Kostal INVEOR MA User manual

Operating manual
INVEOR
Betriebsanleitung_INVEOR_A5.indd 1 28.02.11 10:33

2Operating manual INVEOR
LEGAL NOTICE
KOSTAL Industrie Elektrik GmbH
An der Bellmerei 10
58513 Lüdenscheid
Deutschland
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Exclusion of liability
All names of usage, trade names, product names or other designations given
in this manual may also be legally protected even without special labelling
(e.g. as a trademark). The KOSTAL company assumes no liability for their free
usage.
The illustrations and texts have been compiled with great care. Nevertheless,
the possibility of errors cannot be ruled out. The compilation is made without
any guarantee.
General note on equal treatment
The KOSTAL company publishers are aware of the meaning of language with
regard to the equality of women and men and always make an effort to reflect
this in the documentation. The continuous rendition of gender-equitable
formulations, however, conflicted with the easy readability of the text. For this
reason, the masculine form has been used as a rule.
© 2011 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. The 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 INVEOR 3
Table of contents
1Important information ........................................................................................................ 6
1.1 Notes on the documentation........................................................................................ 6
1.1.1 Other applicable documents ........................................................................... 6
1.1.2 Storing the documentation .............................................................................. 6
1.1.3 Symbols.......................................................................................................... 6
1.2 Qualified staff ............................................................................................................... 7
1.3 CE marking .................................................................................................................. 7
1.4 Safety instructions........................................................................................................ 7
1.4.1 General information ......................................................................................... 8
1.4.2 Transport & storage ........................................................................................ 9
1.4.3 Commissioning ............................................................................................. 10
1.4.4 Operation ...................................................................................................... 11
1.4.5 Repairs.......................................................................................................... 12
1.4.6 Disassembly & disposal................................................................................. 12
1.5 Proper use ................................................................................................................. 13
1.6 Responsibility............................................................................................................. 13
1.7 Contacts for information............................................................................................. 14
2Overview of the drive control ........................................................................................... 15
2.1 Model description ...................................................................................................... 15
2.2 Scope of delivery ....................................................................................................... 16
2.3 Description of the INVEOR drive control ..................................................................... 17
3Installation....................................................................................................................... 17
3.1 Safety instructions during installation.......................................................................... 17
3.2 Installation requirements ............................................................................................ 18
3.2.1 Suitable ambient conditions .......................................................................... 18
3.2.2 Suitable installation location for the motor integrated drive control................. 19
3.2.3 Basic connection versions............................................................................. 19
3.2.4 Short circuit and ground protection ............................................................... 20
3.2.5 Wiring instructions......................................................................................... 21
3.2.6 Preventing electromagnetic interferences ...................................................... 22
3.3 Installing the drive control integrated in the motor ...................................................... 22
3.3.1 Mechanical installation................................................................................... 22
3.3.2 Power connection ......................................................................................... 25
3.3.3 Connections for brake resistor....................................................................... 26
3.3.4 Control connections ...................................................................................... 26
3.3.5 Terminal connection diagram ........................................................................ 29
3.4 Installing the wall-mounted drive control..................................................................... 29
3.4.1 Suitable installation location for wall mounting ............................................... 29
3.4.2 Mechanical installation................................................................................... 31
3.4.3 Power connection ......................................................................................... 35
3.4.4 Brake chopper .............................................................................................. 35
3.4.5 Control connections ...................................................................................... 35
4Commissioning ............................................................................................................... 36
4.1 Safety instructions during commissioning................................................................... 36
4.2 Communication.......................................................................................................... 37
4.3 Block diagram............................................................................................................ 38
4.4 Start-up steps............................................................................................................ 39

4Operating manual INVEOR
5Parameters ..................................................................................................................... 40
5.1 Safety instructions for dealing with parameters .......................................................... 40
5.2 General information on parameters ............................................................................ 40
5.2.1 Explanation of operating modes .................................................................... 40
5.2.2 Structure of the parameter tables .................................................................. 44
5.3 Application parameters .............................................................................................. 45
5.3.1 Basic parameters .......................................................................................... 45
5.3.2 Preset speed mode....................................................................................... 51
5.3.3 Motorized potentiometer ............................................................................... 52
5.3.4 PID process controller ................................................................................... 53
5.3.5 Analogue inputs ............................................................................................ 56
5.3.6 Digital inputs ................................................................................................. 58
5.3.7 Analogue output............................................................................................ 59
5.3.8 Digital outputs ............................................................................................... 60
5.3.9 Relay............................................................................................................. 61
5.3.10 External fault ................................................................................................. 63
5.3.11 Motor current limit ......................................................................................... 63
5.3.12 Stall detection ............................................................................................... 64
5.4 Performance parameters............................................................................................ 65
5.4.1 Motor data .................................................................................................... 65
5.4.2 I2T68
5.4.3 Switching frequency ...................................................................................... 69
5.4.4 Controller data .............................................................................................. 69
5.4.5 Squared characteristic .................................................................................. 72
5.4.6 Synchronous motor controller data ............................................................... 72
6Error detection and troubleshooting................................................................................. 74
6.1 List of the LED flash codes for error recognition ......................................................... 74
6.2 List of errors and system errors.................................................................................. 76
7Technical data ................................................................................................................ 79
7.1 General data .............................................................................................................. 79
8Optional accessories....................................................................................................... 81
8.1 Adapter plates ........................................................................................................... 81
8.1.1 Motor adapter plates..................................................................................... 81
8.1.2 Motor adapter plates (specific) ...................................................................... 83
8.1.3 Wall adapter plates (standard) ....................................................................... 83
8.2 MMI manual control unit including a 3 m RJ11 connection cable on an M12 plug...... 85
8.3 PC communication cable USB on M12 plug (converter RS485/RS232 integrated)..... 85
9Guidelines, Norms and Standards ................................................................................... 86
9.1 EMV limit classes ....................................................................................................... 86
9.2 Classification acc. to IEC/EN 61800-3 ....................................................................... 87
9.3 Standards and guidelines........................................................................................... 87
9.4 Required markings for UL .......................................................................................... 87
9.5 Quickstart guide......................................................................................................... 89
9.5.1 Quickstart guide for asynchronous motors .................................................... 89
9.5.2 Quickstart guide for synchronous motors ...................................................... 90
10 Stichwortverzeichnis..................................................................................................... 95

Operating manual INVEOR 5
Overview of installation sizes
L
H
B
Dimensioned drawings
The drive controls are available in the following performance classes and
under the specified installation size names.
Installation size
INVEOR
motor integrated
MA MB MC MD
Recommended
motor power [kW]
0.55 / 0.75 / 1.1
/ 1.5 2.2 / 3.0 / 4.0 5.5 / 7.5 11.0 / 15.0 / 18.5 / 22.0
Dimensions
[L x B x H] mm 233 x 153 x 120 270 x 189 x 133 307 x 223 x 181 414 x 294 x 238
Installation sizes

Important information
6Operating manual INVEOR
1Important information
This chapter contains important information on the safe handling of the
product and on the operating manual.
1.1 Notes on the documentation
The following notes are a directory for the overall documentation.
We assume no liability for any damage resulting from the non-observance of
this manual.
Provide this manual to the operator of the system so that it will be available
when required.
1.1.1 Other applicable documents
This refers to all manuals that describe how to operate the drive control
system, and any other manuals for equipment parts in use. Download the 3D
files (.stp) for INVEOR and adapter plates under www.kostal.com/industrie.
A parameter description is available for download (www.kostal.com/industrie)
for parameterising the drive control system. In the download, you will find al
the information required for correct parameterising.
1.1.2 Storing the documentation
Store this manual and all other applicable documents safely so they will be
available when required.
1.1.3 Symbols
DANGER
Note on safety: Non-observance will result in death or serious injury.
WARNING
Note on safety: Non-observance can lead to death or serious injury.

Important information
Operating manual INVEOR 7
ATTENTION!
Non-observance can result in material being damaged and can affect the
function of the drive control.
Supplemental information on operating the drive control.
Action: This symbol indicates that you have to perform an action. The
required actions are described step by step.
This symbol indicates the result of an action.
1.2 Qualified staff
In the context of this operating manual and the notes relating to the product
itself, qualified staff refers to electronic specialists that are familiar with the
installation, assembly, start-up and operation of the drive control and with the
dangers involved, and whose specialist training and knowledge of relevant
standards and regulations provide them with the necessary abilities.
1.3 CE marking
With the CE marking, we as the manufacturer of the device confirm that the
drive control meets the basic requirements of the following guidelines:
– Directive on Electromagnetic Compatibility (Directive 2004/108/EC of the
Council)
– Low Voltage Directive (Directive 2006/95/EC of the Council)
You will find the declaration of conformity for download on
www.kostal.com/industrie.
1.4 Safety instructions
The following warnings, precautionary measures and comments are provided
for your safety and serve to prevent damage to the drive control and the
components connected to it. This chapter contains warnings and notes that
are generally applicable when handling drive controls. They are separated into
general information, transport & storage, start-up, operation, repair and
dismantling & disposal.
Specific warnings and comments that apply to specific activities are placed at
the start of the appropriate chapters and are repeated and enhanced at
different critical points within these chapters.

Important information
8Operating manual INVEOR
Please read this information carefully, as it is provided for your personal safety
and will also support a longer life for the drive control and the connected
devices.
1.4.1 General information
WARNING
This drive control contains dangerous voltage and controls revolving
mechanical parts that may be dangerous.
Disregarding warnings or non-compliance with the notes in this manual can
result in death, serious injury or serious damage to property.
Only appropriately trained persons may perform work on this drive control.
These persons must be familiar with all safety instructions and all measures
relating to installation, operation and maintenance that are contained in this
manual. Proper and safe operation of the drive control requires proper
transport, installation, operation and maintenance.
WARNING
Danger of fire or electric shock.
Improper use, changes and the use of spare parts and accessories not sold
or recommended by the manufacturer of the drive control can cause fire,
electric shock and injury.
The cooling elements in the drive control and motor can reach
temperatures above 70 °C. Ensure that there is sufficient distance from
neighbouring components during installation. Allow sufficient cooling time
before working on the drive control or the motor. If necessary, protection
should be installed against accidental contact.
ATTENTION!
The drive control can only be operated safely if the required environmental
conditions listed in the “Suitable environmental conditions” chapter are
fulfilled.

Important information
Operating manual INVEOR 9
ATTENTION!
This operating manual must be accessible near the device and available to
all users.
ATTENTION!
Please read these safety instructions and warnings before installation and
start-up; this also applies to all warning signs attached to the device. Make
sure that the warning signs are legible and replace missing or damaged
signs.
1.4.2 Transport & storage
ATTENTION!
Risk of damaging the drive control.
If the notes are not observed, the drive control could be damaged and
destroyed during subsequent start-up.
Proper and safe operation of the drive control requires proper storage, set-
up and assembly as well as careful operation and maintenance.
The drive control must be protected from mechanical jolts and vibrations
during transport and storage. Protection from impermissible temperatures
(see technical data) must also be guaranteed.

Important information
10 Operating manual INVEOR
1.4.3 Commissioning
WARNING
Danger of injury through electric shock.
Non-observance of warnings can result in serious injury or damage.
Only hard-wired network connections are permitted. The device must be
grounded (DIN EN 61140; VDE 0140-1).
Frequency inverters of the INVEOR series can contain contact currents
(leakage currents) > 3.5 mA. According to chapter 4.3.5.5.2 of DIN EN
61800-5-1, a reinforced protective ground wire (at least 10 mm2Cu or
16 mm2Al) must be used.
If three-phase frequency inverters are in use, it is not permitted to use
standard type A FI protection switches, or RCDs (residual current-operated
protective devices) to protect from direct or indirect contact. According to
DIN VDE 0160, section 5.5.2 and EN 50178, section 5.2.11.1, the FI
protection switch must be universal current sensitive (RCD type B).
The following terminals can 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
If different voltages are in use (e.g. +24 V/230 V), crossing cable runs are
never permitted. The operator must also ensure compliance with the
applicable regulations (e.g. double or strengthened insulation acc. to DIN
EN 61800-5-1).
The drive control contains components susceptible to electrical discharge.
These components can be destroyed through improper handling;
therefore, precautionary measures against electrostatic charges must be
taken when work is performed on these components.

Important information
Operating manual INVEOR 11
1.4.4 Operation
WARNING
Danger of injury due to electric shocks or restarting motors.
Non-observance of warnings can result in serious injury or damage.
Observe the following instructions during operation:
– The drive control works with high voltages.
– When electrical devices are operated, some parts of them are always
subject to dangerous voltage.
– Emergency off equipment according to DIN EN 60204-1; VDE 0113-
1:2007-06 has to be functional in all operating modes of the control
device. 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 all-pole disconnected from the drive control.
– Certain parameter settings can result in the drive control restarting
automatically after the supply voltage has failed.
ATTENTION!
Risk of damaging the drive control.
If the notes are not observed, the drive control could be damaged and
destroyed during subsequent start-up.
Observe the following instructions during operation:
– The motor parameters, especially the l2T settings, have to be configured
properly to provide proper motor overload protection.
– The drive control contains internal motor overload protection. See
P0610 (level 3) and P0335. I2T is ON by default. Motor overload
protection can also be ensured via an external PTC.
– The drive control may not be used as “Emergency-off equipment” (see
DIN EN 60204-1; VDE 0113-1:2007-06).
– Drive controls are maintenance-free if operated properly. If the air
contains dust, the cooling fins of the motor and drive control have to be
cleaned regularly.

Important information
12 Operating manual INVEOR
1.4.5 Repairs
ATTENTION!
Risk of damaging the drive control.
If the notes are not observed, the drive control could be damaged and
destroyed during subsequent start-up.
Repairs of the drive control may only be performed by the KOSTAL Service
department.
WARNING
Danger of injury through electric shock.
Non-observance of warnings can result in serious injury or damage.
When the drive control is disconnected from the mains voltage, parts and
connections of the device subject to current may not be touched
immediately in case the condensers are still charged.
1.4.6 Disassembly & disposal
Screw and snap-on connections are easy to release and
allow the drive control to be dismantled into its individual
parts. These parts can be sorted for recycling. Please
comply with local regulations during disposal.
Components with electronic parts may not be placed in
normal household waste. They have to be collected
separately with old electric and electronic equipment in
accordance with applicable legislation.

Important information
Operating manual INVEOR 13
1.5 Proper use
If the device is installed in a machine, inverters may not be started up (i.e.
intended operation may not begin) until it has been determined that the
machine complies with the regulations in EC Directive 2006/42/EC (machine
directive); DIN EN 60204-1; VDE 0113-1:2007-06 must be observed.
Start-up (i.e. beginning intended operation) is only permitted if the EMV
Directive (2004/108/EC) is complied with.
The harmonised standards of series DIN EN 50178; VDE 0160:1998-04 have
to be applied for this drive control along with DIN EN 60439-1; VDE 0660-
500:2005-01.
This drive control 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 can result in death, injury and damage. The
warranty provided by KOSTAL will be invalidated in this case.
External mechanical loads such as stepping on the housing are not
permitted.
Using drive units 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.
1.6 Responsibility
As a basic principle, electronic devices are not fail-proof. The operator and/or
the contractor setting up the machine or system is responsible for ensuring
that the drive is moved to a safe state if the device fails.
Section “Electrical equipment of machines” in DIN EN 60204-1; VDE 0113-
1:2007-06, “Safety of machinery” describes the safety requirements for
electric control units. These are provided for the safety of persons and
machines, and in order to retain the functional capability of the machine or
system; they have to be observed.
The function of an emergency-off feature does not have to result in the power
supply for the drive being switched off. In order to prevent danger, it can be
useful to keep individual drives in operation or initiate specific safety
procedures. The performance of emergency-off measures is evaluated by

Important information
14 Operating manual INVEOR
means of a risk assessment for the machine or system and its electrical
equipment, and is determined with a selection of the circuit category
according to DIN EN 13849 “Safety of machinery – Safety-related parts of
control systems”.
1.7 Contacts for information
Further information is available from:
Central service hotline
Tel: [phone]
Monday to Friday: 7.00 to 17.00 (local time)
Fax: [phone]
Email: [e-mail]
Internet address
Customers can access technical and general information from the following
address:
www.kostal.com/industrie

Overview of the drive control
Operating manual INVEOR 15
2Overview of the drive control
This chapter contains information on the scope of delivery for the drive control
and the function description.
2.1 Model description
Fig. 1: Article description
Key
1 Drive control series: INVEOR
2 Installation location/installation size: M–
integrated into a motor, installation size: A, B,
C, D
6 Housing: G0 – standard (black with
inscription);
0– standard (cooling element);
0– standard (with potentiometer); 00 –
standard screw connections
7 Firmware version: S00 – standard
3 Input voltage: 4– 400 V 8 Versions: 000 – standard; 001 – specific
4 Recommended motor power: 0.55; 0.75;
1.1; 1.5; 2.2; 3; 4; 5.5; 7.5; 11; 15; 18.5; 22
kW
9 Equipment generation: 1– current version
5 Printes circuit board: L00 – standard (without
brake chopper);
A00 – standard (without TTL evaluation);
–standard (without field bus)

Overview of the drive control
16 Operating manual INVEOR
2.2 Scope of delivery
Compare your product to the scope of delivery described below.
1
2
3
4
7
6
5
8
Fig. 2: Scope of delivery
Key
Drive control article number Adapter plate article number
1 Drive control (variant) 5 Adapter plate with connecting terminal
2 Poly bag with fastening bolts 6 Poly bag with connecting material for
terminal block
3 Cable screw connections
4 Operating manual
7 Seal (not part of the scope of delivery)
8 Motor (not part of the scope of delivery)

Installation
Operating manual INVEOR 17
2.3 Description of the INVEOR drive control
The INVEOR drive control is a device for speed control in three-phase a.c.
motors.
The drive control can be integrated in the motor (with the standard adapter
plate) or close to the motor (with the wall installation adapter plate).
The permitted ambient temperatures specified under Technical data refer to
operation at nominal load. In many cases of application, higher temperatures
may be permitted after a detailed technical analysis. These have to be
approved by KOSTAL for each individual case.
3Installation
3.1 Safety instructions during installation
WARNING
Installation may be performed only be appropriately qualified employees
who are trained in the set-up, installation, start-up and operation of the
product. Work performed on the drive control by unqualified staff and non-
observance of warnings can result in serious injury or damage.
The device must be grounded in accordance with DIN EN 61140; VDE
0140, NEC and other relevant standards. Mains connections must be
hardwired.

Installation
18 Operating manual INVEOR
3.2 Installation requirements
3.2.1 Suitable ambient conditions
Altitude of the installation
site:
up to 1,000 m above sea level / over 1,000 m with reduced
performance (1% per 100 m) (max. 2,000 m)
Ambient temperature: -25 °C to +50 °C (different ambient temperatures may be possible
in individual cases)
Relative humidity: ≤96%, condensation not permitted
Resistance to vibration and
shock:
acc. to FN 942 017 part 4; 5.3.3.3 Combined test 2;
5...200 Hz for sinusoidal oscillation
Electromagnetic
compatibility:
Immune to interference acc. to DIN EN 61800-3
Cooling: Surface cooling:
installation sizes A to C: free convection;
installation size C: optionally with integrated fan
installation size D: with integrated fans
Tab. 1: Ambient conditions
Make certain that the housing type (protection type) is suitable for the
operating environment:
– Ensure that the seal between the motor and the adapter plate is inserted
correctly.
– All unused cable screw connections have to be sealed.
– Check that the cover of the drive control is closed and bolted down
tightly.
Although the drive control can, in principle, be subsequently painted, the user
must nevertheless check the material compatibility of the paint that is to be
used. A failure to comply with this can eventually result in the loss of the
protection class (particularly in respect of seals and fibre-optic elements). The
standard colour is black (RAL 9005).
Disassembling the circuit boards (even for the purpose of painting the
housing sections) renders the warranty void!
Mounting points and sealing surfaces must be kept free of paint for purposes
of EMC and earthing!

Installation
Operating manual INVEOR 19
3.2.2 Suitable installation location for the motor integrated drive
control
Ensure that the motor with a motor integrated drive control is only installed
and operated if aligned as shown in the following image.
Fig. 3: Motor installation location/permitted alignments
3.2.3 Basic connection versions
Fig. 4: Star or triangle connection for drive controls integrated in the motor

Installation
20 Operating manual INVEOR
ATTENTION!
Risk of damaging the drive control.
The correct phase sequence must be observed when the drive control is
connected, as the motor could otherwise be overloaded.
Ensure that the phase sequence is correct when connecting the motor.
The supplied assembly material can be used to connect core end sleeves
and cable shoes. Fig. 4 shows the different connection options.
Unused open cable ends in the motor terminal box must
be insulated.
If a PTC or Klixxon is used, the electric jumper fitted on
the connection terminal for the PTC in the delivery state
has to be removed.
The cross-section of the supply line has to be designed according to the
transfer category and the maximum permitted current. The contractor starting
up the device must ensure the power line protection.
3.2.4 Short circuit and ground protection
The drive control contains an internal short circuit and ground protection.