Eurotherm 605 Series User manual

EUROTHERM
DRIVES
605 Series
Frequency
Inverter
Product Manual
HA463550U001 Issue 3
Copyright Eurotherm Drives Limited 2001
All rights strictly reserved. No part of this document may be stored in a retrieval system, or transmitted in any form or
by any means to persons not employed by a Eurotherm group company without written permission from Eurotherm
Drives Ltd.
Although every effort has been taken to ensure the accuracy of this document it may be necessary, without notice, to
make amendments or correct omissions. Eurotherm Drives cannot accept responsibility for damage, injury, or expenses
resulting therefrom.
Compatible with Version 5.x Software

Cont.2
WARRANTY
Eurotherm Drives warrants the goods against defects in design, materials and workmanship
for the period of 12 months from the date of delivery on the terms
detailed in Eurotherm Drives Standard Conditions of Sale IA058393C.
Eurotherm Drives reserves the right to change the content and product specification without notice.

Cont.3
Requirements
IMPORTANT: Please read this information BEFORE installing the equipment.
Intended Users
This manual is to be made available to all persons who are required to install, configure or
service equipment described herein, or any other associated operation.
The information given is intended to highlight safety issues, and to enable the user to obtain
maximum benefit from the equipment.
Complete the following table for future reference detailing how the unit is to be installed and
used.
INSTALLATION DETAILS
Serial Number
(see product label)
Where installed
(for your own
information)
Unit used as a:
(refer to Certification
for the Inverter)
❏Component ❏Relevant Apparatus
Unit fitted: ❏Wall-mounted ❏Enclosure
Application Area
The equipment described is intended for industrial motor speed control utilising AC induction or
AC synchronous machines.
Personnel
Installation, operation and maintenance of the equipment should be carried out by qualified
personnel. A qualified person is someone who is technically competent and familiar with all
safety information and established safety practices; with the installation process, operation and
maintenance of this equipment; and with all the hazards involved.
!
Safety Information

Cont.4
Hazards
WARNING!
This equipment can endanger life through rotating machinery and high voltages.
Failure to observe the following will constitute an ELECTRICAL SHOCK HAZARD.
This is a product of the restricted sales distribution class according to IEC 61800-3.
In a domestic environment this product may cause radio interference in which case the
user may be required to take adequate measures.
This product is designated as “professional equipment” as defined in EN61000-3-2.
Permission of the supply authority shall be obtained before connection to the low
voltage supply.
•The equipment must be permanently earthed due to the high earth leakage current.
•The drive motor must be connected to an appropriate safety earth.
•The equipment contains high value capacitors which take time to discharge after removal of
the mains supply.
•Before working on the equipment, ensure isolation of the mains supply from terminals L1,
L2 and L3. Wait for at least 3 minutes for the dc link terminals (DC+ and DC-) to discharge
to safe voltage levels (<50V). Measure the DC+ and DC- terminal voltage with a meter to
confirm that the voltage is less than 50V.
•Never perform high voltage resistance checks on the wiring without first disconnecting the
drive from the circuit being tested.
•When replacing a drive in an application and before returning to use, it is essential that all
user defined parameters for the product’s operation are correctly installed.
•This equipment contains electrostatic discharge (ESD) sensitive parts. Observe static
control precautions when handling, installing and servicing this product.
IMPORTANT: Metal parts may reach a temperature of 90 degrees centigrade in operation.
Application Risk
The specifications, processes and circuitry described herein are for guidance only and may need
to be adapted to the user’s specific application.
Eurotherm Drives does not guarantee the suitability of the equipment described in this Manual
for individual applications.
Risk Assessment
Under fault conditions, power loss or other operating conditions not intended, the equipment
may not operate as specified. In particular:
•The motor speed may not be controlled
•The direction of rotation of the motor may not be controlled
•The motor may be energised
Guards
The user must provide guarding and /or additional safety systems to prevent risk of injury and
electric shock.
Protective Insulation
•All control and signal terminals are SELV, i.e. protected by double insulation. Ensure all
wiring is rated for the highest system voltage.
Note:
Thermal sensors contained within the motor must be double insulated.
•All exposed metalwork in the Inverter is protected by basic insulation and bonding to a
safety earth.
RCDs
These are not recommended for use with this product but ,where their use is mandatory, only
Type B RCDs should be used.
!
Safety Information

Contents
Contents Page
Cont.5
Chapter 1 GETTING STARTED
Introduction...................................................................................................1-1
Optional Equipment.................................................................................................. 1-1
Equipment Inspection....................................................................................1-2
About this Manual.........................................................................................1-2
Initial Steps ............................................................................................................... 1-2
How the Manual is Organised ................................................................................... 1-3
•Application Block Diagrams.................................................................... 1-3
•Information for Users without an Operator Station................................... 1-3
Chapter 2 AN OVERVIEW OF THE INVERTER
Component Identification..............................................................................2-1
Control Features............................................................................................2-2
Understanding the Product Code..................................................................2-3
Functional Overview .....................................................................................2-4
Filter Board............................................................................................................... 2-4
Power Board ............................................................................................................. 2-4
Control Board........................................................................................................... 2-4
•Processor ............................................................................................... 2-4
•Technology Box Interface........................................................................ 2-5
•Operator Station Interface ...................................................................... 2-5
Chapter 3 INSTALLING THE INVERTER
Mechanical Installation.................................................................................3-1
Mounting the Inverter ................................................................................................ 3-1
Minimum Air Clearances........................................................................................... 3-2
•Ventilation.............................................................................................. 3-2
•Air Clearance: Cubicle-Mount Product/Application .................................. 3-2
•Air Clearance: Wall-Mount Product/Application....................................... 3-2
Electrical Installation.....................................................................................3-3
Wiring the Inverter .................................................................................................... 3-3
•Protective Earth (PE) Connections ...................................................... 3-4
•Power Wiring Connections...................................................................... 3-4
•Control Wiring Connections.................................................................... 3-5
Optional Equipment ......................................................................................3-6
•Fitting the Remote 6051 Operator Station ............................................... 3-6
•Top Cover.............................................................................................. 3-7
•External Brake Resistor............................................................................ 3-8
•External AC Supply EMC Filter ................................................................ 3-9

Contents
Contents Page
Cont.6
•EMC Motor Output Filter....................................................................... 3-10
•Output Contactors................................................................................ 3-10
•Earth Fault Monitoring Systems ............................................................. 3-10
•Line Chokes (input)............................................................................... 3-10
•AC Motor Choke (output)...................................................................... 3-10
Chapter 4 OPERATING THE INVERTER
Pre-Operation Checks...................................................................................4-1
Control Philosophy ........................................................................................4-2
Start/Stop and Speed Control .......................................................................4-2
•Selecting Local or Remote Control........................................................... 4-3
Start-up Routines ..........................................................................................4-4
Remote Control using Control Terminals (default set-up) ............................................ 4-4
•Reading the Status LEDs ......................................................................... 4-4
Local Control using the Operator Station ........................................................................ 4-5
Setting-up the Inverter .................................................................................4-5
Quick Set-up as an Open-loop Inverter (V/F fluxing) .................................................. 4-5
Set-up using the Sensorless Vector Fluxing Mode........................................................ 4-6
The Autotune Feature ................................................................................................ 4-6
Manual Tuning ......................................................................................................... 4-7
•Tuning using the Motor Equivalent Circuit................................................ 4-7
•Tuning using a Simple Tuning Sequence ................................................. 4-7
Tuning Difficulties...................................................................................................... 4-8
The Start/Stop Mode Explained ....................................................................4-8
Starting and Stopping Methods ....................................................................4-9
Normal Stopping Methods......................................................................................... 4-9
•Ramp to Stop ......................................................................................... 4-9
•Coast to Stop ....................................................................................... 4-10
Advanced Stopping Methods ................................................................................... 4-10
•Forced Fast Stop................................................................................... 4-10
•Forced Coast Stop ................................................................................ 4-11
•The Trip Condition ............................................................................... 4-11
•Logic Stopping ..................................................................................... 4-11
Normal Starting Method.......................................................................................... 4-12
Advanced Starting Methods ..................................................................................... 4-12
•Starting Several Inverters Simultaneously ............................................... 4-12
•Single Wire Logic Starting ..................................................................... 4-12
•Two Wire Logic Starting ........................................................................ 4-13
•Three Wire Logic Starting...................................................................... 4-13

Contents
Contents Page
Cont.7
Chapter 5 THE OPERATOR STATION
Connecting the Operator Station ..................................................................5-1
•Welcome Screen .................................................................................... 5-1
Customising the Operator Station.................................................................5-1
Controlling the Operator Station ..................................................................5-2
Control Keys ............................................................................................................. 5-2
•Keys for Operating the Inverter Locally.................................................... 5-2
•Keys for Programming the Inverter .......................................................... 5-2
LED Indications ......................................................................................................... 5-3
The Menu System ..........................................................................................5-4
Navigating the Menu System ..................................................................................... 5-4
•The Menu System Map ........................................................................... 5-5
Changing a Parameter Value .................................................................................... 5-6
What do the Symbols mean next to some Parameters? ............................................... 5-6
•Parameter Status Information →←= .................................................. 5-6
•Expanded Menu Information >>........................................................... 5-6
Alert Message Displays.............................................................................................. 5-7
The PROG Key.......................................................................................................... 5-7
The L/R Key .............................................................................................................. 5-7
The MMI DIAGNOSTICS Menu.......................................................................5-8
Special Menu Features ................................................................................5-10
Menu Shortcuts and Special Key Combinations ........................................................ 5-10
•Quick Link Information ......................................................................... 5-10
•Quick Save to Memory ......................................................................... 5-10
•Changing the Display Language........................................................... 5-10
•Quick Drive Copy................................................................................. 5-10
•Changing the Product Code ................................................................. 5-11
•Quick Restore Default........................................................................... 5-11
•Quick Enter Configuration Mode .......................................................... 5-11
Menu Viewing Levels ............................................................................................... 5-11
•Startup Screen Timeouts ....................................................................... 5-12
Selecting the Display Language ............................................................................... 5-12
Control Key Enable/Disable..................................................................................... 5-12
Password Protection ................................................................................................ 5-12
•To Activate Password Protection ............................................................ 5-12
•To Deactivate Password Protection ........................................................ 5-13
Selecting Parameters for the Operator Menu............................................................ 5-13
•Selecting a Startup Screen..................................................................... 5-13
•Customising the Welcome Screen ......................................................... 5-14
•Creating Custom Screens ..................................................................... 5-14
How to Save, Restore and Copy your Settings ............................................5-14
Saving Your Application .......................................................................................... 5-14

Contents
Contents Page
Cont.8
Restoring Saved Settings .......................................................................................... 5-14
Copying an Application........................................................................................... 5-14
•Transferring Your Application to Another Inverter................................... 5-14
•Backing-up Your Application................................................................. 5-15
Chapter 6 PROGRAMMING YOUR APPLICATION
Introducing the Macro...................................................................................6-1
Programming with Block Diagrams..............................................................6-1
Modifying a Block Diagram ....................................................................................... 6-1
•Configuration and Parameterisation Modes ............................................ 6-1
•Making and Breaking Links in Configuration Mode ................................. 6-1
•Programming Rules ................................................................................ 6-2
Execution Rules..............................................................................................6-2
•Saving Your Modifications ...................................................................... 6-3
Understanding the Function Block Description............................................................ 6-3
•MMI Menu Maps .................................................................................... 6-3
Hexadecimal Representation of Trips ......................................................................... 6-4
Function Block Descriptions...........................................................................6-5
•ANALOG DIGIN .................................................................................... 6-6
•ANALOG INPUT .................................................................................... 6-8
•ANALOG OUTPUT............................................................................... 6-10
•AUTO RESTART ................................................................................... 6-12
•AUTOTUNE ......................................................................................... 6-14
•BRAKE CONTROL ................................................................................ 6-15
•COMMS CONTROL ............................................................................. 6-16
•CURRENT FEEDBACK ........................................................................... 6-17
•CURRENT LIMIT.................................................................................... 6-19
•CUSTOM SCREEN................................................................................ 6-20
•DEMULTIPLEXER ................................................................................... 6-22
•DIGITAL INPUT .................................................................................... 6-23
•DIGITAL OUTPUT................................................................................. 6-24
•DYNAMIC BRAKING ............................................................................ 6-25
•ENCODER ........................................................................................... 6-26
•FLUXING ............................................................................................. 6-27
•FLYCATCHING .................................................................................... 6-29
•I/O TRIPS ............................................................................................. 6-31
•I*t TRIP ................................................................................................. 6-32
•INJ BRAKING ....................................................................................... 6-33
•JOG .................................................................................................... 6-34

Contents
Contents Page
Cont.9
•LOCAL CONTROL ............................................................................... 6-35
•LOGIC FUNCTION.............................................................................. 6-36
•MINIMUM SPEED ................................................................................. 6-40
•MULTIPLEXER ....................................................................................... 6-41
•OPERATOR MENU ............................................................................... 6-42
•OP STATION........................................................................................ 6-43
•PASSWORD ......................................................................................... 6-45
•PATTERN GEN ..................................................................................... 6-46
•PID ...................................................................................................... 6-47
•PRESET................................................................................................. 6-49
•RAISE/LOWER ...................................................................................... 6-51
•REFERENCE.......................................................................................... 6-52
•SEQUENCING LOGIC ......................................................................... 6-54
•SETPOINT SCALE ................................................................................. 6-56
•SKIP FREQUENCIES.............................................................................. 6-57
•SLEW RATE LIMIT.................................................................................. 6-59
•SLIP COMP .......................................................................................... 6-60
•STABILISATION .................................................................................... 6-61
•STALL TRIP ........................................................................................... 6-62
•STOP ................................................................................................... 6-63
•SYSTEM PORT (P3) ............................................................................... 6-64
•SYSTEM RAMP...................................................................................... 6-65
•TEC OPTION ....................................................................................... 6-67
•TRIPS HISTORY..................................................................................... 6-68
•TRIPS STATUS....................................................................................... 6-69
•UNDERLAP COMP ............................................................................... 6-71
•VALUE FUNCTIONS............................................................................. 6-72
•VECTOR FLUXING ............................................................................... 6-79
•VOLTAGE CONTROL ........................................................................... 6-80
•ZERO SPEED ........................................................................................ 6-81
Motor-Specific Parameters..........................................................................6-82
Chapter 7 TRIPS AND FAULT FINDING
Trips ..............................................................................................................7-1
What Happens when a Trip Occurs ........................................................................... 7-1
•Inverter Indications ................................................................................. 7-1
•Operator Station Indications (when connected) ........................................ 7-1
Resetting a Trip Condition ......................................................................................... 7-1
Using the Operator Station to Manage Trips .............................................................. 7-2
•Trip Messages ........................................................................................ 7-2

Contents
Contents Page
Cont.10
•Automatic Trip Reset ............................................................................... 7-3
•Setting Trip Conditions ........................................................................... 7-3
•Viewing Trip Conditions.......................................................................... 7-3
Checksum Fail .......................................................................................................... 7-3
•Inverter Indications ................................................................................. 7-3
•Operator Station Indications (when connected) ........................................ 7-4
Fault Finding .................................................................................................7-4
Chapter 8 ROUTINE MAINTENANCE AND REPAIR
Routine Maintenance ....................................................................................8-1
Repair............................................................................................................8-1
Saving Your Application Data .................................................................................... 8-1
Returning the Unit to Eurotherm Drives....................................................................... 8-1
Chapter 9 SEQUENCING LOGIC
Principle State Machine ................................................................................9-1
Main Sequencing States ............................................................................................ 9-1
State Outputs of the SEQUENCING LOGIC Function Block......................................... 9-1
Transition of States.................................................................................................... 9-2
State Diagram........................................................................................................... 9-3
Communications Command ..........................................................................9-4
•Example Commands .............................................................................. 9-5
Communications Status ............................................................................................. 9-6
Chapter 10 PARAMETER SPECIFICATION TABLE
Specification Table: Tag Number Order .....................................................10-2
Product-Related Default Values................................................................10-18
•Language Dependant Defaults ........................................................... 10-18
•AC Supply Voltage and Power Rating Dependant Defaults ................... 10-18
Chapter 11 TECHNICAL SPECIFICATIONS
Environmental Details ............................................................................................. 11-1
EMC Compliance.................................................................................................... 11-1
External AC Supply (RFI) Filters ................................................................................ 11-1
Cabling Requirements for EMC Compliance ............................................................ 11-2
Fuse Rating and Recommended Wire Sizes .............................................................. 11-2
Terminal Block Wire Sizes........................................................................................ 11-3
Earthing/Safety Details ............................................................................................ 11-3
Power Details.......................................................................................................... 11-3