Berges ACP micro 3000 User manual

Operating manual
0.37–15 kW
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21.12.98 Operating manual
04_GB ACP 3000 — 0.37–15.0
Berges electronic •D–51709 Marienheide-Rodt •Tel. [phone] •Fax [phone]
Parameter Code Summary
PARA-
METER DESCRIPTION FACTORY SETTING RANGE PAGE CUSTOMER SETTING
02-RVLVL Software Revision 35
03-IRAT Inverter Rated Current A 35
07-FLT3 Last Fault 36
08-FLT2 Second Fault 36
09-FLT1 First Fault 36
12-FOUT Motor Output Frequency 0.00–400.0 Hz 36
13-VOUT Motor Output Voltage 0–100%
of line voltage 36
14-IOUT Motor Output Current 0.00–60.00 A 36
15-LOAD Inverter Load 0–200%
of
03-IRAT
36
17-TEMP Inverter Temperature 0.00–110.0 °C 36
1A-FSTAT Stator-Frequency (1) Hz 55 Read-only
21-MODE Input Mode 3(2) 0–11 36/55
24-FSEL Speed Setpoint Selector 0 (2) 0–19 38/55
31-FMIN Minimum Frequency 0.00 Hz 0.00–400.0 Hz 38
32-FMAX Maximum Frequency 50.00 Hz 20.00–400.0 Hz 38
33-F2 Preset Frequency 2 5.00 Hz 0.00–400.0 Hz 38
34-F3 Preset Frequency 3 20.00 Hz 0.00–400.0 Hz 38
35-F4 Preset Frequency 4 40.00 Hz 0.00–400.0 Hz 38
36-F5 Preset Frequency 5 50.00 Hz 0.00–400.0 Hz 38
37-F6 Preset Frequency 6 0.00 Hz 0.00–400.0 Hz 38
38-F7 Preset Frequency 7 0.00 Hz 0.00–400.0 Hz 38
39-FTL Minimum Frequency in Torque Limit 10.00 Hz 0.00–400.0 Hz 39
41-RSEL Ramp Selector 0 (2) 0–7 39/56
42-ACC1 Acceleration Time 1 3.00 s 0.10–600.0 s 39
43-DEC1 Deceleration Time 1 3.00 s 0.10–600.0 s 39
44-ACC2 Acceleration Time 2 1.00 s 0.10–600.0 s 40
45-DEC2 Deceleration Time 2 1.00 s 0.10–600.0 s 40
46-DECTL Deceleration Time in Torque Limit 1.00 s 0.10–30.00 s 40
47-DCBRK DC Brake Time 0.20 s 0.00–5.00 s 40
48-DCVLT DC Brake Voltage 2/3 of
52-BOOST 0–15% 40
51-VSEL V/Hz Characteristic Selector 0 0–5 40
52-BOOST Voltage Boost 8.00% 0.00–25.00% 41
53-FKNEE V/Hz Knee Frequency 50.00 Hz 26.00–400.0 Hz 42
54-SKBND Skip Frequency Hysteresis Band 1.00 Hz 0.20–20.00 Hz 42
55-SK1 Skip Frequency 1 0.00 Hz 0.00–400.0 Hz 42
56-SK2 Skip Frequency 2 0.00 Hz 0.00–400.0 Hz 42
57-SK3 Skip Frequency 3 0.00 Hz 0.00–400.0 Hz 42
59-MVOLT Rated Motor Voltage 230/400 V 185–240 V;
370–480 V 42
5B-MSAT Motor Saturation Level 47% 15–80% 42
61-LTLF Load Torque Limit Forward 150% 10–150% 42
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Operating manual 21.12.98
ACP 3000 — 0.37–15.0 04_GB
NOTES:
Level 1 Parameters shown shaded.
(1) Additional parameters that are only availablewhenusing the PI controller andwhen
the
81-PRGNO parameter is set to a value between 80 and 95 (see page 56). See
chapter 6, from page 51 on, for further information about the PI controller.
(2) Extended parameters when using the PI controller. For further information about the
PI controller, see chapter 6, as from page 51.
62-LTLR Load Torque Limit Reverse 150% 10–150% 42
63-RTLF Regenerative Torque Limit Forward 80% 10–110% 42
64-RTLR Regenerative Torque Limit Reverse 80% 10–110% 42
65-SLIP Slip Compensation 0.00% (2) 0.00–12.00% 43/56
66-STAB Current Stability Adjustment 3 0–4 43
67-TOL Timed Overload Trip Point 0% 0–100% 43
68-NRST Trip Restart Number 0 0–8 44
69-DRST Restart Delay Time 0.00 s 0.00–60.00 s 44
6A-TOLC Timed Overload Characteristic 0 0–7 45
70-MCAL Analog Meter Output Calibration MET1 Set for10 VDC 0–255 45
71-METER Analog Meter Output Selector MET1 1(2) 0–5 45/56
72-ST1 Open Collector Output 1 70–10 46
75-STR Auxiliary Relay Output 10–10 46
77-MOL Motor Overload Input 2 0–3 47
78-MCAL2 Analog Meter Output Calibration MET2 0–20 mA or 4–20 mA;
set for 20 mA 0–255 47
79-MET2 Analog Meter Output Selector MET2 3(2) 0–15 47/56
81-PRGNO Special Program/PI Control Characteristics 0 0–9999 48/56
82-START Start Options 1 0–11 48
83-PWM PWM Carrier Frequency Selector 1 0–5 49
84-DISP Display Option Setting 0 0–3000 49
87-ACODE Security Access Code 0 0–999 50
97-RVLVL2 Software Revision Level 2 0.00–12.75 50 Read-only
A1-FCORR Frequency Correction (1) 0.00–400.0 Hz 55
A6-ERROR2 Final Error (1) – 55 Read-only
A7-ERROR1 Initial Error (1) – 55 Read-only
A8-SIPART Integral Sum (1) – 55 Read-only
B3-KP Proportional Gain (1) 0–255 55
B4-KI Integral Gain (1) 0–255 55
B5-KIN VIN1 Scaling (1) 0–255 55
PARA-
METER DESCRIPTION FACTORY SETTING RANGE PAGE CUSTOMER SETTING
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21.12.98 Operating manual
04_GB ACP 3000 — 0.37–15.0 1
Berges electronic •D–51709 Marienheide-Rodt •Tel. [phone] •Fax [phone]
Table of Contents
Page
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Explanation of Symbols and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Safety and Operating Instructions for Drive Converters. . . . . . . . . . . . . . . . . . . . . . 3
1.3 Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Model Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 General Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Dimensional Data (Size I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.1 Dimensional Data (Size II). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.2 Dimensional Data (Size III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4.3 Dimensional Data (Size IV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 General Rules for Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 EMC (Electromagnetic Compatibility) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.1 Suggestion on how to solve the Problem of Radio Frequency Interference
Suppression of Frequency Converters to VDE 0875/EN 55011 . . . . . . . . . . . . . . 12
3.3.2 Mains Filters/Output Chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.3 Filter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.4 Interference Suppression Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 EMC Ordinance (EMC Directive, 89/336 EEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Wiring Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.1 Applicable Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.2 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.3 Control Wiring/Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.6 Mains Power Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6.1 Mains Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6.2 Line Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.6.3 Using Mains Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6.4 Line Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7 Motor Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.8 Reducing Current Surges and Voltage Transients. . . . . . . . . . . . . . . . . . . . . . . . . 23
3.9 Function and Use of Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.10 Terminal Access Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.11 Terminal Assignment (Mains supply 1 ×230 VAC, 0.37–4.0 kW) . . . . . . . . . . . . . 26
3.12 Terminal Assignment (Mains supply 3 ×400 VAC, 0.37–4.0 kW) . . . . . . . . . . . . . 26
3.13 Terminal Assignment (Mains supply 3 ×400 VAC, 5.5–15.0 kW) . . . . . . . . . . . . . 27
3.14 Remote Keypad/Program Memory Unit Connector (J22) . . . . . . . . . . . . . . . . . . . 27
3.15 Control Terminal Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.16 J20 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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Operating manual 21.12.98
ACP 3000 — 0.37–15.0 04_GB
2
Page
4 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 Digital Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4 Operation Mode (RUN and STOP Modes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5 Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.6 Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.7 Description of Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.8 Programming Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.9 Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5 Parameter Configuration and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2 Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6 PI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.2 Overview of PI Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.3 Reference and Feedback Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.4 Calculating PI Controller Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.5 Parameters for PI Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7 Connection Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1 AC Line and Motor Connections (Mains supply 1 ×230 VAC and 3 ×400 VAC) . 58
7.2 2-Wire Run/Stop Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.3 3-Wire Run/Stop Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.4 Auxiliary Relay Output and Digital Output ST1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.5 MOL Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.6 Analog Speed Input Connections (VIN1/VIN2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.7 Optional Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.1 Special Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.2 Fault Trip Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.3 Resetting a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.4 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1 Parameter Code Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.2 Parameters Added or Amended when PI Control is Utilized . . . . . . . . . . . . . . . . . 67
9.3 Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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21.12.98 Operating manual
04_GB ACP 3000 — 0.37–15.0 3
Berges electronic •D–51709 Marienheide-Rodt •Tel. [phone] •Fax [phone]
1 General Information
1.1 Explanation of Symbols and Notes
Work Safety Symbol
You will find this symbol next to all work safety notes in this operating manual if there is a
risk of injury or death for persons involved. Pay attention to these notes and observe par-
ticular caution in such cases. Also pass on all work safety instructions to other users.
Voltage Warning
This symbol is shown wherever particular caution is necessary owing to occurring or ap-
plied voltages (e.g. DC voltages up to 650 V) and where special precautionary measures
have to be taken. The inverter must always be isolated from the mains when working on it.
Caution Note
This note is shown in all parts of this operating manual to which particular attention must be
paid to ensure that the guidelines, specifications, notes and the correct sequence of work
will be obeyed and to prevent damage or destruction of the inverter and/or systems.
1.2 Safety and Operating Instructions for Drive Converters
1. General
In operation, drive converters, depending on their degree of protection, may have live,
unisolated, and possibly also moving or rotating parts, as well as hot surfaces.
In case of inadmissible removal of the required covers, of improper use, wrong installation
or maloperation, there is the danger of serious personal injury and damage to property.
For further information, see documentation.
All operations serving transport, installation and commissioning as well as maintenance are
to be carried out by skilled technical personnel (Observe IEC 364 or CENELEC HD 384
or DIN VDE 0100 and IEC 664 or DIN/VDE 0110 and national accident prevention rules!).
Forthe purposes of these basic safety instructions, “skilled technical personnel” means per-
sons who are familiar with the installation, mounting, commissioning and operation of the
product and have the qualifications needed for the performance of their functions.
We draw attention to the fact that no liability can be assumed for damage and malfunctions
resulting from failure to observe the operating manual.
Technical amendments of illustrations and data given in this operating manual are reserved
in the interest of improving the unit and its functions.
2. Intended Use
The application of the drive converter described in this operating manual exclusively serves
the purpose of continuously variable speed control of three-phase motors.
Driveconverters are components designed for inclusioninelectricalinstallationsor machin-
ery.
The drive converters are designed for installation in a switchgear cabinet and for permanent
connection.
The operator of the system is solely liable for damage resulting from improper use of the
drive converter.
ATTENTION!
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Only items expressly approved by BERGES (e.g. mainsfilter,choke, external braking chop-
pers and braking resistors etc.) may be used as accessories.
The installer of the system is liable for any damage resulting from the use of accessories
that have not been approved expressly by BERGES. Please consult us in case of doubt.
In case of installation in machinery, commissioning of the drive converters (i.e. the starting
of normal operation) is prohibited until the machinery has been proved to conform to the
provisions of the directive 89/392/EEC (Machinery Safety Directive – MSD). Account is to
be taken of EN 60204.
Commissioning (i.e. the starting of normal operation) is admissible only where conformity
with the EMC directive (89/336/EEC) has been established.
The drive converters meet the requirements of the low-voltage directive 73/23/EEC. They
are subject to the harmonized standards of the series prEN 50178/DIN VDE 0160 in con-
junction with EN 60439-1/DIN VDE 0660, part 500, and EN 60146/DIN VDE 0558.
The technical data as well as information concerning the supply conditions shall be taken
from the rating plate and from the documentation and shall be strictly observed.
3. Transport, Storage
The instructions for transport, storage and proper use shall be complied with.
Damage established after delivery must be notified to the transport company immediately.
Where necessary, the supplier must also be notified before the damaged drive converter is
put into operation.
The climatic conditions shall be in conformity with prEN 50178.
4. Installation
The installation and cooling of the appliances shall be in accordance with the specifications
in the pertinent documentation.
The drive converters shall be protected against excessive strains. In particular, no compo-
nents must be bent or isolating distances altered in the course of transportation or handling.
No contact shall be made with electronic components and contacts.
Drive converters contain electrostatic sensitive components which are liable to damage
through improper use. Electric components must not be mechanically damaged or de-
stroyed (potential health risks).
5. Electrical Connection
When working on live drive converters, the applicable national accident prevention rules
(e.g. VBG 4) must be complied with.
The electrical installation shall be carried out in accordance with the relevant requirements
(e.g. cross-sectional areas of conductors, fusing, PE connection). For further information,
see documentation.
Instructions for the installation in accordance with EMC requirements, like screening, earth-
ing, location of filters and wiring, are contained in the drive converter documentation. They
must always be complied with, also for drive converters bearing a CE marking. Observance
of the limit values required by EMC law is the responsibility of the manufacturer of the in-
stallation or machine.
6. Operation
The components of the power section and certain elements of the control section are con-
nected to the voltage mains when the drive converter is connected to the mains voltage.
Touching these components involves mortal danger!
Always isolate the drive converter from the mains supply before performing any work on the
electrical or mechanical part of the system.
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Isolate the drive converter from the mains before removing the terminal cover or the hous-
ing (e.g. by removing or deactivating on-site fuses or by deactivating a master switch iso-
lating all poles etc.).
After disconnection of the drive converters from the voltage supply, live appliance parts and
power terminals must not be touched immediately because of possibly energized capaci-
tors. In this respect, the corresponding signs and markings on the drive converter must be
respected. After switching off the mains voltage, wait for at least 5 minutes before begin-
ning work on or in the drive converter. Dangerous voltages are still present as long as the
“STATUS” lamp is still lit. In the event of malfunctions, the discharge time of 5 minutes may
be exceeded substantially.
The drive converter contains protective facilities that deactivate it in the event of malfunc-
tions, whereby the motor is de-energized and comes to a standstill (so-called “coasting” of
the motor is possible depending on the rotating mass of the type of drive involved). Stand-
still of the motor can, however, also be produced by mechanical blockage. Voltage fluctua-
tions, and particularly mains power failures, may also lead to deactivation. In certain
circumstances, the drive may start up automatically once the cause of the fault has been
remedied. As a result of this, certain systems may be damaged or destroyed and there may
be a risk for operators working on the system. Installations which include drive converters
shall be equipped with additional control and protective devices in accordance with the rel-
evant applicable safety requirements, e.g. Act respecting technical equipment, accident
prevention rules etc. Changes to the drive converters by means of the operating software
are admissible.
The motor may be stopped during operation by disabling it or by deactivating the setpoint,
whereby the drive converter and motor may remain live. If inadvertent start-up of the mo-
tor must be excluded to protect operating personnel, electronic interlocking by dis-
abling the motor or by deactivating the setpoint is inadequate. This is why the drive
converter must be isolated from the mains voltage.
During operation, all covers and doors shall be kept closed.
Measuring instruments must be connected and disconnected only in de-energized condi-
tion.
Unauthorized conversions or modifications on or in the drive converter and its components
and accessories will render all warranty claims void.
Please contact BERGES if conversions or modifications are necessary, particularly if elec-
trical components are involved.
7. Maintenance and Servicing
The manufacturer's documentation shall be followed.
KEEP SAFETY INSTRUCTIONS IN A SAFE PLACE!
1.3 Preface
The present manual contains the specifications, installation instructions, description of op-
eration and troubleshooting procedures for ACP 3000 inverters. The information in this
manual must be known before installation of the inverter in order to guarantee fault-free in-
stallation and thus maximum performance.
Before you read on, please check whether technical changes are at-
tached in the annex to this operating manual!
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2 Technical Data
2.1 Model Identification Number
All ACP 3000 models bear a systematic identification number designating the rated input
voltage, the rated power and the housing type. This model number appears both on the
shipping carton label and the technical data label on the drive.
2.2 Power Specifications
Models with Supply Voltage 1 ×230 VAC
Models with Supply Voltage 3 ×400 VAC
* = Maximum inverter capacity. Value = 1.1 × 03-IRAT (see page 35).
Example type marking
Model ACP 3300-3 3300-5 3300-7 3301-1 3301-5 3302-2
Kilowatt (kW) 0.37 kW 0.55 kW 0.75 kW 1.1 kW 1.5 kW 2.2 kW
Output Voltage Three Phase 3.5–230 VAC
Rated current 1.94 A 2.6 A 3.4 A 4.8 A 6.4 A 9.0 A
Maximum Output Current * 2.1 A 2.9 A 3.7 A 5.3 A 7.0 A 9.9 A
Input Volts (±10%) 208–230 V~
Maximum Input Current 3.1 A 4.7 A 6.4 A 9.4 A 12.7 A 18.6 A
Table 2.1
Model ACP 3600-7 3601-5 3602-2 3603-0 3604-0 3605-5 3607-5 3611-0 3615-0
Kilowatt (kW) 0.75 kW 1.5 kW 2.2 kW 3.0 kW 4.0 kW 5.5 kW 7.5 kW 11.0 kW 15.0 kW
Output Voltage Three Phase 7.0–460 VAC
Rated current 1.95 A 3.7 A 5.2 A 6.8 A 9.2 A 13.0 A 18.0 A 24.0 A 30.0 A
Maximum Output Current * 2.1 A 4.1 A 5.7 A 7.5 A 10.1 A 14.3 A 19.8 A 26.4 A 33.0 A
Input Volts (±10%) 400–460 V~
Maximum Input Current 2.11 A 4.2 A 6.2 A 8.4 A 11.2 A 16.0 A 22.2 A 31.0 A 37.9 A
Table 2.2
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2.3 General Drive Specifications
Inverter
Power Ratings Input Frequency 50/60 Hz (±2%)
Phase Imbalance (3 ∅ only) ±2%
Overload Capacity 150% for 60 seconds
Running Torque 100% at 3 Hz
Starting Torque Greater than 100%
Control
Specifications Control System Sine-weighted voltage vector (PWM)
PWM Frequency 4–16 kHz (plus Autoselect feature)
Frequency Range 1.00–400.0 Hz programmable in 0.05 Hz increments
(0.1 Hz above 99.95 Hz)
Frequency resolution 0.05 Hz up 0.00 to 99.95 Hz,
0.1 Hz above 100.0 Hz
Minimum Frequency 0.00–400.0 Hz
Maximum Frequency 20.00–400.0 Hz
Preset Speeds Up to 8 available; programmable to maximum frequency
Frequency Command
Selections 0–5 VDC, 0–10 VDC, 0–20 mA, 4–20 mA, direct or inverted; Digital Keypad; Program Memory Unit; Remote Keypad Unit;
external Potentiometer
Acceleration and Deceleration
Range Programmable 0.1 to 600 seconds to maximum frequency (2 Each)
V/Hz Ratio 0.19–9.23 V/Hz (230 VAC models)
0.39–18.46 V/Hz (400 VAC models)
Torque Limit Automatic or fixed adjustment possible
Dynamic Braking Up to 60% for 6 sec. with standard DB resistor; higher braking
powervaluescanbeachievedbymeans of an externalbraking
chopper (option)
Protection
Features Ground Fault Protected from damage
Short Circuit Protected from damage
Motor Overload Programmable inverse time overload trip
Torque Limit All four quadrants individually programmable
Overvoltage Short voltage peaks are bridged; an error is triggered if an ov-
ervoltage lasts for longer than 500 ms
Undervoltage Shortvoltagedipsarebridged;adefined“Restart” isperformed
if an undervoltage lasts for longer than 200 ms
Over Temperature Protected from damage, warning display
MOL Input Terminal Programmable for N.C. or N.O. contacts
Operating
Features Operating Controls 1. Keypad. 2. Remote keypad unit.
3. Terminal strip.
4. Program memory unit.
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2.4 Dimensional Data (Size I)
Operating
Features LED Indicators Red and Green for operation and fault annunciation
Keypad Display 6 digit, backlit LCD with special annunciators
and unit symbols
Auxiliary Relay Programmable analog output;
programmable status signalling relay
Programming Levels Level 1 – Operator
Level 2 – Engineer
Inputs/Outputs Inputs 6 Digital: Pull-up or pull-down logic
2 Analog: VIN1 Current or voltage;
VIN2 Voltage only
Outputs 2 Digital: 1 Open collector (internal or external power supply)
up to 24 VDC;
1 Relay (Form C)
2 Analog: MET1 (0 to 10 VDC);
MET2 (0/4 to 20 mA DC)
Ambient
Conditions Operating Temperature 0 °C to +40 °C (IP 21 models) 0 °C to +50 °C (with detached cover)
Storage temperature -20 °C to +60 °C
Humidity 90% RH or less, non-condensing
Vibration 0.6 G Maximum
Elevation 1000 Meters (3,300 Feet) without derating
UL-/CSA-
Certifications Agency Listings Marked, UL/cUL listed, CSA-certified
Table 2.3
UL
®UL
C®
®
∅22
∅5.5
34
30
84
12
159
137
5
6105
94 123 3
Size for devices:
ACP 3300-3 (230 V)
ACP 3300-5 (230 V)
ACP 3600-7 (400 V)
Weight: 1.4 kg
I
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2.4.1 Dimensional Data (Size II)
2.4.2 Dimensional Data (Size III)
65140
129 125 3
137
159
∅5.5
∅22
54
38
84
12
Size for devices:
ACP 3300-7 (230 V)
ACP 3301-1 (230 V)
ACP 3601-5 (400 V)
Weight: 1.9 kg
II
140
129 153 5
220
188
5
119
41 47
∅29
∅22
∅5.5
Size for devices:
ACP 3301-5 (230 V)
ACP 3302-2 (230 V)
ACP 3602-2 (400 V)
ACP 3603-0 (400 V)
ACP 3604-0 (400 V)
Weight: 3.45 kg
III
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2.4.3 Dimensional Data (Size IV)
221
200 180 6
280
327
133
46 47
53
∅35
∅29
∅5.5
Size for devices:
ACP 3605-5 (400 V)
ACP 3607-5 (400 V)
ACP 3611-0 (400 V)
ACP 3615-0 (400 V)
Weight: 8.6 kg
IV
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3 Installation
3.1 Inspection
A. Upon receipt, unpack and carefully inspect for any damage sustained in transit (depres-
sion in the enclosure, damage to parts, missing parts).
B. Remove the cover (see page 25) and inspect the inverter for any apparent damage or
foreign objects. Ensure that all mounting hardware and terminal connection hardware is
properly seated, securely fastened, and undamaged.
C. Read the technical data label and ensure that the correct rated output and input voltage
for the application has been purchased.
D. If the inverter is to be stored for a long period of time, repack and store in a clean, dry
place, free from direct sunlight or corrosive fumes, and in a location where the ambient
temperature will not be less then -20 °C nor more than +60 °C.
3.2 General Rules for Installation
Improper installation of the inverter will greatly effect its life. Be sure to observe the following
points when selecting a mounting location. VIOLATING THE CONDITIONS LISTED BE-
LOW MAY VOID THE WARRANTY!
A. Mount the unit vertically and do not restrict the airflow to the heat sink fins on the back
of the controller. The fan and fins allow cooling of internal components. Any air restric-
tion could greatly reduce the life of the inverter, as well as resulting in nuisance overtem-
perature trips.
B. The ACP inverter generates heat, and therefore there must be a sufficient amount of
free space around the unit (see Figure 3.1). If the unit is accommodated in a housing
together with a different unit, the prescribed minimum distances must be observed so
that adequate ventilation can be ensured.
C. If the inverter has to be installed in a different position, external cooling is required for
full capacity utilization. In certain circumstances, the internal air circulation does not suf-
fice when installing the unit in a control cabinet with a small volume. Therefore, when
installing the unit, you must ensure that a heat buildup is prevented.
D. Do not mount the ACP near heat generating equipment, or in direct sunlight. BERGES
inverters are generally designed so that they can be operated at ambient temperatures
of 0 °C to +50 °C (IP 00) or 0 °C to 40 °C (IP 21) and at a relative humidity of up to 90%.
The occurrence of condensate must be avoided!
Figure 3.1
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E. Do not install the inverter in a place subjected to high temperature, high humidity, or ex-
cessive vibration (see Table 2.3, “Ambient Conditions”)
F. The units should never be installed in the proximity of corrosive or flammable gases,
conductive dust or large magnetic and electric fields.
G. Pay close attention during installation to ensuring that no objects (such as drilling swarf,
wire or anything else) fall into the unit. Otherwise, a device fault cannot be excluded,
even after longer periods of operation.
H. Do not use wire end ferrules for the control terminals. The terminals are designed
so that the wires can be inserted in the terminals after twisting the individual
wires.
I. Table 3.1 shows the watts generated by the inverter when at full current. The heat gen-
erated is dependent on the carrier frequency used. For carrier frequencies other than
those shown in Table 3.1, consult BERGES or use the worst-case scenario (16 kHz car-
rier).
3.3 EMC (Electromagnetic Compatibility)
3.3.1 Suggestion on how to solve the Problem of Radio Frequency Interference
Suppression of Frequency Converters to VDE 0875/EN 55011
It is necessary to connect a mains filter type “BE/(xxx) xxxx” before every frequency con-
verter. The size (xxx) depends on the rated current of the unit. A motor choke can be dis-
pensed with.
The motor choke type BV... may be necessary as from a cable length in excess of 20 m and
when operating several motors in parallel on one frequency converter output. This choke
attenuates the capacitive earth leakage currents and considerably reduces wire-borne in-
terference voltages.
HEAT GENERATED BY INVERTER (IN WATTS)
Inverter Model Number @ 4 kHz Carrier @ 16 kHz Carrier
3300-3 19 27
3300-5 37 42
3300-7 66 75
3301-1 66 75
3301-5 70 79
3302-2 129 154
3600-7 40 62
3601-5 67 99
3602-2 118 186
3603-0 184 281
3604-0 184 281
3605-5 280 640
3607-5 360 790
3611-0 470 1120
3615-0 610 1400
Table 3.1
ATTENTION!
HINT!
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The converter and accessories must be wired in accordance with the following schematic.
To render the remaining interference voltage at the PE conductor potential ineffective for
“external measurement systems”, the following proposed circuit will achieve successful re-
sults if applied consistently.
3.3.2 Mains Filters/Output Chokes
ACP 3000
DEVICE TYPE MAINS FILTER ARTICLE NO. INPUT PHASES VOLTAGE (V) CURRENT (A) WEIGHT (kg) FOOTPRINT
ACP 3300-3 BE I 1005 32501739 1~ 250 5 0.60 (1)
(1) FOOTPRINT means that these filters have been prepared for the installation of an ACP converter on the filter (securing).
ACP 3300-5 BE I 1005 32501739 1~ 250 5 0.60 (1)
ACP 3300-7 BE II 1010 32501740 1~ 250 10 0.70 (1)
ACP 3301-1 BE II 1010 32501740 1~ 250 10 0.70 (1)
ACP 3301-5 BE III 1020 32501741 1~ 250 20 1.05 (1)
ACP 3302-2 BE III 1020 32501741 1~ 250 20 1.05 (1)
ACP 3600-7 BE I 3003 32501742 3~ 380/480 3 0.75 (1)
ACP 3601-5 BE II 3005 32501743 3~ 380/480 5 0.80 (1)
ACP 3602-2 BE III 3012 32501744 3~ 380/480 12 1.15 (1)
ACP 3603-0 BE III 3012 32501744 3~ 380/480 12 1.15 (1)
ACP 3604-0 BE III 3012 32501744 3~ 380/480 12 1.15 (1)
ACP 3605-5 BE IV 3038 32501745 3~ 380/480 38 1.90 (1)
ACP 3607-5 BE IV 3038 32501745 3~ 380/480 38 1.90 (1)
ACP 3611-0 BE IV 3038 32501745 3~ 380/480 38 1.90 (1)
ACP 3615-0 BE IV 3038 32501745 3~ 380/480 38 1.90 (1)
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3.3.3 Filter Specifications
All BERGES line filters are provided in IP20 enclosures. They can operate over a temper-
ature range of -10 to +50 °C (-23 to +122 °F). The filters can be mounted parallel or per-
pendicular to the control panel. The filter is supplied with the correct mounting hardware for
mounting the inverter on top of the filter enclosure (Footprint).
The mains filters and chokes must be installed and connected in conformity with the rec-
ommendations given in chapters 3.3.1 (page 12), 3.3.4 (page 15) and 3.6.3 (page 22).
ACP 3000
DEVICE TYPE CHOKE ARTICLE NO. INPUT PHASES VOLTAGE (V) CURRENT (A) WEIGHT (kg) FOOTPRINT
ACP 3300-3 BV 20394/307 32501345 – 440 7 0.25 –
ACP 3300-5 BV 20394/307 32501345 – 440 7 0.25 –
ACP 3300-7 BV 20394/307 32501345 – 440 7 0.25 –
ACP 3301-1 BV 20394/307 32501345 – 440 7 0.25 –
ACP 3301-5 BV 20394/307 32501345 – 440 7 0.25 –
ACP 3302-2 BV 20394/313 32501346 – 440 13 0.70 –
ACP 3600-7 BV 20394/307 32501345 – 440 7 0.25 –
ACP 3601-5 BV 20394/307 32501345 – 440 7 0.25 –
ACP 3602-2 BV 20394/307 32501345 – 440 7 0.25 –
ACP 3603-0 BV 20394/307 32501345 – 440 7 0.25 –
ACP 3604-0 BV 20394/313 32501346 – 440 13 0.70 –
ACP 3605-5 BV 20394/313 32501346 – 440 13 0.70 –
ACP 3607-5 BV 20394/325 32501347 – 440 25 1.10 –
ACP 3611-0 BV 20394/325 32501347 – 440 25 1.10 –
ACP 3615-0 BV 20394/330 32501348 – 440 30 1.15 –
ATTENTION!
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NOTE: Dimensions in mm.(1)
3.3.4 Interference Suppression Measures
Electrical/electronic devices are capable of influencing or disturbing each other through
connecting cables or other metallic connections. “Electromagnetic compatibility” consists of
the factors “interference resistance” and “interference emission”. Correct installation of
the inverter in conjunction with any possible local interference suppression meas-
ures has a crucial effect on minimizing or suppressing mutual interference.
TYPE OUTER DIMENSIONS SECURING SECURING ON THE
INVERTER CONNECTIONS FOOT- PRINT
A B C D E F G H I J (PE) K
BE I 1005 200 108 40 183 80 M5 137 94 M5 M4 2,5 mm2(1)
BE II 1010 200 145 40 183 110 M5 137 129 M5 M4 2,5 mm2(1)
BE III 1020 250 145 45 235 110 M5 188 129 M5 M4 2,5 mm2(1)
BE I 3003 200 108 40 183 80 M5 137 94 M5 M4 2,5 mm2(1)
BE II 3005 200 145 40 183 110 M5 137 129 M5 M4 2,5 mm2(1)
BE III 3012 250 145 45 235 110 M5 188 129 M5 M5 2,5 mm2(1)
BE IV 3038 360 222 50 342 160 M6 280 200 M6 M5 16 mm2(1)
BE V 3012 360 222 50 342 160 M6 280 200 M6 M5 16 mm2(1)
BE VI 3040 496 232 50 478 180 M6 419 200 M6 M5 16 mm2(1)
Table 3.2
(1) FOOTPRINT means that these filters have been prepared for the installation of an ACP converter on the filter (securing).
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The scope of noise suppression measures depends on the limit value class, the local situ-
ation and the application.
The following notes refer to a mains power supply that is not “contaminated” by high fre-
quency interference. Other measures may be necessary to reduce or suppress interference
if the mains voltage is “contaminated”. No generally valid recommendations can be given
in such cases. Please consult BERGES if all recommended interference suppression
measures should not produce the desired result.
Basically, it is not the cross section of the conductor that is important for radio-frequency
interference suppression but the surface area. Since the high-frequency interference does
not flow through the entire cross section but mainly on the outer surface of the conductor
(skin effect), braided copper tapes of corresponding cross section should be used.
All conductive housing parts must be interconnected using corresponding lines. Minimum
cross sections are prescribed for a fault case at 50 Hz (referred to the range of the safety
regulations) which must be observed under all circumstances.
The inverter and all other components used for interference suppression (especially also
the shield of the motor cable) should be contacted over as large an area as possible when
connected to metal (control panels, switchgear cabinets and similar) (skin effect). Remove
the paint at the respective areas to ensure good contacting over a large area!
A central earthing point should be used for interference suppression (e.g. equipotential
bonding strip or centrally at an interference suppression filter). The earthing lines are routed
to the respective terminals radially from this point. Conductor loops of the earthing lines
are impermissible and can lead to unnecessary interference.
The shield cross section must not be reduced when the shield is connected to continuing
lines. This would give rise to RF resistance at a cross section reduction, and the resulting
RF energy would consequently not be discharged but radiated. Shields – particularly
shields of control lines – must not be contacted via pin contacts of plug connectors. In these
cases, the metallic hand guard of the plug connector should be used for large-area connec-
tion of the shield.
Use a shielded motor cable (earthed over a large area at both sides). The shield should be
routed uninterrupted from the PE terminal of the inverter to the PE terminal of the motor.
If a shielded motor line cannot be used, the unshielded motor line should be laid in a metal
duct. The metal duct must be uninterrupted and adequately earthed. The following points
are prescribed if radio interference suppression is to be realized in accordance with EN
55011, EN 55014 and EN 50081-1:
• Preceding the unit by a mains filter or a mains filter and a output choke (mains filter and
output choke not included in the scope of delivery).
• Laying the motor cable in a shielded configuration.
• Laying the control cable in a shielded configuration.
• Observe general RFI suppression measures (refer to the chapters 3.3.1 and 3.3.4).
Laymotor, mains power and signal cables as far away from each other as possible and sep-
arately.
If a mains filter is used, the smallest possible spatial distance from the frequency inverter
must be selected so that both units can be connected by short connection leads.
If an output choke is used (option), it must be fitted in the direct vicinity of the inverter and
connected to the inverter via screened cables earthed at both ends.
Shielded signal cables should be laid at a minimum distance of 10 cm from power cables
running parallel. A separate earthed metal cable duct is advisable for such signal cables. If
signal cables intercept with a power cable, they should do so at an angle of 90°.
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