Kostal inveor User manual

Operating manual
INVEOR Drive Controller α

2Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN
Legal notice
KOSTAL Industrie Elektrik GmbH
An der Bellmerei 10
58513 Lüdenscheid
Germany
Tel. [phone]
Fax + 49 (0)2351 16-2400
info[email protected]
Exclusion of liability
All general names, trade names, product names or other designations used in this manual may be
legally protected even if not labelled as such (e.g. as a trademark). KOSTAL assumes no liability for
their free usage.
The illustrations and texts have been compiled with great care. However, the possibility of errors
cannot be ruled out. The compilation is made without any guarantee.
General note on gender equality
KOSTAL is aware of how language impacts on gender equality and always make an effort to reflect
this in documentation. Nevertheless, for the sake of readability we are unable to use non-gender-
specific terms throughout and use the masculine form instead.
© 2016 KOSTAL Industrie Elektrik GmbH
All rights reserved by KOSTAL, including those of reproduction by photocopy and storage in
electronic media. Commercial use or distribution of the texts, displayed models, diagrams and
photographs appearing in this product are not permitted.
This manual may not be reproduced, stored, transmitted or translated in any form or by means of
any medium - in whole or in part - without prior written permission.

Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN 3
Contents
1. General information.....................................................................................................6
1.1 Information about documentation .................................................................................7
1.1.1 Other applicable documents.........................................................................................7
1.1.2 Storing the documentation ...........................................................................................8
1.2 Notes in this manual.....................................................................................................8
1.2.1 Warnings .....................................................................................................................8
1.2.2 Warning symbols used.................................................................................................9
1.2.3 Signal words................................................................................................................9
1.2.4 Information notes .......................................................................................................10
1.3 Symbols used in this manual ......................................................................................11
1.4 Labels on the drive controller......................................................................................12
1.5 Qualified staff .............................................................................................................13
1.6 Proper use.................................................................................................................13
1.7 Responsibility.............................................................................................................14
1.8 CE marking................................................................................................................14
1.9 Safety instructions......................................................................................................15
1.9.1 General information....................................................................................................15
1.9.2 Transport & storage ...................................................................................................17
1.9.3 Long-term storage of devices.....................................................................................17
1.9.4 Information about commissioning ...............................................................................18
1.9.5 Instructions concerning operation...............................................................................19
1.9.6 Maintenance and inspection.......................................................................................21
1.9.7 Repairs......................................................................................................................22
2. Overview of the drive controller.................................................................................23
2.1 Model description ......................................................................................................24
2.2 Scope of delivery .......................................................................................................25
2.3 Description of INVEOR α drive controller .....................................................................26
3. Installation.................................................................................................................27
3.1 Safety instructions for installation ................................................................................28
3.2 Recommended preliminary fuses / line protection........................................................28
3.3 Installation requirements.............................................................................................29
3.3.1 Suitable ambient conditions........................................................................................29
3.3.2 Suitable installation location for the motor-integrated drive controller............................30
3.3.3 Basic connection versions..........................................................................................31
3.3.4 Short circuit and ground protection.............................................................................33
3.3.5 Wiring instructions......................................................................................................34
3.3.6 Preventing electromagnetic interferences....................................................................36
3.4 Installing the drive controller integrated in the motor ....................................................36
3.4.1 Mechanical installation................................................................................................36
3.4.2 Power connection......................................................................................................40
3.4.3 Control connections of application board....................................................................42
3.4.4 Placing cooling elements on adapter plate ..................................................................44
3.4.5 Connection diagram...................................................................................................46

Contents
4Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN
3.5 Installing the wall-mounted drive controller ..................................................................47
3.5.1 Suitable installation location for wall mounting .............................................................47
3.5.2 Mechanical installation................................................................................................48
3.5.3 Power connection ......................................................................................................51
3.5.4 Control connections...................................................................................................51
4. Commissioning .........................................................................................................52
4.1 Safety instructions for commissioning .........................................................................53
4.2 Communication..........................................................................................................54
4.3 Block diagram............................................................................................................55
4.4 Commissioning steps.................................................................................................56
4.4.1 Commissioning using the PC:.....................................................................................57
5. Parameter .................................................................................................................59
5.1 Safety instructions for working with parameters...........................................................60
5.2 General information on parameters.............................................................................60
5.2.1 Explanation of operating modes..................................................................................60
5.2.2 Structure of the parameter tables................................................................................64
5.3 Application parameters...............................................................................................65
5.3.1 Basic parameter.........................................................................................................65
5.3.2 Fixed frequency..........................................................................................................73
5.3.3 Motor potentiometer ..................................................................................................74
5.3.4 PID process controller................................................................................................75
5.3.5 Analogue input...........................................................................................................80
5.3.6 Digital inputs ..............................................................................................................83
5.3.7 Digital output .............................................................................................................84
5.3.8 Relay .........................................................................................................................86
5.3.9 Virtual output .............................................................................................................89
5.3.10 External fault..............................................................................................................91
5.3.11 Motor current limit......................................................................................................92
5.4 Gearbox factor...........................................................................................................93
5.4.1 Blocking detection .....................................................................................................93
5.4.2Field bus....................................................................................................................96
5.5 Performance parameters............................................................................................98
5.5.1 Motor data.................................................................................................................98
5.5.2 I2T ...........................................................................................................................102
5.5.3 Switching frequency................................................................................................. 103
5.5.4 Controller data .........................................................................................................103
5.5.5 Quadratic characteristic curve ..................................................................................105
5.5.6 Synchronous motor controller data...........................................................................106
6. Error detection and troubleshooting........................................................................108
6.1 List of the LED flash codes for error recognition ........................................................110
6.2 List of errors and system errors ................................................................................111

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7. Disassembly and disposal.......................................................................................115
7.1 Drive controller disassembly .....................................................................................116
7.2 Information on correct disposal.................................................................................116
8. Technical data ........................................................................................................117
8.1 General data ............................................................................................................118
8.1.1 General technical data for 230 V devices ..................................................................118
8.1.2 Specification of interfaces.........................................................................................119
8.2 Derating of output power..........................................................................................120
8.2.1 Derating due to increased ambient temperature........................................................120
8.2.2 Derating due to installation altitude ...........................................................................121
8.2.3 Derating due to switching frequency ......................................................................... 122
9. Optional accessories...............................................................................................123
9.1 Adapter plates .........................................................................................................124
9.1.1 Motor adapter plates................................................................................................124
9.1.2 Motor adapter plates (specific)..................................................................................125
9.1.3 Wand adapter plates (standard)................................................................................126
9.2 Foil keypad ..............................................................................................................127
9.3 MMI* handheld controller including a 3 m RJ9 connection cable with M12 plug ......... 132
9.3.1 MMI/connecting cable PIN assignment.....................................................................133
9.4 PC communication cable USB on M12/RS485 plug (converter integrated)................ 134
9.5 INVEOR α adapter cable ..........................................................................................135
9.6 Internal potentiometer ..............................................................................................135
9.7 MMI M12 plug (JST plug) .........................................................................................136
9.8 CANopen connection cable......................................................................................137
9.9 Connection and screw-in information for "Optional accessories"................................138
9.10 Cable set extension..................................................................................................139
10.Approvals, standards and guidelines ...................................................................... 140
10.1 EMC limit classes.....................................................................................................141
10.2 Classification acc. to IEC/EN 61800-3 ......................................................................141
10.3 Standards and guidelines .........................................................................................142
10.4 UL approval .............................................................................................................143
10.4.1 UL Specification (English version).............................................................................. 143
10.4.2 Homologation CL (Version en française).................................................................... 144
11. Quickstart guide...................................................................................................... 145
11.1 Quickstart guide for asynchronous motors................................................................146
11.2 Quickstart guide for synchronous motors..................................................................147
12. Index.......................................................................................................................148
13. List of figures ..........................................................................................................153

6Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN
1. General information
1.1 Information about documentation .................................................................................7
1.1.1 Other applicable documents.........................................................................................7
1.1.2 Storing the documentation ...........................................................................................8
1.2 Notes in this manual.....................................................................................................8
1.2.1 Warnings .....................................................................................................................8
1.2.2 Warning symbols used .................................................................................................9
1.2.3 Signal words................................................................................................................9
1.2.4 Information notes .......................................................................................................10
1.3 Symbols used in this manual ......................................................................................11
1.4 Labels on the drive controller......................................................................................12
1.5 Qualified staff .............................................................................................................13
1.6 Proper use.................................................................................................................13
1.7 Responsibility.............................................................................................................14
1.8 CE marking................................................................................................................14
1.9 Safety instructions......................................................................................................15
1.9.1General information....................................................................................................15
1.9.2 Transport & storage ...................................................................................................17
1.9.3 Long-term storage of devices.....................................................................................17
1.9.4 Information about commissioning ...............................................................................18
1.9.5 Instructions concerning operation...............................................................................19
1.9.6 Maintenance and inspection.......................................................................................21
1.9.7 Repairs......................................................................................................................22

General information
Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN 7
Thank you for choosing an INVEOR αdrive controller from KOSTAL Industrie Elektrik GmbH!
Our INVEOR αdrive controller platform is designed to be universally usable with all common motor
types.
If you have any technical questions, please call our central service hotline:
Tel.: [phone]
Monday to Friday: 7 am to 5 pm (UTC/GMT +1)
Fax: [phone]
E-mail: [e-mail]
Website
www.kostal-industrie-elektrik.com
1.1 Information about documentation
The following information explains how to navigate through the documentation.
Read this manual carefully in its entirety. It contains important information for operating the
INVEOR α.
We assume no liability for any damage resulting from non-observance of this manual.
This manual is an integral part of the product and applies exclusively to the INVEOR αfrom
KOSTAL Industrie Elektrik GmbH.
Provide the operator of the system with this manual so it is available when needed.
1.1.1 Other applicable documents
This refers to all manuals that describe how to operate the drive controller system and any other
manuals for the equipment used. Download the 3D files (.stp) for INVEOR and adapter plates from
www.kostal-industrie-elektrik.com.
A description of parameters is available for download (www.kostal-industrie-elektrik.com) for
parametrising the drive controller system. In the download, you will find all the information required
for correct parameterisation.

General information
8Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN
1.1.2 Storing the documentation
Store this operating manual and all other applicable documents carefully so they are available
when needed.
1.2 Notes in this manual
1.2.1 Warnings
The warnings refer to life-threatening dangers. Serious injuries possibly resulting in death may
occur.
Each warning consists of the following elements:
DANGER!
Risk of death due to electrical shock!
Death or serious injury!
De-energise drive controller and secure it against being restarted.
Fig.: 1 Structure of warnings
1 Warning symbol
2 Signal word
3 Type of danger and its source
4 Possible consequence(s) of failure to comply
5 Corrective actions
3
4
5
2
1

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1.2.2 Warning symbols used
Symbol Meaning
Danger
Danger due to electrical shock and discharge
Danger due to burns
Danger due to electromagnetic fields
1.2.3 Signal words
Signal words are used to identify the severity of the danger.
DANGER
Indicates a direct hazard with a high level of risk, which, if not avoided, will result in death or
serious injury.
WARNING
Indicates a hazard with a moderate level of risk, which, if not avoided, will result in death or serious
injury.
CAUTION
Indicates a hazard with a low level of risk, which, if not avoided, may result in minor or slight injury
or property damage.

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10 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN
1.2.4 Information notes
Information notes contain important instructions for the installation and problem-free operation of
the drive controller. These must be followed at all times. The information notes also point out that
failure to observe can result in damage to property or financial damages.
IMPORTANT INFORMATION
The drive controller may only be assembled, operated, maintained and installed by trained and
qualified staff.
Fig.: 2 Example of an information note
Symbols within the information notes
Symbol Meaning
Important information
Damage to property possible
Fig.: 3 Symbols within the information notes
Other notes
Symbol Meaning
INFORMATION
Enlarged view

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1.3 Symbols used in this manual
Symbol Meaning
1., 1., 3. … Consecutive steps in a handling instruction
Effect of a handling instruction
Final result of a handling instruction
List
Fig.: 4 Symbols and icons used
Abbreviations used
Abbreviation Explanation
Tab. Table
Fig. Figure
It. Item
Ch. Chapter
MATorque

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12 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN
1.4 Labels on the drive controller
Fig.: 5 Labels on the drive controller
Signs and labels are affixed to the drive controller. These may not be altered or removed.
Symbol Meaning
Danger due to electrical shock and discharge
Danger due to burns WARNING
HOT SURFACE
RISK OF BURN
Danger due to electrical shock and discharge. Wait two minutes (discharge time of
the capacitors) after shut-down
Additional earth connection
Observe and read operating manual

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1.5 Qualified staff
In the context of this operating manual, qualified staff refers to electronics specialists who are
familiar with the installation, assembly, commissioning and operation of the drive controller and the
dangers involved, and whose specialist training and knowledge of relevant standards and
regulations provide them with the necessary abilities.
1.6 Proper use
If the device is installed in a machine, drive controllers may not be commissioned (i.e. intended
operation may not begin) until it has been determined that the machine complies with the
regulations of EC Directive 2006/42/EC (Machinery Directive); DIN EN 60204-1;
VDE 0113-1:2007-06 must be observed.
Commissioning (i.e. beginning intended operation) is only permitted if the EMC Directive
(2004/108/EC) is complied with.
The harmonised standards of DIN EN 50178; VDE 0160:1998-04 must be applied for this drive
controller along with DIN EN 60439-1; VDE 0660-500:2005-01.
This drive controller may not be operated in areas where there is a danger of explosion!
Repairs may only be performed by authorised repair bodies. Independent and unauthorised
intervention may result in death, injury or property damage.
The warranty provided by KOSTAL will be invalidated in such cases.
External mechanical loads such as stepping on the housing are not permitted!
IMPORTANT INFORMATION
Using drive controllers in equipment that is not fixed is considered as an exceptional
environmental condition and is only permitted if allowed by the standards and guidelines
applicable on site.

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14 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN
1.7 Responsibility
As a basic principle, electronic devices are not fail-safe. The operator and/or the contractor setting
up the machine or system is responsible for ensuring that the drive switches to a safe state if the
device fails.
The “Electrical equipment of machines” section in DIN EN 60204-1; VDE 0113-1:2007-06, “Safety
of machinery” describes the safety requirements for electrical control units. These are provided for
the safety of people and machines and must be observed in order to retain the functional capability
of the machine or system.
An emergency stop feature does not have to result in the voltage supply to the drive being
switched off. To avoid dangerous situations, it may be useful for individual drives to remain
operational or for specific safety procedures to be initiated.
The effectiveness of emergency stop measures is evaluated by means of a risk assessment for the
machine or system and its electrical equipment, and is determined by selecting a circuit category
according to DIN EN 13849 “Safety of machinery – Safety-related parts of control systems”.
1.8 CE marking
With the CE marking, we, as the manufacturer of the device, confirm that the drive controller meets
the basic requirements of the following guidelines:
Directive on Electromagnetic Compatibility (Directive 2004/108/EC of the Council EN 61800-
3:2004).
Low Voltage Directive (Directive 2006/95/EC of the Council EN 61800-5-1:2003).
You can download the Declaration of Conformity from www.kostal-industrie-elektrik.com.

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1.9 Safety instructions
The following warnings, precautionary measures and information are provided for your safety and
serve to prevent damage to the drive controller and the components connected to it.
This chapter contains warnings and information that are generally applicable when handling drive
controls. They are split into general information, transport & storage and dismantling & disposal.
Specific warnings and comments that apply to specific activities can be found at the start of the
appropriate chapters and are repeated or added to at various critical points in these chapters.
Please read this information carefully as it is provided for your personal safety and will also prolong
the life of the drive controller and connected devices.
1.9.1 General information
IMPORTANT INFORMATION
Carefully read this operating manual and the warning signs affixed to the drive controller before
installation and commissioning. Make sure that all warning signs on the drive controller are
legible; replace any missing or damaged signs.
They contain important information on the installation and operation of the drive controller.
In particular, note the information in the "Important information" chapter.
KOSTAL Industrie Elektrik GmbH assumes no liability for damages arising from the
non-observance of this operating manual.
This operating manual is an integral part of the product. It applies exclusively to the drive
controller from KOSTAL Industrie Elektrik GmbH.
Keep the operating manual close to the drive controller so it is easily accessible to all users.
IMPORTANT INFORMATION
The drive controller can only be operated safely if the required environmental conditions listed in
the “Suitable environmental conditions” chapter are met.

General information
16 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN
DANGER!
Risk of death due to electrical shock!
Death or serious injury!
De-energise drive controller and secure it against being restarted.
DANGER!
Risk of death due to revolving mechanical parts!
Death or serious injury!
De-energise drive controller and secure it against being restarted.
DANGER!
Risk of death due to fire or electrical shock!
Death or serious injury!
Always use the drive controller as intended.
Do not modify the drive controller.
Only use spare parts and accessories sold or recommended by the manufacturer.
During assembly, ensure a sufficient distance from neighbouring parts.
DANGER!
Risk of death due to electrical shock!
Death or serious injury!
De-energise drive controller and secure it against being restarted.
CAUTION!
Risk of burns from hot surfaces!
Serious burns to the skin from hot surfaces!
Allow the drive controller's cooling elements to cool sufficiently.

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Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN 17
IMPORTANT INFORMATION
Do not place flammable parts (e.g. cable ducts) directly or indirectly on the drive controller.
1.9.2 Transport & storage
DAMAGE TO PROPERTY POSSIBLE
Risk of damage to drive controller!
Risk of damage to drive controller from improper transport, storage, installation and assembly!
Transport the drive controller properly in its original packaging.
Always store the drive controller properly.
Only allow qualified staff to undertake installation and assembly.
1.9.3 Long-term storage of devices
IMPORTANT INFORMATION
If drive controllers have been in storage for more than 2 years, the following regeneration
process is required before installation / use under the nominal conditions:
The drive controller must be connected to supply voltage (+/- 3 %) for 30 minutes without
the device being loaded. This applies to the motor connection as well as possible
consumers and connections to the application.
Perform this process once before commissioning.
In all cases, observe the general requirements for storing drive controllers!

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18 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN
1.9.4 Information about commissioning
DANGER!
Risk of death due to electrical shock!
Death or serious injury!
De-energise drive controller and secure it against being restarted.
Supply terminals X1: L
Motor connection terminals X411: T1, T2, U, V, W
Connecting terminals X6: Relay contacts
IMPORTANT INFORMATION
Only use mains connections with hardwiring.
Ground the drive controller in accordance with DIN EN 61140;
VDE 0140-1.
The INVEOR α may have touch currents of > 3.5 mA.
In accordance with DIN EN 61800-5-1, an extra protective grounding conductor of the
same cross-section as the original protective grounding conductor should therefore be
fitted. A second protective grounding conductor can be connected on the outside of the
device. A suitable M6 x 8 screw (torque MA= 4.0 Nm) is provided by INVEOR.
If 1~INVEOR devices are used, it is permitted to use standard type A FI protection
switches or RCDs (residual current-operated protective devices) in accordance with
DIN VDE 0160 and EN 50178 to protect against direct or indirect contact.
If 3~ INVEOR devices are used, it is not permitted to use standard type A FI protection switches
or RCDs (residual current-operated protective devices) to protect against direct or indirect
contact.
According to DIN VDE 0160 and EN 50178, the FI protection switch must be universal
current sensitive (RCD type B)!

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Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN 19
IMPORTANT INFORMATION
If different voltages are used (e.g. +24 V/230 V), crossing cable runs are not permitted
under any circumstances. The operator must also ensure compliance with the applicable
regulations (e.g. double or reinforced insulation acc. to DIN EN 61800-5-1).
The drive controller contains components susceptible to electrical discharge.
These may be destroyed through improper handling. Therefore, precautionary measures
against electrostatic charges must be taken when work is performed on these
components.
1.9.5 Instructions concerning operation
DANGER!
Risk of death due to electrical shock!
Death or serious injury!
De-energise drive controller and secure it against being restarted.
DANGER!
Risk of death due to revolving mechanical parts!
Death or serious injury!
De-energise drive controller and secure it against being restarted.

General information
20 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN
IMPORTANT INFORMATION
Observe the following instructions during operation:
The drive controller runs at high voltages.
When electrical devices are operated, some of their parts are always subject to dangerous
voltage.
Emergency stop equipment according to DIN EN 60204-1; VDE 0113-1:2007-06 must
function in all the control device's operating modes. Resetting the emergency stop
equipment may not result in uncontrolled or undefined restarting.
In order to ensure safe disconnection from the mains, the mains cable has to be fully
disconnected from the drive controller in a synchronous manner.
A pause of at least 1 to 2 mins must be observed between consecutive mains activations
for devices with a single-phase feed.
Certain parameter settings may result in the drive controller restarting automatically after
the supply voltage has failed.
DAMAGE TO PROPERTY POSSIBLE
If the information is not observed, the drive controller could be damaged and destroyed during
subsequent commissioning.
Observe the following instructions during operation:
The motor parameters, especially the I2T settings, have to be configured properly to
provide proper motor overload protection.
The drive controller has internal motor overload protection. See parameters 33.010 and
33.011.
I2T is ON by default. Motor overload protection can also be ensured via an external PTC.
The drive controller must not be used as "Emergency stop equipment"
(see DIN EN 60204-1; VDE 0113-1:2007-06).