one CDA3000 inverter module In this application cas...

Page 112: ...phase In the event of a short circuit or ground fault in the motor cable the power stage is disabled and an appropriate error message is delivered The CDA3000 inverter modules are short circuit and ground fault proof 3 2 11 Motor cable length The maximum motor cable length depends on a number of different factors see following table Voltage drop on the motor cable In designing a drive solution it ...

Page 113: ...ltage drop referred to the respective mains voltage Line choke with 4 UK approx 1 Mains filter 0 1 Inverter module 3 Motor choke 1 Motor cable l Length of motor cable in m I Current in A A Cable cross section in mm2 1 Typical factor for inverter operation 1 73x0 9 Table 3 21 Typical voltage drops U 56 m A ...

Page 114: ...windings and insulated winding heads However the decisive factor in each individual case is the specifi cations of the motor manufacturer 3 2 13 Motor protection possibilities The following chart presents a summary of frequently occurring overload types and the possibilities for protection offered by various devices motor circuit breakers thermistor protective relays inverter functions Technology ...

Page 115: ...tor protective relay Motor PTC monitoring of the CDA3000 Software function motor protection of the CDA3000 Motor PTC moni toring and motor protection of the CDA Overload in continu ous operation 1 Heavy starting 2 Blocking 1 Blocking 2 Ambient tempera ture 50 C 1 Impairment of cooling 1 Inverter operation 50 Hz No protection Limited protection Full protection 1 The inverter and motor have the same...

Page 116: ...s such as the mains voltage motor cable length power stage clock frequency or ambient temperature change the max permissible current load on the inverter modules also changes For details of which current load on the power stage modules is permissible under which changed background conditions refer to the following char acteristic diagrams and tables Maximum output current as a function of mounting...

Page 117: ... 25 m motor cable Inverter modules Rated current A Rated current A Rated current A Rated current4 A Rated current4 A Rated current4 A CDA32 003 Cx x1 2 40 2 40 2 40 2 25 2 15 2 00 CDA32 004 Cx x2 4 00 4 00 3 00 3 85 3 70 2 60 CDA32 006 Cx x 5 60 5 40 4 00 5 45 5 25 3 85 CDA32 008 Cx x3 7 10 7 10 5 20 6 95 6 85 4 80 1 Mounted side by side with no additional cooling area 2 Mounted side by side with ...

Page 118: ...dules Rated current A Rated current A Rated current A Rated current A Rated current A Rated current A CDA34 003 Cx x1 2 2 2 2 1 4 2 0 1 7 0 5 CDA34 005 Cx x2 4 1 4 2 2 3 3 9 3 6 1 4 CDA34 006 Wx x 5 7 5 7 3 5 5 7 5 7 2 6 CDA34 008 Wx x 7 8 7 8 7 8 CDA34 010 Wx x 10 10 10 CDA34 014 Wx x 14 14 14 CDA34 017 Wx x 17 17 17 CDA34 024 Wx x 24 24 24 CDA34 032 Wx x 32 32 32 CDA34 045 Wx x 45 45 45 CDA34 06...

Page 119: ...5 m motor cable 40 C ambient temperature 8 kHz clock frequency 25 m motor cable 40 C ambient temperature 16 kHz clock frequency 25 m motor cable Inverter modules Rated current A Rated current A Rated current A Rated current A Rated current A Rated current A CDA34 003 CDA34 005 CDA34 006 CDA34 008 CDA34 010 CDA34 014 CDA34 017 CDA34 024 CDA34 032 CDA34 045 CDA34 060 CDA34 072 CDA34 090 CDA34 110 CD...

Page 120: ...tional cooling area Motor cable length 10 m Rated current 2 4 A Switching frequency of power stage 4 8 16 kHz Mounting type side by side Mounting height 1000 m Figure 3 8 Max current load of the CDA32 003 Cx x 0 37 kW side by side without additional cooling area 20 25 30 35 40 45 50 55 1 5 1 75 2 2 25 2 5 I A 16 kHz 4 8 kHz C Cooling air temperature JK 2 4 A 2 A 2 4 A ...

Page 121: ...or cable length 10 m Rated current 4 A Switching frequency of power stage 4 8 16 kHz Mounting type side by side Mounting height 1000 m Figure 3 9 Max current load of the CDA32 004 Cx x 0 75 kW side by side without additional cooling area 20 25 30 35 40 45 50 55 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 I A 16 kHz 8 kHz 4 kHz 3 75 A 4 A 3 1 A 2 6 A 2 A C Cooling air temperature JK ...

Page 122: ...oling area Motor cable length 10 m Rated current 4 A Switching frequency of power stage 4 8 16 kHz Mounting type side by side Mounting height 1000 m Figure 3 10 Max current load of the CDA32 004 Cx x 0 75 kW side by side with backplane 0 065 m as additional cooling area 20 25 30 35 40 45 50 55 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 I A 16 kHz 8 kHz 4 kHz 4 A 3 3 A 2 8 A 2 2 A C Cooling air temperature JK ...

Page 123: ...otor cable length 10 m Rated current 7 1 A Switching frequency of power stage 4 8 16 kHz Mounting type side by side Mounting height 1000 m Figure 3 11 Max current load of the CDA32 008 Cx x 1 5 kW side by side without additional cooling area 20 25 30 35 40 45 50 55 I A 16 kHz 8 kHz 4 kHz 1 2 3 4 5 6 7 8 9 K 7 1 A 5 4 A 4 9 A 4 1 A 3 1 A C Cooling air temperature J ...

Page 124: ... length 10 m Rated current 7 1 A Switching frequency of power stage 4 8 16 kHz Mounting type side by side Mounting height 1000 m Figure 3 12 Max current load of the CDA32 008 Cx x 1 5 kW side by side with 20 mm clearance between the units with accessory heat sink HS32 200 20 25 30 35 40 45 50 55 I A 16 kHz 8 kHz 4 kHz 1 2 3 4 5 6 7 8 9 7 1 A 6 1 A 5 4 A 4 2 A C Cooling air temperature JK ...

Page 125: ...tor cable length 10 m Rated current 7 1 A Switching frequency of power stage 4 8 16 kHz Mounting type not side by side Mounting height 1000 m Figure 3 13 Max current load of the CDA32 008 Cx x 1 5 kW not side by side with backplane 0 3 m2 as additional cooling area 20 25 30 35 40 45 50 55 I A 16 kHz 8 kHz 4 kHz 1 2 3 4 5 6 7 8 9 7 1 A 6 1 A 5 4 A 4 2 A C Cooling air temperature JK ...

Page 126: ...e length 10 m Rated current 2 2 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 400 V Mounting type side by side Mounting height 1000 m Figure 3 14 Max current load of the CDA34 003 Cx x 0 75 kW side by side without additional cooling area mains voltage 3 x 400 V 20 25 30 35 40 45 50 55 0 5 1 1 5 2 2 5 I A 16 kHz 8 kHz 4 kHz C Cooling air temperature JK 2 2 A 2 2 A 1 3 A 1 A 2 A ...

Page 127: ... Rated current 2 2 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 460 V Mounting type side by side Mounting height 1000 m Figure 3 15 Max current load of the CDA34 003 Cx x 0 75 kW side by side without additional cooling area mains voltage 3 x 460 V 20 25 30 35 40 45 50 55 0 5 1 1 5 2 2 5 I A C Cooling air temperature JK 16 kHz 8 kHz 4 kHz 2 2 A 2 2 A 1 25 A 1 A 1 8 A ...

Page 128: ...0 m Rated current 4 1 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 400 V Mounting type side by side Mounting height 1000 m Figure 3 16 Max current load of the CDA34 005 Cx x 1 5 kW side by side without additional cooling area mains voltage 3 x 400 V 20 25 30 35 40 45 50 55 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 I A 16 kHz 8 kHz 4 kHz C Cooling air temperature JK 4 1 A 3 6 A 2 A 2 2 A 1...

Page 129: ...ted current 4 1 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 460 V Mounting type side by side Mounting height 1000 m Figure 3 17 Max current load of the CDA34 035 Cx x 1 5 kW side by side without additional cooling area mains voltage 3 x 460 V 20 25 30 35 40 45 50 55 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 I A C Cooling air temperature JK Not available at time of going to press ...

Page 130: ...10 m Rated current 4 1 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 400 V Mounting type side by side Mounting height 1000 m Figure 3 18 Max current load of the CDA34 035 Cx x 1 5 kW side by side with additional heat sink HS32 200 mains voltage 3 x 400 V 20 25 30 35 40 45 50 55 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 I A 16 kHz 8 kHz 4 kHz 4 1 A 3 6 A 3 2 A 2 6 A 1 4 A C Cooling air temp...

Page 131: ...ated current 4 1 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 460 V Mounting type side by side Mounting height 1000 m Figure 3 19 Max current load of the CDA34 035 Cx x 1 5 kW side by side with additional heat sink HS32 200 mains voltage 3 x 460 V 20 25 30 35 40 45 50 55 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 I A C Cooling air temperatureJK Not available at time of going to press ...

Page 132: ...0 m Rated current 4 1 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 400 V Mounting type not side by side Mounting height 1000 m Figure 3 20 Max current load of the CDA 34 005 Cx x 1 5 kW not side by side with backplane as additional cooling area mains voltage 3 x 400 V 20 25 30 35 40 45 50 55 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 I A 16 kHz 8 kHz 4 kHz 4 1 A 3 6 A 3 2 A 2 6 A 1 4 A C C...

Page 133: ...ed current 4 1 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 460 V Mounting type not side by side Mounting height 1000 m Figure 3 21 Max current load of the CDA 34 005 Cx x 1 5 kW not side by side with backplane as additional cooling area mains voltage 3 x 460 V 20 25 30 35 40 45 50 55 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 I A C Cooling air temperature JK Not available at time of going...

Page 134: ...Rated current 5 7 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 400 V Mounting type side by side Mounting height 1000 m Figure 3 22 Max current load of the CDA 34 006 Wx x 2 2 kW side by side wall mounting mains voltage 3 x 400 V 20 25 30 35 40 45 50 55 1 5 2 2 5 3 3 5 4 4 5 5 5 5 6 I A C Cooling air temperature JK 1 A 4 7 A 5 1 A 5 7 A 2 6 A 4 kHz 8 kHz 16 kHz ...

Page 135: ...ated current 5 7 A Switching frequency of power stage 4 8 kHz Mains voltage 3 x 460 V Mounting type side by side Mounting height 1000 m Figure 3 23 Max current load of the CDA 34 006 Wx x 2 2 kW side by side wall mounting mains voltage 3 x 460 V 20 25 30 35 40 45 50 55 1 5 2 2 5 3 3 5 4 4 5 5 5 5 6 I A C Cooling air temperature JK 4 7 A 5 1 A 5 7 A 4 kHz 8 kHz ...

Page 136: ...10 m Rated current 7 8 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 400 V Mounting type side by side Mounting height 1000 m Figure 3 24 Max current load of the CDA 34 008 Wx x 3 kW side by side wall mounting mains voltage 3 x 400 V 20 25 30 35 40 45 50 55 I A 16 kHz 8 kHz 4 kHz 1 2 3 4 5 6 7 8 9 K 8 A 4 8 A 6 5 A 5 5 A 3 5 A C Cooling air temperature J ...

Page 137: ...current 10 A Switching frequency of power stage 4 8 16 kHz Mains voltage 3 x 400 V Mounting type side by side Mounting height 1000 m Figure 3 25 Max current load of the CDA 34 010 Wx x 4 kW side by side wall mounting mains voltage 3 x 400 V 20 25 30 35 40 45 50 55 I A 16 kHz 8 kHz 4 kHz 10 A 6 2 A 8 2 A 7 0 A 4 4 A 2 3 4 5 6 7 8 9 10 K C Cooling air temperature J ...

Page 138: ... length 10 m Rated current 10 A Switching frequency of power stage 4 8 kHz Mains voltage 3 x 460 V Mounting type side by side Mounting height 1000 m Figure 3 26 Max current load of the CDA 34 010 Wx x 4 kW side by side wall mounting mains voltage 3 x 460 V 20 25 30 35 40 45 50 55 I A 8 kHz 4 kHz 10 A 8 8 A 7 5 A 6 2 A 2 3 4 5 6 7 8 9 10 K C Cooling air temperature J ...

Page 139: ...3 56 Engineering Guide CDA3000 3 Selection of inverter module The current characteristics of the other inverter modules were not available at the time of going to press ...

Page 140: ...sses resulting from the additio nal motor cable length must be taken into account Table 3 27 applies to motor cable lengths up to 150 m Clock Frequency Mains voltage 1 x 230 V Mains voltage 1 x 400 V Mains voltage 1 x 460 V Motor choke Motor choke Motor choke without mA per m with mA per m without mA per m with mA per m without mA per m with mA per m 4 10 15 20 8 15 30 40 16 25 60 70 Not available...

Page 141: ...ive inverter capacity utilization Figure 3 27 Effective inverter capacity utilization The inverter module is defined by Ieff IN Inverter The condition ILoad 2 IN Inverter 2 x tOverload 75A2s must additionally be met otherwise the inverter module will shut down due to overload For ease of effective value calculation we recommend the LUDRIVE drive dimensioning program V m s 0 5 1 0 1 5 1 8 I A t1 t2...

Page 142: ...o 1 1 8 IN 15 s 0 0 1 8 IN 15 s 70 s Ieff IN X 2 1 8 IN 15 s 0 3 IN 75 s 1 8 IN 15 s 0 s Ieff IN X 3 1 5 IN 30 s 0 0 1 5 IN 30 s 80 s Ieff IN X 4 1 5 IN 1 s 0 7 IN 3 s 1 5 IN 1 s 1 s Ieff IN X 5 1 8 IN 0 2 s 0 2 IN 0 5 s 1 8 IN 0 2 s 0 45 s Ieff IN X 6 1 8 IN 0 2 s 0 3 IN 0 3 s 1 8 IN 0 2 s 0 2 s Ieff IN X 7 1 8 IN 0 1 s 0 3 IN 0 3 s 1 8 IN 0 1 s 0 2 s Ieff IN X 8 1 7 IN 0 1 s 0 0 1 7 IN 0 1 s 0 4...

Page 143: ... values have been read they can be reset 1 Acceleration max acceleration current in parameter IMAXBE 2 Stationary operation max current in stationary operation in parameter IMAXST 3 Braking max braking current in parameter IMAXBR Figure 3 28 Peak current value storage for checking of drive dimensioning The peak current value memory continuously stores the absolute peak values in the acceleration s...

Page 144: ...asuring equipment are permitted Since such equipment is not usually available to practicians on site conventional measuring equipment can be used as a fallback A measuring circuit with device data is shown in Figure 3 29 on the follo wing page However it should be made clear that the measuring device displays in particular at the inverter output are only guide values When using an oscilloscope to ...

Page 145: ...3 62 Engineering Guide CDA3000 3 Selection of inverter module Figure 3 29 Measuring circuit for a voltage inverter suggested configura tion with oscillograms block diagrams ...

Page 146: ... service in a three phase AC system a rotat ing field is created in the motor which drives the rotor The rotation speed is determined by the following variables The motor type is determined by the rotor introduced into the rotating field Overview of three phase AC motors ns synchronous speed P number of pole pairs f stator frequency A ns f 60 P 3 phase AC motor Synchronous motor Asynchronous motor...

Page 147: ...us synchronous In the textile industry for Spoolers viscose pumps galette drives or roller drives etc Further areas of application are in drafting equipment and for synchronous running of two axles High frequency motor asynchronous In the timber processing industry as the main drive Further areas of application are grinding and milling spindles centrifuges vacuum pumps and winders Asynchronous ser...

Page 148: ...a favorable way In this way outstand ing control characteristics are attained even without the use of a cost intensive encoder Motor type Project planning notes Standard three phase AC motor See section 2 5 1 and 3 3 Asynchronous servomotor See section 2 5 2 Displacement type armature motor In a displacement type armature motor the brake is ventilated by the magnetic field of the motor The motor m...

Page 149: ...ol SFC Sensorless Flux Control FOR Field Oriented Regulation Torque rise time approx 10 ms 2 ms 2ms Dynamic disturbance correction NO YES YES Standstill torque NO NO YES Correction time for a load surge of 1 x MN 100 ms 100 ms 100 ms Anti stall protection limited YES YES Speed manipulating range MConst 1 20 1 50 1 10000 Static speed accuracy n nN 2 1 quartz accurate Frequency resolution 0 01 Hz 0 ...

Page 150: ...d by the inverter module to 2 x IN Motor For data relating to the servomotors refer to section 2 5 2 Property VFC Voltage Frequency Control SFC SensorlessFlux Control FOR Field Oriented Regulation Break away torque1 with standard motor UN 400 V 1 6 x MN 1 8 x MN 2 x MN Break away torque1 with servomo tor UN 330 V 2 5 x MN 2 6 x MN 2 8 x MN Acceleration torque1 with standard motor UN 400 V 1 2 x MN...

Page 151: ...rectly after read in of control signals on inverter 4 Slip range depending on control mode the braking ramp is slip dependent Figure 3 30 Start stop positioning Property VFC Voltage Frequency Control SFC SensorlessFlux Control FOR Field Oriented Regulation Braking time 100 ms external moment of inertia motor moment of inertia Standard motor UN 400 V 1500 rpm to 0 rpm 10 9 9 Standard motor UN 400 V...

Page 152: ...ration refer to section 1 3 3 d Diameter of drive pinion in mm Standard motor UN 400 V 1500 rpm to 0 rpm 9 9 9 Standard motor UN 400 V 1500 rpm to 0 rpm 4 4 3 Servomotor UN 330 V 1500 rpm to 0 rpm 12 10 8 Servomotor UN 330 V 1500 rpm to 0 rpm 6 5 4 Values referred to the motor shaft Property VFC Voltage Frequency Control SFC SensorlessFlux Control FOR Field Oriented Regulation Table 3 33 Typical p...

Page 153: ...r in standard inverter operation 2 Permissible torque characteristic of an internally cooled standard three phase AC motor in standard inverter operation 2 1 Typical characteristic at motor power output 4 kW 2 2 Typical characteristic at motor power outputs 15 kW Note Precise data can only be given by the manufacturers of the motors 3 Permissible torque characteristic of an adequately externally c...

Page 154: ...e section 2 3 1 and 2 5 1 In applications requiring high overload torques Motor power higher than power output of inverter modules Area of application of solution In applications in which internally cooled motors are to be used in continuous operation S1 over a very broad manipu lating range Note The motor current consumer in continuous operation must not exceed the rated current of the inverter m...

Page 155: ...pm on the gear output shaft Output torque on gear output shaft of 150 Nm Operation mode S1 continuous operation ED 100 There is no time requirement for the startup and braking response Operation of a motor with 25 field weak ening Area of application of solution In applications such as traction and lifting drives For more information see section 3 3 4 Operation of a motor with 87 Hz character isti...

Page 156: ... up all three motor control methods 2 Drive design with 70 Hz Figure 3 33 70 Hz drive design In the 70 Hz drive design with 25 field weakening the maximum speed of the 1 5 kW motor is increased by way of the inverter module from 1421 rpm 50Hz to 2000 rpm 70Hz The adaptation of the desired output speed on the gearbox is compensated by a higher transmission However since a two stage gearing is requi...

Page 157: ...gns with 50 Hz and 70 Hz characteristic Figure 3 34 Comparison of gear output torque in a drive design for 50 and 70 Hz Curve 50 Hz Curve 70 Hz Explanation 1 2 Typical permissible torque characteristic of an internally cooled standard motor 1 5 kW 3 4 Typical permissible torque characteristic of an externally cooled standard motor 1 5 kW 5 6 Maximum attainable torque for 60 s of a drive with 1 5 t...

Page 158: ...que a 40 higher maximum torque is of course also achieved see characteristics 5 and 6 in Figure 3 34 and thus also a 40 higher break away torque 60 larger speed manipulating range The motor speed increased by a factor of 1 4 produces an approx 60 larger speed manipulating range on the gear output shaft Referred to to the application set out in Figure 3 32 Figure 3 33 and Figure 3 34 the 70 Hz desi...

Page 159: ...can be expanded to 87 Hz in delta configuration Example Motor 4 kW 50 Hz in delta configuration Rated power 4 kW Nominal speed 1420 rpm Rated voltage 230 400 V Delta star configuration 1 Reconfigure motor to delta configuration 230 V delta 2 Select inverter output 4 kW 1 73 6 9 kW Selected inverter module CDA34 017 Rated power 7 5 kW Rated voltage 0 400 V Max output frequency 0 100 Hz PInverter PM...

Page 160: ...o 50 Hz Motor with 4 kW 50 Hz in delta configura tion on inverter module CDA34 017 7 5 kW Area of application of solution In applications with constant torque delivery to 87 Hz e g lifting drives Precise data relating to the full load power S1 ED 100 can only be given by the motor manufactur ers During initial commissioning all the parameters for this application are automatically set Table 3 36 A...

Page 161: ...s a major influence on the accelera tion power The acceleration power rises with the square of the speed increase e g caused by the choice of max 87 Hz instead of 50 Hz JM Moment of inertia of the motor rotor in kgm tBE Acceleration time in s PMBE Motor acceleration power in W PMBE JM n 2 91 2 tBE ...

Page 162: ...A3000 inverter modules can be run with several motors config ured in parallel Depending on drive task various project planning condi tions must be met L1 Line choke See section 6 1 L2 Motor choke See section 6 2 Figure 3 36 Multi motor operation on one inverter K2 U V W PE L1 L2 L3 PE L1 L2 L3 PE F1 K1 L1 CDA3000 M 3 L2 K3 Kn M 3 M 3 ...

Page 163: ...tion the parallel connected motors cannot be pro tected by the inverter module For that reason depending on specific depending on the motor should be protected by means of external motor circuit breakers or thermistor protective relays see 3 2 13 All motors have the same power output In this application the torque characteristics of all motors remain roughly equal The motors have different power o...

Page 164: ...vation of individ ual motors Shut off of motors See section 3 2 9 When connecting motors ensure that the connection current is not higher than the inverter peak current It is advantageous if the inverter load is 40 This 40 base load backs up the output voltage of the inverter module at the moment of connection of the motor During connection the motor must not be run in the field weakening range si...

Page 165: ... DC network which is consumed by the motorized inverter modules The regenerative energy does not need to be delivered from the mains DC network operation of several inverter modules minimizes the energy consumption from the mains and in most cases eliminates the need for use of braking chopper units Figure 3 37 Circuitry example DC network operation M 3 U1 U V W PE L1 L2 L3 PE L1 L2 L3 PE F1 L1 M1...

Page 166: ...to the mains power DC link connection Make short cable connections to the common DC link center point Use cable cross section corresponding to mains power cable cross section see Operation Manual and section 3 2 Select DC link fuses corresponding to the cable cross section and local regulations The fuses protect the cable The DC fuses can be omitted if the cable cross section used to wire the DC n...

Page 167: ...r must not be less than the minimum ohmic connected load permitted by the inverter module 2 Adding together the peak braking powers of all braking resistors operated in the DC network produces the peak braking power referred to the DC network PSDC PSW1 PSW2 PSWn PSDC total peak braking power in the DC network PSW1 peak braking power of braking resistor 1 3 The continuous braking power of the indiv...

Page 168: ...dule DE EN 1 2 3 4 5 6 7 A Figure 3 39 DC network operation with PTC precharging circuit DC network operation with VF1000S M L MC6000 and MC7000 is not permitted M 3 3 M1 M 3 3 M2 F1 L1 3 Mains F4 L2 3 Mains F2 3 F5 6 M 3 3 Mn Fn Ln 3 Mains Fn 1 n 2 U1 U2 Un ...

Page 169: ...rgy back into the inverter This increases the voltage in the DC link If the volt age exceeds a permissible value the internal braking transistor is acti vated and the regenerative energy is converted into heat by way of the externally connected braking resistor Figure 3 40 Block diagram of an inverter with braking chopper Asynchronous motor External braking resistor ...

Page 170: ...ctive braking power PS Peak braking power PD Continuous braking power T Sampling time work cycle t1 0 2 s t2 3 s t3 0 2 s t4 0 2 s t5 3 s t6 0 2 s T 8 4 s The continuous braking power of the braking resistor must be Peff The sampling time T must be 150 s V t m s t1 t2 t3 t4 t5 t6 T 1580 998 0 P W PS1 PS2 t t3 t6 0 Peff Ps1 2 t3 Ps2 2 t6 T ...

Page 171: ...r 180 Ω Load cycle see Figure 3 41 1 Calculation with LUDRIVE Figure 3 42 Calculation of effective braking power with LUDRIVE 2 Choice of braking resistor See section 6 3 Braking resistor BR 270 02 541 was chosen Peak braking power 2080 W Continuous braking power 300 W Resistance 270 Ω The resistance must not be less than the minimum ohmic connected load permitted by the inverter module ...

Page 172: ...n By means of a series configuration the continuous braking power can be adapted to the specific application Figure 3 43 Parallel configuration of two resistors Figure 3 44 Series configuration of tworesistors Figure 3 45 Calculation of peak braking power Table 3 39 Table 3 40 PS Peak braking power in W U DC link voltage in V 390 V or 750 V RBR Resistance of braking resistor in Ω R1 R2 replaceable...

Page 173: ...3 90 Engineering Guide CDA3000 3 Selection of inverter module 3 3 9 Power failure bridging Not available at time of going to press ...

Page 174: ...ommissioning 4 6 4 1 3 Operation via KEYPAD KP200 4 11 4 1 4 Operation via DRIVEMANAGER 4 12 4 2 Device and terminal view 4 15 4 2 1 Specification of control terminals 4 16 4 2 2 Isolation method and connection tips 4 19 4 3 Preset solutions 4 20 4 3 1 Traction and lifting drive 4 24 4 3 2 Rotational drive 4 39 4 3 3 Field bus operation 4 49 4 3 4 Master Slave operation 4 56 ...

Page 175: ...eration of the inverter module See Figure 4 1 Application data set Application data sets are complete preset parameter sets for handling a wide variety of movement tasks See Figure 4 2 Loading an application data set into the RAM automatically configures the inverter module All subject areas and the signal processing inputs and outputs are automatically preset to the desired solution Use of the ap...

Page 176: ...Option modules Driving profile generator VFC I x R load compensation Slip compensation Current injection Magnetizing Encoder evaluation Current controller Speed controller FOR Motor data Motor protection KP 200 Device capacity utilization Device data Power failure bridging Warning messages Error messages Actual values Analog inputs Analog output Digital inputs Digital outputs Clock input clock out...

Page 177: ... parameter ASTER By way of the application data sets and the assist ance parameter 15 preset solutions can be selected See section 4 3 Figure 4 2 Data structure of the CDA3000 Traction and lifting drive 001 MODE 999 xyz 001 MODE 999 xyz Rotational drive Bus operation User data set 3 User data set 3 4 Active data set RAM Load Load Save Application data sets User data sets Unassigned Master Slave op...

Page 178: ... set In the inverter module four user data sets can be managed See 4 1 The user data sets can be selected and activated via KEYPAD DRIVE MANAGER bus access or terminals Terminal 1 Terminal 2 User data set Custom data set 0 0 1 0 0 1 1 1 Table 4 1 Example of selection of user data sets via terminals User data set 1 001 MODE 999 xyz User data set 2 001 MODE 999 xyz User data set 3 001 MODE 999 xyz U...

Page 179: ... in operation Sequence of initial commissioning 1 Sensorless Flux Control 2 Field Oriented Regulation 3 Voltage Frequency Control Activate application data set Select control terminal presetting Select control mode Motor data input Enter application data Motor identification and controller setting Save setting in user data set Step Function Explanation 1 Activate application data set Traction and ...

Page 180: ...lication 2 1 Call up parameter ASTER and select setting DRV_3 The control terminal is assigned the quick jog slow jog driving pro file and limit switch evaluation functions 6 Select control mode Voltage Frequency Control Sensorless Flux Control Field Oriented Regulation 7 Save all settings in a user data set Initial commissioning com plete For more information on application data sets and assistan...

Page 181: ...ers and enter the read values Parameter Setting Function MOTYP ASM Motor type asynchronous machine 1 MOPNM 1 5 kW Motor rated power 2 MOVNM 400 V Motor rated voltage 3 MOFN 50 Hz Motor rated frequency 4 MOSNM 1450 rpm Motor nominal speed 5 MOCNM 6 A Motor rated current 6 MOCOS 0 8 cos ϕ of motor Table 4 3 Parameters for the motor data 400 V 1 5 kW 1450 rpm 6 0 A cos j 0 8 50 Hz 1 2 3 4 5 6 ...

Page 182: ...al moment of inertia is set equal to that of the motor shaft moment of inertia adapta tion JM Jred Calculation of reduced moment of inertia on motor shaft Figure 4 4 Example In the example the moment of inertia of the load is known Select parameter SCJ1 and set to 0 003 kgm 4 2 Enter motor moment of inertia If the motor is a standard motor to DIN VDE 0530 it is not neces sary to give the moment of...

Page 183: ...rol mode 6 1 Call up parameter CFCON and set to SFC The Sensorless Flux Control mode for optimum dynamics with out speed feedback is activated 7 Save all parameters to one of the four user data sets 7 1 Call up parameter UMWR and enter the value 1 for user data set 1 Note Only by saving the data sets to one of the user data sets are the data from the volatile device RAM permanently stored Otherwis...

Page 184: ...r Figure 4 5 Mounting the KEYPAD max cable length 3 meters The KEYPAD KP200 has a user friendly menu structure which is identical to the menu structure of the KP100 for the SMARTDRIVE VF1000 inverters and for the MASTERCONTROL servocontrollers Figure 4 6 Overview of the KP200 menu structure Actual values Select Display Capacity indicator Subject area Select Parameter Select Change Initial commissi...

Page 185: ...editor with plain text dis play See Figure 4 8 Status display to monitor the operation specific actual and reference values Direct control of the inverter by PC User friendly four channel digital scope for real time recording of actual values such as current curve or v t diagram See Figure 4 10 Comparison function for problem solving and data administration and print functions Call up menu subject...

Page 186: ... Figure 4 9 CDA3000 with DRIVEMANAGER H1 H2 H3 X4 X2 X1 X3 ACHTUNG Kondensatorent ladezeit 3 Min Betriebsanleitung beachten WARNING capacitor disscharge time 3 minutes Pay attention to the operation manual ATTENTION temps de decharge du condensteur 3 min observer le mode dèmploi ANTRIEBSTECHNIK SN 000 000 00000000 Typ Netz Ausg D 35633 Lahnau L3 U V W RB RB L L1 L2 DRIVE MANAGER yy 3m max ...

Page 187: ...gineering Guide CDA3000 4 Software functions Digital scope With the digital scope up to four channels can be recorded simultane ously permitting comprehensive diagnosis Figure 4 10 Example Speed step response ...

Page 188: ...n Function H1 H2 H3 LEDs Device status display X1 Power terminal Mains motor braking resistor DC feed X2 Control terminal 4 digital inputs 3 digital outputs of which 1 relay 2 analog inputs 1 analog output Table 4 4 Key to Figure 4 11 X4 X2 X1 X1 X3 1 2 X10 X11 X12 CDA34 xxx CANopen CANLust CDA32 xxx X15 X10 X11 PROFIBUS DP 1 2 X13 X13 UM 8I4O ...

Page 189: ...n 2 Boot button No Designation Function Table 4 4 Key to Figure 4 11 Des Terminal Specification floating Analog inputs ISA00 X2 2 UIN 10 V DC 10 V DC IIN 0 4 20 mA DC software switchable to 24 V digital input PLC compatible IEC1131 Switching level Low High 4 8 V 8 V DC Resolution 10 bit Rin 110kΩ Floating against digital ground U 1 of MV I 1 of MV ISA01 X2 3 UIN 10 V DC software switchable to 24 V...

Page 190: ...s Data input in reference coupling ISD02 X2 11 Limit frequency 500 kHz PLC compatible IEC1131 Switching level Low High 5 V 12 V DC Imax at 24 V 10 mA RIN 3 kΩ Delay 2µs A input with square encoder evaluation for 24V HTL encoder against GND_EXT Permissible pulse counts 32 16384 pulses per rev 2n with n 5 14 ISD03 X2 12 Limit frequency 500 kHz PLC compatible IEC1131 Switching level Low High 5 V 12 V...

Page 191: ...ide driver Data output with reference coupling restricted Relay output OSD02 X2 18 X2 19 X2 20 Relay 48 V 1 A AC changeover contact Usage category AC1 Operating delay approx 10 ms Motor temperature PTC1 2 X3 1 X3 2 Measured voltage max 12 V DC Measuring range 100 Ω 15 kΩ suitable for PTC to DIN 44082 suitable for temperature sensor KTY84 yellow Sampling time 5 ms Voltage supply 10 5V X2 1 Auxiliar...

Page 192: ...sult of this split an n analog signal e g for the speed reference is immune to interference entering the inverter module over the digital signal lines The two analog inputs may be used either both with analog or both with digital function If the analog inputs are to be assigned digital functions when using the internal 24 V auxiliary voltage it is necessary to interconnect the two grounds DGND and...

Page 193: ...plications With two additional basic settings the inverter module can be very easily preset for operation on the field bus and for network operation with several inverter modules Master Slave operation When one of these four basic settings has been selected the inverter module also offers the user the opportunity to select various control termi nal settings In this way the inputs and outputs of th...

Page 194: ... 5 6 7 A Application data set Traction and lifting drive Application data set Designation Application Traction and lifting drive Section 4 3 1 Conveyor belt Rack drive Spindle drive Trolley drive Lifting drive Table 4 6 Application specific basic settings m2 m2 m2 m2 ...

Page 196: ... 23 4 Software functions DE EN 1 2 3 4 5 6 7 A Application data set Master Slave operation Application data set Application Master Slave operation Section 4 3 4 CPU CPU i1 CPU i1 M 3 M 3 M 3 Process X3 X3 X3 n2 n1 i1 n3 n1 i2 n1 ...

Page 197: ...ts and outputs for the traction and lifting drive application see Figure 4 13 CPU M 3 PTC n1 n2 m2 m2 m2 m2 9 5 5 5 4 5 3 5 2 5 1 1 2 3 4 6 7 8 Mains 3 5 9 9 1 Braking resistor 2 Inverter module 3 IEC standard motor 4 Gearing 5 Application 5 1 Conveyor belt 5 2 Rack drive 5 3 Spindle drive 5 4 Trolley drive 5 5 Lifting drive 6 Thermistor 7 Motor holding brake 8 Encoder 9 Safety limit switch Figure...

Page 198: ...t traction and lifting drive solution at the press of a button without having to read through the Operation Manual in detail to do so Setting of parameter ASTER for traction and lifting drives Function ASTER DRV_1 1 DRV_2 2 DRV_3 3 DRV_4 4 DRV_5 5 Quick jog driving profile Quick jog slow jog driving profile Table sets with fixed frequencies and ramps Motor brake actuation Characteristic data switc...

Page 199: ... Ready to start Speed reached Warnings Inverter module overloaded 80 of IN reached Motor overloaded Inverter ambient temperature too high 1 DRV_1 Page 27 2 DRV_2 Page 29 3 DRV_3 Page 31 4 DRV_4 Page 34 5 DRV_5 Page 36 Function ASTER DRV_1 1 DRV_2 2 DRV_3 3 DRV_4 4 DRV_5 5 Table 4 9 Application specific basic settings 001 MODE 999 xyz 1 001 MODE 999 xyz 2 M 3 ...

Page 200: ...tc X2 Function 1 Reference voltage 10V 10mA 2 not assigned 3 not assigned 4 Actual frequency 0 10 V corresponding to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware enable 9 Start Stop quick jog clockwise 10 Start Stop quick jog anti clock wise 11 Selection of slow jog 12 not assigned 13 Auxiliary voltage 24 V 14 Output signal for Motor holding brake 15 16 Reference reached m...

Page 201: ...PRStop ramp Figure 4 15 Example of a quick jog slow jog driving profile for two directions of rotation ASTER DRV_1 Output signals Figure 4 16 Output signals dependent on driving profile ASTER DRV_1 to DRV_5 t ms 0 0 1 0 1 0 1 STR STL S1 FMAX f Hz FMAX 592 DECR 594 STOPR 590 ACCR t ms 0 0 1 f Hz v m s 0 1 K1 H1 ...

Page 202: ...g profile or Quick jog slow jog driving profile Application switchover Switchover of setting when load changed Conveyor belt Trolley drive Rack drive Spindle drive Lifting drive etc X2 Function 1 10 1 Reference voltage 10 V 10 mA 2 User data set selection 3 4 Actual frequency 0 10 V corresponding to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware enable 9 Start Stop quick jog...

Page 203: ...S1 S2 Active UDS Example 0 0 UDS 1 for application 1 x axis traction drive 1 0 UDS 2 for application 2 y axis traction drive 0 1 UDS 3 for application 3 z axis lifting drive 1 1 UDS 4 for application 4 Sorting belt Table 4 10 User data set switchover S4 Active characteristic data set Example 0 Characteristic data set 1 Lifting drive with load 1 Characteristic data set 2 Lifting drive without load ...

Page 204: ... jog driving profile or Quick jog slow jog driving profile Application switchover Evaluation of safety limit switches Rack drive Spindle drive Trolley drive Lifting drive etc X2 Function 1 Reference voltage 10 V 10 mA 2 User data set switchover 3 Selection of slow jog 4 Actual frequency 0 10 V corresponding to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware enable 9 Start Sto...

Page 205: ...TER 3 The output signals are shown in Figure 4 16 User data set switchover switchable offline S1 Active UDS Example 0 UDS 1 for application 1 x axis traction drive 1 UDS 2 for application 2 z axis lifting drive Table 4 12 User data set switchover t ms 0 0 1 f Hz v m s 0 1 0 1 0 1 STR STL S1 1 303 FMAX1 303 FMAX1 270 FFIX1 590 ACCR1 592 DECR1 594 STPR1 ...

Page 206: ...ion of S4 and S3 Example Limit switch right resets Start Clockwise Resetting of Start Clockwise is not evaluated The Start Anti clockwise com mand can be used to move out of the limit switch zone The limit switch must not be overrun The signal must be applied continu ously no pulse evaluation S3 S4 t ms 0 1 0 1 f Hz 0 1 0 1 S3 STR STL S4 0 303 FMAX1 303 FMAX1 592 DECR1 590 ACCR1 ...

Page 207: ...ction Application Clock drive with time optimized quick jog driving profile Switchover for application Encoder evaluation Conveyor belt Rack drive Spindle drive Trolley drive Lifting drive etc X2 Function 1 Reference voltage 10 V 10 mA 2 User data set switchover 3 4 Actual frequency 0 10 V corresponding to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware enable 9 Start Stop cl...

Page 208: ...als Figure 4 25 Example of a quick jog driving profile for two directions of rota tion ASTER DRV_4 The output signals are shown in Figure 4 14 User data set switchover switchable offline S1 S2 Active UDS Example 0 0 UDS 1 for application 1 x axis traction drive 1 0 UDS 2 for application 2 y axis traction drive 0 1 UDS 3 for application 3 z axis lifting drive 1 1 UDS 4 for application 4 Sorting bel...

Page 209: ...ure 4 16 Function Application Clock drive with time optimized quick jog driving profile Selection of fixed frequencies Encoder evaluation Limit switch evaluation Switchover of applications Conveyor belt Rack drive Trolley drive Spindle drive Lifting drive X2 Function 1 Reference voltage 10 V 10 mA 2 not assigned 3 not assigned 4 Actual frequency 0 10 V corresponding to 0 FMAX 5 6 Auxiliary voltage...

Page 210: ...triebsanleitung beachten WARNING capacitor disscharge time 3 minutes Pay attention to the operation manual ATTENTION temps de decharge du condensteur 3 min observer le mode dèmploi X15 Function 1 24 V supply 20 0 6 A 2 Digital ground 21 Auxiliary voltage 24 V 22 Selection of table sets for fixed frequencies 23 24 25 26 Limit switch right 27 Limit switch left 28 User data set switchover 29 30 Digit...

Page 211: ...over switchable offline S1 S2 Active UDS Example 0 0 UDS 1 for application 1 x axis traction drive 1 0 UDS 2 for application 2 y axis traction drive 0 1 UDS 3 for application 3 z axis lifting drive 1 1 UDS 4 for application 4 Sorting belt Table 4 14 User data set switchover t ms 0 f Hz v m s 0 1 0 1 0 1 S3 S2 S1 0 1 STR 0 1 S4 270 FFIX1 600 FFTB0 601 FFTB1 602 FFTB2 604 FFTB4 TDCR4 615 TACR7 602 F...

Page 213: ... of a button without having to read through the Operation Manual in detail to do so Setting of assistance parameter ASTER for rotational drives Function Aster ROT_1 1 ROT_2 2 ROT_3 3 Speed input 10 V 10 V switchable to 0 10 V 0 4 20 mA Speed correction 0 to 10 V Speed change via button MOP function Table sets with fixed frequencies and ramps User data set switchover Encoder evaluation necessary fo...

Page 214: ...Reference reached Standstill Ready to start Warnings Inverter module overloaded 80 of IN reached Motor overloaded Inverter ambient temperature too high 1 ROT_1 Page 42 2 ROT_2 Page 44 3 ROT_3 Page 46 Function Aster ROT_1 1 ROT_2 2 ROT_3 3 Table 4 15 Application specific basic settings ...

Page 215: ...unction 1 Reference voltage 10 V 10 mA 2 Reference 10 V 10 V 3 not assigned 4 Actual frequency 0 10V corr to 0 FMAX 5 6 Auxiliary voltage 24V max 200 mA 7 8 Power stage hardware enable 9 Start Stop clockwise 10 Start Stop anti clockwise 11 Increase speed 12 Reduce speed 13 Auxiliary voltage 24 V 14 Digital ground 15 Message References reached 16 Standstill 17 Digital ground 18 Relay contact break ...

Page 216: ...ving profile for two directions of rotation ASTER ROT_1 Output signals H1 Speed reached H2 Standstill Figure 4 32 Output signals dependent on driving profile ASTER ROT_1 ROT_2 and ROT_4 t ms 0 0 1 0 1 f Hz v m s 0 1 S2 STL S1 0 1 STR 590 ACCR1 590 ACCR1 592 DECR1 590 ACCR1 592 DECR1 592 DECR1 1 1 t ms 0 f Hz v m s 0 1 0 1 H2 H1 ...

Page 217: ...igure 4 30 and Figure 4 32 Function Application Analog speed input for two directions of rotation Adjustment of speed via correction value Encoder evaluation Spindle Winding drive Extruder etc X2 Function 1 Reference voltage 10 V 10 mA 2 Reference 10 V 10 V 3 Correction value 0 V 10 V 4 Actual frequency 0 10 V corresponding to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware e...

Page 218: ... 5 6 7 A Input signals 1 Reference value of ISA00 Figure 4 34 Example of a driving profile for two directions of rotation ASTER ROT_2 The output signals are shown in Figure 4 32 t ms 0 f Hz v m s 0 1 0 1 STR STL 590 ACCR1 590 ACCR1 590 ACCR1 1 594 STPR1 592 DECR1 1 1 ...

Page 219: ...e 4 32 Function Application Analog speed input for two directions of rotation Adjustment of speed via correction value Selection of fixed frequencies Switchover of applications Encoder evaluation Spindle Winding drive etc X2 Function 1 Reference voltage 10 V 10 mA 2 Reference 10 V 10 V 3 Correction value 0 V 10 V 4 Actual frequency 0 10 V corresponding to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 ...

Page 220: ... ground 31 Warning Inverter module overloaded 32 Warning Motor overloaded 33 Warning 80 of IN exceeded 34 Warning Ambient temperature too high 35 Digital ground S6 H6 H5 H4 H3 S5 S4 S3 S2 S1 3 4 5 6 7 8 9 10 11 12 1 2 16 17 18 19 20 X15 H1 H2 H3 X4 X2 X1 X3 ANTRIEBSTECHNIK D 35633 Lahnau L3 U V W RB RB L L1 L2 1 2 3 4 5 16 17 18 19 20 11 12 13 14 15 6 7 8 9 10 ACHTUNG Kondensatorent ladezeit 3 Min...

Page 221: ... S2 Active UDS Example 0 0 UDS 1 for application 1 Spindle 1 1 0 UDS 2 for application 2 Spindle 2 0 1 UDS 3 for application 3 Spindle 3 1 1 UDS 4 for application 4 Sorting belt Table 4 16 User data set switchover t ms 0 f Hz v m s 0 1 0 1 0 1 S3 S2 S1 0 1 STR 0 1 S4 270 FFIX1 600 FFTB0 601 FFTB1 602 FFTB2 604 FFTB4 TDCR4 615 TACR7 602 FFTB7 590 ACCR1 608 TACR0 609 TACR1 610 TACR2 619 TDCR3 611 TA...

Page 222: ...presets the inverter functions for field bus operation This requires that an appropriate communication module is fitted to the CDA3000 1 Field bus 2 Inverter module 3 IEC standard motor 4 Gearing 5 Application Figure 4 39 Drive solution Field bus operation SPS CPU CPU CPU M 3 n1 n2 M 3 n1 n2 M 3 n1 n2 2 3 4 2 3 4 2 3 4 Process 5 1 ...

Page 223: ...l via PLC Digital inputs and outputs readable and writable over the bus Manual mode independent of bus Limit switch evaluation 1 BUS_1 Page 51 2 BUS_2 Page 52 3 BUS_3 Page 54 Table 4 17 Preset control terminal functionality 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 SPS PLC IN1 IN2 IN3 IN4 OUT1 OUT2 OUT3 ...

Page 224: ... 3 min observer le mode dèmploi X10 X11 X12 1 2 Function Application Control of the inverter module over the field bus All digital inputs and outputs can be set and read over the bus Traction and lifting drive Rotational drive X2 Function 1 10 1 Reference voltage 10V 10mA 2 Analog input 1 3 Analog input 2 4 Analog ground 5 Analog output 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware ...

Page 225: ...ield bus Control of the device in emergency also independently of field bus Manual automatic switchover Setting and reading of digital inputs and outputs over the bus Traction and lifting drive Rotational drive X2 Function 1 Reference voltage 10 V 10 mA 2 Reference for manual mode 0 V 10 V 3 not assigned 4 Actual frequency 0 10 V corr to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage...

Page 226: ...ions DE EN 1 2 3 4 5 6 7 A Input signals 1 Analog reference value of ISA00 Figure 4 42 Example of use of manual mode independent of bus mode ASTER BUS_2 t ms 0 f Hz v m s 0 1 0 1 S1 STR 0 1 STL 590 ACCR1 590 ACCR1 590 ACCR1 1 594 STPR1 592 DECR1 1 1 ...

Page 227: ...rter module over the field bus Control of the device in emergency also independently of bus Manual automatic switchover Evaluation of safety limit switches Traction and lifting drive X2 Function 1 Reference voltage 10 V 10 mA 2 Reference for manual mode 0 V 10 3 Selection of manual mode 4 Actual frequency 0 10 V corr to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware enable 9...

Page 228: ...igure 4 44 Example of use of emergency operation independent of bus mode ASTER BUS_3 The mode of functioning of the limit switch evaluation is shown in Figure 4 21 and Figure 4 22 t ms 0 f Hz v m s 0 1 0 1 S1 STR 0 1 STL 590 ACCR1 590 ACCR1 590 ACCR1 1 594 STPR1 592 DECR1 1 1 ...

Page 229: ...ing can be effected with up to six units with one unit being the master The reference value of the master is also the guide value for the devices connected to the master slaves The master transmits the reference value to the slaves by way of a data telegram In each slave the guide value received from the master can be scaled meaning that any desired transmission ratios can be set In this way it is...

Page 230: ...f five slave drives can be connected Characteristics VFC VoltageFrequency Control SFC Sensorless Flux Control FOR Field Oriented Regulation Speed manipulating range M MNom 1 20 1 50 1 10000 Static speed accuracy referred to the nominal speed typically 1 to 5 typically 0 5 quartz accurate Frequency resolution 0 01 Hz 0 065 Hz 2 16 Hz Table 4 18 Comparison of motor control methods M3 3 M2 3 M1 3 16 ...

Page 231: ...4 58 Engineering Guide CDA3000 4 Software functions Figure 4 47 Speed curve in Master Slave operation n rpm n 3000 rpm n 1500 rpm n 1000 rpm n 600 rpm t ms Master Slave 1 i 2 Slave 2 i 3 Slave 5 i 5 ...

Page 232: ...S1 1 M S2 2 M S3 3 M S4 4 Inverter module is master Inverter module is slave Speed change via but ton MOP function Encoder evaluation Messages Standstill Ready to start Message Reference reached 1 M S1 Page 60 2 M S2 Page 62 3 M S3 Page 64 4 M S4 Page 66 Table 4 19 Application specific basic settings MASTER SLAVE SLAVE MASTER SLAVE SLAVE n n M 3 ...

Page 233: ...gle syn chronous Winding drive Drafting equipment Trolley drive X2 Function 1 Reference voltage 10 V 10 mA 2 Reference 10 V 10 V 3 not assigned 4 Actual frequency 0 10 V corresponding to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware enable 9 Start Stop clockwise 10 Start Stop anti clockwise 11 Increase speed 12 Reduce speed 13 Auxiliary voltage 24 V 14 Digital ground 15 Mes...

Page 234: ...braking torque Figure 4 49 Example of a driving profile for two directions of rotation ASTER M S1 Output signals H1 Standstill Figure 4 50 Output signals dependent on driving profile ASTER M S1 and M S2 t ms 0 0 1 0 1 f Hz v m s 0 1 S2 STL S1 0 1 STR 2 590 ACCR1 590 ACCR1 590 ACCR1 1 1 594 STPR1 592 DECR1 592 DECR1 t ms 0 f Hz v m s 0 1 H1 ...

Page 235: ...o nous Winding drive Drafting equipment Trolley drive X2 Function 1 Reference voltage 10V 10mA 2 Reference 10 V 10 V 3 not assigned 4 Actual frequency 0 10V corr to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware enable 9 Start Stop clockwise 10 Start Stop anti clockwise 11 Encoder track A 12 Encoder track B 13 Auxiliary voltage 24 V 14 Digital ground 15 Message Standstill 16...

Page 236: ...braking torque 2 Analog reference value of ISA00 Figure 4 52 Example of a driving profile for two directions of rotation ASTER M S2 The basic characteristic of the output signals is shown in Figure 4 50 t ms 0 f Hz v m s 0 1 0 1 STR STL 1 590 ACCR1 590 ACCR1 590 ACCR1 2 2 1 594 STPR1 592 DECR1 ...

Page 237: ...s and line shafts not angle synchro nous Winding drive Drafting equipment Trolley drive X2 Function 1 Reference voltage 10 V 10 mA 2 Reference 10 V 10 V 3 not assigned 4 Actual frequency 0 10 V corresponding to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware enable 9 Start Stop clockwise 10 Master interface 11 Increase speed 12 Reduce speed 13 Auxiliary voltage 24 V 14 Digita...

Page 238: ...torque Figure 4 54 Example of a driving profile with Master Slave coupling ASTER M S3 Output signals H1 Reference reached H2 Standstill Figure 4 55 Output signals dependent on driving profile ASTER M S3 and M S4 t ms 0 0 1 0 1 f Hz v m s S2 S1 0 1 STR 2 0 1 590 ACCR1 590 ACCR1 594 STPR1 592 DECR1 t ms 0 0 1 0 1 f Hz v m s H2 H1 ...

Page 239: ... Drafting equipment Trolley drive X2 Function 1 Reference voltage 10V 10mA 2 Reference 10 V 10 V 3 not assigned 4 Actual frequency 0 10 V corresponding to 0 FMAX 5 6 Auxiliary voltage 24 V max 200 mA 7 8 Power stage hardware enable 9 Start Stop clockwise 10 Master interface 11 Encoder track A 12 Encoder track B 13 Auxiliary voltage 24 V 14 Digital ground 15 Reference reached message 16 Message Sta...

Page 240: ...3 4 5 6 7 A Input signals 1 Guide value from master 2 DC braking torque Figure 4 57 Example of a driving profile with Master Slave coupling ASTER M S4 The basic characteristic of the output signals is shown in Figure 4 55 t ms 0 f Hz v m s 0 1 STR 2 0 1 594 STPR1 ...

Page 241: ...ic switchover Master Slave operation DC braking DC holding Modulation Fixed frequencies Reference structure Initial commissioning LUSTBUS Option modules Driving profile generator VFC I x R load compensation Slip compensation Current injection Encoder evaluation Current controller Speed controller FOR Motor data Motor protection KP 200 Device capacity utilization Device data Power failure bridging ...

Page 242: ...ess Rapid diagnosis and monitoring of actual values with the aid of a simple voltmeter Flexible function assignment of all digital inputs The inverter can be used to control the input signals and to influence the refer ence structure and the open loop and closed loop control functions Flexible function assignment of all digital outputs The output signals can be used to deliver control signals and ...

Page 243: ...ntly visible actual value and a bar graph display Protection of the inverter module against unauthorized access An actual value relevant to the process can be read from the KEYPAD Storage of the max current in the phases Acceleration stationary operation and deceleration The mean device capacity utilization is additionally registered Good verifiability of the inverter dimen sioning and helpful dia...

Page 244: ...atus of the user module The option modules are adapted to the field bus and the user module to the process LUSTBUS Option modules Open loop and closed loop control functions Subject area Function Effect Actuation of a motor holding brake when a programmable lower frequency limit is infringed Safe standstill even when inverter is inactive Facility to increase or reduce the refer ence value with two...

Page 245: ...ng Only in FOR mode is there speed synchronism Feed of a direct current into the motor causing it to brake No braking resistor is required to stop motors The braking energy is converted as heat in the motor Shutdown of the motor after braking with direct current Rotation due to the load on the motor is counteracted Setting of the switching frequency of the inverter power stage Optimization of the ...

Page 246: ...ip of the motor is compensated and the speed thereby kept constant inde pendent of the load An adjustable current is injected into the motor up to a limit frequency Increase in starting torque Prior to acceleration of the motor a magnetic field is injected into the motor When the motor is started the full torque is available immediately V F characteristic I x R load compensation Slip compensation ...

Page 247: ...ion of the software functions refer to the CDA3000 Application Manual Setting of the current control loop Optimum current usage of the motor and prevention of current overload shut offs Setting of the speed control loop for Field Oriented Regulation Very smooth running and good dynamics of the drive with encoder evaluation Current controller Speed controller FOR ...

Page 248: ...3 CAN BUS 5 4 5 3 1 Interconnection of inverter modules on the CAN bus 5 6 5 3 2 Communication via CANLUST 5 8 5 3 3 Communication via CANopen 5 12 5 4 PROFIBUS DP 5 13 5 4 1 Interconnection of LUST drive units with the PROFIBUS DP Gateway 5 14 5 4 2 Interconnection via the PROFIBUS DP module 5 17 5 4 3 Communication via PROFIBUS DP 5 18 ...

Page 249: ...unting the base unit is 25 mm wider Communication module e g CANLust CANopen PROFIBUS DP Control terminal expansion e g eight additional inputs and four addi tional outputs Figure 5 1 Inverter module with one control terminal expansion module and one communication module 1 2 3 4 5 6 7 8 9 10 11 12 1 2 16 17 18 19 20 X5 H1 H2 H3 X4 X2 X1 X3 ANTRIEBSTECHNIK D 35633 Lahnau L3 U V W RB RB L L1 L2 1 2 ...

Page 250: ...t of the I Os of the inverter module Figure 5 2 UM 8I4O Technical data UM 8I4O Voltage supply 24 VDC 20 Current consumption 0 6 A Eight inputs Input voltage for signal 0 from 0 to 5 V Input voltage for signal 1 15 V Input current with signal 1 3 5 mA to 7 0 mA 6 mA at 24 VDC Four outputs Output current Permissible range with signal 1 min 5 mA max 0 5 A Mean 125 mA Total current 0 5 A Short circuit...

Page 251: ...nd messages on the bus which can in turn be received by any other station on the bus Typically however transmissions are exchanged between two stations on the bus The basic rule is Any one can evaluate the information from an identifier for its own ends But only one station can have transmission rights for each identifier Each transmission is assigned a priority by the selection of the identifier ...

Page 252: ... EN 1 2 3 4 5 6 7 A CAN bus Topology Line Data transfer ISO 11898 Transmission speed 25 kBit s to 500 kBit s Transmission range 1000 m to 40 m Data security Hd 6 Number of stations 30 Number of data bytes 0 to 8 Bus access Master Master Table 5 2 CAN characteristics ...

Page 253: ...he CAN bus Figure 5 4 Communication module CM CAN1 or CM CAN2 CM CAN 1 Ambient temperature 10 C to 60 C Voltage supply 24 20 Current consumption 100 mA Protection Ip 20 Standards VBG 4 Address input Coding via bus connector coding plug address switch or parameter in the device Table 5 3 Technical data CM CAN2 ...

Page 254: ...ble to make your own cables 1 1 connection This relates to LS BUS cable type I Voltage supply CAN bus Voltage 24 V 20 Voltage ripple 3 Vss Current 100 mA per station Table 5 4 Voltage supply Cable type Shielded with at least nine wires Wires Twisted pair 0 25 mm2 Surge impedance 120 Ω Length Any total distance must not exceed 80 mm Table 5 5 Cable type 24VDC 24 VDC PLC 4 3 VF1000M VF1000M VF1000S ...

Page 255: ...NLUST Two modes are available for control of the inverter modules via CAN 1 Control of the drive unit by way of the state machine defined in DRIVECOM profile no 22 of January 1994 for Interbus 2 Direct selection of the following functions of the drive unit by way of the control word Transfer of reference and actual values Starting and stopping the drive Selection of fixed frequencies and ramps Err...

Page 256: ...profile no 22 of January 1994 5 6 7 Reset fault Table 5 6 DRIVECOM control word OPERATION ENABLED 4 x01x 0111 NOT READY 0 x0xx 0000 SWITCH ON INHIBIT 1 x1xx 0000 READY 2 x01x 0001 ON 3 x01x 0011 ERROR RESPONSE ACTIVE 6 x0xx 1111 ERROR 5 Reset error 1xxx xxxx EMERGENCY STOP ACTIVE 7 x00x 0111 13 0 15 x0xx 1000 Disable voltage xxxx xx0x 12 Disable voltage xxxx xx0x Emergency stop xxxx xx0x 10 Transi...

Page 257: ...serve 9 Reserve 10 Reserve 11 vacant 12 vacant 13 vacant 14 vacant 15 vacant Bit Status 0 Ready for start 1 On 2 Operation enabled 3 Fault 4 Power disabled 5 Emergency stop 6 Switch on inhibit 7 Warning 8 No function 9 Remote 10 Reference reached 11 Limit value 12 Mode dependent More detailed definition DRIVECOM profile no 22 of January 1994 13 14 vacant 15 vacant Table 5 7 DRIVECOM status word Bi...

Page 258: ...ice to error state 4 Selection of table reference 5 Selection of table reference 6 Selection of table reference 7 Reset error 8 Data set selection 9 Selection of user mode 10 Selection of user mode 11 OSD 00 reference state 12 OSD 01 reference state 13 OSD 02 reference state 14 Reserve 15 Reserve Table 5 8 CANLust control word Bit Function 0 Device in error state 1 One or more warning thresholds h...

Page 259: ...ing to press Summary Control of the CDA3000 via CANopen Reference and actual value transfer State machine to CiA DS 402 8 Status of input ENPO 9 Reserve 10 Reserve 11 Reserve 12 Actual status of ISD 00 13 Actual status of ISD 01 14 Actual status of ISD 02 15 Actual status of ISD 03 Bit Function Table 5 9 CANLust status word ...

Page 260: ...es required in drive engi neering Bus topology Device type Function DP Master class 1 Centralized control DP Master class 2 Programming project planning or operator control device Slave Peripheral device I O drive valves Table 5 10 Topology of PROFIBUS DP PROFIBUS DP Topology Line Data transfer RS 485 Bus access Master Slave access Transmission speed 9 6 kBit s to 12 MBit s Transmission range 1200...

Page 261: ... to the PROFIBUS DP Gateway the drive units must be fitted with the CANLust interface 2 PROFIBUS DP module PROFIBUS DP expansion module for CDA3000 Optimized for connection of a CDA3000 inverter module to the PROFIBUS DP Supports the expanded PROFIBUS DP functions in accordance with Directive 2 084 5 4 1 Interconnection of LUST drive units with the PROFIBUS DP Gateway The PROFIBUS DP Gateway conne...

Page 262: ...DP1 Ambient temperature 0 50 C Voltage supply 24 V DC 20 Current consumption max 1 4 A Protection IP20 Address input DIL switch Table 5 12 Technical data PROFIBUS DP Gateway DP Master Slave 1 Slave 2 Gateway CP DP1 1 2 10 SPS PROFIBUS DP Slave 3 1 2 3 4 5 16 17 18 19 20 11 12 13 14 15 6 7 8 9 10 CDA3000 1 2 3 4 5 16 17 18 19 20 11 12 13 14 15 6 7 8 9 10 CDA3000 ...

Page 263: ...lied with Gateway Cable type for self assembly If the supplied cables are not of the required length it is also possible to make your own cables 1 1 connection This relates to LS BUS cable type I Cable type Shielded with at least 9 wires Wires Twisted pair 0 25 mm2 Surge impedance 120 Ω Length Any total distance must not exceed 80 m Table 5 13 Cable type 24 VDC 1 6 2 4 3 5 MC7000 À À À À À À À À À...

Page 264: ...SUB connectors ensure that the shield is connected via the connector housing 2 For that reason the screw fittings 1 of the connectors must always be tightened Figure 5 11 Open connectors with strain relief and cable shield 5 4 2 Interconnection via the PROFI BUS DP module Not available at time of going to press Summary Layout and technical data of the PROFIBUS DP module 1 1 2 ...

Page 265: ...igure 5 12 Parameter process data object for user data traffic The PPO illustrated in Figure 5 12 includes a control word and a refe rence value for process data transfer from the master to the slave as well as a status word and an actual value for the reverse direction The param eter area in the PPO is optional which means it must be planned as required during slave configuration and is then tran...

Page 266: ...4 PKW PZD PKE IND PWE Parameter identifier value Process data Parameter identifier Index Parameter value STW1 ZSW1 HSW HIW Control word 1 Status word 1 Primary reference Primary actual Table 5 14 PPO 1 to PPO 4 Is transfer of parameter data required yes no Are reference and actual values to be transferred as 16 bit values Are reference and actual values to be transferred as 16 bit or 32 bit values...

Page 267: ...y Transparent mode provides the following functions Control of the drive unit according to the DRIVECOM state machine Direct selection of the following functions of the drive unit by way of the control word Transfer of reference and actual values Starting and stopping the drive Selection of fixed frequencies and ramps Error resets User data set switchover Characteristic switchover Setting of digit...

Page 268: ... 8 6 2 1 Technical data of the motor chokes 6 8 6 2 2 Assignment to the inverter modules 6 10 6 3 Braking resistors 6 12 6 3 1 Technical data of series BRxxx xx xx 6 12 6 3 2 Assignment to inverter modules CDA3000 6 13 6 4 Radio interference suppression filter 6 14 6 4 1 Technical data of RFI filters EMC34 xxx 6 14 6 4 2 Permissible motor cable length with internal RFI filter 6 15 6 4 3 Permissibl...

Page 269: ...o be observed for variable speed electric drives are laid down in the standards EN61800 3 and IEC1800 3 Of course the line choke also offers protection against transient system voltage peaks Reduction of voltage distortion THD 1 Reduction of commutation notches Reduction of the amplitude of the line charging current Increase in service life of the DC link capacitors Attenuation of transient voltag...

Page 270: ...to with line choke Voltage distortion THD 99 33 67 Mains current amplitude 18 9 A 9 7 A 48 Mains current effective 8 5 A 6 23 A 27 Commutation notches referred to the mains voltage 28 V 8 V 70 Life of the DC link capacitors Nominal life 2 to 3 times nominal life 200 to 300 Table 6 2 Change in system load resulting from insertion of a line choke with 4 short circuit voltage based on the example of ...

Page 271: ...easurement duration typically seven days Only in this way is a practise oriented assessment of your power supply system possible 6 1 2 Operation with reactive current compensation system Estimation of the resonance point Capacitors in systems with inverters cause oscillations which additionally distort the mains voltage The frequency of those oscillations depends on a number of different system pa...

Page 272: ... the vicinity of the harmonic numbers generated by the inverter of 5 7 9 11 13 etc it can be assumed that no resonance problems will occur It should be mentioned that additional motor loads shift the resonance points toward higher values and the ohmic resistance component in the system brings about an attenuation of the resonant circuit In complex system layouts in particular pre calculation of an...

Page 273: ...IN for 40 s 1 8 x IN for 40 s up to rated current 32 A 1 5 x IN for 60 s above rated current 45 A Ambient temperature typically 25 C to 45 C with power reduction to 60 C Mounting height 1000 m with power reduction to 4000 m Relative air humidity 15 95 condensation not permitted Storage temperature 25 C to 70 C Protection IP00 terminals VBG4 Short circuit voltage UK 4 at 230 V 9 2 V UK 4 at 400 V 9...

Page 274: ...with 4 UK Type Rated current Power loss W Dimensions HxWxD mm CDA34 003 0 75 kW LR34 4 4 2 A 20 120x100x70 CDA34 005 1 5 kW LR34 6 6 A 26 1 140x125x65 CDA34 006 2 2 kW LR34 6 6 A 26 1 140x125x65 CDA34 008 3 0 kW LR34 8 8 A 29 140x125x65 CDA34 010 4 0 kW LR34 10 10 A 33 140x125x75 CDA34 014 5 5 kW LR34 14 14 A 45 160x155x80 CDA34 017 7 5 kW LR34 17 17 A 45 160x155x80 CDA34 024 11 kW LR34 24 24 A 50...

Page 275: ...e of rise of voltage du dt at the motor terminals Suppression of faults caused by switching in the motor cable Increase in motor cable length Characteristic Motor choke MR32 xxx 3x230 V Motor choke MR34 xxx 3x400 460 V Table 6 6 Technical data of the motor chokes Inverter module Inverter rated power Line choke with 4 UK Type Rated current Power loss Dimensions HxWxD mm CDA34 003 CDA34 004 CDA34 00...

Page 276: ...014 CDA34 017 CDA34 024 CDA34 034 CDA34 045 CDA34 060 CDA34 072 CDA34 090 CDA34 110 CDA34 143 CDA34 170 Inverter module Inverter rated power Line choke with 4 UK Type Rated current Power loss Dimensions HxWxD mm Table 6 7 Technical data of line choke with 4 UK Not available at time of going to press ...

Page 277: ...004 CDA32 006 CDA32 008 CDA32 008 1 Rate of rise of voltage in V µs 2 Maximum motor cable shielded without current reduction Table 6 8 Technical data of motor choke for inverter modules Not available at time of going to press Inverter module Rec 4 pole standard motor Motor choke du dt 1 withoutmotor choke du dt 1 with motor choke Motor cable length2 without motor choke Motor cable length2 with mot...

Page 278: ...election of supplementary components DE EN 1 2 3 4 5 6 7 A In multi motor operation ensure that the total motor cable length is the sum of all individual motor cables The permissible total length of the motor cable must not be exceeded ...

Page 279: ...o prevent the DC link voltage of the inverter from reaching impermissible values in such cases the braking energy in the braking resistor is con verted into heat Technical data BR 270 02 XX0 BR 160 02 XX0 BR 270 03 XX1 BR 160 03 XX1 BR 090 03 XX1 BR 090 10 XX1 to BR 010 80 XX1 Surface temperature 200 C 80 C 80 C Touch protection no yes 80 C yes 80 C Voltage max 800 V max 800 V max 800 V High volta...

Page 280: ...ak braking power W Protection 390 VDC1 750 VDC2 BR 270 02 540 270 150 560 2080 IP54 BR 270 03 541 270 300 560 2080 IP54 BR 160 02 540 160 150 950 3500 IP54 BR 160 03 541 160 300 950 3500 IP54 BR 090 03 541 90 300 1690 6250 IP54 BR 090 10 201 90 1000 1690 6250 IP20 BR 090 10 541 90 1000 1690 6250 IP54 BR 042 20 201 42 2000 13390 IP20 BR 042 20 541 42 2000 13390 IP54 BR 015 60 541 15 6000 37500 IP20...

Page 281: ...rs RFI filters between the inverter module and the system reduces the line borne interference down to the permissible level Protection against line borne interference emission to EN 55011 A and EN 55022 B Characteristic RFI filter EMC34 xxx Table 6 12 Technical data RFI filter Rated current Power loss Dimensions H x W x D mm Table 6 13 Technical data Not available at time of going to press Not ava...

Page 282: ...A m 1 Class B m 1 Class A m 1 Class B m 1 CDA32 003 0 375 kW 25 10 25 10 25 10 25 10 25 25 CDA32 004 0 75 kW 25 10 25 10 25 10 25 10 25 25 CDA32 006 1 1 kW 15 10 15 10 25 15 25 15 25 25 CDA32 008 1 5 kW 15 15 15 15 25 15 25 15 25 25 CDA34 003 0 75 kW 15 15 25 15 25 10 25 15 25 25 CDA34 004 1 1 kW 15 15 25 15 25 10 25 15 25 25 CDA34 005 1 5 kW 15 15 25 15 25 10 25 15 25 25 CDA34 006 2 2 kW 15 15 25...

Page 283: ...lter With A and line choke UK 4 With external mains filter With C and line choke UK 4 With external mains filter With C and line choke UK 4 Class A m 1 Class B m 1 Class A m 1 Class B m 1 Class A m 1 Class B m 1 Class A m 1 Class B m 1 Class A m 1 Class B m 1 Class A m 1 Class B m 1 CDA34 024 EMC34 0 24 CDA34 034 EMC34 xxx CDA34 045 EMC34 xxx CDA34 060 EMC34 xxx CDA34 072 EMC34 xxx CDA34 090 EMC34...

Page 284: ...7 System installation 7 1 Heat discharge from the switch cabinet 7 2 7 1 1 Basic terms for calculation 7 2 7 1 2 Effective switch cabinet surface 7 3 7 1 3 Calculation of filter fans 7 4 7 1 4 Calculation of heat exchangers 7 5 7 2 Heat transfer by conduction 7 7 ...

Page 285: ...ture is higher than the interior temperature Ti Tu heat is radiated into the cabinet Qs 0 QE Watt Necessary cooling power of an air conditioning component this refers to the heat output which the device must discharge from the switch cabinet QH Watt Necessary heat output of a switch cabinet heater Ti C Maximum permissible cabinet interior temperature specified by the manufacturers of the electrica...

Page 286: ...se regulations as to how the effec tive switch cabinet surface is to be calculated dependent on the mode of installation The formulae to calculate A are laid down in DIN 57660 Part 500 VDE 0660 DIN 500 See Figure 7 1 Figure 7 1 Calculation of the effective emitting switch cabinet surface R l k m 2 K W Enclosure installation type to VDE 0660 Part 500 Single enclosure all round freestanding Single e...

Page 287: ... calculation See Figure 7 2 Figure 7 2 Radiated power of a switch cabinet surface 7 1 3 Calculation of filter fans The necessary volumetric flow of a filter fan depends on the power loss of the components installed in the switch cabinet and on the difference between the maximum permissible interior and exterior temperatures Necessary volumetric flow 2 QS k A Ti Tu 2000 1500 1000 900 800 700 600 50...

Page 288: ...becomes increasingly clogged with dirt and the heat discharge is thereby impaired For this rea son the heat emission via the switch cabinet surface should also be ignored when calculating the necessary volumetric flow of the fan 7 1 4 Calculation of heat exchangers In contrast to the filter fans the heat discharge via the switch cabinet sur face certainly does need to be taken into account in desi...

Page 289: ...depth of the cabinet in meters Thus in our example A 1 8 2 0 6 0 5 1 4 0 6 0 5 m 4 38 m Applying the approximation 4 4 m for A formula 1 produces 5 5 4 4 10 W 242 W Therefore the necessary cooling power of the heat exchanger according to formula 3 is QE QV QS 900 W 242 W 658 W Then a number of other variables need to be considered depending on whether an air to air or air to water heat exchanger i...

Page 290: ...uctivity A Area of wall m d Thickness of wall m ϑ1 ϑ2 Surface temperatures C or K Figure 7 3 Stationary heat conductance through a wall The thermal conductivity λ is a temperature dependent material property In electronic devices it can be considered as constant for most applica tions Tabelle 7 2 summarizes λ values for a number of key materials Depending on the task at hand provision of good heat...

Page 291: ...l comprises more than one layer the resultant temperature lag is equal to the sum of the temperature lags of the individual layers The specific thermal contact resistance of metal on metal is halved when heat transfer compound is used between two metal sur faces Good heat conductors Material λ Aluminum pure 230 Cast iron 58 V2A steel 15 Sheet steel 59 Tabelle 7 2 Thermal conductivity of some mater...

Page 292: ...uations A 5 A 2 2 Power output A 6 A 2 3 Torques A 11 A 2 4 Work A 12 A 2 5 Friction A 14 A 2 6 Effective motor torque power output A 15 A 2 7 Choice of max acceleration A 17 A 2 8 Mass moments of inertia A 20 A 2 9 v t diagram A 27 A 2 10 Efficiencies coefficients of friction and density A 30 A 2 11 Motor lists A 34 A 3 Protection A 40 A 3 1 Protection to IEC EN A 40 A 3 2 Protection to EEMAC and...

Page 293: ...gruent not parallel angle equivalent to parallel distance AB opposite to parallel arc AB rectangular to perpendicular to similar triangle Table 7 3 Geometric symbols Variable Formula symbol Units Formula A cross sectional area Name Abbreviation Voltage U Volt V U I R Current rating I Ampere A I U R Resistance R Ohm Ω R U I Conductivity elec G Siemens S 1 Ω G 1 R Specif el resistance ρ Ohm m Ωm Vm ...

Page 294: ...l displacement flux ψ Coulomb C As El displacement den sity D Coulomb m2 C m2 D Q A El current density S i Ampere m2 A m2 S I A El loading θ Ampere A J Wb θ H I Magnetic flux Φ Weber Maxwell Wb Vs M Φ B A Magn voltage V Ampere A J Wb V H s Magn field strength H Amp m Oerstedt A m N Wb Ö H B µ I w l Magn inductance flux density B Tesla Weber m2 Gauß T Wb m2 G B µ H Magn field constant µo Henry m H ...

Page 295: ...units Force Force 1 kp 9 80665 N Power output Work energy Moment of inertia Acceleration due to gravity Table 1 2 Important units Variable Formula symbol Units Formula A cross sectional area Name Abbreviation Note For vector values many formula symbols are designated by German letters Table 1 1 SI units A 1 2 Important units 1N 1 kg m s 2 1PS 75 kp m s 0 7355kW 735 5 kg m 2 s 3 735 5 Nm s 1Ws 1Nm ...

Page 296: ...ocity Angular velocity Acceleration Force Torque Power output Energy Energy Table 7 4 Basic physical equations A 2 Drive engineer ing equations A 2 1 Basic physical equations s v t ϕ ω t v s t v ω r π n 60 d ω ϕ 2 π n 60 ϕ t a v t ω ϕ ω t F m a F m r ω 2 M F r M J ω P F v P M ω W F s W M ϕ W 1 2 m v 2 W 1 2 J ω 2 ...

Page 297: ...s η Efficiency α Angle of inclination deg µ Coefficient of friction Rotational power Rotational acceleration Translation friction power Translation friction power with rise Translation with acceleration Lift Table 7 5 General drive capacity A 2 2 Power P M n 9 55 P J n 2 91 2 tBE P F v η m g µ v η P m g v η µ α α sin cos P m a v η P m g v η ...

Page 298: ...ting force for various cutting thicknesses N mm kC11 Specific cutting force for face cross section 1 mm x 1 mm N mm lS Length of cut line mm nB Drill speed rpm nF Cutter speed rpm Basic equation Turning Milling Shearing and cutting Drilling Cutting speed during drilling Pressing Table 7 6 Work output for metalworking machinery Work output for metal working machinery Ps FH vs 60000 Ps FH nP 2 π r 6...

Page 299: ... bank nP Face plate speed rpm PS Cutting power kW PP Drive capacity of a press kW r Turn radius m s Sheet thickness mm sZ Advance per cutting edge mm vS Cutting speed m min vSt Plunger speed m min zE Number of active cutting edges κ Setting angle deg ...

Page 300: ...60 3390 3130 2890 2680 55 Ni Cr Mo 6 G 940 1740 3470 3070 2720 2390 2170 55 Ni Cr Mo 6 V 1220 1920 3470 3310 2950 2860 2380 100 Cr 6 G 620 1730 3680 3320 2900 2560 2240 Mn Cr Ni steels 850 1000 2350 4200 3800 3450 3150 2850 Cr Mo other alloy steels 1000 1400 2600 4450 4050 3700 3350 3100 Stainless steels 600 700 2550 4200 3850 3530 3250 3000 Mn hard steels 3300 6100 5500 4980 4500 4080 X 12 Cr Ni ...

Page 301: ...ve power kWh kg η Fan efficiency pump efficiency For fans η 0 3 at 1 kW η 0 5 at 10 kW η 0 65 at 100 kW The following table shows the specific drive power for various thermo plasts Drive capacities in process engineering Fan Pump Extruder Table 7 8 Drive capacities in process engineering Thermoplast Specific drive power in kWh kg ABS 0 2 to 0 3 CAB 0 1 to 0 2 Table 7 9 Specific drive power for var...

Page 302: ... Acceleration time s ν Differential speed rpm ω Angular velocity 1 s PA 6 and PA 66 0 2 to 0 4 PE LD 0 2 to 0 25 PE HD 0 25 to 0 3 PP 0 25 to 0 3 PVC 0 15 to 0 2 Torques Torque to produce translational movement Acceleration torque Acceleration time Table 7 10 Torques Thermoplast Specific drive power in kWh kg Table 7 9 Specific drive power for various thermoplasts A 2 3 Torques M F r 1000 9 55 P n...

Page 303: ...tion force Work of acceleration force Work of gravity Work of spring force Work of friction torque Work of acceleration torque Table 7 11 Work A 2 4 Work W FR s m g µ1 α s cos W m v2 2 2 v1 2 2 W m g h 2 h1 W c x2 2 2 x1 2 2 W M µr ϕ W J ϕ 2 2 2 ϕ 1 2 2 J ω2 2 2 ω1 2 2 ...

Page 304: ...ty m s v1 Velocity at time t t1 m s v2 Velocity at time t t2 m s W Work Nm x Spring travel m x1 Spring travel at time t t1 m x2 Spring travel at time t t2 m α Angle of inclination of inclined plane deg µ1 Coefficient of friction for longitudinal movement µr Coefficient of friction for rotational movement ϕ1 Angle of revolution at time t t1 rad ϕ2 Angle of revolution at time t t2 rad ω Angular velo...

Page 305: ... Lever arm of rolling friction m g Acceleration due to gravity m s m Mass kg MR Friction torque Nm α Angle of inclination of inclined plane deg µl Coefficient of friction in longitudinal movement µr Coefficient of friction in rotational movement ρ Friction angle in threaded spindles deg Friction force of Coulomb friction dry friction Tractive resistance to rolling friction Friction torque in threa...

Page 306: ... A Formula bank DE EN 1 2 3 4 5 6 7 A Table 7 14 Effective motor torque power output A 2 6 Effective motor torque power output Meff 1 T Σ n i 1 M 2 i ti Meff M 2 1 t1 M2 2 t2 M3 2 t3 T Peff 1 T Σ n i 1 P 2 i ti Peff P1 2 t1 P2 2 t2 P3 2 t3 T ...

Page 307: ...ix A Formula bank The following diagrams relating to a working example illustrate the mean ings of the formula symbols used The motor is defined at MN Meff The motor is defined at PN Peff v m s t1 t2 t3 T t M Nm t M1 M2 M3 P kW t P1 P2 P3 ...

Page 308: ...eleration Maximum acceleration a Belt acceleration in m s g Acceleration due to gravity in m s µ Coefficient of friction Tip limit of a conveyed item Figure 8 2 Conveyor belt with a high body and small standing area Maximum acceleration a Belt acceleration in m s b Width of body in m g Acceleration due to gravity in m s h Height of body in m m m a S m g M m g µ a g µ m m a S m g M b a b h g ...

Page 309: ... difference during acceleration The value z indicates the height difference of the liquid level in a vessel of length x accelerated at speed a At the point of the lowest liquid level z is always 0 a Belt acceleration in m s g Acceleration due to gravity in m s x Coordinates in horizontal direction in m z Coordinates in vertical direction in m g M a P0 x z z a g x ...

Page 310: ... 8 4 Schematic view of a crane with suspended load Maximum acceleration a Belt acceleration in m s g Acceleration due to gravity in m s α Angle of deflection of cable in degrees In most applications the angle α should not exceed a value of 3 With this value the result for the acceleration is m m a a m g a g α tan ...

Page 311: ...on Thick walled hollow cylinder Long thin bar with pivot point at center of gravity Table 7 15 Mass moments of inertia of bodies A 2 8 Mass moments of inertia Mass moments of inertia of bodies J m dm 4 d 3 m 4 π b ρ δ b rm dm J m 2 d 2 2 π b ρ 2 d 2 4 b r d J m 2 da 2 2 di 2 2 b r a r i d i d a J m 12 l 2 A ρ 12 l 3 l A m ...

Page 312: ...ectangular plate with pivot point at center of gravity Solid ball with rotary axis through center of gravity Thin walled ball shell with rotary axis through center of gravity Table 7 15 Mass moments of inertia of bodies J m 3 l 2 A ρ 3 l 3 l A m J m 12 h 2 b 2 b l h J 2 m 5 d 2 2 π ρ d 5 60 d m J 2 m 3 d 2 2 π ρ δ d 4 6 d m ...

Page 313: ...A 22 Engineering Guide CDA3000 Appendix A Formula bank Steiner s set Table 7 15 Mass moments of inertia of bodies JA JS m s 2 s A S rotary axis axis through centre of gravity m ...

Page 314: ...Engineering Guide CDA3000 A 23 Appendix A Formula bank DE EN 1 2 3 4 5 6 7 A Reduction via a gear Reduction via two gears Movement by conveyor roller ...

Page 315: ...A 24 Engineering Guide CDA3000 Appendix A Formula bank Movement by rack Movement by cable reel Movement by spindle ...

Page 316: ...Engineering Guide CDA3000 A 25 Appendix A Formula bank DE EN 1 2 3 4 5 6 7 A Conversion from translation into rotation Conversion from translation into rotation with several motors ...

Page 317: ...A 26 Engineering Guide CDA3000 Appendix A Formula bank Indexing table with eccentric loads ...

Page 318: ...g Guide CDA3000 A 27 Appendix A Formula bank DE EN 1 2 3 4 5 6 7 A A 2 9 V t diagram Acceleration time Acceleration travel Braking time Braking travel Travel with v const Time for v const Total travel Total time ...

Page 319: ...A 28 Engineering Guide CDA3000 Appendix A Formula bank v t diagram for minimum torque Acceleration time Acceleration travel Braking time Braking travel Total travel Total time ...

Page 320: ...gineering Guide CDA3000 A 29 Appendix A Formula bank DE EN 1 2 3 4 5 6 7 A v t diagram with sinusoidal characteristic Period Acceleration time Acceleration travel Braking time Braking travel Acceleration ...

Page 321: ...95 V belt Each complete wrap of the V belt pulley nor mal belt tension η 0 88 0 93 Plastic belts Each complete wrap rollers on roller bearings normal belt tension η 0 81 0 85 Rubber belts Each complete wrap rollers on roller bearings normal belt tension η 0 81 0 85 Chains Each complete wrap chains on roller bearings depending on chain size η 0 90 0 96 Spindles Trapezoidal threaded spindle Recircul...

Page 322: ...adial self aligning ball bearing 0 0010 Radial self aligning roller bearing 0 0018 Radial groove ball bearing 0 0015 Radial taper roller bearing 0 0018 Radial cylinder roller bearing 0 0011 Radial needle bearing 0 0045 Table 7 18 Coefficients of friction for roller bearing friction Spindle type Coefficient of friction Trapezoidal threaded spindle µ 0 05 0 08 greased µ 0 1 0 18 dry Recirculating ba...

Page 323: ... µ0 0 40 0 75 µ 0 30 0 50 Plastic belt on steel Static friction dry Sliding friction dry µ0 0 25 0 45 µ 0 25 Steel on plastic Static friction dry Sliding friction dry µ0 0 20 0 45 µ 0 18 0 35 Table 7 21 Coefficients of friction of various material pairings Material pairing Lever arm of rolling friction Steel on steel f 0 5 mm Wood on steel roller conveyor f 1 2 mm Plastic on steel f 2 0 mm Hard ru...

Page 324: ...m Epoxy resin 1200 kg m Rubber 920 990 kg m Phenol resin type 31 1400 kg m Polyethylene 900 950 kg m PVC 1300 1400 kg m Transmission elements Comments Supplement fz Cogwheels 17 cogs 17 cogs 1 1 15 Chain wheels 20 cogs 20 cogs 13 cogs 1 1 25 1 4 Narrow V belt pulley dependent on pre tension 1 5 2 Flat belt with tension roller dependent on pre tension 2 2 5 Flat belt without tension roller dependen...

Page 325: ... 90S 2 1 5 78 5 1 0 00137 5 8 3 4 90L 2 2 2 82 7 4 0 00183 8 4 4 9 100S 2 3 0 73 10 0 0 00282 12 5 7 3 112M 2 4 0 80 13 3 0 00556 14 8 8 6 132S 2 5 5 85 18 3 0 00837 21 1 12 1 132S 2a 7 5 84 24 9 0 012 27 1 15 7 160M 2 11 0 87 36 0 0 033 37 3 21 6 160M 2a 15 0 88 49 0 0 045 48 1 28 1 160L 2 18 5 92 60 0 0 054 59 1 34 1 180M 2 22 0 91 71 0 0 073 74 1 43 1 200L 2 30 0 90 97 0 0 12 96 1 56 1 200L 2a ...

Page 326: ...75 80 5 1 0 00165 3 4 2 0 90S 4 1 1 72 7 5 0 00235 5 1 3 0 90L 4 1 5 77 10 2 0 00313 6 5 3 8 90L 4a 2 2 76 15 0 0 00316 9 6 5 6 100L 4 2 2 76 14 9 0 00450 9 5 5 5 100L 4a 3 0 77 20 3 0 00600 12 9 7 5 112M 4 4 0 83 27 0 0 0199 15 7 9 1 132S 4 5 5 85 36 0 0 0233 20 0 11 6 132M 4 7 5 87 49 0 0 0317 28 1 16 3 132M 4a 9 2 87 60 0 0 0354 35 1 20 1 160M 4 11 0 89 72 0 0 062 39 4 23 1 160L 4 15 0 89 98 0 ...

Page 327: ... 0 2 54 240 1 315M 4a 160 0 96 1029 0 2 97 285 1 315M 4b 200 0 93 1286 0 3 25 370 1 Size Power P in kW Efficiency η in Nominal torque Mn in Nm Mass moment of inertia J in kgm Rated current at 230 400 V The data given represent mean values which may vary slightly depending on manufacturer Table 7 26 Standard 3 phase AC motor 1500 rpm 50 Hz ...

Page 328: ...75 69 7 83 0 0037 4 1 2 3 90L 6 1 1 68 11 5 0 0050 5 6 3 4 100L 6 1 5 73 15 1 0 010 7 2 4 2 112M 6 2 2 81 22 1 0 018 9 85 5 75 132S 6 3 0 82 29 8 0 031 13 5 7 9 132M 6 4 0 84 39 8 0 038 16 8 9 8 132M 6a 5 5 81 55 8 0 045 23 3 13 5 160M 6 7 5 85 74 0 0 093 28 6 16 6 160L 6 11 0 86 109 0 0 127 42 1 24 1 180M 6 13 0 85 130 0 0 168 49 1 28 1 180L 6 15 0 85 148 0 0 192 55 1 32 1 200LK 6 20 0 88 196 0 0...

Page 329: ...7 0 35 0 0 0209 1500 12 6 ASM H 24 2 1 84 0 10 0 0 00298 2000 5 3 ASM H 25 2 7 85 0 13 0 0 00384 2000 6 6 ASM H 11 0 41 76 0 1 3 0 00028 3000 1 4 ASM H 12 0 54 77 0 1 7 0 00037 3000 1 8 ASM H 13 0 72 79 0 2 3 0 00047 3000 2 3 ASM H 14 1 1 80 0 3 5 0 00065 3000 3 3 ASM H 15 1 5 82 0 4 7 0 00089 3000 4 5 ASM H 21 1 1 82 0 3 5 0 00109 3000 3 0 ASM H 22 1 5 83 0 4 7 0 00144 3000 3 9 ASM H 23 2 2 84 0 ...

Page 330: ... 32 0 0 0130 1500 11 6 ASF V 3 4 7 4 87 0 47 0 0 0209 1500 15 4 ASF V 2 4 2 7 83 0 13 0 0 00298 2000 6 7 ASF V 2 5 3 4 85 0 16 5 0 00384 2000 8 2 ASF V 1 1 0 54 76 0 1 7 0 00028 3000 1 8 ASF V 1 2 0 72 78 0 2 3 0 00037 3000 2 4 ASF V 1 3 0 94 79 0 3 0 0 00047 3000 2 9 ASF V 1 4 1 5 81 0 4 7 0 00065 3000 4 3 ASF V 1 5 2 0 82 0 6 5 0 00089 3000 6 2 ASF V 2 1 1 5 82 0 4 7 0 00109 3000 3 9 ASF V 2 2 2...

Page 331: ...r of 12 5 mm and larger 3 Protection against for eign bodies 2 5 mm Protection against touch contact with live parts or internal moving parts by tools wires or similar items of a thickness of 2 5 mm and thicker Protected against solid foreign bodies with a diameter of 2 5 mm and larger 4 Protection against for eign bodies 1 mm Protection against touch contact with live parts or internal moving par...

Page 332: ...ave any damaging effect when the housing is at a tilt angle of 15 to either side of the vertical 3 Protection against splash ing water Water splashing at any angle up to 60 on either side of the vertical must not have any damaging effect 4 Protection against splash ing water Water splashing onto the housing from any direction must not have any damaging effect 5 Protection against water jet spray A...

Page 333: ...immersion Water must not intrude in damaging quantities when the equipment is permanently immersed in water under conditions which must be agreed between the manufacturer and the user The conditions must be more severe than those for code digit 7 9K Protection in case of high pressure steam jet cleaning Water directed from any direction under very high pressure onto the housing must not have any d...

Page 334: ...1 Housing type 1 General use Housing 1 Housing for general use IP 20 Housing type 2 Drip tight Housing type 2 Drip proof Housing 2 Drip proof housing IP 22 Housing type 3 dust tight rain tight Housing type 3 Dust tight rain tight resist ant to sleet and ice Housing 3 Weather proof housing IP 54 Housing type 3 R Rain proof Housing type 3 R Rain proof resistant to sleet and ice Housing type 3 S Dust...

Page 335: ...d Electronic Manufacturers Association of Canada allgemeine Verwendung tropfdicht staubdicht regendicht regensicher wettersicher wasserdicht eintauchbar eisbeständig hagelbeständig korrosionsbeständig öldicht general purpose drip tight dust tight rain tight rain proof weather proof water tight submersible ice resistant sleet resistant corrosion resistant oil tight Marking of the housing and the pr...

Page 336: ...Engineering Guide CDA3000 A 45 DE EN FR 1 2 3 4 5 6 A Appendix B Practical working aids for the project engineer ...

Page 337: ...uide CDA3000 Appendix B Practical working aids for the project engineer Industry Application Goal Special background conditions Author Date Sheet of Company Name Function Comments Recording of movement task Project name ...

Page 338: ...EN FR 1 2 3 4 5 6 A Movement requirement for processing Project name Continuous material flow Discontinuous batch process Discontinuous unit process Rotational movement n f t Translational movement v f t Radius of drive shaft by which the movement is generated mm Author Date Sheet of Comments t ...

Page 339: ...uthor Date Sheet of Comments Moment of kgm Mass kg or inertia Mode of movement Speed manipulating range Static speed accuracy Dynamic speed accuracy Torque rise time Positioning accuracy rpm rpm ms ms ML 1 n P constant ML constant P n ML f n P f n ML n P n ML f n ML f s ML f a ML f t Load torque of processing process ML P MN PN 1 5 1 0 0 5 ...

Page 340: ...endix B Practical working aids for the project engineer DE EN FR 1 2 3 4 5 6 A Additional environmental data Project name Author Date Sheet of Automation process Environmental and installation conditions Standards regulations and safety ...

Page 341: ...250 300 400 4 5 6 7 8 9 10 15 20 25 30 40 50 60 70 80 90 100 150 200 250 300 400 Rated power inverter and motor 0 5 0 6 0 7 0 8 0 9 1 0 M MM UR f Hz 10 20 30 40 50 60 70 80 90 100 750 rpm 8 pole 100 200 300 400 500 600 700 800 750 900 1000 1100 1200 1300 1400 1500 200 400 600 800 1000 1200 1400 1000 rpm 6 pole 1600 1800 2000 1500 rpm 4 pole 200 400 600 800 1000 1200 1400 1500 1600 1800 2000 2200 2...

Page 342: ...rsig ISBN 3 18 401372 3 VDE Publishing Feldschwächung bei Umrichterantrieben bietet viele Vorteile Joachim Schäfer Specialist article in Antriebstechnik 36 1997 no 4 Projektmanagement J Boy C Dudek S Kuschel ISBN 3 930799 01 4 Gabal Taschenbuch der Technik T Krist ISBN 3 87807 124 8 Technik Tabellen Publishing Der Drehstrommotor Karl Falk ISBN 3 8007 2078 7 VDE Publishing Elektrische Antriebstechn...

Page 343: ...erarbeitung Teil 1 Joachim Schäfer Specialist article in Antriebstechnik 1991 no 3 Positionieren mit Frequenzumrichtern durch Echtzeitverarbeitung Teil 2 Joachim Schäfer Specialist article in Antriebstechnik 1991 no 5 Klöckner Moeller Schaltungsbuch Klöckner Moeller Bonn Oberschwingungen Albert Kloss ISBN 0175 9965 VDE Publishing Absicherung von Maschinen vor gefahrbringenden Bewegungen Elan Corpo...

Page 344: ...FR 1 2 3 4 5 6 A Frequenzumformer Dr Ing P F Brosch ISBN 3 478 93036 7 Moderne Industrie Publishing Schaltschrank Klimatisierung Heinrich Styppa ISBN 3 478 93080 4 Moderne Industrie Publishing Elektronische Gerätetechnik Prof Dipl Ing Hans Brümmer ISBN 3 8023 0610 4 Vogel Publishing ...

Page 345: ...n of effective inverter capacity utilization 3 55 Calculation with LuDrive 3 85 CAN bus 5 4 CAN characteristics 5 5 CANLust Control word 5 11 Status word 5 11 CANLust control word 5 11 Characteristic data set switchover 4 30 Characteristic values of asynchronous servomotors ASx 2 35 of HF motors 2 47 of machinery 1 9 of planetary gears 2 49 of reluctance motors 2 41 of standard gears 2 49 of stand...

Page 346: ...2 8 Example of use of control terminal presetting 4 30 Example of use of emergency operation 4 55 Example of use of manual mode 4 53 F Field bus operation 4 49 Forming of the DC link capacitors 3 25 Formula bank A 1 Friction A 14 Functional analysis 1 6 1 8 G General points on the mains connection 3 21 General technical data 2 36 H Harmonics load 6 2 Heat discharge from the switch cabinet 7 2 High...

Page 347: ...ssing process 1 10 Movement solution split into traction and mechanical function 1 11 Multi motor operation 3 28 N Network printing 2 14 O Operating characteristic standard three phase AC motor 2 26 Operating conditions extreme 3 14 Operation of fault current breakers 3 23 Operation via DriveManager 4 12 Operation via KeyPad KP200 4 11 Operation with reactive current compensation system 6 4 Output...

Page 348: ...ing at the inverter input 3 24 System conditions 3 19 System environment 1 3 System installation 7 1 System load 6 3 System resonance 6 5 Systematic thinking 1 2 T Technical data 3 3 of line chokes LR3x xxx 6 6 of series BRx xxx xxxx 6 12 of series EMC3x xxx 6 14 of series MR3x xxx 6 8 Self cooling 2 38 2 39 Technical data PROFIBUS DP Gateway 5 15 Three phase inverter modules 3 4 Topology of CAN 5...

Page 349: ...Engineering Guide CDA3000 DE EN FR Appendix D Index 1 2 3 4 5 6 A A 59 W Work A 12 Work output for metalworking machinery A 7 ...

Page 350: ...triebstechnik GmbH Gewerbestrasse 5 9 D 35631 Lahnau Tel 0 64 41 9 66 0 Fax 0 64 41 9 66 137 Internet http www lust tec de e mail lust lust tec de ID no 0840 25B 1 00 Date 12 99 We reserve the right to make technical changes ...

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