Danaher Motion ACOMEL K 4000 User manual
Empty page
Page 2 / 48 User Manual K4000 S476-gb-0348
TABLE OF CONTENT
Safety instructions 5
Information on the Operating Manual 5
The Basic Safety Rules 5
Working instruction 5
Overspeed protection 6
Proper installation 6
Responsibility 6
A comprehensive range of product 7
Product basics 7
Main technical data 7
Current and Power ratings 7
Dissipation and Dynamic Braking Resistors ratings 8
Type Part Numbering 8
Overload protection 8
Connecting the K4000 to a transformer 8
The 19” – rack versions, KL4000 10
Current and Power ratings 10
Type Part Numbering 10
The dimensions of the KL4000 10
K4000 - Drive overview 11
The KT4005, KT4010, KT4015, KT4020 and KT4030 11
The KT4040 and KT4060 12
The KT4090 and KT4120 13
The 19” – rack version KL4000 13
The 19” – rack version KL4000 14
K4000 - Terminals descriptions 15
Input circuit breaker 15
The power terminals 15
Terminal bloc X1 of the KT4005 to KT4030 15
Terminal bloc X1 of the KT4040 and the KT4060 16
Terminal bloc X1 of the KT4090 and the KT4120 16
View of the control terminal bloc X2 16
View of the control terminal bloc X2 17
The + 25 VDC - Auxiliary Power Supply 17
The + 25 VDC - Auxiliary Power Supply 18
The control terminals description 18
Compulsory Connections 20
The START / STOP functions 20
The Speed Reference Input 20
The digital and analog programmable outputs and Inputs 21
Selection of the MCM reference 21
Selection of the speed control source 21
The Sample Hold of the MCM function 21
Current parametric resistor RTRIP 21
Digital Output SDIG 21
Digital speed input 21
The relay contact outputs 22
Reversing from the terminal block 22
Partition selection from terminal block 22
External Interlocks 22
The programmable analog output SAN1 and SAN2 23
Catch a spinning motor 23
The access key 23
The RESET 23
Connecting a NTC temperature sensor 23
S476-gb-0348 User Manual K4000 Page 3 / 48
Connecting the PTC - motor temperature protection 24
The analog input AI1 24
Inhibit the analog speed reference input 24
Selecting one of the pre-set speeds 24
Connecting the dynamic braking resistor 25
Programming the K4000 26
The Menus 26
The User Interface PC560 26
QUICK START 27
3. Compulsory connections 27
4. The characteristic Voltage / Frequency or Power / Frequency 27
5. The input of the parameters 27
6. The START 28
The programmable parameters 29
Menu A : Inverter Related Parameters 29
Menu B – Part 1: Operation related parameters 29
Menu B - Part 2: Motor related parameters 31
Menu C : Allocation of the relay outputs 36
Menu C : Allocation of the analog output 37
Menu D: The parameters accessible in START mode 37
Menu E : reversing from KEYPAD 38
Menu F : Setting a new speed using the KEYPAD 38
Menu G : Selection of the display bloc 38
Display of the digital I/O status 39
Menu H : Display of the last 8 failures 40
Menu I : RESET 40
Menu J : Save the last speed reference as default 40
Setting a value using the “Arrow UP” and “Arrow DOWN” 40
The Tachobox Option 41
Galvanic insulation of the power circuitry 41
Galvanic insulation of the power circuitry 42
K4000 – List of Error messages 43
Part numbers for spares, options and accessories 44
Assistance and Trouble shooting 45
Overview of Menu A, B and C 46
DECLARATION OF CONFORMITY 47
Valid from Software Version V15 dated January 2002 or later
Page 4 / 48 User Manual K4000 S476-gb-0348
Safety instructions
Information on the Operating Manual
This operating manual applies to the K4000 frequency inverter family. It describes
the connections and basic functions of the standard models.
CAUTION! Danger of death by electrocution
CAUTION! Absolutely essential
FORBIDDEN! Incorrect operation, may lead to damage.
The Basic Safety Rules
First read the user manual
Before installing and commissioning, it is important for such personal to read carefully
the operating instructions and safety warnings.
Electric drives are potentially dangerous
• Electrical voltages > 230 V/460 V
High voltages may still be present up to 5 minutes after the power has been cut off.
Therefore you must always check for presence of power and voltages!
• In STOP mode, the drive remains active and the motor terminals are at a potential
of 300 VDC against the ground.
• Rotating parts
• Hot surfaces
Your qualification
• In order to prevent personal injury and damage to property, only personnel with
electrical engineering qualifications may work on the device.
• According to IEC364, DIN VDE0100, the qualified personnel must be familiar with
the User Manual
• Have knowledge of national standards and accident prevention regulations
Working instruction
During installation observe the following instructions:
• Always comply with the connection conditions and technical specifications.
• Comply with the standards for electrical installations, such as regarding wire
gauges, grounding lead and ground connections
S476-gb-0348 User Manual K4000 Page 5 / 48
The converter control board uses a large number of MOS (Metal Oxide
Semiconductor) which are highly sensitive to electrostatic charge.
To avoid any damages to the control board
• wear an earthing strap and always handle the board by the extractors
• make sure you are working on an earthen anti-static floor
• use anti-static packing material only
Overspeed protection
If an overspeed protection is required, it must be provided by the motor manufacturer
as this function is not integrated in the drive
Proper installation
Inverter drives are components that are intended for installation within electrical
systems or machines. The inverter may not be commissioned or put into operation
until it has been established that the machine as a unit complies with the provisions
of the EC Machinery Directive (89/392/EEC) as well with the standard EN 60204
(Safety of machines).
If the frequency inverter is used for special applications the specific standards and
regulations for this environment must always be observed.
Repairs may only be carried out by authorized repair workshops. Unauthorized
opening and incorrect intervention could lead to physical injury or material damage.
The warranty provided by DANAHER-MOTION would thereby be void.
Responsibility
Electronic devices are fundamentally not fail-safe. The company setting up and/or
operating the machine or plant is itself responsible for ensuring that the drive is
rendered safe if the device fails.
The standard EN 60204-1/DIN VDE 0113 “Safety of machines”, in the section on
“Electrical equipment of machines”, stipulates safety requirements for electrical
controls. The requirements to comply with are intended to protect the integrity of
personnel and machines and to maintain the function capability of the machine or
plant. The function of an emergency off system does not necessarily have to cut the
power supply to the drive.
To protect against risk of injury, it may be more beneficial to maintain individual
drives in operation or to initiate specific safety sequences. The emergency stop
process may be assessed by means of a risk analysis of the machine or plant,
including the electrical equipment to EN 1050. Part of this analysis is determined by
the selection of the circuit category in accordance with prEN 954 “Safety of machines
– Safety related parts of controls”.
Page 6 / 48 User Manual K4000 S476-gb-0348
A comprehensive range of product
Product basics
The K4000 is a high frequency inverter designed for application up to 4000 Hz. The
K4000 family consists of several models with output ratings from 5 to 120 kVA. the
selective harmonic suppression -SHS - developed by DANAHER-MOTION, is aimed
at reducing motor losses and winding stresses without output filter.
• The KEYPAD PC560 control unit can be integrated on the front panel or supplied
as a separate remote control unit.
• The drive is equipped with a RS232 / 422 serial link. A communication protocol in
terminal mode for PC is available on request
• The UL certification of the KT4000 is in process
• The 19” rack version KL4000 will not be UL certified
Main technical data
• Input voltage, all units, 3 x 200 V to 3 x 480 V auto-ranging, no line transformer
• Output voltage VRMS : 0 … UIN, max. 3 x 460 V
• Output frequency range 0 … 4000 Hz
• Ambient temperature 40°C
• Continuous current overload 120% without time limitation
• Max current overload 150% for 1 min / every 10 min
• Short-circuit protection: suitable for use on a circuit capable of delivery not more
than 5000 ARMS symmetrical Amperes, 480 V maximum.
Current and Power ratings
Model Output Current ARMS Typical motor power
Nominal Continuous Peak kW @ 3 x 400 V
KT4005 5 6 10 2.5
KT4010 10 12 15 5
KT4015 15 18 23 7.5
KT4020 20 24 30 10
KT4030 30 36 45 15
Input current: All units are rated for a maximal input current of 32 ARMS
Input terminals: 10 mm2
Input cables: Minimum section 6 mm2resp. 10 AWG
Use copper conductors 75°C only
Model Output Current ARMS Typical motor power
Nominal Continuous Peak kW @ 3 x 400 V
KT4040 40 50 60 20
KT4060 60 75 90 30
Input current: All units are rated for a maximal input current of 63 ARMS
Input terminals: 35 mm2
Input cables: Minimum section 25 mm2resp. AWG 4
Use copper conductors 75°C only
Model Output Current ARMS Typical motor power
Nominal Continuous Peak kW @ 3 x 400 V
KT4090 90 110 135 45
KT4120 120 145 180 60
Input current: All units are rated for a maximal input current of 160 ARMS
Input terminals: 70 mm2
Input cables: Minimum section 50 mm2resp. AWG 1
Use copper conductors 75°C only
S476-gb-0348 User Manual K4000 Page 7 / 48
Dissipation and Dynamic Braking Resistors ratings
Model Dissipation Braking resistors
Watts Ω/ Watts - external
KT4005 200 22Ω/400W
KT4010 400 22Ω/400W
KT4015 600 22Ω/400W
KT4020 750 15Ω/1200W
KT4030 900 15Ω/1200W
KT4040 1200 6Ω/1500W
KT4060 1800 6Ω/1500W
KT4090 2700 4Ω/2000W
KT4120 3600 4Ω/2000W
Type Part Numbering
Standalone IP20 units
KT40xx-00 Without PC560 and external dynamic braking resistor
KT40xx-01 Without PC560, with external dynamic braking resistor
KT40xx-10 With PC560 and without external dynamic braking resistor
KT40xx-11 With PC560 and with external dynamic braking resistor
IP54 cabinet unit
KU40xx for cabinet with convection cooling up to KU4015
for cabinet with fan cooling for larger power ratings
KV40xx for cabinet with heat exchanger air – air
KW40xx for cabinet with heat exchanger air – water
KQ40xx for cabinet with air conditioning
Overload protection
UL requires an external overload protection
Connecting the K4000 to a transformer
The K4000 can be connected to any input voltage from 3 x 200 V to 3 x 480 V, 50 /
60 Hz, without a line transformer.
Nevertheless, if the input voltage is higher than 480 V or the installation requires a
galvanic insulation in front of the drive, following rules must be respected:
• Don't use an auto-tranformer but only a transformer with separated windings.
• The output voltage of the transformer should not be higher than 460 V.
Page 8 / 48 User Manual K4000 S476-gb-0348
The dimensions of the KT4000
∅F
D
A
C
B E
Model Overall Dimensions Mounting Dimensions Weight
A B C D E F Screws
KT4005
KT4010
KT4015
KT4020
KT4030
223
557
265
199
537
7
4 x M6
29 kg
KT4040
KT4060
71 kg
KT4090
KT4120
484
820
350
450
800
11
4 x M10
91 kg
All dimensions are in mm
Cabinet enclosure
1. The cabinet size and / or cabinet fan cooling, heat exchanger, air conditioning must
be sized according the power dissipation shown on the table page 7.
2. The minimum distances between cabinet walls and the drive (left, right, top and
bottom) as well between drives mounted side by side in the same cabinet are 100
mm.
S476-gb-0348 User Manual K4000 Page 9 / 48
The 19” – rack versions, KL4000
Current and Power ratings
Model Output Current ARMS Typical motor power
Nominal Continuous Peak kW @ 3 x 400 V
KL4005 5 6 10 2.5
KL4010 10 12 15 5
KL4015 15 18 23 7.5
KL4020 20 24 30 10
KL4030 30 36 45 15
Input current: All units are rated for a maximal input current of 32 ARMS
Input terminals: 10 mm2
Input cables: Minimum section 6 mm2resp. 10 AWG
Use copper conductors 75°C only
Type Part Numbering
Connection from front
KL40xx-00F Without PC560 and external dynamic braking resistor
KL40xx-01F Without PC560, with external dynamic braking resistor
KL40xx-10F With PC560 and without external dynamic braking resistor
KL40xx-11F With PC560 and with external dynamic braking resistor
Connection from rear
KL40xx-00R Without PC560 and external dynamic braking resistor
KL40xx-01R Without PC560, with external dynamic braking resistor
KL40xx-10R With PC560 and without external dynamic braking resistor
KL40xx-11R With PC560 and with external dynamic braking resistor
The dimensions of the KL4000
Mounting Instructions
1. The area on top of the 3 fans, whole
width and 112 mm depth, must
remain free for correct cooling of the
heat sink. At least 50 mm must be
available on bottom and top of this
area.
2. On the left side they are ventilation
opening to allow a correct cooling of
the chopper inductance. Those
opening must not be covered.
Unit height: 6U = 265.9 mm
Weight: 29 kg
All units have the same dimensions
Page 10 / 48 User Manual K4000 S476-gb-0348
K4000 - Drive overview
The KT4005, KT4010, KT4015, KT4020 and KT4030
Switching power supply board
and control signal connecting board
Display 2 lines of 20 Characters
Serial link RS485 to control board
Terminal bloc removable cove
r
Control board with signal control
terminals X2/61 to X2/80
Serial link connectors CN2 and
CN3, display or PC connection
X2 - control terminal block X2/01 to X2/60
DC bus capacitors
IGBT drivers
Power connecting board, current
sensing and drive protection
Cho
pp
er inductance
Input capacitor
Heat sink with input rectifier and
integrated IGBT modules, including
braking chopper
Input circuit breaker
Input / Output power terminal
block X1
Connecting cables and shielding
grounding clamps with strenght relief
CN4 – RS232 / RS422 / D-Sub 9 pins
switchable for direct programming and
controlling of the drive using a PC in
terminal mode
S476-gb-0348 User Manual K4000 Page 11 / 48
The KT4040 and KT4060
Input circui
t
breake
r
Power terminal
bloc X1
Driver
braking
chopper
Chopper
drive
r
IGBT drivers
Switching power supply board
and control signal connecting
board
The control board
Page 12 / 48 User Manual K4000 S476-gb-0348
S476-gb-0348 User Manual K4000 Page 13 / 48
The KT4090 and KT4120
The Twin-
Chopper drivers
The 3 input
fuses
S476-gb-0348 User Manual K4000 Page 13 / 48
The 19” – rack version KL4000
The terminal blocks, connection for front access:
CN2
CN3
Circuit breaker
X2 control
terminals
power terminals X1
The terminal blocks, connection for access from the back
CN2
CN3
X2 control terminals
X1 power terminals
Page 14 / 48 User Manual K4000 S476-gb-0348
K4000 - Terminals descriptions
Input circuit breaker
This is not a power switch
The converter is protected against ground short circuit by a fast
circuit breaker.
Resetting is performed manually by pushing a lever, during this
operation tripping is disabled, so that the converter is no longer
protected.
It is therefore important to disconnect the converter from the
power line prior to resetting the circuit breaker.
The power terminals
Motor output terminals U-V-W
In STOP mode, the drive remains active and the motor terminals are at a
potential of 300 VDC against the ground. Before any intervention on the drive,
make sure that the power supply has been removed.
DC-bus voltage
Large capacitors are installed on the intermediate DC-bus voltage.
Please wait at least > 5 min. before to remove the cover of the
terminal bloc and to access to the internal part of the drive. Please
check of voltage free intermediate DC bus.
Terminal bloc X1 of the KT4005 to KT4030
L1 L2 L3 PE UVW
BB
PE Principal earth terminals
L1-L2-L3 Line input, 3 phases 200 V to 480 V +10% / -15%
U-V-W Motor output, MAX. 460 V
B, B Terminals for dynamic braking resistor
S476-gb-0348 User Manual K4000 Page 15 / 48
Terminal bloc X1 of the KT4040 and the KT4060
Terminal bloc X1 of the KT4090 and the KT4120
3 Fuses 160 A
Super quick-acting
Use only original model
Page 16 / 48 User Manual K4000 S476-gb-0348
View of the control terminal bloc X2
The Power switching board with terminals X2/1 – 60 and the D-sub connectors
CN2 and CN3. Reference P/N HB7451
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
The control Board with terminals X2/ 61 – 80 and the D-sub connector CN4
Reference part number HB7701
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
Switch RS232 / 422
Factory setting RS232
CN4 - RS232 / RS422 / D-Sub
9 pins
For direct programming and
controlling the drive through a
PC in terminal mode
For additional information see
“Terminal Mode Programming
Manual”
CN2 - 9 pins D-Sub
connector for RS485
serial link. to be used
for KEYPAD PC560
CN3 - 9 pins D-Sub connector
for remote display DD550 only.
A PC560 must be
Connected to CN2.
RS232
PIN 2
Transmit from K4000 to PC
PIN 3 Receive from PC to K4000
PIN 5 Ground
All other PIN are not used for this connection
RS422
PIN 5
Ground
PIN 6 Transmit from K4000 to PC –
PIN 7 Transmit from K4000 to PC +
PIN 8 Receive from PC to K4000 +
PIN 9 Receive from PC to K4000 –
All other PIN are not used for this connection
S476-gb-0348 User Manual K4000 Page 17 / 48
The + 25 VDC - Auxiliary Power Supply
On the control terminal bloc X2, they are a number of terminals where
the +25 VDC internal power supply is available. This power supply is
only available for the inputs and outputs of the K4000, no other device
must be connected.
The total load must not exceed 400 mA.
The control terminals description
Our digital inputs are not galvanic insulated. You must take care that no external
potential (24 VDC) is applied to those inputs before our own internal auxiliary power
supply 25 VDC has been built up. Non respect of this process could lead to major
damages to the motor and / or the drive.
Term
No
Short
Name
Description
How to activate
K3000
X2 Ref.
1 Pot. + + 10 VDC To connect an external pot. 7
2 Pot. - - 10 VDC for speed reference input 4
3 AGND Analog Ground 1
4 CMD1 + Diff. speed reference analog input Use to connect the 0 ...10V 6
5 CMD1 - Diff. speed reference analog input analog reference from CNC 5
6 20MCM selection – value 1 Apply +25 VDC N/A
7 21MCM selection - value 2 Apply +25 VDC N/A
8 COM Common terminal to Start / Stop Show 25 VDC if no failure 8
9 STOP Stop input - stop the drive if open 9
10 START Start input Apply +25 VDC 10
11 +25VDC 25 VDC auxiliary power supply Available for input activation 19
12 COMC Return the control of the speed to
the KEYPAD
Apply +25 VDC N/A
13 +25VDC 25 VDC auxiliary power supply Available for input activation 22
14 SH Sample hold for MCM function Apply +25 VDC 25
15 RT- RTRIP - External resistor to set the 54
16 RT+ RTRIP + (AGND) motor current reference 24
17 SDIG+ Digital output + Digital pulses train as 11
18 SDIG- Digital output + frequency digital output 12
19 CDI+ Digital speed signal input + Speed input using a 13
20 CDI- Digital speed signal input - pulse sensor 14
21 +25VDC 25 VDC auxiliary power supply Available for input activation 26
22 RE5-NO Output relay 5 - contact NO Contact will close 44
23 RE5-COM Output relay 5 - common When relay is energized 45
24 RE5-NC Output relay 5 - contact NC Contact will open 46
25 RE1-NO Output relay 1 - contact NO Contact will close 31
26 RE1-COM Output relay 1 - common When relay is energized 32
27 RE1-NC Output relay 1 - contact NC Contact will open 33
28 RE2-NO Output relay 2 - contact NO Contact will close 34
29 RE2-COM Output relay 2 - common When relay is energized 35
30 RE2-NC Output relay 2 - contact NC Contact will open 36
31 +25VDC 25 VDC auxiliary power supply Available for input activation 28
32 ISR Reverse the rotation direction Apply + 25VDC 20
33 +25VDC 25 VDC auxiliary power supply Available for input activation 55
34 20Partition selection - value 1 Apply + 25VDC 56
35 21Partition selection - value 2 Apply + 25VDC 57
36 22Partition selection - value 4 Apply + 25VDC 58
37 23Partition selection - value 8 Apply + 25VDC 59
38 24Partition selection - value 16 Apply + 25VDC 60
39 +25VDC 25 VDC auxiliary power supply Available for input activation 30
40 EXT External interlock - Apply 25 VDC Drive stop when open 21
Page 18 / 48 User Manual K4000 S476-gb-0348
Term
No
Short
Name
Description
How to activate
K3000
X2 Ref.
41 SAN1 Analog output 1 Internal programmable 17
42 AGND Analog ground parameter 0 ... 10 VDC 18
43 SAN2 Analog output 2 Internal programmable na
44 AGND Analog ground parameter 0 ... 10 VDC na
45 CSM+ Catch a spinning motor To activate apply +25 VDC na
46 CSM- Catch a spinning motor Must be connected to AGND na
47 KEY Program access key Access possible when na
48 AGND Analog ground connected to AGND na
49 RST Reset Apply +25VDC to RESET 29
50 +25VDC 25 VDC auxiliary power supply Available for input activation 50
51 +25VDC 25 VDC auxiliary power supply Available for input activation na
52 RE3-NO Output relay 3 - contact NO Contact will close 37
53 RE3-COM Output relay 3 - common When relay is energized 38
54 RE3-NC Output relay 3 - contact NC Contact will open 39
55 RE4-NO Output relay 4 - contact NO Contact will close 41
56 RE4-COM Output relay 4 - common When relay is energized 42
57 RE4-NC Output relay 4 - contact NC Contact will open 43
58 PTC+ Terminal for motor PTC + Activated when motor 23
59 AGND Analog ground temperature too high 24
60 NOT USED 40
61 AI1 Analog input 1 Analog input 0 … 10 V
Comparator level and time
delay to be programmed in
menu C
na
62 AGND Analog ground
63 INHA Inhibition of the analogue speed
reference input
Apply + 25VDC 27
64 AGND Analog ground
65 NOT USED
66 NOT USED
67 25Partition selection - value 32 Apply + 25VDC na
68 NOT USED
69 NOT USED
70 AGND Analog ground parameter 0 ... 10 VDC na
71 AGND Analog ground Connect NTC return na
72 NTC+ Terminal for motor NTC Connect NTC+ na
73 20Pre-set speed - value 1 Apply + 25VDC na
74 21Pre-set speed - value 2 Apply + 25VDC na
75
76
77
78
79
80
S476-gb-0348 User Manual K4000 Page 19 / 48
Compulsory Connections
Some of the connections are optional, depending on what functions are required and
whether these functions are to be accessed in digital mode from KEYPAD or from the
TERMINAL BLOC X2 . For further information, refer to the bloc diagram. Even to
control the drive through the user interface PC560, the following connections are
compulsory:
• Mains input: terminals X1: L1, L2, L3 and PE
• Converter outputs: X1: U, V, W and PE
• STOP: terminals X2/8 - X2/9 must be strapped together. In case of KEYPAD
PC560 control, opening this contact will stop the motor.
• External interlocks: terminals X2/39 - X2/40 must be strapped together if the
external interlocks are not used.
• The access key terminals must be strapped, terminals X2/47 – X2/48
• Motor temperature probe PTC: terminals X2/58 - X2-59 must be strapped
together if the motor has no temperature probe. UL requires an External Motor
Overload Protection.
The START / STOP functions
START
STOP
COM
9
8
10
X2
START command with impulse contact.
The START remains active until the STOP circuit between terminals 8
and 9 is interrupted.
When the drive is “READY”, +24VDC is available on terminal COM
9
8
10
X2
START
STOP
COM
START / STOP command using permanent contact.
Caution: If the permanent start contact is closed when the
inverter is powered up, the motor will start automatically if a
RESET is performed.
The Speed Reference Input
Note: Any input reference voltage < 100 mV is considered as
speed reference 0 i.e speed range 1% to 100%.
Ω
Ω
X2
-10V Pot.
0V-AGND
CMD1+
CMD1-
+10V Pot.
-10V Pot.
0V-AGND
CMD1+
CMD1-
CMD1+
CMD1-
Voltage
from CNC
reference
10k
10k 1
2
3
4
5
1
2
3
4
5
4
5
+10V Pot.
Input 0 ... +10 V
Reversing through terminal bloc X2/32 or
user interface PC560, depending on the programming
Input ±10 V
Reversing of direction when crossing 0 V
The reversing from the terminal bloc X2/32 must be open
Differential input from outside source
Can be 0 ... + 10 or ±10 V
Reversing from terminal bloc or crossing 0 V
Page 20 / 48 User Manual K4000 S476-gb-0348
Table of contents
