Emotron VS10 User manual

Emotron VS10 and VS30
AC drive
Operation instruction
Valid from software version 04.01.xx.xx

2 01-6203-01R3, CG Drives & Automation

Contents
1. General information ..................................................................................................................... 13
1.1. Read first, then start........................................................................................................................ 13
2. Safety instructions ........................................................................................................................ 14
2.1. Basic safety measures...................................................................................................................... 14
2.2. Residual hazards.............................................................................................................................. 15
2.3. Application as directed.................................................................................................................... 15
3. Mounting ..................................................................................................................................... 16
3.1. Important notes............................................................................................................................... 16
3.2. Electrical installation ....................................................................................................................... 17
3.2.1. 1-phase mains connection 230/240 V..................................................................................... 17
3.2.1.1. Connection plan............................................................................................................... 17
3.2.1.2. Fusing and terminal data ................................................................................................. 18
3.2.2. 1/3-phase mains connection 230/240 V ................................................................................. 20
3.2.2.1. Connection plan............................................................................................................... 20
3.2.2.2. Fusing and terminal data ................................................................................................. 21
3.2.3. 3-phase mains connection 400 V............................................................................................. 23
3.2.3.1. Connection plan............................................................................................................... 23
3.2.3.2. Fusing and terminal data ................................................................................................. 24
3.2.4. 3-phase mains connection 480 V............................................................................................. 27
3.2.4.1. Connection plan............................................................................................................... 27
3.2.4.2. Fusing and terminal data ................................................................................................. 28
3.2.5. CANopen/Modbus RTU ........................................................................................................... 31
4. Commissioning ............................................................................................................................. 32
4.1. Important notes............................................................................................................................... 32
4.2. Operating interfaces........................................................................................................................ 33
4.2.1. Keypad ..................................................................................................................................... 33
4.2.2. Engineering tool »Emotron EASY Starter« .............................................................................. 34
4.2.2.1. Generate a connection between inverter and »Emotron Easy starter« ......................... 35
4.3. Parameter setting............................................................................................................................ 37
4.3.1. General notes on parameters.................................................................................................. 37
4.3.2. Basic inverter settings.............................................................................................................. 39
4.3.3. Basic motor settings ................................................................................................................ 42
4.3.4. Function assignment of the inputs and outputs ..................................................................... 43

4 01-6203-01R3, CG Drives & Automation
4.4. Keypad parameter list ..................................................................................................................... 46
4.5. Save parameter settings in the memory module............................................................................ 73
4.5.1. Save parameter settings with keypad ..................................................................................... 73
4.5.2. Save parameter settings with »Emotron Easy starter«........................................................... 73
5. Diagnostics and fault elimination .................................................................................................. 74
5.1. LED status display ............................................................................................................................ 74
5.2. Diagnostics parameter..................................................................................................................... 75
5.2.1. Logbook ................................................................................................................................... 76
5.2.2. Error history buffer.................................................................................................................. 77
5.2.3. Inverter diagnostics ................................................................................................................. 81
5.2.4. Network diagnostics ................................................................................................................ 85
5.2.4.1. CANopen diagnostics....................................................................................................... 86
5.2.4.2. Modbus diagnostics......................................................................................................... 89
5.2.5. Diagnostics of the inputs and outputs..................................................................................... 90
5.2.5.1. Digital inputs and outputs ............................................................................................... 90
5.2.5.2. Analog inputs and outputs .............................................................................................. 91
5.2.6. Wireless-LAN diagnostics......................................................................................................... 93
5.2.7. Setpoint diagnostic .................................................................................................................. 94
5.2.8. Process controller status ......................................................................................................... 95
5.2.9. Sequencer diagnostics ............................................................................................................. 96
5.2.10. Device identification................................................................................................................ 97
5.2.11. Device overload monitoring (i*t)............................................................................................. 98
5.2.12. Heatsink Temperature Monitoring.......................................................................................... 99
5.2.13. Life-diagnosis ........................................................................................................................... 99
5.3. Error handling................................................................................................................................ 100
5.3.1. Error types ............................................................................................................................. 100
5.3.2. Error configuration ................................................................................................................ 101
5.3.3. Error reset.............................................................................................................................. 101
5.3.4. Keypad error messages ......................................................................................................... 102
5.4. Data handling................................................................................................................................. 103
6. Basic setting ............................................................................................................................... 106
6.1. Mains voltage ................................................................................................................................ 106
6.2. Control source selection................................................................................................................ 108
6.3. Selection of setpoint source.......................................................................................................... 109
6.3.1. Keypad setpoint default setting ............................................................................................ 113
6.4. Starting/stopping performance..................................................................................................... 114
6.4.1. Starting performance ............................................................................................................ 114
6.4.2. Stopping performance........................................................................................................... 116

6.5. Frequency limits and ramp times .................................................................................................. 117
6.6. Quick stop...................................................................................................................................... 120
6.7. S-shaped ramps ............................................................................................................................. 122
6.8. Optical device identification.......................................................................................................... 123
7. Motor control............................................................................................................................. 124
7.1. Motor data..................................................................................................................................... 125
7.1.1. Manual setting of the motor data ......................................................................................... 125
7.2. Motor control selection................................................................................................................. 126
7.2.1. V/f characteristic control (VFC) ............................................................................................. 127
7.2.1.1. Linear V/f characteristic................................................................................................. 128
7.2.1.2. Square-law V/f characteristic ........................................................................................ 130
7.2.1.3. User-definable V/f characteristic................................................................................... 132
7.2.1.4. V/f characteristic control energy-saving (VFC Eco) ....................................................... 133
7.2.2. Sensorless vector control (SLVC) ........................................................................................... 134
7.2.3. Sensorless control for synchronous motors (SL-PSM)........................................................... 137
7.2.3.1. Stall monitoring ............................................................................................................. 140
7.3. Optimisation of motor control ...................................................................................................... 141
7.3.1. V/f voltage boost ................................................................................................................... 142
7.3.2. Skip frequencies..................................................................................................................... 143
7.3.3. Optimising the stalling behaviour.......................................................................................... 145
7.3.4. Slip compensation ................................................................................................................. 147
7.3.5. Oscillation damping ............................................................................................................... 149
7.3.6. Synchronous motor: Pole position identification (PPI) ......................................................... 150
7.3.6.1. Pole position identification (PPI) without movement ................................................... 151
7.4. Optimisation of the control loops.................................................................................................. 152
7.4.1. Options for optimized motor tuning ..................................................................................... 155
7.4.1.1. Tuning of the motor and the speed controller.............................................................. 156
7.4.1.2. Automatic motor identification (energized).................................................................. 157
7.4.1.3. Automatic motor calibration (non-energized)............................................................... 158
7.4.2. Inverter Characteristics.......................................................................................................... 159
7.4.3. Motor equivalent circuit diagram data.................................................................................. 160
7.4.4. Motor controller settings....................................................................................................... 161
7.4.4.1. Current controller .......................................................................................................... 161
7.4.4.2. Field controller............................................................................................................... 161
7.4.4.3. Field weakening controller ............................................................................................ 162
7.4.4.4. Field weakening controller (advanced) ......................................................................... 162
7.4.4.5. Imax controller............................................................................................................... 163

6 01-6203-01R3, CG Drives & Automation
7.4.4.6. Flying restart controller ................................................................................................. 164
7.4.4.7. SLVC controller .............................................................................................................. 164
7.4.4.8. Torque control w/ freq. limit ......................................................................................... 165
7.4.4.9. Slip controller................................................................................................................. 169
7.4.5. 7Speed controller .................................................................................................................. 170
7.5. Motor rotating direction................................................................................................................ 171
7.6. Switching frequency changeover................................................................................................... 172
7.7. Motor protection........................................................................................................................... 173
7.7.1. Motor overload monitoring (i²*t).......................................................................................... 173
7.7.1.1. Speed compensation for protecting motors at low speed............................................ 175
7.7.2. Current limits ......................................................................................................................... 177
7.7.3. Overcurrent monitoring......................................................................................................... 179
7.7.4. Motor phase failure detection............................................................................................... 180
7.7.5. Motor speed monitoring ....................................................................................................... 181
7.7.6. Motor torque monitoring ...................................................................................................... 182
8. Configuring the network ............................................................................................................. 183
8.1. General network settings............................................................................................................... 184
8.2. Predefined process data words ..................................................................................................... 202
8.2.1. Device profile CiA 402............................................................................................................ 203
8.2.2. AC Drive Profile...................................................................................................................... 204
8.2.2.1. Customer specific configurations .................................................................................. 205
8.2.3. Further process data.............................................................................................................. 206
8.3. Parameter access monitoring (PAM) ............................................................................................. 211
8.4. Acyclic data exchange .................................................................................................................... 212
8.5. CANopen........................................................................................................................................ 213
8.5.1. CANopen introduction........................................................................................................... 213
8.5.2. CANopen node address ......................................................................................................... 214
8.5.3. CANopen baud rate ............................................................................................................... 214
8.5.3.1. CANopen initialisation ................................................................................................... 215
8.5.4. CANopen diagnostics............................................................................................................. 216
8.5.5. CANopen emergency telegram.............................................................................................. 217
8.5.6. CANopen heartbeat protocol ................................................................................................ 217
8.5.7. CANopen process data objects.............................................................................................. 219
8.5.8. CANopen data mapping......................................................................................................... 224
8.5.9. CANopen service data objects............................................................................................... 227
8.5.10. CANopen error responses...................................................................................................... 229
8.5.11. CANopen diagnostic counter................................................................................................. 230
8.5.12. CANopen LED status displays................................................................................................. 231

8.5.13. Resetting the CANopen interface .......................................................................................... 232
8.5.14. CANopen short setup ............................................................................................................ 233
8.6. Modbus RTU .................................................................................................................................. 236
8.6.1. Modbus RTU introduction ..................................................................................................... 236
8.6.2. Modbus RTU node address.................................................................................................... 236
8.6.3. Modbus RTU baud rate.......................................................................................................... 237
8.6.4. Modbus RTU data format ...................................................................................................... 238
8.6.5. Modbus RTU time-out monitoring ........................................................................................ 238
8.6.6. Modbus RTU diagnostics ....................................................................................................... 238
8.6.7. Modbus RTU function codes.................................................................................................. 241
8.6.8. Modbus RTU data mapping ................................................................................................... 242
8.6.9. Modbus RTU LED status displays ........................................................................................... 246
8.6.10. Reset Modbus RTU interface ................................................................................................. 246
8.6.11. Modbus RTU response time .................................................................................................. 246
8.6.12. Short setup of Modbus RTU .................................................................................................. 247
9. Configuring the process controller............................................................................................... 249
9.1. Basic process controller settings.................................................................................................... 250
9.2. Process controller idle state and rinse function ............................................................................ 256
9.2.1. Process controller idle state .................................................................................................. 256
9.2.2. Process controller rinse function........................................................................................... 257
10. Additional functions................................................................................................................ 258
10.1. Device Commands ..................................................................................................................... 259
10.1.1.1. 10.1.1 Reset parameters todefault ............................................................................... 259
10.1.1.2. Details ............................................................................................................................ 259
10.1.2. Saving/loading the parameter settings.................................................................................. 260
10.1.2.1. 10.1.3 Device commands for parameter change-over .................................................. 263
10.1.3. Delete logbook....................................................................................................................... 264
10.2. Keypad ....................................................................................................................................... 265
10.2.1. Keypad language selection .................................................................................................... 265
10.2.2. Keypad setpoint increment.................................................................................................... 265
10.2.3. Keypad scaling of speed display ............................................................................................ 265
10.2.4. Keypad status display............................................................................................................. 265
10.2.5. Keypad Configuration of R/F and CTRL buttons .................................................................... 266
10.3. Wireless LAN (WLAN) ................................................................................................................ 269
10.3.1. WLAN LED status displays...................................................................................................... 269
10.3.2. WLAN basic settings............................................................................................................... 270
10.3.2.1. Resetting WLAN settings to default setting ................................................................... 272
10.3.3. WLAN access point mode ...................................................................................................... 273

8 01-6203-01R3, CG Drives & Automation
10.3.3.1. Establishing a direct WLAN connection between Emotron Easy starter PC and inverter
274
10.3.4. WLAN client mode................................................................................................................. 276
10.4. DC braking.................................................................................................................................. 278
10.4.1. Example 1: Automatic DC braking when the motor is started .............................................. 280
10.4.2. Example 2: Automatic DC braking when the motor is stopped............................................. 281
10.5. Brake energy management........................................................................................................ 283
10.5.1. Stopping the deceleration ramp function generator............................................................. 284
10.5.2. Inverter motor brake ............................................................................................................. 285
10.6. Load loss detection.................................................................................................................... 286
10.7. Access protection ...................................................................................................................... 287
10.7.1. Write access protection......................................................................................................... 287
10.7.1.1. Write access protection in the »Emotron Easy starter« ............................................... 289
10.7.1.2. Write access protection in the keypad .......................................................................... 292
10.7.1.3. Configuring the write access protection with the keypad............................................. 293
10.8. Favorites .................................................................................................................................... 296
10.8.1. Accessing the "Favorites" with the keypad............................................................................ 296
10.8.2. Favorites parameter list (default setting) .............................................................................. 297
10.8.3. Configuring the "Favorites" ................................................................................................... 299
10.9. Parameter change-over ............................................................................................................. 302
10.9.1. Example: Selective control of several motors with one inverter........................................... 313
10.10. Device profile CiA 402................................................................................................................ 315
10.11. Holding brake control ................................................................................................................ 318
10.11.1. Basic setting ....................................................................................................................... 319
10.11.2. "Automatic" brake mode (automatic operation) .............................................................. 320
10.11.3. Brake holding load ............................................................................................................. 322
10.11.3.1. General mode of operation........................................................................................... 323
10.11.4. Brake closing level.............................................................................................................. 324
10.11.5. Manual release of the holding brake................................................................................. 326
10.12. Flying restart circuit ................................................................................................................... 327
10.13. Timeout für fault reaction ......................................................................................................... 329
10.14. Automatic restart....................................................................................................................... 330
10.15. Mains failure control.................................................................................................................. 331
10.15.1. Activating the mains failure control................................................................................... 333
10.15.2. Restart protection.............................................................................................................. 334
10.15.3. Fast mains recovery ........................................................................................................... 334
10.15.4. Commissioning the mains failure control.......................................................................... 335
10.16. Process data............................................................................................................................... 336

10.16.1. Position counter................................................................................................................. 336
10.17. Firmware download................................................................................................................... 337
10.17.1. Firmware download with »Emotron Easy starter (Firmwareloader)«.............................. 337
10.18. Additive voltage impression ...................................................................................................... 338
10.18.1. Example: Using the function with a 400-V inverter........................................................... 339
10.19. Parameter for engineeringtools................................................................................................ 340
11. Sequencer............................................................................................................................... 343
11.1. Segment configuration .............................................................................................................. 346
11.2. Sequence configuration............................................................................................................. 356
11.3. Sequencer basic settings............................................................................................................ 371
12. Flexible I/O configuration ........................................................................................................ 374
12.1. Control source change-over....................................................................................................... 375
12.1.1. Example 1: Change-over from terminal control to keypad control ....................................... 378
12.1.2. Example 2: Change-over from terminal control to network control ..................................... 379
12.2. Start / stop motor ...................................................................................................................... 380
12.2.1. Example 1: Start/stop (1 signal) and reversal ........................................................................ 386
12.2.2. Example 2: Start forward/start reverse/stop (edge-controlled) ............................................ 387
12.2.3. Example 3: Run forward/Run reverse/stop (status-controlled)............................................. 389
12.2.4. Example 4: Quick stop ........................................................................................................... 391
12.2.5. Example 5: Jog forward/Jogreverse ...................................................................................... 393
12.2.6. Example 6: Enable inverter.................................................................................................... 395
12.3. Setpoint change-over................................................................................................................. 396
12.3.1. Priority of the setpoint sources ............................................................................................. 398
12.3.2. Analog input setpoint source................................................................................................. 398
12.3.3. Keypad setpoint source ......................................................................................................... 401
12.3.4. Network setpoint source ....................................................................................................... 403
12.3.5. Setpoint source of preset setpoints....................................................................................... 404
12.3.6. Motor potentiometer setpoint source (MOP)....................................................................... 409
12.3.7. Setpoint source segment setpoints ....................................................................................... 413
12.4. Reset error ................................................................................................................................. 415
12.5. Activating DC braking manually................................................................................................. 417
12.6. Releasing holding brake manually ............................................................................................. 419
12.7. Activating ramp 2 manually....................................................................................................... 421
12.8. Triggering a user-defined fault .................................................................................................. 423
12.9. Functions for parameter change-over ....................................................................................... 424
12.9.1. Example 1: Activation via command (only when disabled)................................................... 426
12.9.2. Example 2: Activation via command (immediately) .............................................................. 428
12.9.3. Example 3: Activation if the selection is changed (only if the inverter is disabled) .............. 429

10 01-6203-01R3, CG Drives & Automation
12.9.4. Example 4: Activation if the selection is changed (immediately).......................................... 431
12.10. Process controller function selection ........................................................................................ 433
12.11. Sequencer control functions...................................................................................................... 436
12.12. Frequency threshold for "Frequency threshold exceeded"trigger ........................................... 441
12.13. Configuration of digital inputs ................................................................................................... 443
12.14. Configuration of analog inputs .................................................................................................. 444
12.14.1. Analog input 1.................................................................................................................... 444
12.14.1.1. Example 1: Input range 0 ... 10 V ≡setting range 0 ... 50Hz ....................................... 446
12.14.1.2. Example 2: Input range 0 ... 10 V ≡setting range -40 ... +40 Hz .................................. 446
12.14.1.3. Example 3: Error detection............................................................................................ 447
12.14.2. Analog input 2.................................................................................................................... 448
12.15. Configuration of digital outputs ................................................................................................ 450
12.15.1. Relay .................................................................................................................................. 450
12.15.2. Digital output 1.................................................................................................................. 454
12.15.3. NetWordOUT1 statusword ............................................................................................... 454
12.16. Configuration of analog outputs................................................................................................ 459
12.16.1. Analog output 1 ................................................................................................................. 459
12.16.1.1. Example 1: Output voltage 0 ... 10 V ≡output frequency 0 ... 100 Hz ........................ 461
12.16.1.2. Example 2: Output voltage 2 ... 10 V ≡output frequency 30 ... 60 Hz ........................ 461
13. Technical data......................................................................................................................... 462
13.1. Standards and operating conditions.......................................................................................... 462
13.1.1. Protection of persons and device protection ........................................................................ 462
13.1.2. EMC data................................................................................................................................ 462
13.1.3. Motor connection.................................................................................................................. 462
13.1.4. Environmental conditions...................................................................................................... 463
13.1.5. Electrical supply conditions ................................................................................................... 463
13.2. 1-phase mains connection 230/240 V....................................................................................... 464
13.2.1. Rated data.............................................................................................................................. 464
13.3. 1/3-phase mains connection 230/240 V ................................................................................... 465
13.3.1. Rated data.............................................................................................................................. 465
13.4. 3-phase mains connection 400 V............................................................................................... 466
13.4.1. Rated data.............................................................................................................................. 466
13.5. 3-phase mains connection 480 V............................................................................................... 468
13.5.1. Rated data.............................................................................................................................. 468
14. Appendix ................................................................................................................................ 470
14.1. Operate and parameterise the inverter with keypad ................................................................ 470
14.1.1. Keypad operating mode ........................................................................................................ 471
14.1.1.1. Keypad status display..................................................................................................... 471