Ghisalba VFD-E Series User manual

Manuale di istruzioni
Inverter vettoriale
serie VFD – E
COMPLETO
Gennaio 2008

Preface
Thank you for choosing Ghisalba’s high-performance VFD-E Series. The VFD-E Series is
manufactured with high-quality components and materials and incorporate the latest microprocessor
technology available.
This manual is to be used for the installation, parameter setting, troubleshooting, and daily
maintenance of the AC motor drive. To guarantee safe operation of the equipment, read the
following safety guidelines before connecting power to the AC motor drive. Keep this operating
manual at hand and distribute to all users for reference.
To ensure the safety of operators and equipment, only qualified personnel familiar with AC motor
drive are to do installation, start-up and maintenance. Always read this manual thoroughly before
using VFD-E series AC Motor Drive, especially the WARNING, DANGER and CAUTION notes.
Failure to comply may result in personal injury and equipment damage. If you have any questions,
please contact your dealer.
PLEASE READ PRIOR TO INSTALLATION FOR SAFETY.
DANGER!
1. AC input power must be disconnected before any wiring to the AC motor drive is made.
2. A charge may still remain in the DC-link capacitors with hazardous voltages, even if the power
has been turned off. To prevent personal injury, please ensure that power has been turned off
before opening the AC motor drive and wait ten minutes for the capacitors to discharge to safe
voltage levels.
3. Never reassemble internal components or wiring.
4. The AC motor drive may be destroyed beyond repair if incorrect cables are connected to the
input/output terminals. Never connect the AC motor drive output terminals U/T1, V/T2, and W/T3
directly to the AC mains circuit power supply.
5. Ground the VFD-E using the ground terminal. The grounding method must comply with the laws
of the country where the AC motor drive is to be installed. Refer to the Basic Wiring Diagram.
6. VFD-E series is used only to control variable speed of 3-phase induction motors, NOT for 1-
phase motors or other purpose.
7. VFD-E series shall NOT be used for life support equipment or any life safety situation.

WARNING!
1. DO NOT use Hi-pot test for internal components. The semi-conductor used in the AC motor
drive is easily damaged by high-pressure.
2. There are highly sensitive MOS components on the printed circuit boards. These components
are especially sensitive to static electricity. To prevent damage to these components, do not
touch these components or the circuit boards with metal objects or your bare hands.
3. Only qualified personnel are allowed to install, wire and maintain AC motor drive.
CAUTION!
1. Some parameter settings will cause the motor to run immediately after applying power.
2. DO NOT install the AC motor drive in a place subjected to high temperature, direct sunlight,
high humidity, excessive vibration, corrosive gases or liquids, or airborne dust or metallic
particles.
3. Only use AC motor drives within specification. Failure to comply may result in fire, explosion or
electric shock.
4. To prevent personal injury, please keep children and unqualified people away from the
equipment.
5. When the motor cable between the AC motor drive and motor is too long, the layer insulation of
the motor may be damaged. Please use a frequency inverter duty motor or add an AC output
reactor to prevent damage to the motor. Refer to appendix B Reactor for details.
6. The rated voltage for the AC motor drive must be d240V (d480V for 460V models) and the
mains supply current capacity must be d5000A RMS (d10000A RMS for the t40hp (30kW)
models).

Table of Contents
Preface ..............................................................................................................i
Table of Contents ...........................................................................................iii
Chapter 1 Introduction .................................................................................1-1
1.1 Receiving and Inspection.................................................................... 1-1
1.1.1 Nameplate Information................................................................ 1-1
1.1.2 Model Explanation ...................................................................... 1-1
1.1.3 Series Number Explanation ........................................................ 1-2
1.1.4 Drive Frames .............................................................................. 1-2
1.2 Appearances....................................................................................... 1-2
1.3 Preparation for Installation and Wiring................................................ 1-3
1.3.1 Remove Keypad ......................................................................... 1-3
1.3.2 Remove Front Cover................................................................... 1-3
1.3.3 Remove RST Terminal Cover ..................................................... 1-3
1.3.4 Remove UVW Terminal Cover.................................................... 1-4
1.3.5 Remove Fan ............................................................................... 1-4
1.4 Lifting .................................................................................................. 1-4
1.5 Storage ............................................................................................... 1-4
Chapter 2 Installation and Wiring ...............................................................2-1
2.1 Ambient Conditions............................................................................. 2-1
2.2 Installation........................................................................................... 2-1
2.3 Dimensions......................................................................................... 2-3

2.4 Wiring..................................................................................................2-6
2.4.1 Basic Wiring ................................................................................2-7
2.4.2 External Wiring..........................................................................2-11
2.4.3 Main Terminals Connections..................................................... 2-12
2.4.4 Control Terminals ...................................................................... 2-14
2.4.5 Main Circuit Terminals............................................................... 2-17
2.5 External Parts.................................................................................... 2-20
2.6 RFI Jumper .......................................................................................2-21
2.7 Connected the DC BUS of the AC Motor Drives in Parallel .............. 2-22
Chapter 3 Start Up ..................................................................................... 3-23
3.1 Preparations before Start-up ............................................................. 3-23
3.2 Operation Method ............................................................................. 3-24
3.3 Trial Run ........................................................................................... 3-24
Chapter 4 Digital Keypad Operation .......................................................... 4-1
4.1 Description of the Digital Keypad ........................................................ 4-1
4.2 How to Operate the Digital Keypad ..................................................... 4-3
Chapter 5 Parameters.................................................................................. 5-1
5.1 Summary of Parameter Settings ......................................................... 5-2
5.2 Parameter Settings for Applications .................................................. 5-18
5.3 Description of Parameter Settings..................................................... 5-23
Chapter 6 Fault Code Information .............................................................. 6-1
6.1 Common Problems and Solutions....................................................... 6-1
6.2 Reset................................................................................................... 6-4
Chapter 7 Troubleshooting ......................................................................... 7-1
7.1 Over Current (OC)...............................................................................7-1

7.2 Ground Fault....................................................................................... 7-2
7.3 Over Voltage (OV) .............................................................................. 7-2
7.4 Low Voltage (Lv)................................................................................. 7-3
7.5 Over Heat (OH)................................................................................... 7-4
7.6 Overload ............................................................................................. 7-4
7.7 Keypad Display is Abnormal............................................................... 7-5
7.8 Phase Loss (PHL)............................................................................... 7-5
7.9 Motor cannot Run ............................................................................... 7-6
7.10 Motor Speed cannot be Changed ..................................................... 7-7
7.11 Motor Stalls during Acceleration ....................................................... 7-8
7.12 The Motor does not Run as Expected .............................................. 7-8
7.13 Electromagnetic/Induction Noise ...................................................... 7-9
7.14 Environmental Condition................................................................... 7-9
7.15 Affecting Other Machines ............................................................... 7-10
Chapter 8 Maintenance and Inspections ....................................................8-1
Appendix A Specifications ......................................................................... A-1
Appendix B Accessories ............................................................................ B-1
B.1 All Brake Resistors & Brake Units Used in AC Motor Drives .............. B-1
B.1.1 Dimensions and Weights for Brake resistors..............................B-3
B.2 Remote Controller RC-01...................................................................B-6
B.3 AC Reactor.........................................................................................B-7
B.3.1 AC Input Reactor Recommended Value.....................................B-7
B.3.2 AC Output Reactor Recommended Value.................................. B-7
B.3.3 Applications for AC Reactor .......................................................B-8

B.4 Zero Phase Reactor (RF220X00A)...................................................B-11
B.5 Non-fuse Circuit Breaker Chart.........................................................B-12
B.6 Fuse Specification Chart...................................................................B-13
B.7 KPE-LE01.........................................................................................B-14
B.7.1 Description of the Digital keypad KPE-LE01.............................B-14
B.8 PU06.................................................................................................B-14
B.8.1 Description of the Digital keypad VFD-PU06 ............................B-14
B.8.2 Explanation of Display Message...............................................B-15
B.8.3 Operation Flow Chart................................................................B-16
B.9 Extension Card .................................................................................B-17
B.9.1 Relay Card................................................................................B-17
B.9.2 I/O Card ....................................................................................B-17
B.10 Fieldbus Modules............................................................................B-18
B.10.1 DeviceNet Communication Module (CME-DN01) ...................B-18
B.10.2 LonWorks Communication Module (CME-LW01)....................B-20
B.10.3 Profibus Communication Module (CME-PD01).......................B-22
B.11 DIN Rail ..........................................................................................B-24
B.11.1 MKE-DRA ...............................................................................B-24
B.11.2 MKE-DRB ...............................................................................B-24
B.11.3 MKE-EP ..................................................................................B-25
Appendix C How to Select the Right AC Motor Drive ...............................C-1
C.1 Capacity Formulas............................................................................. C-2
C.2 General Precautions.......................................................................... C-4
C.3 How to Choose a Suitable Motor ....................................................... C-5
Appendix D How to Use PLC Function ......................................................D-1

D.1 The Steps for PLC Execution .............................................................D-1
D.2 The Limit of PLC ................................................................................D-3
D.3 Edition Explanation of Ladder Diagram..............................................D-4
D.4 The Edition of PLC Ladder Diagram ..................................................D-7
D.5 The Example for Designing Basic Program .....................................D-10
D.6 PLC Devices ....................................................................................D-14
D.6.1 Summary of DVP-PLC Device Number....................................D-14
D.6.2 Device Reference Table...........................................................D-16
D.6.3 Devices Functions ....................................................................D-16
D.6.4 Value, constant [K] / [H]............................................................D-17
D.6.5 The Function of Auxiliary Relay................................................D-18
D.6.6 The Function of Timer ..............................................................D-18
D.6.7 The Features and Functions of Counter...................................D-19
D.6.8 Register Types .........................................................................D-20
D.6.9 Special Auxiliary Relays ...........................................................D-21
D.6.10 Special Registers ...................................................................D-22
D.6.11 Communication Addresses for Devices (only for PLC2 mode)D-23
D.6.12 Function Code (only for PLC2 mode) .....................................D-24
D.7 Commands.......................................................................................D-24
D.7.1 Basic Commands .....................................................................D-24
D.7.2 Output Commands ...................................................................D-25
D.7.3 Timer and Counters..................................................................D-25
D.7.4 Main Control Commands..........................................................D-25
D.7.5 Rising-edge/falling-edge Detection Commands of Contact ......D-25

D.7.6 Rising-edge/falling-edge Output Commands ........................... D-26
D.7.7 End Command......................................................................... D-26
D.7.8 Description of the Application Commands ............................... D-26
D.7.9 Explanation for the Commands................................................ D-26
Appendix E CE .............................................................................................E-1

Revision August 2006, 01EE, SW--PW V1.03/CTL V2.03 1-1
Chapter 1 Introduction
1.1 Receiving and Inspection
This VFD-E AC motor drive has gone through rigorous quality control tests at the factory before
shipment. After receiving the AC motor drive, please check for the following:
 Check to make sure that the package includes an AC motor drive, the User
Manual/Quick Start and CD, dust covers and rubber bushings.
 Inspect the unit to assure it was not damaged during shipment.
 Make sure that the part number indicated on the nameplate corresponds with the part
number of your order.
1.1.1 Nameplate Information
Example for 1HP/0.75kW 3-phase 230V AC motor drive
MODEL VFD007E23A :
INPUT :3PH 200-240V 50/60Hz 5.1A
OUTPUT :3PH 0-240V 4.2A 1.6kVA 0.75kW/1HP
FREQUENCY RANGE : 0.1~400Hz
Serial Number & Bar Code
AC Drive Model
Input Spec.
Output Spec.
Output Frequency Range
007E23A0T5011230
01.03
02.03
Software Version
Power Board
Control Board
1.1.2 Model Explanation
VFD
A
Version Type
23
Mains Input Voltage
11:115 Single phaseV21: phase230V Single
23:230 Three phaseV
E
E Series
007
Applicable motor capacity
004: 0.5 HP(0.4kW)
015: 2 HP(1.5kW)
022: 3 HP(2.2kW)
Series Name ( ariable requency rive) VF D
43:460 Three phaseV
002: 0.25 HP(0.2kW)
055: 7.5 HP(5.5kW)
110: 15 HP(11kW)
037: 5 HP(3.7kW)

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1.1.3 Series Number Explanation
01
6
0T007E23A
Production number
Production year 2006
Production factory
Production week
(Taoyuan)
Model
230V 3-phase 1HP(0.75kW)
If the nameplate information does not correspond to your purchase order or if there are
any problems, please contact your distributor.
1.1.4 Drive Frames
Frame Power range Models
A 0.25-2hp (0.2-1.5kW)
VFD002E11A/21A/23A, VFD004E11A/21A/23A/43A,
VFD007E21A/23A/43A, VFD015E23A/43A
B 1-5hp (0.75-3.7kW)
VFD007E11A, VFD015E21A,
VFD022E21A/23A/43A, VFD037E23A/43A
C 7.5-15hp (5.5-11kW) VFD055E23A/43A, VFD075E23A/43A, VFD110E43A
Please refer to Chapter 2.3 for exact dimensions.
1.2 Appearances
(Refer to chapter 2.3 for exact dimensions)
0.25-2HP/0.2-1.5kW (Frame A) 1-5HP/0.75-3.7kW (Frame B)

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Revision August 2006, 01EE, SW--PW V1.03/CTL V2.03 1-3
NOTE
Models of frame C (7.5-15HP/5.5-11kW) are under development.
1.3 Preparation for Installation and Wiring
1.3.1 Remove Keypad
1.3.2 Remove Front Cover
Step 1 Step 2
1.3.3 Remove RST Terminal Cover
Frame B and Frame C

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1.3.4 Remove UVW Terminal Cover
Frame B and Frame C
1.3.5 Remove Fan
1.4 Lifting
Please carry only fully assembled AC motor drives to prevent machine damage.
1.5 Storage
The AC motor drive should be kept in the shipping carton or crate before installation. In order to
retain the warranty coverage, the AC motor drive should be stored properly when it is not to be used
for an extended period of time. Storage conditions are:
Store in a clean and dry location free from direct sunlight or corrosive fumes.
Store within an ambient temperature range of -20 °C to +60 °C.
Store within a relative humidity range of 0% to 90% and non-condensing environment.
Store within an air pressure range of 86kPa to 106kPa.

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CAUTION!
1. DO NOT store in an area with rapid changes in temperature. It may cause condensation and
frost.
2. DO NOT place on the ground directly. It should be stored properly. Moreover, if the surrounding
environment is humid, you should put exsiccator in the package.
3. If the AC motor drive is stored for more than 3 months, the temperature should not be higher
than 30 °C. Storage longer than one year is not recommended, it could result in the degradation
of the electrolytic capacitors.
4. When the AC motor drive is not used for a long time after installation on building sites or places
with humidity and dust, it’s best to move the AC motor drive to an environment as stated above.

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Revision August 2006, 01EE, SW--PW V1.03/CTL V2.03 2-1
Chapter 2 Installation and Wiring
2.1 Ambient Conditions
Install the AC motor drive in an environment with the following conditions:
Operation Air Temperature: -10 ~ +50°C (14 ~ 122°F)
-10 ~ +40°C (14 ~ 104°F) for side-by-side
mounting
Relative Humidity: <90%, no condensation allowed
Atmosphere pressure: 86 ~ 106 kPa
Installation Site Altitude: <1000m
Vibration: <20Hz: 9.80 m/s2(1G) max
20 ~ 50Hz: 5.88 m/s2(0.6G) max
Storage
Transportation
Temperature: -20°C ~ +60°C (-4°F ~ 140°F)
Relative Humidity: <90%, no condensation allowed
Atmosphere pressure: 86 ~ 106 kPa
Vibration: <20Hz: 9.80 m/s2(1G) max
20 ~ 50Hz: 5.88 m/s2(0.6G) max
Pollution Degree 2: good for a factory type environment.
CAUTION!
1. Operating, storing or transporting the AC motor drive outside these conditions may cause
damage to the AC motor drive.
2. Failure to observe these precautions may void the warranty!
2.2 Installation
1. Mount the AC motor drive vertically on a flat vertical surface by using bolts or screws. Other
directions are not allowed.
2. The AC motor drive will generate heat during operation. Allow sufficient space around the unit
for heat dissipation.
3. The heat sink temperature may rise to 90°C when running. The material on which the AC motor
drive is mounted must be noncombustible and be able to withstand this high temperature.
4. When the AC motor drive is installed in a confined space (e.g. cabinet), the surrounding
temperature must be within 10 ~ 40°C with good ventilation. DO NOT install the AC motor drive
in a space with bad ventilation.

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2-2 Revision August 2006, 01EE, SW--PW V1.03/CTL V2.03
5. When installing multiple AC motor drives in the same cabinet, they should be adjacent in a row
with enough space. When installing one AC motor drive below another one, use a metal
separation barrier between the AC motor drives to prevent mutual heating. Refer to figure below
for details.
6. Prevent fiber particles, scraps of paper, saw dust, metal particles, etc. from adhering to the
heatsink.
Frame A Mounting Clearances
Option 1 (-10 to +50qC)
120mm
120mm
50mm
50mm
Air Flow
Option 2 (-10 to +40qC)
120mm
120mm
Air Flow
Frame B and C Mounting Clearances
Option 1 (-10 to +50qC)
150mm
150mm
Air Flow
50mm
50mm
Option 2 (-10 to +40qC)
150mm
150mm
Air Flow

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Revision August 2006, 01EE, SW--PW V1.03/CTL V2.03 2-3
2.3 Dimensions
(Dimensions are in millimeter and [inch])
Frame A: VFD002E11A/21A/23A, VFD004E11A/21A/23A/43A VFD007E21A/23A/43A,
VFD015E23A/43A

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2-4 Revision August 2006, 01EE, SW--PW V1.03/CTL V2.03
Frame B: VFD007E11A, VFD015E21A, VFD022E21A/23A/43A, VFD037E23A/43A
5.5[0.22]
UNIT : mm(inch)
174.0 [6.86]
162.0 [6.38]
89.0 [3.50]
100.0 [3.94]
152.0 [5.98]
5.5 [0.22]
9.3 [0.36]

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Revision August 2006, 01EE, SW--PW V1.03/CTL V2.03 2-5
Frame C: VFD055E23A/43A, VFD075E23A/43A, VFD110E43A
260.0 [10.24]
246.5 [9.70]
116.0 [4.57]
130.0 [5.12]
6.5 [0.26]
Unit: mm [inch]
5.5 [0.22]
1.5 [0.06]
5.5 [0.22]
9.8 [0.38]
169.2 [6.66]