Emerson EV1000-2S0004G User manual

EV1000 Series General Purpose Variable Speed Drive
User Manual
Version: V1.4
Revision Date: February 1, 2004
BOM：31010988
Emerson Network Power provides customers with technical support.
Users may contact the nearest Emerson local sales office or service
center.
Copyright © 2004 by Emerson Network Power Co., Ltd.
All rights reserved. The contents in this document are subject to change
without notice.
Emerson Network Power Co., Ltd.
Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District
518057, Shenzhen China
Homepage: www.emersonnetworkpower.com.cn
Customer Service Hotline: [phone],
(86) 755-86011668
E-mail: [email protected]
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Contents
Preface............................................................... 1
Chapter 1 Safety Information ........................... 2
1.1 Danger and Warning Definitions ......... 2
1.2 Notes for Installations ......................... 2
1.3 Notes for Using the Drive.................... 3
1.3.1 About Motor and Load .............. 3
1.3.2 About Variable Speed Drive ..... 3
1.4 Disposing Unwanted Drive ................. 4
Chapter 2 Specifications and Optional Parts ... 5
2.1 Specifications...................................... 5
2.2 Product Series Introduction ................ 7
2.2.1 EV1000 Models ........................ 7
2.2.2 Ordering Information................. 7
2.2.3 Size .......................................... 7
2.2.4 LED Keypad Display Unit
TDP-LED02 Size.................................. 8
2.3 Optional Parts..................................... 8
2.3.1 Braking Resistor ....................... 8
2.3.2 LED Status Indicator Unit
TDP-LED03.......................................... 9
2.3.3 TDP-LED02 Holders and Wires 9
2.3.4 Communication Parts ............. 10
Chapter 3 Installation and Wiring................... 11
3.1 Installation ........................................ 11
3.1.1 Installation Methods Compliant
With EMC Requirements.................... 11
3.1.2 Noise Suppression ................. 13
3.1.3 Using Surge Suppressor......... 15
3.1.4 Leakage current...................... 15
3.1.5 Applications of Power Filter .... 15
3.1.6 AC Line Reactor Applications . 16
3.2 Wiring ............................................... 16
3.2.1 Overview................................. 17
3.2.2 Power Terminals..................... 19
3.2.3 Control Circuit Wiring.............. 20
3.2.4 Onsite Wiring Requirements... 27
3.2.5 Earthing .................................. 28
Chapter 4 Operation Procedures ................... 29
4.1 Definitions of Terms.......................... 29
4.1.1 The Drive’s Control Modes......29
4.1.2 Frequency Setting Methods ....29
4.1.3 Drive’s Operating Status .........29
4.1.4 Operating Mode ......................29
4.2 Operation Guide................................30
4.2.1 Operation of LED Keypad .......30
4.2.2 Keypad Function Explanation .31
4.2.3 Indicator Description ...............31
4.2.4 Parameter Setting Method ......31
4.2.5 Speed Setting .........................33
4.2.6 How to Lock/Unlock Keypad ...34
Chapter 5 Parameters ....................................35
5.1 Basic Parameters (F0) ......................35
5.2 Reference Frequency (F1)...................38
5.3 Start/Brake Parameter (F2)...............39
5.4 Auxiliary Operating Parameters (F3).42
5.5 PLC Parameters (F4) ........................45
5.6 Close-loop Control (F5).....................48
5.7 Traverse Parameters (F6).................52
5.8 Multi-function Terminal (F7) ..............54
5.9 Display Control (F8) ..........................65
5.10 Enhanced Function (F9)..................67
5.11 Reserved (FA).................................73
5.12 Communication (FF) .......................73
5.13 Moter’s Parameters (FH).................74
5.14 Protection (FL) ................................76
5.15 Operating Time (Fn)........................79
5.16 Protection of Parameters (FP).........79
Chapter 6 Troubleshooting.............................81
Chapter 7 Maintenance ..................................86
7.1 Routine Maintenance ........................86
7.2 Periodic Maintenance........................86
7.3 Replacing of Easily-worn Parts .........87
7.4 Storage of the Drive ..........................87
7.5 Warranty ...........................................88
Appendix 1 Parameter Set .............................89
Appendix 2 Communication Protocol ...........135
Appendix 3 Optional Parts............................151
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Preface 1
EV1000 Series General Purpose Variable Speed Drive User Manual
Preface
Thank you for using EV1000 Series variable speed drive made by Emerson Network Power Co., Ltd.
EV1000 Series satisfies high performance requirements by using a unique control method to achieve
high torque, high accuracy and wide speed-adjusting range. Its anti-tripping function and capabilities of
adapting to severe power network, temperature, humidity and dusty environment exceed those of similar
product made by other companies, which improves the product’s reliability noticeably;
EV1000 considers customers’ needs and combines general-purpose function and industrial-oriented
functions. It features PI control, simpe PLC, flexible I/O terminals and pluse frequency setting, You can
select whether to save the parameters upon poweroff or stop, bind frequency setting channel with
command channel, zero frequency return difference control zero frequency hysteresis, main and
auxiliary frequency setting, traverse operation, length control, etc. It is an integral, cost-effective and
highly reliable solution for manufacturer in the related fields.
EV1000 Series can satisfy the customers’ requirements on low noise and EMI by using optimized PWM
technology and EMC design.
This manual provides information on installation, wiring, parameter setting, trouble-shooting, and routine
maintenance. In order to ensure the correct installation and operation of the drive, please read this
manual carefully before using and keep it in a safe place.
Unpacking and Inspection
Upon unpacking, please check for:
Any damage occurred during transportation;
Check whether the rated values on the nameplate of the drive are in accordance with your order.
Our product is manufactured and packed at the factory with great care. If there is any error, please
contact any of our distributors or us.
The user manual is subjected to change without notifying the customers due to the continuous process
of product improvements.
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2 Chapter 1 Safety Information
EV1000 Series General Purpose Variable Speed Drive User Manual
Chapter 1 Safety Information
1.1 Danger and Warning
Definitions
Danger
!
Operations without following instructions
can cause personal injury or death
Attention
!
Operations without following instructions
can cause personal injury or damage to
product or other equipment.
1.2 Notes for Installations
Danger
!
Please install the drive on fire-retardant
material such as metal.
·Keep the drive away from combustible
materials.
·Keep the drive away from explosive gas.
·Only qualified personnel shall wire the drive.
·Note that the control terminal of EV1000 drive
is of ELV（Extra Low Voltage）circuit, therefore,
do not connect the control terminal with other
devices directly. For example, before
connecting the RS485 terminal with the PC’s
RS232 terminal, an adapter with isolating
protections must be connected in between;
·Never wire the drive unless the input AC
supply is totally disconnected; otherwise, there
is danger of electric shock. During power-on,
do not touch the cables, control terminals,
radiator and the pore plate on the housing of
the drive.
·The drive must be properly earthed to reduce
electrical accident.
·Install the cover before switching on the drive,
to reduce the danger of electric shock and
explosion.
·For drives that have been stored for longer
than 2 years, increase its input voltage
gradually before supplying full rated input
voltage to it in order to avoid electric shock and
explosion.
·Perform the maintenance job after confirming
that the charging LED is off or the DC Bus
voltage is below 36V.
·Only trained professionals can change the
components, it is prohibited to leave wires or
metal parts inside the drive to avoid the risk of
fire.
·Parameter settings of the control board that
has been changed must be revised, otherwise
accidents may occur.
·The bare portions of the power cables must
be bound with insulation tapes.
·When using optional parts, it is recommended
to use those provided by Emerson Network
Power, to secure safety.
Attention
!
·Don’t carry the drive by its cover. Its cover
cannot sustain the weight and may drop.
·Please install the drive on a strong support,
failing which the drive may fall off.
·Don’t install the drive in places where water
pipes may leak onto it.
·Don't allow screws, washers and other metal
foreign matters to fall inside the drive,
otherwise there is a danger of fire or damage;
·Don't operate the drive if parts are not
complete; there is a danger of a fire or human
injury;
·Don't install the drive under direct sunshine; it
may be damaged by heat;
·Don’t short circuit P1/PB and terminal (-),
there is a danger of fire or the drive may be
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Chapter 1 Safety Information 3
EV1000 Series General Purpose Variable Speed Drive User Manual
damaged.
·Cable lugs must be connected to main
terminals firmly.
·Don’s apply supply voltage (AC 110V or
higher) to the control terminals except
terminals TA, TB and TC.
1.3 Notes for Using the Drive
Pay attention to the following issues when using
EV1000 Series drive:
1.3.1 About Motor and Load
Compared to working at mains frequency, there
will be some increase in temperature, noise and
vibration in the motor. The EV1000 Series are
voltage source inverters. Its output voltage is in
PWM wave. Being non-sinusoidal, there will be
some harmonics.
Low Speed Rotation with Constant Torque
When a standard motor is driven at low speed for
a long time, there will be insufficient cooling for a
self-ventilated motor. Overheating can result in
insulation damaged. Special variable frequency
motor is recommended for constant torque
operation at low speed.
Motor’s over-temperature protecting
threshold
The drive can protect the motor from
over-temperature. If the power rating of the drive
is greater than the motor, be sure to adjust the
protection parameters to ensure the motor is
properly protected.
Operate above 50Hz
When running the motor above 50Hz, there will
be increase in vibration and noise. The rate at
which the torque is available from the motor is
inversely proportionally to its increase in running
speed. Ensure that the motor can still provide
sufficient torque to the load.
Lubrication of mechanical devices
Over time, the lubricants in mechanical devices,
such as gear box, geared motor, etc. when
running at low speed, will deteriorate. Frequent
maintenance is recommended.
Regenerative Energy
When lifting load, regenerative energy is
produced, the drive will trip on overvoltage when
it cannot absorb the regenerative energy of the
load. Therefore, a proper braking unit is required.
Mechanical resonance point of load
The drive system may encounter mechanical
resonance with the load when operating within
certain band of output frequency. Skip
frequencies have to be set to avoid it.
Frequent start and stop
The drive should be started and stopped via its
control terminals. It is prohibited to start and stop
the drive directly through contactors at the input
side, which may damage the drive.
Insulation of Motors
Before using the drive, the insulation of the
motors must be checked, especially, if it is used
for the first time or if it has been stored for a long
time. This is to reduce the risk of the Drive from
being damaged by the poor insulation of the
motor winding. Wiring diagram is shown in Fig.
1-1. Please use 500V insulation tester to measure
the insulation resistance. It should not be less
than 5MΩ.
1.3.2 About Variable Speed Drive
Varistors for Surge Protection or Capacitors Used
to Improve the Power Factor
Don't connect any varistor or capacitor to the
output terminals of the drive, because the drive's
output voltage waveform is pulse wave. Tripping
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4 Chapter 1 Safety Information
EV1000 Series General Purpose Variable Speed Drive User Manual
or damage to components may occur as shown in
Fig.1-1.
M
U
V
W
EV1000
Drive
Fig. 1-1 Capacitors at output are prohibited
Circuit breakers connected to the output of
the drive
If circuit breaker or contactor needs to be
connected between the drive and the motor, be
sure to operate these circuit breakers or contactor
when the drive has no output to avoid damaging
of the drive.
Using host communication function
When frequently modifying the parameters
through host communication function, improper
command will cause physical damage to the
EEROM inside the drive. Please refer to
Appendix 2.
Using outside the range of rated voltage
The drive is not suitable to be used out of the
specified range of operation voltage. If needed,
please use suitable voltage regulation device.
Protection against lightning strike
There are transient surge suppressors inside the
Drive which protects it against lighting strike.
Derating due to Altitude
Derating must be considered when the drive is
installed at high altitude, greater than 1000m.
This is because the cooling effect of the Drive is
less effective in the thin air. Fig.1-2 that shows the
relationship between the altitude and rated
current of the Drive.
100%
90%
80%
1000 400030002000 (m)
Iout
Fig. 1-2 Drive Derating at different altitudes.
1.4 Disposing Unwanted Drive
When disposing the Drive, pay attention to the
following factors:
The capacitors may explode when they are burnt.
Poisonous gas may be generated when the
plastic parts like front covers are burnt.
Disposing method: Please dispose the Drive as
industrial waste.
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Chapter 2 Specifications and Optional Parts 5
EV1000 Series General Purpose Variable Speed Drive User Manual
Chapter 2 Specifications and Optional Parts
2.1 Specifications
Table 2-1 EV1000 Specifications
Item Description
Rated voltage & frequency
EV1000-4Txxxxx: 380V～440V; 50Hz/60Hz
EV1000-2Sxxxxx: 200V～240V; 50Hz/60Hz
Input
Permissible fluctuation range
Continuous fluctuation rate: ≤±10%,
short time fluctuation rate: ≤–15%~+10%;
Voltage unbalance rate: <3%; Frequency: ±5%
Rated voltage EV1000-4Txxxxx: 0~380V/440V
EV1000-2Sxxxxx: 0~200V/240V
Frequency 0Hz~650Hz
Output
Over load ability
G type: 150% rated current for 1 minute, 180% rated current for
3s/1s (380V/220V series)
P type: 120% rated current for 1 minute
Modulation mode Flux vector PWM modulation
Speed range 1:50
Starting torque 150% rated torque at 1Hz
Accuracy of speed at steady
state
≤±1% rated synchronous speed
Accuracy of frequency
Digital setting: highest frequency×±0.01%.
Analog setting: highest frequency×±0.2%
Setting frequency resolution Digital setting:0.01Hz. Analog setting: highest frequency×0.1%
Torque boost Auto torque boost, Manual torque boost 0.1%~30.0%
V/F curve 4 modes: 1 self-defined V/F curve and 3 kinds of quadratic V/F
modes (power exponent: 2.0, 1.7 and 1.2)
Acc/dec curve 3 modes: linear, S curve and automatic acc/dec;
4 acc/dec time: unit (minute/second), 60 hours at most
DC braking Start frequency: 0.00~60.00Hz, duration: 0.1~60.0s
Threshold current: G type: 0.0~150.0%, P type: 0.0~130.0%
Jog Jog frequency: 0.10~50.00Hz; Acc/Dec time: 0.1~60.0s.
Jog interval adjustable
Main control
functions
On-board PI controller Able to configure close-loop control system easily
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6 Chapter 2 Specifications and Optional Parts
EV1000 Series General Purpose Variable Speed Drive User Manual
Item Description
Auto-energy saving operation V/F curve is optimized automatically according to the load condition
to perform energy-saving operation.
Auto voltage regulation (AVR) Constant output voltage even if electric network voltage fluctuates
Auto current limiting Operating current is limited automatically to avoid frequent tripping
of the drive.
Traverse for texile motor Traverse control, central Traverse adjustable
Set length control When reaching set length, the drive will stop
Droop control When many drives control single load
Tone selection Set the tone of the motor when it is running
Immunity to transient power
failure The drive gives output even if power failure occurs
Customized
functions
Channel binding Command channel can bind with frequency setting channel and
switched synchronizingly
Methods of inputting commands Via keypad panel, terminals and serial ports.
Methods of setting up frequency Digital setting; Analog voltage/current setup; pulse setting, serial
port
Pulse output terminal 0~50kHz pulse signal output. Signals can be reference frequency
and output frequency
Operating
function
Analog output terminals 2 analog outputs of 0/4~20mA and 0~10V(selectable). Able to
output signals like reference frequency and output frequency.
LED keypad
Able to show 21 parameters, such as: frequency setting, output
frequency, output power and current during operation; frequency
setting.
Control
panel
Keypad lock and key definition Total lock or partially lock. Some keys’ function definable.
Protection function Phase loss failure, Over/Under current, Over/Under voltage
protection, Over heat, and Overload protections
Optional parts Flush mount faceplate for remote keypad, remote keypad cables
and Profibus adapter
Operating environment In-door, free from moisture, dust, corrodent or flammable gases, oil
mist, vapor, water leakage or salt water.
Altitude Less than 1000m
Ambient temperature
-10℃~+40℃( derating is required from 40℃to 50℃, increase
every 1℃above 40℃, derate 2%, highest temperature allowed:
50℃)
Humidity Less than 95%RH, no condensing
Vibration Less than 5.9m/s2 (0.6g)
Environment
Storage temperature -40℃~+70℃
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Chapter 2 Specifications and Optional Parts 7
EV1000 Series General Purpose Variable Speed Drive User Manual
Item Description
Protection level IP20
Enclosure
Cooling Fan cooling
Mounting mode Mounted in a cabinet
2.2 Product Series Introduction
2.2.1 EV1000 Models
Table 2-2 Drive series
Drive Model
(G: contant torque;
P:pump,fan load)
Rated
Capacity
(kVA)
Rated
input
current
(A)
Rated
output
current
(A)
Motor
power
(kW)
EV1000-2S0004G 1.0 5.3 2.5 0.4
EV1000-2S0007G 1.5 8.2 4.0 0.75
EV1000-2S0015G 3.0 14.0 7.5 1.5
EV1000-2S0022G 4.0 23.0 10.0 2.2
EV1000-4T0007G 1.5 3.4 2.3 0.75
EV1000-4T0015G 3.0 5.0 3.7 1.5
EV1000-4T0022G 4.0 5.8 5.0 2.2
EV1000-4T0037G
EV1000-4T0037P
5.9 10.5 8.8 3.7
EV1000-4T0055G
EV1000-4T0055P
8.9 14.6 13.0 5.5
2.2.2 Ordering Information
Refer to Fig. 2-1a and Fig. 2-1b
series
motor
power(kW)
code
0004
0007
0015
0022
0037
0055
0.4
0.75
1.5
2.2
3.7
5.5
4 T 0 0 2 2 G
EV1000
input code
voltage code
220V 2
380V 4
code type
fan, pump
contant torque
P
G
Fig. 2-1a Explanations of Drive Models
EV1000-4T0022G
2.2kW
3PH AC 380V-440V 5.8A 50Hz/60Hz
4kVA 5A 0-650Hz 0-440V
MODEL：
POWER：
INPUT：
OUTPUT：
S/N：
Emerson Network Power Co., Ltd.
Drive model
Motor power
Rated input voltage, current, freq.
Rated output capacity,
current, freq., voltage
Bar code
Fig. 2-1b EV1000 Drive Nameplate
2.2.3 Size
Please refer to Fig. 2-2 and Table 2-3.
W
D
A
B
H
E
Fig. 2-2 EV1000 Drive Size
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8 Chapter 2 Specifications and Optional Parts
EV1000 Series General Purpose Variable Speed Drive User Manual
Table 2-3 Dimensions and Weights
Drive Model Moter
power (kW)
A
(mm)
B
(mm)
H
(mm)
W
(mm)
D
(mm)
E
(mm)
Diameter of
mounting hole (mm)
Gross
weight (kg)
EV1000-2S0004G 0.4
EV1000-2S0007G 0.75
91 137 145 101 130 4 1.2
EV1000-2S0015G 1.5
EV1000-4T0007G 0.75
EV1000-4T0015G 1.5
EV1000-4T0022G 2.2
120 170 180 130 146 4 1.8
EV1000-2S0022G 2.2
EV1000-4T0037G 3.7
EV1000-4T0037P 3.7
EV1000-4T0055G 5.5
EV1000-4T0055P 5.5
140 230 245 155 160
10
5 4.0
2.2.4 LED Keypad Display Unit
TDP-LED02 Size
The LED keypad display unit TDP-LED02
(standard configuration) also applies to TD1000
series drives. Through it, operation and
configuration of the drive can be done. Refer to its
size in Fig. 2-3.
Fig. 2-3 LED keypad display unit
2.3 Optional Parts
You may order the optional parts below from our
company.
2.3.1 Braking Resistor
The drive is equipped with braking unit. If there is
a need for energy-consuming braking, please
select a braking resistor in Table 2-4. Please refer
the wiring of braking resistor and the drive to Fig.
2-4. The wire specifications are listed in Table
3-2.
M
R
S
T
U
V
W
PE
PB P(+)
braking
resistor
Fig. 2-4 Wiring the drive with braking resistor
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Chapter 2 Specifications and Optional Parts 9
EV1000 Series General Purpose Variable Speed Drive User Manual
Table 2-3 Braking Resistor Specs
Model Specs
Usage
rate
（％）
Torque
（％）
Max.
continuous
work time
（s）
EV1000-2S0004G 200Ω/100W 10 100 10
EV1000-2S0007G 150Ω/200W 10 100 10
EV1000-2S0015G 100Ω/400W 10 100 10
EV1000-2S0022G 70Ω/500W 10 100 10
EV1000-4T0007G 300Ω/400W 10 100 10
EV1000-4T0015G 300Ω/400W 10 100 10
EV1000-4T0022G 200Ω/500W 10 100 10
EV1000-4T0037G 200Ω/500W 10 100 10
EV1000-4T0037P 200Ω/500W 10 100 10
EV1000-4T0055G 100Ω/1000W 10 100 10
EV1000-4T0055P 100Ω/1000W 10 100 10
Note:
If you have any special braking requirement, please
contact the supplier or us.
2.3.2 LED Status Indicator Unit
TDP-LED03
TDP-LED03 has no configuration or operation
function, but it can indicate powerup, run or fault
status of the drive by the red, green and yellow
LEDs on it.
Refer to Fig. 2-5.
If you buy many EV1000 drives and plan to use
terminal control mode after testing and no need to
modify the parameters thereafter, you may order
one TDP-LED02 display unit to do the test and for
the rest, TDP-LED03 can satisfy your need as
well. In this case, the frequency setting and
operation control are done through terminals. You
can know the status of the drive through
TDP-LED03.
POW
RUN
ERR
Attention: the panel is
for status display only.
Fig. 2-5 TDP-LED03
TDP-LED03 indicators definitions:
Mark Color of LED MEANING
POW RED ON: drive standby
RUN GREEN ON: drive is running
ERR YELLOW ON: drive fault
Note：
TDP-LED03 and TDP-LED02 are of same sizes.
2.3.3 TDP-LED02 Holders and Wires
The holders and wires of TDP-LED02 LED
display unit are matched, you should order them
as a kit.
We provide 3 kinds of the wires:
TDC-CB00P6A（0.6m）
TDC-CB0015A（1.5m）
TDC-CB0030A（3.0m）
Holder model: TDF-KB01. Please refer to Figure
2-6.
Note：
1. Both ends of TDP-LED02 wire should be secured
by M3*8 screw.
2. When using the keypad separated from the drive,
it is recommended to use the cable special for
EV1000 drive, to avoid reverse connection.
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10 Chapter 2 Specifications and Optional Parts
EV1000 Series General Purpose Variable Speed Drive User Manual
Fig. 2-6 TDF-KB01 Holders Dimensions
2.3.4 Communication Parts
1. Flush Mount Faceplate for Remote Keypad
Model: TDO-RC02
RS485 serial communication mode is used
between the drive and the remote control panel. A
4-core cable is used to connect the drive and the
panel, and the maximum distance is up to 1000m.
Master/slave communication mode is used. The
panel is the master and the drive is the slave.
One flush mount faceplate can control several
drives by connecting the communication cables of
485+ and 485- of each drive to form a RS485
network.
Functions:
1. Able to control the start, stop, jog operation,
fault reset of slaves and change the frequency
settings and direction of rotation.
2. Identify the type of slave machine automatically.
Able to monitor the operating frequency,
frequency setting, output voltage and current,
analog close-loop feedback, analog close-loop
setting and external counting value automatically.
2. Cable for the Flush Mount Faceplate
Model: FRC21W1 (3.0M)
FRC21W2 (30M)
For connecting the flush mount faceplate and the
drive.
3. Profibus Adapter
Model: TDS-PA01
Able to connect EV1000 drive to PROFIBUS
network via the TDS-PA01. In the PROFIBUS
network system, the drive operates as a slave.
Functions:
1. To send control commands to drive (such as:
start, stop and jog);
2. To send speed or frequency reference signal to
the drive;
3. To read operating status information and actual
values from the drive;
4. To reset the drive when fault occurs in it.
4．DrvWindows Supervision Software
Version: DrvWindows V1.2
Applicable to the RS485 industrial control network
made up of TD1000, EV1000, TD2000, TD2100,
or EV2000. It can real-time monitor the status of
the drive. It features friendly interface and easy
operation.
Function: slave polling, frequency setting, run and
stop control, function code query and modification.
one side
one side
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Chapter 3 Installation and Wiring 11
EV1000 Series General Purpose Variable Speed Drive User Manual
Chapter 3 Installation and Wiring
3.1 Installation
Please mount the drive vertically indoors, with
good ventilative conditions.
When selecting mounting environment, the
followings should be taken into account:
Ambient temperature should be within the range
of -10℃~40 ℃. If the temperature is higher than
40 ℃, the Variable Speed Drive should be
derated and forced heat dissipation is required;
Humidity should be lower than 95%,
non-condensing
Mount in the location where vibration is less than
5.9m/ s2(0.6G);
Mount in the location free of direct sunlight, dust,
metal powder, corrosive gas or combustible gas.
If there are any special requirements for
installation, please contact us for clarifications.
The requirements on mounting space and
clearance are shown in Fig. 3-1 and Fig. 3-2.
When two Variable Speed Drives are mounted
one on top the other, an air flow diverting plate
should be fixed in between as shown in Fig. 3-2.
10cm
or above
5cm
or
above
5cm
or
above
10cm
or above
air expulsion by fan
Fig. 3-1 Installation clearances
DRIVEⅠDRIVEⅡ
Electric cabinet
...
Fig. 3-2 Installation of several drives
drive1
drive
Fig. 3-2 Installation of one on top the other
3.1.1 Installation Methods Compliant With
EMC Requirements
In a traction system composed of the drive and a
motor, if the drive, controllers and transducer are
installed in one cabinet, the disturbance they
generate should be depressed at the connection
points, therefore, a noise filter and inrush reactor
should be installed in the cabinet, so that EMC
requirement is met inside it.
The drive is usually installed in a metal cabinet.
The instruments outside the metal cabinet is
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12 Chapter 3 Installation and Wiring
EV1000 Series General Purpose Variable Speed Drive User Manual
shielded and may be disturbed lightly. The cables
are the main EMI source, if you connect the
cables according to the manual, the EMI can be
suppressed effectively.
In system design phase, to reduce EMI, insulating
the noise source and using noise snubber are
best choice. But the cost is considerable. If there
are a few sensitive devices on site, just install
power line filter beside them is enough. Note that
the drive and contactor are noise source, and the
automatic devices, encoder and transducer are
sensible to them.
Divide the system into several EMC areas, refer
to Fig. 3-4.
Hint:
1. After installing EMI filter and AC reactor, the drive can satisfy IEC 61800-3 standard.
2. The input/output EMI filter should be installed close to the drive as possible.
3. Refer to Appendix 3 for the specifications of optional parts.
Mechanical
system
manufacturing
mechanics
Sensor（such as：
temperature, position,
pressure）
Control
Equipment
（Such as: PC）
Mains
Input reactor
Linear
noise filter
Input Filter
Drive
electric cabinet Area Ⅴ
Area Ⅲ
Area Ⅰ
Area Ⅵ
Motor
Area Ⅱ
earthing separation
board
Area Ⅳ
detecting signal cable
Motor cables
Fig. 3-4 Recommended System Layout
Attention:
·Area Ⅰshould be used to install transformers for control power supply, control system and sensor.
·Area Ⅱshould be used for interface of signal and control cables with good immunity level.
·Area Ⅲshould be used to install noise generating devices such as input reactor, drive, brake unit and
contactor.
·Area Ⅳshould be used to install output noise filter.
·Area Ⅴshould be used to install power source and cables connecting the RFI filter.
·Area Ⅵshould be used to install the motor and motor cables.
·Areas should be isolated in space, so that electro-magnetic decoupling effect can be achieved.
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Chapter 3 Installation and Wiring 13
EV1000 Series General Purpose Variable Speed Drive User Manual
·The shortest distance between areas should be 20cm.
·Earthing bars should be used for decoupling among areas, the cables from different area should be
placed in different tubes.
·The filter should be installed at the interfaces between different areas if necessary.
·Bus cable(such as RS485) and signal cable must be shielded.
10kV
Power
Transformer
Motor
metal
cabinet
AC input reactor
Metal
cabinet
PLC or
meters
circuit breaker
filter
AC Output
reactor
>30cm
>50cm
Drive
motor cable
control cable
>20cm
Power
source
cable of
inverter
Isolation
Transformer
power
source cable
of meters
Fig. 3-5 Installation of the drive
3.1.2 Noise Suppression
The noise generated by the drive may disturb the equipment nearby. The degree of disturbance is
dependent on the drive system, immunity of the equipment, wire connections, installation clearance and
earthing methods.
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14 Chapter 3 Installation and Wiring
EV1000 Series General Purpose Variable Speed Drive User Manual
Table 3-1 Method of Noise Suppression
Noise emission paths Actions to reduce the noise
If the external equipment shares the same
AC supply with the drive, the drive’s noise
may be transmitted along its input power
supply cables, which may cause nuisance
tripping to other external equipment.
Install noise filter at the input side of the drive, and use an isolation
transformer or line filter to prevent the noise from disturbing the external
equipment.
If the signal cables of measuring meters,
radio equipment and sensors are installed
in a cabinet together with the drive, these
equipment cables will be easily disturbed.
(1)The equipment and the signal cables should be as far away as
possible from the drive. The signal cables should be shielded and the
shielding layer should be grounded. The signal cables should be placed
inside a metal tube and should be located as far away as possible from
the input/output cables of the drive. If the signal cables must cross over
the power cables, they should be placed at right angle to one another.
(2)Install radio noise filter and linear noise filter(ferrite common-mode
choke) at the input and output sides of the drive to suppress the emission
noise of power lines.
(3)Motor cables should be placed in a tube thicker than 2mm or buried in
a cement conduit. Power cables should be placed inside a metal tube
and be grounded by shielding layer (Motor cable should be a 4-core
cable, where one core should be connected to the PE of the drive and
another should be connected to the motor’s enclosure).
If the signal cables are routed in parallel
with the power cables or bundle these
cables together, the induced
electro-magnetic noise and induced ESD
noise may disturb the signal cables.
Avoide this kind of routing. Other equipment sensibleto EMI should also
be located as far away as possible from the drive. The signal cables
should be placed inside a metal tube and should be placed as far away
as possible from the input/output cables of the drive. The signal cables
and power cables should be shielded cables. EMC interference will be
further reduced if they could be placed inside metal tubes. The clearance
between the metal tubes should be at least 20cm.
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Chapter 3 Installation and Wiring 15
EV1000 Series General Purpose Variable Speed Drive User Manual
3.1.3 Using Surge Suppressor
The devices such as relay, contactor and
electro-magnetic braking kit, which may generate
great noises, should be installed with surge
suppressors even if installed outside of the drive
cabinet.
220VAC
Varistor
Diode
Drive
220VAC
RC-Filter
+24VDC
Fig. 3-6 Installation of Relay, contactor and
electro-magnetic braking kit
3.1.4 Leakage current
Leakage current may flow through the drive’s
input and output capacitors and the motor’s
capacitor. The leakage current value is
dependent on the distributed capacitance and
carrier wave frequency. The leakage current
includes ground leakage current and the leakage
current between lines.
Ground leakage current
The ground leakage current not only flows into
the drive system, but also into other equipment
via earthing cables. It may cause leakage current
circuit breaker and relays to be falsely activated.
The higher the drive’s carrier wave frequency, the
higher the leakage current, and also, the longer
the motor cable, the greater is the leakage
current.
Suppressing methods:
Reduce the carrier wave frequency, but the motor
noise may be higher.
Motor cables should be as short as possible;
The drive and other equipment should use
leakage current circuit breaker designed for
protecting the product against high-order
harmonics/surge leakage current.
Leakage current between lines
The line leakage current flowing outside through
the distributed capacitors of the drive may false
trigger the thermal relay, especially for the drive of
which power rating is less than 7.5kW. When the
cable is longer than 50m, the ratio of leakage
current to motor rated current may increase to a
level that can cause the external thermal relay to
trigger unexpectedly.
Suppression methods:
Reduce the carrier wave frequency, but the motor
audible noise is higher.
Install reactor at the output side of the drive.
In order to protect the motor reliably, it is
recommended to use a temperature sensor to
detect the motor’s temperature, and use the
drive’s over-load protection device (electronic
thermal relay) instead of an external thermal
relay.
3.1.5 Applications of Power Filter
Power source filter should be used in the
equipment that may generate strong EMI or the
equipment that is sensitive to EMI. The power
source filter should be a low pass filter through
which only 50Hz current can flow and high
frequency current is rejected.
The power line filter ensures the equipment can
satisfy the conducting emission and conducting
sensitivity in EMC standard. It can also suppress
the radiated emission of the equipment.
It can prevent the EMI generated by the
equipment from entering power cable, and also
prevent the EMI generated by power cable from
entering equipment.
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16 Chapter 3 Installation and Wiring
EV1000 Series General Purpose Variable Speed Drive User Manual
Common mistakes in using power line filter
1. Too long power cable
The filter inside the cabinet should be located
near to the input power source. The length of the
power cables should be as short as possible.
2. The input and output cables of the AC supply
filter are too close
The distance between input and output cables of
the filter should be as far apart as possible,
otherwise the high frequency noise may be
coupled between the cables and bypass the filter.
Thus, the filtering effect becomes ineffective.
3. Bad earthing of filter
The filter’s enclosure must be connected properly
to the metal casing of the drive. In order to be
earthed well, a special earthing terminal on the
filter’s enclosure should be used. If you use one
cable to connect the filter to the case, the earthing
is useless due to high frequency interference.
When the frequency is high, so too is the
impedance of cable, hence there is little bypass
effect.
The filter should be mounted in the enclosure of
equipment. Ensure to clear away the insulation
paint between the filter case and the enclosure for
good earth contact.
3.1.6 AC Line Reactor Applications
Input AC Line Reactor
A line reactor should be used if the distortion of
power network is severe or the input current
harmonic level is high even after a DC reactor has
been connected to the drive. It can also be used
to improve the AC input power factor of the drive.
Output AC Line Reactor
When the cables from the drive to motor are
longer than 80m, multi-strand cables and an AC
line reactor should be used to suppress the high
frequency harmonics. Thus, the motor insulation
is protected. At the same time, leakage current
and unexpected trigger are reduced.
3.2 Wiring
Danger
!
·Wiring can only be done after the Variable Speed
Drive’s AC power is disconnected, all the LEDs on
the operation panel are off and after waiting for at
least 5 minutes. Then, you can remove the panel.
·Wiring job can only be done after confirming the
Charge indicator inside the drive has extinguished
and the voltage between main circuit power terminals
+ and - is below DC36V.
·Wire connections can only be done by trained and
authorized personnel.
·Check the wiring carefully before connecting
emergency stopping or safety circuits.
·
For the sake of safety, the drive and motor must be
earthed because there is leakage current inside the
drive.
·Check the Variable Speed Drive’s voltage level
before supplying power to it, otherwise human
injuring or equipment damage may happen.
Attention
!
·Check whether the Variable Speed Drive’s rated
input voltage is in compliant with the AC supply
voltage before using.
·Dielectric strength test of the drive has been done
in factory and the user needs not do it again.
·Refer to chapter 2 on how to connect braking
resistor or braking kit.
·It is prohibited to connect the AC supply cables to
the drive’s terminals U, V and W.
·Grounding cables should be copper cables with
cross-sectional area bigger than 3.5mm
2
, and the
grounding resistance should be less than 10Ω.
·The drive should be connected to the AC supply via
a circuit breaker or fuse to provide input over-current
protection and also for maintenance purpose.
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