ANTEK FU 3 AE-03 User manual

Operating Manual – Digital Frequency Converter Page 1 of 14
09/99 R0048GB.doc
Antriebstechnik GmbH
Operating Manual
Servo Frequency Converter
FU 3 AE -03
Digital Frequency converter for stepless speed control of 3-phase a.c. motors up to
1,1 kW
1. Important Pre-operation information.............................................................. 2
2. Brief description............................................................................................... 5
3. Specification FU 3 AE - 03.............................................................................. 6
4. Description of connection............................................................................... 7
5. Initiation and Parameterisation..................................................................... 10
-Errors and omissions excepted, subject to alterations-

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1. Important Pre-operation information
1.1 Safety informationElectrical units are a source of danger.
Comply with the relevant laws and regulations when electrical units
are used in installations and control systems which require
observation of safety rules, and when carrying out installation work.
When working on live units, always comply with the current accident
prevention regulations.
For reasons of safety and in order to maintain the documented
system data and functions the unit or its components may only be
repaired by the manufacturer.
No liability can be accepted if the drive parameters have an
unsuitable, incorrect manual or automatic setting.
Incorrect handling may cause injuries and/or damage property!
Prior to installation technicians who are familiar with electrical drive
equipment must read the unit handbook thoroughly.
Ensure that the voltage is not dangerous before touching electrical
contacts.
The user must use independent monitoring units in order to ensure
that a malfunctioning drive is stopped safely.
The user is responsible for installing and connecting the motor, the
converter and auxiliary units pursuant to the acknowledged technical
rules in the country of installation and other current regional
regulations. In particular, cable dimensioning, shielding, earthing,
disconnection, isolation and overcurrent protection must be taken
into account.
Regulations pursuant to DIN 57100 are applicable.
The modules are fitted with electrostatically sensitive CMOS and
MOS components. Always comply with the following information
when handling and testing the units, otherwise these integrated
circuits may be damaged.
 When servicing the unit, first ensure that there is equipotential
bonding (static charging) between the unit, tools, measuring
instruments and personnel.
 Take hold of the modules only by the edges; do not touch the
components or their connections.

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1.2 General information
Check for any transport damage after unpacking the control
unit and before the initial start-up.
Check that all plug-in and screwed connections are secure.
Minimum requirements for installation site:
♦The room should be as dust-free as possible (fit filters to
control cabinets which have floor fans).
♦The ambient temperature must be within the range 5-40 °C
(if required provide separate cooling).
♦The relative air humidity must not exceed 90%.
♦The ambient air must not contain any corrosive gases.
The control unit causes power loss and heats the environment.
Ensure that there is adequate distance between the control
unit and heat-sensitive units.
The units are designed for installation in card racks.
The unit must be installed vertically.
The air flow of the unit must not be obstructed.
The air inlet and outlet must be kept clear.
Important information regarding protective earthing
As the servo controller (>3.5 mA) leaks current via the
protective conductor (PE), the feeder cross section of the
protective conductor to the control cabinet must be at least 10
mm² Cu pursuant to DIN 57100, or a second protective
conductor must be laid electrically parallel.
If the connected loads are larger, the minimum cross section of
the protective conductor must correspond to the cross section
of the outer conductors.
The converter leakage currents may be up to 100 mA.
Operation with 30 mA residual-current-operated circuit-
breakers is therefore not possible.
Important information regarding cables
Control lines and power cables are always isolated and must
not be laid in close proximity.
Set-point input, analogue control inputs and measuring outputs
must be installed with shielded cables.

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1.1 Information on EMC
In order to guarantee electromagnetic compatibility (EMC) in your switch cabinets in an
electrically raw environment, the following EMC rules are to be observed during construction
and set-up:
♦All metallic parts of the switch cabinet are to be connected flatly and in a well-conducting
manner (not lacquer on lacquer!). If necessary, use contact or scraper wafers. The
cabinet door is to be connected with as short a circuit as possible via the metal powder
tapes (upper, middle, lower).
♦Signal lines and power cables are to be laid separate from each other in order to avoid
coupling intervals. Minimum distance: 20 cm:
♦Signal lines should be led to the cabinet from only one level, if possible.
Unshielded lines from the same electrical circuit (outgoing and return circuit) are to be
transposed, if possible.
♦Contactors, relays and magnetic valves in the switch cabinet, if necessary in the adjacent
cabinets, are to be wired with quench combinations, e.g. with RC elements, varistors,
diodes.
♦The screens from signal lines are to be laid two-way (source and target), large-area and
well-conducting to a ground1. In case of poor potential equalization between shielded
connections, an additional balancing network of at least 10 mm² must be laid parallel to
the screen to reduce the screen current.
♦Wiring is not to be laid freely in the cabinet, but should rather lead as tightly as possible
to the cabinet frame or to installation plates. This also applies to reserve cables. At least
one end of them must lie grounded, but preferably both (additional shield effect).
♦Unnecessary wire lengths are to be avoided. Coupling capacities and coupling
inductances are thereby kept small.
♦The screen from leads, such as resolver or incremental director cables, must be laid to
the frame grounding. Approximately 2 cm of the insulation is to be removed in the area
where the cable is to be led into the frame in order to expose the braided cable. The
braided cable may not be damaged while removing the insulation. The cable is to be led
at the position where the insulation has been removed by grounded terminals or taut
supports.
cable taut support
1Generally all metallic conducting parts which can be connected to a protective conductor,
such as cabinet frames, motor frames, foundation grounding, etc. are designated as a
ground.

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2. Brief description
♦Digital frequency converter for the operation of 3-phase a.c.
motors
♦digital tachometer feedback
♦Input voltage is fit to the supply network within the the range of
400 ... 480 VAC
♦Temperature monitoring of output stage
♦Overvoltage monitoring of intermediate circuit
♦Monitoring of actual / nominal r.p.m. in regulator mode
♦19“ rack mount with 3 standard european boards 160 mm
♦Integrated switching power supply
Advantages: ♦Compact and space-saving type as 3HE / 19“ insert
♦Operation with industry standard motors (min. Inductivity 2mH)
♦Sinusoidal excitation of the motor ensures that the latter runs true
run even at low speeds
♦Potential-free electronics
♦Overload-proof protection
♦Change direction of rotation by electronic system
2.1 Extend of delivery Frequency converter completely prewired for insertion in card
rack. The frequency converter has been tested for correct
functioning and continuous operation.
2.2 View and dimensions
190
FU x AE
19 TE (96,52)
3 HE (132,5)

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123
20
40
60
0
0
Pv[W]
Ia[A]
3. Specification FU 3 AE - 03
for application compliant with UL (UL 508) and CSA regulations
Input voltage: UNetz 3x 400 VAC -10% ... 480 VAC +6%; 50/60 Hz
Rated input current: IN3x 3 AAC
Peak input current: 3x 5 AAC
Connection power: 2,1 kVA
Fuse external: 3x 10 A Z-Characteristic, e.g.. ABB S283-Z10
24 VDC supply external: 24 VDC ±20% current consumption ca. 0,4 A
fuse 1 A intern
Nominal output voltage: Ua0 ... Ue
Nominal output current Ia3x 3 AAC
Peak output current: 3x 5 AAC
Output frequency: fout 0 ... 160 Hz
Frequency resolution: 200 Steps relevant to output frequency
Nominal output power: S 2,1 kVA
min. output inductivity:: L 2 mH
Control range pulse generator 1:100
(Graduations > 100)
Efficiency at nominal load: ca. 95%
Power loss at no-load: ca. 20 W
Power loss nominal load: ca. 60 W
Clock frequency of output
transformer:: ca. 3,9 kHz
Digital Control inputs: Reglerfreigabe, Reset-Fault
Outputs: Potential-free signal output for
actual / nominal monitoring, ready
Max. load: 35 VDC; 0,2 A
Set point input: 0 ... 10VDC
Actual r.p.m. feedback: Pulse generator 24VDC
Installation: card rack, cooling plate vertical
Ambient temperature: 5 ... 40 °C
Cooling: Ducted cooling 60 m³/h
Connection: Power plug E-L12 form H11
Card connector GDS-AC32 form C
SUB-D 9 pole (female)
Degree of protection IP 00
Geometry: 19“ plug-in module, 3 HE x 19 TE, depth ca. 190 mm
Standards and instructions: DIN 57110b
EN 60204
EN 55011b only with main filter A395
UL-Approbation File E181898
Note:
There is no fuse in the unit for the main supply. Always fit an automatic circuit-breaker with 3 x 10 A Z
characteristic, otherwise the unit is not protect.
Technical Specifications applicable by 400 VAC mains input voltage

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4. Description of connection
(back view of unit)
X1X2
4.1 Power plug X1
X1-2 +24 VDC Supply voltage for internal controlling equipment
X1-5 GND of the controller 24 VDC ±20%
Internal fuse: 1A
X1-8..PE
X1-11 L1 Supply voltage connection 3x 400 VAC -10% ... 480 VAC +6%
X1-14 L2 50 ... 60 Hz
X1-17 L3 External fuse: 3x 10 A Z - characteristics
(Wire behind the main filter must always be shielded)
X1-20 UZK+ Intermediate circuit voltage
X1-23 UZK - to connect a feed-back module or to couple several units with
common intermediate circuits.
X1-26 U Motor connection 3x 0 ... Ue, 0 ... 160 Hz
X1-29 V Warning! The motor cable always must be shielded
X1-32 W All “PE must be earth on both sides (look on EMC rules).

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4.2 Control plug X2
Control inputs
X2-2a RF-L Enable left
X2-4a RF-R Enable right
X2-10a Reset-fault Reset-fault message
X2-12a Ref. 2a-10a Potential reference of the inputs X2-2a, X2-4a and X2-
10a.
The inputs X2-2a, X2-4a and X2-10a are separated by
optoelectronic couplers from the residual electronic. A
voltage between 12 ... 30 VDC subtend Pin X2-12a
activate the respective inputs.
X2-16a set-point The input of the rotation speed set
point
0 ... 10 VDC
Ri= 10 kΩreference GND (X2-
22a)
Warning! This connection always must be shielded.
X2-18a Tacho Connection for pulse generator
Warning! This connection always must be shielded..
Auxiliary voltage
X2-20a +15 VDC These connections have a direct
X2-22a GND voltage of ± 15 VDC for external components
X2-24a -15 VDC (e.g. pulse generator).
Current carrying capacity: ± 25 mA
Outputs
potential free outputs Current carrying capacity: 35 VDC; 0,2 A
X2-26a Act./Nom.1 Signal connection for
X2-28a Act./Nom.2 Act./Nom. monitoring.
ok = Relay contact closed
Error = Relay contact open
X2-30a ready 1 Connection for “ready” signal.
X2-32a ready 2 ok = Relay contact closed
Fault = Relay contact open
Digital-Eingang 2k2
X2-12
10k
10n
K

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4.3 Connections
Mainfilter
A395
-1 -2 -3X2
-1 -2 -3X1
L1 L2 L3
Main connectuib
3x 400 VAC -10%... 480 VAC +6%, 50 .. 60 Hz
Pre fuse: ABB, S283-Z10
-11 -14 -17X1
-26 -29 -32X1
M
3~ DT
SE
-5
X1-2
24VDC Voltage supply
+-
X2-2a
X2-4a
X2-10a
X2-12a
X2-18a
Right
Left
Reset-fault
GND
X2-16a +
SE
All "PE" must be earth on both sides (look on EMC-rules)!
SE
Set point 0 ... 10 VDC
FU3AE-03
SE
X2-22a
Optional

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5. Initiation and Parameterisation
5.1 On / Off Switching Sequence
The minimum delay times are shown in the sketch:
Main- or auxiliary voltage
Enable
30 sec 200ms
switch off switch on
5.2 Displays
Ready (GN) Indication of readiness for working and fault of the controlling
equipment. The following parameters are evaluted:
♦UZK to high
♦IZK to high
♦Temperature of the heat sink to high
If „ready“ the free relay contacts X2-30a and X2-32a are
closed.
VARIANCE (GN) The Act. / Nom. r.p.m. monitor has detected the r.p.m.
difference. Threshold ca. ±1,5% from n-max.
Relay contacts opened (X2-26a and X2-28a).
LEFT (YE) Indicates Enable left (Pin X2-2a).
RIGHT (YE) Indicates Enable right (Pin X2-4a).
5.3 Measuring points
GND Reference potential for measuring points.
PWM Pulse width modulated square wave to control output stage
5V Amplitude; Ri = 4,7kΩ
Measurement: Oscilloscope
fMotor frequency: Square wave 5V peak; Ri = 4,7KΩ
Measurement: Multimeter Frequency measurement range
TACHO Square wave signal received from motor: 100Imp/U; 5V
Amplitude; Ri = 4,7kΩ
Measurement: Oscilloscope
5.4 Acknowledgement of fault messages
The fault message is saved till the reset is active. The reasons
are:
♦OFF/ON of 24 VDC supply voltage
♦LOW-HIGH-Flank on control input „Reset fault“.
SOLL/IST - BEREIT
RFR - RFL
PWM - f
TACHO - GND

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5.5 Program installation
5.5.1 System requirements
“Windows 95” or “Windows 98” must be correctly installed on the computer in order to use
the ANTEK Monitor program. Additionally, the following minimum requirements must be
fulfilled:
♦8 MB available memory
♦700 KB available disk-space
The program will not run under “Windows 3.11“. If needed, please request the Win3.11-
Version from ANTEK GmbH.
5.5.2 Installation
To start Set-up:
1) Start Windows (if not already active).
2) Insert ANTEK Monitor program Disk 1 in disk-drive A.
3) Using “Start“, “Run“, “Search“, click on “Set-up“ on drive A and confirm with
“Open“.
4) Click “OK“ to start Installation. The Set-up-Menu recommends the folder
“ANTEK”, confirm with “Beenden“.
5) Set-up installs the program in the folder “ANTEK” and adds the program
“Monitorprogramm FUxAE“ to the program menu.
6) Double-click “Monitorprogramm FUxAE“ in the program menu to start the
monitor program.
5.5.3 De-installation
A “Deinstaller“ is also included in the program menu to remove the program files.
5.5.4 Serial Interface
Communication between the monitor program and the frequency converter is sent over a
standard RS232 interface cable. This cable should be kept as short as possible.
RS232
9-pol. D-SUB-Buchse
Datenleitung RXD, TXD nicht
gekreuzt
Regelgerät
RS232
Achtung !
Bei 25-pol. PC-Schnittstelle ist Pin 7=GND
ATRXD
TXD
GND
RXD
TXD
GND
2
3
5
2
3
5

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5.6 Parameterisation
The frequency converter is parameterised using the ANTEK monitor program “FUxAE” and
a standard RS232 interface. The interface parameters are set automatically.
The parameters can be sent / received using the following commands:
[CTRL+U] Freq. converter Î PC
[CTRL+D] PC Î Freq. converter
Parameters
Mode Steller: Frequency converter sets frequency
Regler: Frequency conversion combined with r.p.m. regulation
U-Netz Mains input voltage
Range: 0 ... 480 VAC
Caution! Re-check parameters after changing mains input voltage.
Boost Compensation for winding resistance at lower output
frequencies.
Range: 0 ... 100 VAC
Caution! The motor will become unusually warm if set too high. Check
motor current.
Hoch-, Rücklauframpe Ramp times from 0 to maximum r.p.m.
Range: 0,1 ... 20,0 sec
f-max Maximum frequency at maximum nominal value setting
Range: 0 ... 160 Hz
Eckfrequenz Frequency where max. output voltage is reached
Range: 0 ... 160 Hz
Offset Offset adjustment of analogue nominal r.p.m. input
Range: -2750 ... 2750 mV

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The following parameters can only be set in “Regler – Mode“
Istwertanpassung Tacho signal matching for r.p.m. feedback
Range: 100 ... 10000
z
p
maxf
assngIstwertanp •
−
=
f-max ... Maximum frequency [Hz]
p ... number of pole pairs
z ... number of increments (resolution)
P-Anteil, I-Anteil Regulating behaviour
Range: 0,00 ... 10
Achtung! Improper regulator parameters can cause the drive to oscillate.
Schwelle, Verzögerung The actual r.p.m. are compared to the nominal r.p.m. value and
switches (delayed) the output “Act. / Nom. monitor”
. Threshold
and delay time are programmable.
Range threshold: 0 ... 10% Maximum r.p.m.
Range delay: 0,1 ... 25 sec
5.7 Process window
Visualisation of process states.

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5.8 Fault diagnosis
Fault diagnosis Possible cause Fault removal measures
LED „Ready“ does not light - 24V control voltage too low - Check control voltage
- UZK too high - Check mains voltage
- IZK too high - Check wiring
- Reduce motor load
- Heat-sink temperature too high - Allow unit to cool
- Reduce motor load
- Check cooling
Motor does not run - no mains voltage - Check mains voltage
- Check circuit-breakers and fuses
- Cable fault - Check motor phases
- Thermo-switch in Motor has
tripped - Allow motor to cool - Reduce motor load
- Check cooling
- Boost setting in “Steller”-mode
too low - Increase boost setting (Caution Motor temperature
increases!)
Drive regulator oscillates - PI behaviour improperly set - Adjust regulation for current
application
Motor runs out-of-round - EMV - Connect reference ground for
analogue and digital inputs
- Shield analogue and digital
inputs.
sensor, si
g
nal and motor cables-
Ensure large ground area
ANTRIEBSTECHNIK GmbH
Im Köchersgrund 3
D - 71717 Beilstein
Tel. 07062 / 9406-0 Fax. 23518