Emotron FDU 2.0 User manual

Emotron FDU 2.0
AC drive
Instruction manual
English
Software version 4.3X

Emotron FDU 2.0
INSTRUCTION MANUAL - ENGLISH
Software version 4.3X
Document number: 01-5325-01
Edition: r1
Date of release: 02-07-2012
© Copyright CG Drives & Automation Sweden AB 2005 - 2012
CG Drives & Automation Sweden AB retains the right to change
specifications and illustrations in the text, without prior notification. The
contents of this document may not be copied without the explicit
permission of CG Drives & Automation Sweden AB.

CG Drives & Automation, 01-5325-01r1
Safety Instructions
Congratulations for choosing a product from CG Drives &
Automation!
Before you begin with installation, commissioning or
powering up the unit for the first time it is very important
that you carefully study this Instruction manual.
Following symbols can appear in this manual. Always read
these first before continuing:
Handling the AC drive
Installation, commissioning, demounting, taking
measurements, etc, of or on the AC drive may only be
carried out by personnel technically qualified for the task.
A number of national, regional and local regulations govern
handling, storage and installation of the equipment. Always
observe current rules and legislation.
Opening the AC drive
Always take adequate precautions before opening the AC
drive. Although the connections for the control signals and
the switches are isolated from the main voltage, do not
touch the control board when the AC drive is switched on.
Precautions to be taken with a
connected motor
If work must be carried out on a connected motor or on the
driven machine, the mains voltage must always be
disconnected from the AC drive first. Wait at least 7 minutes
before starting work.
Earthing
The AC drive must always be earthed via the mains safety
earth connection.
Earth leakage current
Residual current device (RCD)
compatibility
This product cause a DC current in the protective
conductor. Where a residual current device (RCD) is used
for protection in case of direct or indirect contact, only a
Type B RCD is allowed on the supply side of this product.
Use RCD of 300 mA minimum.
EMC Regulations
In order to comply with the EMC Directive, it is absolutely
necessary to follow the installation instructions. All
installation descriptions in this manual follow the EMC
Directive.
Mains voltage selection
The AC drive may be ordered for use with the mains voltage
range listed below.
FDU48: 230-480 V
FDU52: 440-525 V
FDU69: 500-690 V
Voltage tests (Megger)
Do not carry out voltage tests (Megger) on the motor, before
all the motor cables have been disconnected from the AC
drive.
NOTE: Additional information as an aid to avoid
problems.
CAUTION!
Failure to follow these instructions can result
in malfunction or damage to the AC drive.
Warning!
Failure to follow these instructions can result
in serious injury to the user in addition to
serious damage to the AC drive.
HOT SURFACE!
Failure to follow these instructions can result
in injury to the user.
WARNING!
Always switch off the mains voltage before
opening the AC drive and wait at least
7minutes to allow the buffer capacitors to
discharge.
!
CAUTION!
This AC drive has an earth leakage current
which does exceed 3.5 mA AC. Therefore the
minimum size of the protective earth
conductor must comply with the local safety regulations
for high leakage current equipment which means that
according the standard IEC61800-5-1 the protective
earth connection must be assured by one of following
conditions:
PE conductor cross-sectional area shall for cable size
<16mm2be equal to the used phase conductors, for
cable size above 16mm2but smaller or equal to 35mm2
the PE conductor cross-sectional area shall be at least
16mm2 . For cables >35mm2the PE conductor cross-
sectional area should be at least 50% of the used phase
conductor.
When the PE conductor in the used cable type is not in
accordance with the above mentioned cross-sectional
area requirements, a separate PE conductor should be
used to establish this.
!

CG Drives & Automation, 01-5325-01r1
Condensation
If the AC drive is moved from a cold (storage) room to a
room where it will be installed, condensation can occur.
This can result in sensitive components becoming damp. Do
not connect the mains voltage until all visible dampness has
evaporated.
Incorrect connection
The AC drive is not protected against incorrect connection
of the mains voltage, and in particular against connection of
the mains voltage to the motor outlets U, V and W. The AC
drive can be damaged in this way.
Power factor capacitors for improving
cos
Remove all capacitors from the motor and the motor outlet.
Precautions during Autoreset
When the automatic reset is active, the motor will restart
automatically provided that the cause of the trip has been
removed. If necessary take the appropriate precautions.
Transport
To avoid damage, keep the AC drive in its original
packaging during transport. This packaging is specially
designed to absorb shocks during transport.
IT Mains supply
The AC drives can be modified for an IT mains supply,
(non-earthed neutral), please contact your supplier for
details.
Alarms
Never disregard an alarm. Always check and remedy the
cause of an alarm.
Heat warning
DC-link residual voltage
HOT SURFACE!
Be aware of specific parts on the AC drive
having high temperature.
WARNING!
After switching off the mains supply,
dangerous voltage can still be present in the
AC drive. When opening the AC drive for
installing and/or commissioning activities
wait at least 7 minutes. In case of malfunction a
qualified technician should check the DC-link or wait for
one hour before dismantling the AC drive for repair.

CG Drives & Automation, 01-5325-01r1 5
Contents
Safety Instructions
Contents.......................................................... 5
1. Introduction..................................................... 7
1.1 Delivery and unpacking ............................................ 7
1.2 Using of the instruction manual............................... 7
1.3 Warranty .................................................................... 7
1.4 Type code number..................................................... 7
1.5 Standards .................................................................. 8
1.5.1 Product standard for EMC ........................................ 8
1.6 Dismantling and scrapping....................................... 9
1.6.1 Disposal of old electrical and electronic
equipment ................................................................. 9
1.7 Glossary ................................................................... 10
1.7.1 Abbreviations and symbols..................................... 10
1.7.2 Definitions................................................................ 10
2. Mounting ...................................................... 11
2.1 Lifting instructions................................................... 11
2.2 Stand-alone units .................................................... 12
2.2.1 Cooling ..................................................................... 12
2.2.2 Mounting schemes.................................................. 12
2.3 Cabinet mounting.................................................... 15
2.3.1 Cooling ..................................................................... 15
2.3.2 Recommended free space in front of cabinet ...... 15
2.3.3 Mounting schemes.................................................. 16
3. Installation ................................................... 19
3.1 Before installation................................................... 19
3.2 Cable connections for model 003 to 074 ............. 19
3.2.1 Mains cables ........................................................... 19
3.2.2 Motor cables............................................................ 20
3.3 Connection of motor and mains cables for model
090 and up.............................................................. 22
3.3.1 Connection of mains and motor cables on IP20
modules ................................................................... 23
3.4 Cable specifications................................................ 24
3.5 Stripping lengths ..................................................... 24
3.5.1 Dimension of cables and fuses.............................. 25
3.5.2 Tightening torque for mains and motor cables..... 25
3.6 Thermal protection on the motor ........................... 25
3.7 Motors in parallel .................................................... 25
4. Control Connections.................................... 27
4.1 Control board........................................................... 27
4.2 Terminal connections ............................................. 28
4.3 Inputs configurationwith the switches................... 28
4.4 Connection example ............................................... 29
4.5 Connecting the Control Signals.............................. 30
4.5.1 Cables ...................................................................... 30
4.5.2 Types of control signals .......................................... 31
4.5.3 Screening................................................................. 31
4.5.4 Single-ended or double-ended connection? ......... 31
4.5.5 Current signals ((0)4-20 mA).................................. 32
4.5.6 Twisted cables......................................................... 32
4.6 Connecting options ................................................. 32
5. Getting Started............................................. 33
5.1 Connect the mains and motor cables ................... 33
5.1.1 Mains cables ........................................................... 33
5.1.2 Motor cables............................................................ 33
5.2 Using the function keys .......................................... 33
5.3 Remote control........................................................ 34
5.3.1 Connect control cables ........................................... 34
5.3.2 Switch on the mains ............................................... 34
5.3.3 Set the Motor Data.................................................. 34
5.3.4 Run the AC drive...................................................... 34
5.4 Local control............................................................ 35
5.4.1 Switch on the mains ............................................... 35
5.4.2 Select manual control............................................. 35
5.4.3 Set the Motor Data.................................................. 35
5.4.4 Enter a Reference Value......................................... 35
5.4.5 Run the AC drive...................................................... 35
6. Applications.................................................. 37
6.1 Application overview ............................................... 37
6.1.1 Pumps...................................................................... 37
6.1.2 Fans ......................................................................... 37
6.1.3 Compressors ........................................................... 38
6.1.4 Blowers .................................................................... 38
7. Main Features .............................................. 39
7.1 Parameter sets........................................................ 39
7.1.1 One motor and one parameter set ........................ 40
7.1.2 One motor and two parameter sets....................... 40
7.1.3 Two motors and two parameter sets..................... 40
7.1.4 Autoreset at trip ...................................................... 40
7.1.5 Reference priority.................................................... 41
7.1.6 Preset references.................................................... 41
7.2 Remote control functions ....................................... 42
7.3 Performing an Identification Run........................... 44
7.4 Using the Control Panel Memory............................ 44
7.5 Load Monitor and Process Protection [400]......... 45
7.5.1 Load Monitor [410]................................................. 45
7.6 Pump function ......................................................... 47
7.6.1 Introduction ............................................................. 47
7.6.2 Fixed MASTER ......................................................... 48
7.6.3 Alternating MASTER ................................................ 48
7.6.4 Feedback 'Status' input .......................................... 49
7.6.5 Fail safe operation .................................................. 49
7.6.6 PID control ............................................................... 50
7.6.7 Wiring Alternating Master....................................... 51
7.6.8 Checklist And Tips................................................... 52
7.6.9 Functional Examples of Start/Stop Transitions .... 53
8. EMC and standards...................................... 55
8.1 EMC standards........................................................ 55
8.2 Stop categories and emergency stop .................... 55
9. Operation via the Control Panel.................. 57
9.1 General .................................................................... 57
9.2 The control panel .................................................... 57
9.2.1 The display............................................................... 57

6CG Drives & Automation, 01-5325-01r1
9.2.2 Indications on the display....................................... 58
9.2.3 LED indicators ......................................................... 58
9.2.4 Control keys............................................................. 58
9.2.5 The Toggle and Loc/Rem Key ................................ 59
9.2.6 Function keys .......................................................... 60
9.3 The menu structure................................................. 60
9.3.1 The main menu ....................................................... 60
9.4 Programming during operation .............................. 61
9.5 Editing values in a menu ........................................ 61
9.6 Copy current parameter to all sets ........................ 61
9.7 Programming example............................................ 62
10. Serial communication ................................. 63
10.1 Modbus RTU ............................................................ 63
10.2 Parameter sets........................................................ 63
10.3 Motor data ............................................................... 64
10.4 Start and stop commands ...................................... 64
10.5 Reference signal ..................................................... 64
10.5.1 Process value .......................................................... 64
10.6 Description of the EInt formats .............................. 65
11. Functional Description ............................... 67
11.1 Preferred View [100]............................................... 67
11.1.1 1st Line [110].......................................................... 67
11.1.2 2nd Line [120] ........................................................ 68
11.2 Main Setup [200].................................................... 68
11.2.1 Operation [210]....................................................... 68
11.2.2 Remote Signal Level/Edge [21A]........................... 72
11.2.3 Mains supply voltage [21B].................................... 72
11.2.4 Motor Data [220] .................................................... 73
11.2.5 Motor Protection [230] ........................................... 79
11.2.6 Parameter Set Handling [240]............................... 83
11.2.7 Trip Autoreset/Trip Conditions [250]..................... 85
11.2.8 Serial Communication [260] .................................. 93
11.3 Process and Application Parameters [300] .......... 97
11.3.1 Set/View Reference Value [310] ........................... 97
11.3.2 Process Settings [320] ........................................... 98
11.3.3 Start/Stop settings [330] ..................................... 102
11.3.4 Mechanical brake control..................................... 107
11.3.5 Speed [340]........................................................... 111
11.3.6 Torques [350]........................................................ 113
11.3.7 Preset References [360] ...................................... 116
11.3.8 PID Process Control [380] .................................... 117
11.3.9 Pump/Fan Control [390] ...................................... 121
11.4 Load Monitor and Process Protection [400]....... 128
11.4.1 Load Monitor [410]............................................... 128
11.4.2 Process Protection [420]...................................... 133
11.5 I/Os and Virtual Connections [500]..................... 134
11.5.1 Analogue Inputs [510].......................................... 134
11.5.2 Digital Inputs [520] ............................................... 141
11.5.3 Analogue Outputs [530] ....................................... 143
11.5.4 Digital Outputs [540] ............................................ 147
11.5.5 Relays [550] .......................................................... 149
11.5.6 Virtual Connections [560]..................................... 151
11.6 Logical Functions and Timers [600] .................... 152
11.6.1 Comparators [610] ............................................... 152
11.6.2 Logic Output Y [620] ............................................. 162
11.6.3 Logic Output Z [630]............................................. 164
11.6.4 Timer1 [640] ......................................................... 165
11.6.5 Timer2 [650] ......................................................... 167
11.6.6 Counters [660]...................................................... 169
11.7 View Operation/Status [700] ............................... 172
11.7.1 Operation [710]..................................................... 172
11.7.2 Status [720] .......................................................... 174
11.7.3 Stored values [730] .............................................. 178
11.8 View Trip Log [800] ............................................... 179
11.8.1 Trip Message log [810]......................................... 179
11.8.2 Trip Messages [820] - [890] ................................ 180
11.8.3 Reset Trip Log [8A0] ............................................. 180
11.9 System Data [900]................................................ 181
11.9.1 VSD Data [920] ..................................................... 181
12. Troubleshooting, Diagnoses and
Maintenance .............................................. 183
12.1 Trips, warnings and limits..................................... 183
12.2 Trip conditions, causes and remedial action ...... 184
12.2.1 Technically qualified personnel............................ 185
12.2.2 Opening the AC drive ............................................ 185
12.2.3 Precautions to take with a connected motor ...... 185
12.2.4 Autoreset Trip ........................................................ 185
12.3 Maintenance ......................................................... 189
13. Options........................................................ 191
13.1 Options for the control panel................................ 191
13.2 Handheld Control Panel 2.0................................. 191
13.3 EmoSoftCom.......................................................... 191
13.4 Brake chopper....................................................... 192
13.5 I/O Board ............................................................... 193
13.6 Encoder.................................................................. 193
13.7 PTC/PT100 ............................................................ 193
13.8 Serial communication and fieldbus ..................... 194
13.9 Standby supply board option................................ 194
13.10 Safe Stop option.................................................... 195
13.11 Output chokes ....................................................... 197
13.12 Liquid cooling ........................................................ 197
13.13 AFE - Active Front End........................................... 197
14. Technical Data ........................................... 199
14.1 Electrical specifications related to model ........... 199
14.2 General electrical specifications.......................... 204
14.3 Operation at higher temperatures ....................... 205
14.4 Operation at higher switching frequency............. 205
14.5 Dimensions and Weights...................................... 206
14.6 Environmental conditions..................................... 207
14.7 Fuses, cable cross-sections and glands.............. 208
14.7.1 According to IEC ratings........................................ 208
14.7.2 Fuses and cable dimensions according to
NEMA ratings......................................................... 210
14.8 Control signals....................................................... 212
15. Menu List ................................................... 213
Index ........................................................... 219

CG Drives & Automation, 01-5325-01r1 Introduction 7
1. Introduction
Emotron FDUis used most commonly to control and
protect pump and fan applications that put high demands
on flow control, process uptime and low maintenance costs.
It can also be used for e.g. compressors and blowers. The
used motor control method is V/Hz-control.
Several options are available, listed in chapter 13. page 191,
that enable you to customize the AC drive for your specific
needs.
Users
This instruction manual is intended for:
• installation engineers
• maintenance engineers
•operators
• service engineers
Motors
The AC drive is suitable for use with standard 3-phase
asynchronous motors. Under certain conditions it is possible
to use other types of motors. Contact your supplier for
details.
1.1 Delivery and unpacking
Check for any visible signs of damage. Inform your supplier
immediately of any damage found. Do not install the AC
drive if damage is found.
The AC drives are delivered with a template for positioning
the fixing holes on a flat surface. Check that all items are
present and that the type number is correct.
1.2 Using of the instruction
manual
Within this instruction manual the abbreviation “AC drive”
is used to indicate the complete variable speed drive as a
single unit.
Check that the software version number on the first page of
this manual matches the software version in the AC drive.
See chapter 11.9 page 181
With help of the index and the table of contents it is easy to
track individual functions and to find out how to use and set
them.
The Quick Setup Card can be put in a cabinet door, so that
it is always easy to access in case of an emergency.
1.3 Warranty
The warranty applies when the equipment is installed,
operated and maintained according to instructions in this
instruction manual. Duration of warranty as per contract.
Faults that arise due to faulty installation or operation are
not covered by the warranty.
1.4 Type code number
Fig. 1 gives an example of the type code numbering used on
all AC drives. With this code number the exact type of the
drive can be determined. This identification will be required
for type specific information when mounting and installing.
The code number is located on the product label, on the
front of the unit.
Fig. 1 Type code number
NOTE: Read this instruction manual carefully before
starting installation, connection or working with the AC
drive.
Position
for 003-
074
Position
for 090-
3K0
Configuration
11ACdrivetype
FDU
VFX
22Supplyvoltage
48=400 V mains
52=525 V mains
69=690 V mains
33Rated current (A)
continuous
-003=2.5 A
-
-3K0=3000 A
44Protectionclass
20=IP20
54=IP54
5 5 Control panel –=Blank panel
C=Standard panel
6 6 EMC option
E=Standard EMC
(Category C3)
F=Extended EMC
(Category C2)
I=IT-Net
77Brake chopper
option
–=No chopper
B=Chopper built in
D=DC+/- interface
88Stand-by power
supply option
–=No SBS
S=SBS included
-9
Safe stop option
(Only valid for
090-3k0)
–=No safe stop
T=Safe stop incl.
910Brandlabel A=Standard
FDU48-175-54 C E – – – A – N N N N A N –
Position number:
1 2 3 4 5 6 7 8 9 10111213141516 1718

8Introduction CG Drives & Automation, 01-5325-01r1
1.5 Standards
The AC drives described in this instruction manual comply
with the standards listed in Table 1. For the declarations of
conformity and manufacturer’s certificate, contact your
supplier for more information or visit www.emotron.com/
www.cgglobal.com.
1.5.1 Product standard for EMC
Product standard EN(IEC)61800-3, second edition of 2004
defines the:
First Environment (Extended EMC) as environment that
includes domestic premises. It also includes establishments
directly connected without intermediate transformers to a
low voltage power supply network that supplies buildings
used for domestic purposes.
Category C2: Power Drive System (PDS) of rated
voltage<1.000 V, which is neither a plug in device nor a
movable device and, when used in the first environment, is
intended to be installed and commissioned only by a
professional.
Second environment (Standard EMC) includes all other
establishments.
Category C3: PDS of rated voltage <1.000 V, intended for
use in the second environment and not intended for use in
the first environment.
Category C4: PDS or rated voltage equal or above 1.000 V,
or rated current equal to or above 400 A, or intended for use
in complex systems in the second environment.
The AC drive complies with the product standard
EN(IEC) 61800-3:2004 (Any kind of metal screened cable
may be used). The standard AC drive is designed to meet the
requirements according to category C3.
By using the optional “Extended EMC” filter the AC drive
fulfils requirements according to category C2,
10 - Painted AC drive A=Standard paint
11 11 Coated boards,
option
- =Standard boards
V=Coated boards
12 12 Option position 1 N=No option
C=Crane I/O
E=Encoder
P=PTC/PT100
I=Extended I/O
S=Safe Stop (only
003-074)
13 13 Option position 2
14 14 Option position 3
15 15 Option position,
communication
N=No option
D=DeviceNet
P=Profibus
S=RS232/485
M=Modbus/TCP
E= EtherCAT
A=Profinet IO 1-port
B=Profinet IO 2-port
16 16 Software type A=Standard
17 - Motor PTC. (Only
valid for 003-074)
N=No option
P=PTC
18 -
Gland kit.
(Only valid for
003-074)
–=Glands not
included
G=Gland kit
included
Position
for 003-
074
Position
for 090-
3K0
Configuration
WARNING!
In a domestic environment this product may
cause radio interference, in which case it
may be necessary to take adequate
additional measures.
WARNING!
The standard AC drive, complying with
category C3, is not intended to be used on a
low-voltage public network which supplies
domestic premises; radio interference is
expected if used in such a network. Contact
your supplier if you need additional
measures.