gefran BDI50 Series User manual

COMPACT V/f & SENSORLESS
INVERTER
BDI50
English
User manual
Rev. 0.7 – 7-11-2017

------------------------------------------------------------------------------------------------------------------------------
Software version
This manual is updated according the software version V 1.06
The identification number of the software version is indicated on the identification plate of the drive or can be checked
with the par. 13.01.
Thank you for choosing this Gefran product.
We will be glad to receive any possible information which could help us improving this manual. The e-mail address is
the following: techdoc@ gefran.com.
Before using the product, read the safety instruction section carefully.
Keep the manual in a safe place and available to engineering and installation personnel during the product functioning
period.
Gefran S.p.A has the right to modify products, data and dimensions without notice.
The data can only be used for the product description and they can not be understood as legally stated properties.
All rights reserved

I
Table of Contents
Chapter 0
Preface
0-1
0.1 Preface
0-1
Chapter 1
Safety Precautions
1-1
1.1 Before Power UP
1-1
1.2 During Power UP
1-2
1.3 Before Operation
1-2
1.4 During Operation
1-3
1.5 Inverter Disposal
1-3
Chapter 2
Part Number Definition
2-1
2.1 Model part number
2-1
2.2 Standard Product Specification
2-2
Chapter 3
Environment & Installation
3-1
3.1 Environment
3-1
3.2 Installation
3-3
3.2.1 Installation methods
3-3
3.2.2 Installation space
3-6
3.2.3 Derating curves
3-9
3.2.4 Capacitor reforming Guide after long storage
3-10
3.3 Wiring guidelines
3-11
3.3.1 Main considerations
3-11
3.3.2 Power cables
3-13
3.3.3 Control cable selection and wiring
3-13
3.3.4 Wiring and EMC guidelines
3-14
3.3.5 Failure liability
3-15
3.3.6 Considerations for peripheral equipment
3-17
3.3.7 Ground connection
3-18
3.4 Specifications
3-19
3.4.1 Product Specifications
3-19
3.4.2 General Specifications
3-21
3.5 Standard wiring
3-23
3.5.1 200V Single phase (NPN input)
3-23
3.5.2 200V Single phase (PNP input)
3-24
3.5.3 230V Three phase (NPN input)
3-25
3.5.4 400V Three phase (PNP input)
3-26
3.5.5 400V Three phase (NPN input)
3-27
3.6 Terminal Description
3-29
3.6.1 Description of main circuit terminals
3-29
3.6.2 Control circuit terminal description
3-30
3.7 Dimensions and weight
3-32
3.8 EMC filter Disconnection
3-37

II
Chapter 4
Software Index
4-1
4.1 Keypad Description
4-1
4.1.1 Operator Panel Functions
4-1
4.1.2 Digital Display Description
4-2
4.1.3 Digital Display Setup
4-4
4.1.4 Example of Keypad Operation
4-6
4.1.5 Operation Control
4-8
4.2 Programmable Parameter Groups
4-9
4.3 Parameter Function Description
4-24
Chapter 5
Troubleshooting and Maintenance
5-1
5.1 Error Display and Corrective Action
5-1
5.1.1 Manual Reset and Auto-Reset
5-1
5.1.2 Keypad Operation Error Instruction
5-3
5.1.3 Special conditions
5-4
5.2 General troubleshooting
5-5
5.3 Routine and periodic inspection
5-6
5.4 Maintenance
5-7
Chapter 6
Accessories
6-1
6.1 Input choke Specifications
6-1
6.2 Output choke Specifications
6-1
6.3 Fuse Specification
6-1
6.4 Fuse Specification (UL Model Recommended)
6-2
6.5 Braking Resistor
6-3
6.6 Copy Unit (KB-BDI/VDI)
6-4
6.7 Communication options
6-4
6.8 RJ45 to USB connecting Cable (1.8m)
6-5
Appendix 1
BDI50 Parameters Setting List
App1-1
Appendix 2
Instructions for UL
App2-1
Appendix 3
BDI50 Communication protocols
App3-1
A3.1 Modbus communication protocol
App3-1
A3.2 BACnet communication protocol
App3-18
Appendix 4
Cable RJ45 to USB instruction manual
App4-1
Appendix 5
BDI50 series accessories manual
App5-1
Appendix 6
Consignes de sécurité
App6-1

0-1
Chapter 0 Preface
0.1 Preface
To extend the performance of the product and ensure personnel safety, please read
this manual thoroughly before using the inverter. Should there be any problem in
using the product that cannot be solved with the information provided in the manual,
contact our technical or sales representative who will be willing to help you.
※
Precautions
The inverter is an electrical product. For your safety, there are symbols such as
“Danger”, “Caution” in this manual as a reminder to pay attention to safety
instructions on handling, installing, operating, and checking the inverter. Be sure to
follow the instructions for highest safety.
Danger
Indicates a potential hazard that could cause death or serious
personal injury if misused.
Caution
Indicates that the inverter or the mechanical system might be damaged
if misused.
Danger
Risk of electric shock. The DC link capacitors remain charged for five
minutes after power has been removed. It is not permissible to open the
equipment until 5 minutes after the power has been removed.
Do not make any connections when the inverter is powered on. Do not check
parts and signals on circuit boards during the inverter operation.
Do not disassemble the inverter or modify any internal wires, circuits, or
parts.
Ensure that the Inveter Ground terminal is connected correctly.
Caution
Do not perform a voltage test on parts inside the inverter. High voltage can
destroy the semiconductor components.
Do not connect T1, T2, and T3 terminals of the inverter to any AC input
power supply.

CMOS ICs on the inverter’s main board are susceptible to static electricity. Do
not touch the main circuit board.

1-1
Chapter 1 Safety Precautions
1.1 Before Power Up
Danger

Make sure the main circuit connections are correct. Single phase L1(L),L3(N), and
Three phase L1(L),L2,L3(N); 400V : L1,L2,L3 are power-input terminals and must
not be mistaken for T1,T2 and T3. Otherwise, inverter damage can result.
Caution

The line voltage applied must comply with the inverter’s specified input
voltage.(See the nameplate)

To avoid the front cover from disengaging, or other damge do not carry the inverter
by its covers. Support the drive by the heat sink when transporting. Improper
handling can damage the inverter or injure personnel and should be avoided.
To avoid the risk of fire, do not install the inverter on a flammable object.Install on
nonflammable objects such as metal.
If several inverters are placed in the same control panel, provide heat removal
means to maintain the temperature below 50 degree C to avoid overheat or fire.
When disconnecting the remote keypad, turn the power off first to avoid any
damage to the keypad or the inverter.
Warning

This product is sold subject to EN 61800-3 and EN 61800-5-1.
In a domestic environment this product may cause radio interference in which
case the user may be required to apply corrective measures.
Motor over temperature protection is not provided.
Caution
Work on the device/system by unqualified personnel or failure to comply with
warnings can result in severe personal injury or serious damage to material. Only
suitably qualified personnel trained in the setup, installation, commissioning and
operation of the product should carry out work on the device/system.

Only permanently-wired input power connections are allowed.

1-2
1.2 During Power Up
Danger
When the momentary power loss is longer than 2 seconds, the inverter will not
have sufficient stored power for its control circuit. Therefore, when the power is
re-applied, the run operation of the inverter will be based on the setup of
following parameters:
•Run parameters. 00-02 or 00-03.
•Direct run on power up. Parameter. 07-04 and the status of external run
switch,
Note-: the start operation will be regardless of the settings for parameters
07-00/07-01/07-02.
Danger. Direct run on power up.
If direct run on power up is enabled and inverter is set to external run
with the run FWD/REV switch closed then the inverter will restart.
Danger
Prior to use, ensure that all risks and safety implications are considered.
When the momentary power loss ride through is selected and the power loss is
short, the inverter will have sufficient stored power for its control circuits to
function, therefore,when the power is resumed the inverter will automatically
restart depending on the setup of parameters 07-00 & 07-01.
1.3 Before Operation
Caution
Make sure the model and inverter capacity are the same as that set in
parameter 13-00.
Note :On power up the supply voltage set in parameter 01-01 will flash on display
for 2 seconds.

1-3
1.4 During Operation
Danger
Do not connect or disconnect the motor during operation. Otherwise, It may
cause the inverter to trip or damage the unit.
Caution

Do not touch heat radiating components such as heat sinks and brake resistors.

The inverter can drive the motor from low speed to high speed. Verify the allowable
speed ranges of the motor and the associated machinery.
Note the settings related to the braking unit.
Risk of electric shock. The DC link capacitors remain charged for five minutes after
power has been removed. It is not permissible to open the equipment until 5
minutes after the power has been removed.
Caution
The Inverter should be used in environments with temperature range from
-10… +40°C / 14…104℉(size 1) or -10…+50°C / 14…122℉(all other
sizes) and relative humidity of 95%.
Danger
Make sure that the power is switched off before disassembling or checking
any components.
1.5 Inverter Disposal
Caution
Please dispose of this unit with care as an industrial waste and according to your
required local regulations.
The capacitors of inverter main circuit and printed circuit board are considered as
hazardous waste and must not be burnt.
The Plastic enclosure and parts of the inverter such as the cover board will release
harmful gases if burnt.
Danger

To avoid electric shock, do not take the front cover off while power is on.
The motor will restart automatically after stop when auto-
restart function is enabled.
In this case, care must be taken while working around the drive and associated
equipment .
The o
peration of the stop switch is different than that of the emergency stop switch.
The stop switch has to be activated to be effective. Emergency stop has to be
de-activated to become effective.

2-1
Chapter 2 Part Number Definition
2.1 Model part number
BDI50
-X XXX -K X X -X -Y -Y
EMC Filter:
F = included; [Empty] = not included
PNP / NPN: N = NPN input;
P = PNP input;
NP = PNP and NPN
Rated voltage:2M = 230 Vac, 1ph;
2T = 230 Vac, 3ph;
4 = 400 Vac, 3ph
Software: X = standard
Braking unit:
B = included; X = not included
Keypad:
K = Integrated (LED keypad with 5-digits 7-segment display)
Drive power, in
kW
Mechanical drive sizes
BDI50 drive series

2-2
2.2 Standard Product Specification
Model Supply Voltage
(Vac)
Frequency
(Hz) (HP) (kW) Model EMC Filter Braking
Unit
NPN PNP Built-in None Built-in
BDI50-1004-KXX-2M-N
1ph,
200~240V
+10%/-15%
50/60Hz
0.5 0.4 ◎◎
BDI50-1007-KXX-2M-N 1 0.75 ◎◎
BDI50-2015-KXX-2M-N 2 1.5 ◎◎
BDI50-2022-KXX-2M-N 3 2.2 ◎◎
BDI50-1004-KXX-2M-P-F 0.5 0.4 ◎◎
BDI50-1007-KXX-2M-P-F 1 0.75 ◎◎
BDI50-2015-KXX-2M-P-F 2 1.5 ◎◎
BDI50-2022-KXX-2M-P-F 3 2.2 ◎◎
BDI50-1007-KXX-2T-N
3ph,
200~240V
+10%/-15%
50/60Hz
1 0.75 ◎◎
BDI50-2015-KXX-2T-N 2 1.5 ◎◎
BDI50-2022-KXX-2T-N 3 2.2 ◎◎
BDI50-3037-KBX-2T-NP 5 3.7 ◎◎◎◎
BDI50-4055-KBX-2T-NP 8 5.5 ◎◎◎◎
BDI50-4075-KBX-2T-NP 10 7.5 ◎◎◎◎
BDI50-2007-KBX-4-N
3ph,
380~480V
+10%/-15%
50/60Hz
1 0.75 ◎◎◎
BDI50-2015-KBX-4-N 2 1.5 ◎◎◎
BDI50-2022-KBX-4-N 3 2.2 ◎◎◎
BDI50-3037-KBX-4-NP 5 3.7 ◎◎◎◎
BDI50-3055-KBX-4-NP 8 5.5 ◎◎◎◎
BDI50-4075-KBX-4-NP 10 7.5 ◎◎◎◎
BDI50-4110-KBX-4-NP 15 11 ◎◎◎◎
BDI50-2007-KBX-4-P-F 1 0.75 ◎◎◎
BDI50-2015-KBX-4-P-F 2 1.5 ◎◎◎
BDI50-2022-KBX-4-P-F 3 2.2 ◎◎◎
BDI50-3037-KBX-4-NP-F 5 3.7 ◎◎◎◎
BDI50-3055-KBX-4-NP-F 8 5.5 ◎◎◎◎
BDI50-4075-KBX-4-NP-F 10 7.5 ◎◎◎◎
BDI50-4110-KBX-4-NP-F 15 11 ◎◎◎◎
Short circuit capacity is below 5000A/240V or 5000A/480V.
The voltage for 200~240V models is 240V, 380~480V models is 480V.

3-1
Chapter 3 Environment & Installation
3.1 Environment
Installation environment has a direct effect on the correct operation and the life expectancy of the
inverter, Install the inverter in an environment complying with the following conditions:
Protection
Protection
class
IP20
Suitable environment
Operating
temperature
-10~40°C (size 1) -10~50°C (other sizes)
If several inverters are installed in the same control panel, ensure
adequate spacing and provide the necessary cooling and ventilation for
successful operation.
Storage
temperature
-20~60°C
Relative
Humidity
Max 95% (without condensation)
Altitude
Altitude
：
Below 1000m (3281ft)
It is required to reduce 2% of inverter rated current at each additional
100m. The maximum altitude is 3000m
See ch. 3.2.3 Derating curves.
Shock
2G (19.6m/s²) for 57~150Hz and below.
0.3mm for 10~57Hz (According to IEC60068-2-6 standard)
Installation site
Install in an environment that will not have an adverse effect on the operation of the unit
and ensure that there is no exposure to areas such as that listed below:

Direct sunlight, Rain or moisture
Oil mist and salt
Dust, lint fibres, small metal filings and corrosive liquid and gas
Electromagnetic interference from sources such as welding equipment

Radioactive and flammable materials
Excessive vibration from machines such as stamping, punching machines
Add vibration-proof pads if necessary

3-2
Product Overview
Size 3
Size 4
RS485
port
Operator
Panel
TM2
terminal
TM1
terminal
Ground
terminal
Operator
Panel
RS485
port
TM2
terminal
TM1
terminal
Ground
terminal
Size 1
Size 2

3-3
3.2 Installation
3.2.1 Installation methods
Size1. Mounting on a flat surface.
Din rail type installation
：
Din rail kit includes a plastic and a metal adaptor plates.
Assembly Steps:
1) Attach the metal adaptor plate to the inverter base with the screws provided.
2) Attach the plastic Din rail adaptor to the metal adaptor plate.
3) Push the plastic adaptor forward to lock into position.
Disassembly Steps:
1) Unlock by pushing the snap hooks
2) Retract and remove the plastic Din rail adaptor.
3) Unscrew the metal plate &Remove
Note
：
KIT DIN BDI50 Size 1 (Din rail kit part model), including the following parts
1. Metal plate adaptor
2. Plastic adaptor
3. Chamfer head screw: M3×6
M4
1. Metal plate adaptor
2. Plastic adaptor
Snap hooks
1. Metal plate adaptor
2. Plastic adaptor
Snap hooks
3. screws
3. screws
Assembly:
Disassembly:

3-4
Size 2: Mounting on a flat surface.
Din rail type installation
：
Din rail kit includes a plastic adaptor plate as an attachment for the inverter base.
Refer to Diagram below:
Din Rail Mounting & Dismounting as shown in the diagram below:Use a 35mm Din Rail.
Plastic adaptor plate.
KIT DIN BDI50 Size 2 (Size 2 Din rail kit model)
M4
Mounting
Dismounting
Assembly:
Disassembly:
Plastic Adaptor plate
Snap hook
Middle Snap hook
Snap hook

3-5
Size 3. Mounting on a flat surface
M4 螺丝
Size 4. Mounting on a flat surface
M4 螺丝
M4 screw
M4 screw

3-6
3.2.2 Installation space
Provide sufficient air circulation space for cooling as shown in examples below.
Install the Inverter on surfaces that provide good heat dissipation.
Single unit Installation
Install the inverter verticality to obtain effective cooling.
Multiple Installation
5cm
5cm
12cm
12cm
Front view
Fan
Fan
Side view
Provide the necessary
physical space and cooling
based on the ambient
temperature and the heat
loss in the panel
CONTROL
PANEL
5cm

3-7
Installation for Grounding kit
Grounding kit
：
As bellowed diagram, use screw to install EMC metal plate into heatsink.
Size 1 Size 2

3-8
Grounding kit option installation diagram and instruction (Example)
Size 1 Size 2
1
2
6
4
3
5
5
1
2
6
3
4
5
5
1. Grounding kit to be mounted on the drive (earth casing), please follow the diagram to
install.
2. Unshielded power supply lines or cable.
3. Unshielded wires or cable for the output of the relay contacts.
4. Stainless steel cable clamps.
Attach and earth the shielding of cables 5 and 6 as close as possible to the drive:
Strip the cable to expose the shielding;
Attach the cable to the plate 1, attaching the clamp on the stripped part of the
shielding.
The shielding must clamped tightly enough to metal sheet to ensure good contact.
5. Shielded power supply cable for connecting motor which connect to earth at both
ends. The shielding must be continuous, and if intermediate terminals are used, they
must be placed in EMC shielded metal boxes.
6. Shielded cable for control-signal wiring.
For applications requiring several conductors, use cables with small cross-section
(0.5 mm2, 20 AWG).
For cables 5 and 6, the shielding must be connected to earth at both ends. The
shielding must be continuous, and if intermediate terminals are used, they must be
placed in EMC shielded metal boxes.
Notice
：
●If using external EMC input filter, it must be mounted under the drive and connected
directly to the line supply via an unshielded cable. Link 3 on the drive is then via the
filter output cable.
●The HF equipotential earth connection between the drive, motor and cable shielding
does not remove the need to connect the PE conductors (green-yellow) to the
appropriate terminals on each device.

3-9
3.2.3 Derating curves
Curves below show the applicable output current derate due to setting of carrier
frequency, the ambient operating temperatures of 40 and 50 degree C and installation
altitude.
1004-…2M, 1007-…2M/2T (40℃)
2015/2022-…2M/2T (50℃)
100%
80%
516
Rated Current(In)
Carrier Frequency(kHz)
100%
90%
10 16
Rated Current(In)
Carrier Frequency(kHz)
3037-..2T (50℃) (*)
4055-…2T (50℃)
100%
94%
10 16
Rated Current(In)
Carrier Frequency(kHz)
4075-…2T (50℃)
2007 / 2015 /2022-…4 (50℃)
100%
70%
10 16
Rated Current(In)
Carrier Frequency(kHz)
3037-…4 (50℃)
3055-…4 (50℃)
100%
87%
10 16
Rated Current(In)
Carrier Frequency(kHz)
100%
84.6%
61.5%
5 10 16
Rated Current(In)
Carrier Frequency(kHz)
(*) BDI50-3037-…-2T do not need to decrease the current rating in 50°C ambient temperature.
100%
70%
55%
510 16
Rated Current(In)
Carrier Frequency (kHz)
100%
90%
10 16
Rated Current(In)
Carrier Frequency(kHz )

3-10
4075-…4 (50℃)
4110-…4 (50℃)
100%
60.6%
816
Rated Current(In)
Carrier Frequency(kHz)
100%
70%
55%
5 10 16
Rated Current(In)
Carrier Frequency(kHz)
Derating curve for altitude
3.2.4 Capacitor reforming Guide after long storage
For correct performance of this product after long storage before use it is important that
Inverter Capacitors are reformed according to the guide below:
Storage time Procedure to re-apply voltage
≦
1year
Apply rated voltage (1) of inverter in the normal way
Between
1-2 years
Apply rated voltage of inverter to the product for one hour before using
the inverter
≧2 years
Use a variable AC power supply to
1. Connecting 25% rated voltage of inverter for 30 minutes.
2. Connecting 50% rated voltage of inverter for 30 minutes.
3. Connecting 75% rated voltage of inverter for 30 minutes.
4. Connecting 100% rated voltage of inverter for 210 minutes.
Once the procedures completed, inverter just can be used normally.
(1) Please refer the rated voltage according to model label of inverter.