Danaher Motion ACOMEL K 4000 User manual

25-11-03 S476 -gb-0348
K4000 - USER MANUAL

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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
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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