Kostal inveor User manual

Operating manual
INVEOR Drive Controller

2Operating manual for INVEOR | DOC01133971-0019 | 2017-03 | V2.08 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 names, trademarks, product names or other designations given in this manual may be legally
protected even if this is 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 makes 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.
© 2017 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 is 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.

Contents
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Contents
1. General information .................................................................................... 7
1.1 Information about documentation .................................................................................8
1.1.1 Other applicable documents.........................................................................................8
1.1.2 Storing the documentation ...........................................................................................9
1.2 Notes in this manual.....................................................................................................9
1.2.1 Warnings .....................................................................................................................9
1.2.2 Warning symbols used...............................................................................................10
1.2.3 Signal words..............................................................................................................10
1.2.4 Information notes .......................................................................................................11
1.3 Symbols used in this manual ......................................................................................12
1.4 Labels on the drive controller......................................................................................13
1.5 Qualified staff .............................................................................................................14
1.6 Proper use.................................................................................................................14
1.7 Responsibility.............................................................................................................15
1.8 CE marking................................................................................................................15
1.9 Safety instructions......................................................................................................16
1.9.1 General information....................................................................................................16
1.9.2 Transport & storage ...................................................................................................18
1.9.3 Langzeitlagerung der Geräte ( nur bei INVEOR A [1 x 230 V AC]) .................................18
1.9.4 Information about commissioning ...............................................................................19
1.9.5 Instructions concerning operation...............................................................................20
1.9.6 Maintenance and inspection.......................................................................................22
1.9.7 Repairs......................................................................................................................23
2. Overview of the drive controller............................................................... 24
2.1 Model description ......................................................................................................25
2.1.1 Model description (valid until end of February 2016) ....................................................25
2.1.2 Model description (current) .........................................................................................26
2.2 Scope of delivery .......................................................................................................27
2.3 MMI*/connecting cable PIN assignment......................................................................28
2.4 Description of the INVEOR drive controller ..................................................................28
3. Installation ................................................................................................. 29
3.1 Safety instructions for installation ................................................................................30
3.2 Recommended preliminary fuses / line protection........................................................30
3.3 Installation requirements.............................................................................................31
3.3.1 Suitable ambient conditions........................................................................................31
3.3.2 Suitable installation location for the motor-integrated drive controller............................32
3.3.3 Basic connection versions..........................................................................................33
3.3.4 Short circuit and ground protection.............................................................................36
3.3.5 Wiring instructions......................................................................................................37
3.3.6 Preventing electromagnetic interferences....................................................................40

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3.4 Installing the drive controller integrated in the motor ....................................................40
3.4.1 Mechanical installation................................................................................................40
3.4.2 Power connection ......................................................................................................51
3.4.3 Connections for brake resistor....................................................................................57
3.4.4 Control connections X5, X6, X7 ..................................................................................57
3.4.5 Connection diagram...................................................................................................64
3.5 Installing the wall-mounted drive controller ..................................................................65
3.5.1 Suitable installation location for wall mounting .............................................................65
3.5.2 Mechanical installation sizes A - C ..............................................................................66
3.5.3 Mechanical installation of size D..................................................................................71
3.5.4 Power connection ......................................................................................................79
3.5.5 Brake chopper...........................................................................................................80
3.5.6 Control connections...................................................................................................80
3.6 Disassembly and assembly of the INVEOR fan, size "D” .............................................80
3.6.1 Fan disassembly ........................................................................................................81
3.6.2 Fan assembly.............................................................................................................83
4. Commissioning .......................................................................................... 86
4.1 Safety instructions for commissioning .........................................................................87
4.2 Communication..........................................................................................................88
4.3 Block diagram............................................................................................................90
4.4 Commissioning steps.................................................................................................91
4.4.1 Commissioning using the PC:.....................................................................................91
4.4.2 Commissioning using PC, combined with MMI option .................................................92
5. Parameters................................................................................................. 94
5.1 Safety instructions for working with parameters...........................................................95
5.2 General information on parameters.............................................................................95
5.2.1 Explanation of operating modes..................................................................................95
5.2.2 Structure of the parameter tables................................................................................99
5.3 Application parameters.............................................................................................100
5.3.1 Basic parameter.......................................................................................................100
5.3.2 Fixed frequency........................................................................................................109
5.3.3 Motor potentiometer ................................................................................................110
5.3.4 PID process controller..............................................................................................112
5.3.5 Analogue inputs .......................................................................................................117
5.3.6 Digital inputs ............................................................................................................120
5.3.7 Analogue output ......................................................................................................121
5.3.8 Digital outputs..........................................................................................................122
5.3.9 Relay .......................................................................................................................124
5.3.10 Virtual output ...........................................................................................................127
5.3.11 External fault............................................................................................................130
5.3.12 Motor current limit....................................................................................................130
5.3.13 Stall detection..........................................................................................................132
5.3.14 Field bus..................................................................................................................135

Contents
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5.4 Performance parameters..........................................................................................137
5.4.1 Motor data............................................................................................................... 137
5.4.2 I2T ...........................................................................................................................141
5.4.3 Switching frequency................................................................................................. 142
5.4.4 Controller data .........................................................................................................142
5.4.5 Quadratic characteristic curve ..................................................................................145
5.4.6 Synchronous motor controller data...........................................................................146
6. Error detection and troubleshooting ..................................................... 148
6.1 List of the LED flash codes for error recognition ........................................................150
6.2 List of errors and system errors ................................................................................151
7. Disassembly and disposal ...................................................................... 156
7.1 Drive controller disassembly .....................................................................................157
7.2 Information on correct disposal.................................................................................157
8. Technical data ......................................................................................... 158
8.1 General data ............................................................................................................159
8.1.1 General technical data for 400V devices ...................................................................159
8.1.2 General technical data for 230 V devices ..................................................................160
8.2 Derating of output power..........................................................................................162
8.2.1 Derating due to increased ambient temperature........................................................ 162
8.2.2 Derating due to installation altitude ...........................................................................164
8.2.3 Derating due to switching frequency ......................................................................... 165
9. Optional accessories............................................................................... 166
9.1 Adapter plates .........................................................................................................167
9.1.1 Motor adapter plates................................................................................................167
9.1.2 Motor adapter plates (specific)..................................................................................170
9.1.3 Wand adapter plates (standard)................................................................................171
9.2 Foil keypad ..............................................................................................................174
9.3 MMI handheld controller including a 3 m RJ9 connection cable with M12 plug........... 178
9.4 PC communication cable USB on M12/RS485 plug (converter integrated)................. 178
10. Approvals, standards and guidelines .................................................... 179
10.1 EMC limit classes.....................................................................................................180
10.2 Classification acc. to IEC/EN 61800-3 ......................................................................180
10.3 Standards and guidelines .........................................................................................181
10.4 UL approval .............................................................................................................182
10.4.1 UL Specification (English version)..............................................................................182
10.4.2 Homologation CL (Version en française).................................................................... 184

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11. Quickstart guide ...................................................................................... 186
11.1 Quickstart guide.......................................................................................................187
11.2 Quickstart guide for synchronous motors..................................................................188
12. Index ......................................................................................................... 189

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1. General information
1.1 Information about documentation .................................................................................8
1.1.1 Other applicable documents.........................................................................................8
1.1.2 Storing the documentation ...........................................................................................9
1.2 Notes in this manual.....................................................................................................9
1.2.1 Warnings .....................................................................................................................9
1.2.2 Warning symbols used...............................................................................................10
1.2.3 Signal words..............................................................................................................10
1.2.4 Information notes .......................................................................................................11
1.3 Symbols used in this manual ......................................................................................12
1.4 Labels on the drive controller......................................................................................13
1.5 Qualified staff .............................................................................................................14
1.6 Proper use.................................................................................................................14
1.7 Responsibility.............................................................................................................15
1.8 CE marking................................................................................................................15
1.9 Safety instructions......................................................................................................16
1.9.1 General information....................................................................................................16
1.9.2 Transport & storage ...................................................................................................18
1.9.3 Langzeitlagerung der Geräte ( nur bei INVEOR A [1 x 230 V AC]) ................................. 18
1.9.4 Information about commissioning ...............................................................................19
1.9.5 Instructions concerning operation...............................................................................20
1.9.6 Maintenance and inspection.......................................................................................22
1.9.7 Repairs......................................................................................................................23

General information
8Operating manual for INVEOR | DOC01133971-0019 | 2017-03 | V2.08 EN
Thank you for choosing an INVEOR drive controller from KOSTAL Industrie Elektrik GmbH!
Our INVEOR drive 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 address
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.
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 from 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.

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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!jury!
De-energise drive controller and secure it against being restarted.
Fig. 1: Structure of the 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
1 2 5
4
3

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1.2.2 Warning symbols used
Symbol Meaning
Danger
Danger due to electrical shock and discharge
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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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
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. 3: Symbols and icons used
Abbreviations used
Abbreviation Explanation
Tab. Table
Fig. Figure
It. Item
Ch. Chapter

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1.4 Labels on the drive controller
Fig. 4: 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 electrical shock and discharge.
Wait two minutes (discharge time of the capacitors) after shut-down
Additional earth connection
Observe and read operating manual

General information
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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 must
be observed.
Commissioning (i.e. beginning intended operation) is only permitted if the EMC Directive
(2014/30/EU) is complied with.
The harmonised standards of DIN EN 50178; VDE 0160 must be applied for this drive controller
along with DIN EN 61439-1/DIN EN 61439-2; VDE 0660-600.
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.
IMPORTANT INFORMATION
External mechanical loads 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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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, “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
KOSTAL Industrie Elektrik GmbH hereby declares that the drive controller described in this
document complies with the basic requirements and other relevant conditions of the directives
listed below.
Directive 2014/30/EU
(on the approximation of the laws of the Member States relating to electromagnetic
compatibility (EMC)).
Directive 2014/35/EU
(on the harmonisation of the laws of the Member States relating to the making available on
the market of electrical equipment designed for use within certain voltage limits – for short:
Low Voltage Directive).
You will find a detailed EU Declaration of Conformity at:
www.kostal.com/industrie/download/de/Antriebstechnik

General information
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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.

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IMPORTANT INFORMATION
The drive controller can only be operated safely if the required environmental conditions
listed in the “Suitable environmental conditions” chapter are met.
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 electrical shock!
Death or serious injury!
Always ground the device in accordance with DIN EN 61140; VDE 0140, NEC
and other relevant standards.
The drive controller must be grounded with the motor according to relevant
regulations. Non-compliance may result in death or serious injury.
If spring elements are not used when assembling the adapter plate, there must
be an extra connection between the motor and drive controller to produce a
correct protective conductor connection.
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.

General information
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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.
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
(only with INVEOR A [1 x 230 V AC])
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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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.
The following terminals may lead to dangerous currents even when the motor is
not running:
Supply terminals X1: L1, L2, L3
Motor connection terminals X2: U, V, W
Connecting terminals X6, X7: Relay contacts for relays 1 and 2
PTC terminals T1/ T2
IMPORTANT INFORMATION
Only use mains connections with hardwiring.
Ground the drive controller in accordance with DIN EN 61140;
VDE 0140-1.
The INVEOR 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 under the mains
supply (position marked with a ground symbol) on the outside of the device. A suitable
M6 x 12 screw (4.0 Nm torque) is provided with the adapter plate.
If three-phase frequency inverters 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).

General information
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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.