Lenze 530 series User manual

Operating Instructions
L
Speed controllers
530 series
EDB530_E/GB
00460234

These operating instructions are valid for controllers with the nameplate
designation
531__ E
.
3A
532__ E
.
3A
533__ E
.
3A
534__ E
.
3A
Controller type
Chassis type
Hardware version + index
Edition of: 05/1996
revised: 12/2002

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How to use this manual ...
To locate information on specific topics, simply refer to the table of contents at
the beginning and to the index at the end of this manual.
The manual uses a series of different symbols to provide quick reference and
to highlight important items.
This symbol refers to items of information intended to facilitate operation.
Notes which should be observed to avoid possible damage to or destruction of
equipment.
Notes which should be observed to avoid health risks to the operating
personnel.

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Safety and application notes
for drive controllers
(according to: Low Voltage Directive 73/23/EWG)
1. General
During operation, drive controllers may have, according to their type of
protection, live, bare, in some cases also movable or rotating parts as well as
hot surfaces.
Unauthorized removal of the required cover, inappropriate use, incorrect
installation or operation, creates the risk of severe personal injury or damage to
material assets.
Further information can be obtained from the documentation.
All operations concerning transport, installation, and commissioning as well as
maintenance must be carried out by qualified, skilled personnel (IEC 364
and CENELEC HD 384 or DIN VDE 0100 and IEC report 664 or DIN VDE 0110
and national regulations for the prevention of accidents must be observed).
Qualified skilled personnel according to this basic safety information are
persons who are familiar with the erection, assembly, commissiong, and
operation of the product and who have the qualifications necessary for their
occupation.
2. Application as directed
Drive controllers are components which are designed for installation into
electrical systems or machinery.
When installing into machines, commissioning of the drive controllers (i.e. the
starting of operation as directed) is prohibited until it is proven that the machine
corresponds to the regulations of the EC directive 89/392/EWG (Machinery
Directive); EN 60204 must be observed.
Commissioning (i.e. starting of operation as directed) is only allowed when
there is compliance with the EMC Directive (89/336/EWG).
The drive controllers meet the requirements of the Low Voltage Directive
73/23/EWG. The harmonized standards of the prEN 50178/ DIN VDE 0160
series together with EN 60439-1/DIN VDE 0660 part 500 and EN 60146/DIN
VDE 0558 are applicable to drive controllers.
The technical data and information about the connection conditions must be
obtained from the nameplate and must be observed in all cases.
3. Transport, storage
Notes for transport, storage and appropriate handling must be observed.
Climatic conditions must be observed according to prEN 50178.

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4. Erection
The devices must erected and cooled according to the regulations of the
corresponding documentation.
The drive controllers must be protected from inappropriate loads. Particularly
during transport and handling, components must not be bent and/or insulation
distances must not be modified. Touching of electronic components and
contacts must be avoided.
Drive controllers contain electrostatically sensitive components which can
easily be damaged by inappropriate handling. Electrical components must not
be damaged or destroyed mechanically (health risks are possible!).
5. Electrical connection
When working on live drive controllers the valid national regulations for the
prevention of accidents (e.g. VBG 4) must be observed.
The electrical installation must be carried out according to the appropriate
regulations (e.g. cable cross-sections, fuses, PE connection). More detained
information is included in the documentation.
Notes concerning the installation in compliance with EMC - like screening,
grounding, arrangement of filters and laying of cables - are included in the
documentation of the drive controllers. These notes must also be observed in
all cases for drive controllers with the CE mark. The compliance with the
required limit values demanded by the EMC legislation is the responsibility of
the manufacturer of the system or machine.
6. Operation
Systems where drive controllers are installed must be equipped, if necessary,
with additional monitoring and protective devices according to the valid safety
regulations, e.g. law on technical tools, regulations for the prevention of
accidents, etc. Modifications of the drive controllers and the operating software
are prohibited.
After disconnecting the drive controllers from the supply voltage live parts of the
controller and power connections must not be touched immediately because of
possibly charged capacitors. For this, observe the corresponding labels on the
drive controllers.
During operation, all covers and doors must be closed.
7. Maintenance and servicing
The manufacturer´s documentation must be observed.
This safety information must be preserved!
The product specific safety and application notes in these operating
instructions must also be observed!

4L
Contents
1 Features of the 530 series of controllers 5
2 Technical data 6
2.1 Controller-specific data 6
2.2 Dimensions 7
2.3 Scope of supply 8
2.4 Application as directed 8
3 Accessories 9
4 Installation 13
4.1 Installation 13
4.2 Connection 13
4.2.1 Installation corresponding to EMC 16
4.2.2 CE-typical drive system 17
4.3 Connecting voltage 20
4.4 Replacing the fuses 21
4.5 Connection diagram 22
5 Setting 24
5.1 Selection of the current range for type 534 24
5.2 Setting the current limit 25
5.3 Speed setting 25
6 Operating modes 27
6.1 Switching operation 27
6.1.1 Controller enable 27
6.1.2 Controller inhibit 27
6.2 Electrodynamic braking 28
6.3 Reversing 30
Index 31

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1 Features of the 530 series of controllers
The 530 series of controllers series comprises 4 half-controlled single-quadrant
controllers with output powers from 0.36 kW to 2 kW for the operation of DC
shunt or permanent magnet motors.
•Compact single-board controllers for space-saving installation on a mounting
plate or DIN rail 35 x 7.5 mm
•Easy connection through screwless, vibration-proof plug and socket
connectors
•Protective cover prevents accidental contact of live components
•Operation with tacho or armature voltage feedback with "I x R compensation"
•Operational integrity even under mains voltage fluctuations and short-term
mains failure because of static and dynamic voltage monitoring
•Interference immunity from bad mains wave-form because of synchronizing
filter and channel separation of the firing pulses
•Compliance with the EC directive for the design of a CE-conform drive
system

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2 Technical data
2.1 Controller-specific data
Controller 531 532 533 534
Output power Pel [W] 360 720 1360 2040
Mains frequency f [Hz] 50...60
Mains voltage UL1, N
[V]
190...265
(100...132 with solder link)
Armature current
(can be changed
for 534)
IAmax [A] 2 4 8 12
Armature voltage
for VL1, N = 230 V
VA[V] 180 180 180 170
Field voltage VF[V] 0.9 x UL1,⋅N
Max. field current IFmax [A] 0.3 0.6 1.5
Perm. form factor FFmax 1.4 1.4 1.6 1.2
I ⋅R
compensation
RA[Ω]0...20 0...10 0...5 0...2.5
Rated master
voltagae
VLN [V] 10
Rated tacho
voltage
VTN [V] 10...120
Acceleration time Ti[s] 1...10
Min. speed nmin [nN] 0...0.25
Max. speed nmax [nN] 0.75...1
Ambient
temperature
during operation
Ta[°C] 0...45
Set-value pot.
type
10kΩ/ 1Wlin.
ER00322194
Fuse
type
FF6.3 / 250V
EFSFF0063ASA
FF8 / 250V
EFSFF0080A
SA
FF20 / 250 V
EFSFF0200A
SB
Weight m [kg] 0.4 1.2
Chassis type E 33.531_E 33.532_E 33.533_E 33.534_E
Operating
instructions
type
EDB0530/D/GB

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2.2 Dimensions
Type 531
1)
2)
a
b
c
d
1) Jumper "BR1", "BR2" (change 230 V / 120 V)
2) Jumper "BR3" (nmax setting)
Type a [mm] b [mm] c [mm] d [mm]
531 35 160 150 100
Types 532 and 533 Type 534
a
b
c
d
e
f
g
∅
2)
1)
h
I
x
R
L
530
T
i
n
min
max
n
I
max
a
b
c
d
e
2)
1)
∅
f
g
I
x
R
I
max
L
530
max
n
n
min
T
i
1) Jumper "BR1", "BR2" (change 230 V / 120 V)
2) Jumper "BR3" (nmax setting)
Type a [mm] b [mm] c [mm] d [mm] e [mm] f [mm] g [mm] h [mm] ∅
∅∅
∅[mm]
532, 532 120 109 95 7 22.5 45 127 - 4.5
534 120 109 95 7 88 100 150 6 4.5

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2.3 Scope of supply
The scope of supply includes:
•the controller 53x_E
•the operating instructions
•the set-value potentiometer 10 kΩ
•plug-in terminals
2.4 Application as directed
•The controllers of the types 53x are electrical equipment for installation into
control cabinets of electrical systems or machinery.
•The controllers of the types 53x are designed as components for the control
of speed-variable drives with separately-excited DC motors or for the
assembly with other components to form a machine or system.
•Drive systems with drive controllers 53x which are installed according to the
definition of a CE-typical drive system (see chapter 4.2.2), correspond to the
EC EMC Directive and the standards mentioned below.
CE-typical drive systems are
- suitable for the operation on public and non-public mains and
- provided for industrial applications.
•Because of the ground potential reference of the RFI filters, the CE-typical
drive system which is described is not suitable for the connection to IT mains
(mains without ground potential reference).
•The drive controllers are not domestic appliances, but they are designed for
drive systems for commercial use.
•The controllers of the types 53x themselves are not machines according to
the EC Machinery Directive. The final function is only determined when
integrated into the machine construction of the user.
•The user must consider measures in his machine construction which limit the
consequences in case of malfunction or failure of the drive controller
(increase of the motor speed or sudden motor stop) so that hazards for
persons or material assets cannot be caused, such as:
−further independent equipment for the monitoring of safety-relevant
variables (speed, travel, end positions, etc.)
−electrical or non-electrical protective equipment (latching or mechanical
blocking)
−measures covering the complete system

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3 Accessories
Type 531 532 533 534
Armature choke Suitable types depend on motor type
Mains choke
Type
−
−
−
−
−
−
2.5 mH, 18 A
ELN1_0250H018
RFI filter
Type EZF1_004A001 EZF1_01812A001
Spring kit for DIN
rail 15 mm
Type −EJ00329026 −EJ00329061
Knob for pot.
Type ER00308273
Scale for pot.
Type ER00308274
Support for plug-
in boards
Type
EJ00304817 −
Interference
suppression
module
Typ
EZ00341588
Zinc-oxide
varistor
Type
S20 K275
307 957
B32 K275
308 935

10 L
Mains choke
a
f
c
m
k
e
d
b
n
Mains choke for
type 534
L
[mH
]
I
[A]
a
[mm
]
b
[mm
]
c
[mm
]
d
[mm
]
e
[mm
]
f
[mm
]
k
[mm
]
m
[mm
]
n
[mm
]
Weigh
t
[kg]
ELN1_0250H018 2.5 18 96 77 84 61 96 87 90 5.5 9 2.4

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RFI filter (Vmax = 250 V ±0 %)
a
bd
ef
g
c
h
Design A
e
d
b
c
f
a
Design B
Types Filter
[Type]
Desi
gn
a
[mm
]
b
[mm
]
c
[mm
]
d
[mm
]
e
[mm
]
f
[mm
]
g
[mm
]
h
[mm
]
Fixing
531...53
3
EZF1_004A001 A 91.5 70 40 51 63.5 30 33 60.4 2 x M4
534 EZF1_018A001 B 116 85 39 108 50.8 100 - - 4 x M6

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Armature choke
a
f
c
m
k
e
d
b
n
Armature choke L
[mH]
I
[A]
a
[mm]
b
[mm]
c
[mm]
d
[mm]
e
[mm]
f
[mm]
k
[mm]
m
[mm]
n
[mm]
ELK_440H004 40 4,4 104 82 84 66 100 92 100 5.8 11
ELK_500H002 50/15 2/10 120 100 90 84 107 103 115 5.8 11
ELA_400H010 40/12 10/18 150 122 121 101 130 132 140 7.0 13
The suitable type of armature choke depends on the motor type.

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4 Installation
4.1 Installation
The chassis-type controller is to be installed in a vertical position, with the
terminals at the bottom, to ensure sufficient cooling and air circulation. The
ambient temperature mut not exceed +45°C.
Unwanted voltages fed back from the controllers to the supply mains are
reduced by the connection of mains chokes and RFI filters. The components
allocated to type 53x are listed in chapter 3 "Accessories".
4.2 Connection
•The controllers contain electrostatically sensitive components. Prior to
assembly and servicing the personnel must be free of electrostatic charges.
Discharging is possible by touching the PE fixing scew or another grounded
metal part in the control cabinet.
•If you use residual current devices:
−The controllers have an internal mains rectifier. After a short-circuit to
frame a DC fault current may prevent the tripping of the residual current
device. Therefore, take additional measures like zeroing or use universal
current e.l.c.b.
−Observe for the dimensioning of the release current of e.l.c.b. that
capacitive compensating currents of the cable screens and RFI filters
occuring during normal operation may cause false tripping.
−Note for the use of universal e.l.c.b.:
The preliminary standard prEN50178 (in the past VDE0160) about the use
of universal e.l.c.b. has been decided by the German committee K226.
The final decision about the use in compliance with the standard is made
by the CENELEC/CS (European Committee for Electrotechnical
Standardization) in Brussels. Further information on the use of universal
current e.l.c.b. can be obtained from the supplier.

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•The plug connector is suitable for the connection of solid wire or single or
multi-strand conductors of cross-sections between 0.14 and 2.5 mm². The
length of the free wire should be between 8 and 9 mm. It is not necessary to
use ferrules.
1
2
3
12
3
Before removing the protective cover, switch-off the controller and remove the
connectors.
Warning
All controller terminals carry mains potential. It is therefore necessary that
all input and output signals required for the control of the controller are,
electrically, safely separated by measures outside the controller and have
another protection against direct contact (double basic insulation).
When using the supplied set-value potentiometer the mechanical fixing
must have an additional PE connection and the connections must be
insulated and covered.
Prior to commissioning make sure that there is no earth fault in the connecting
cables. The protective conductor must only be connected to the PE connection
(6.3-mm spade connector). PE or ground connections to any other terminals
cause a controller failure.
Screen motor cables A, B, I and K as well as the control cables. The screen
must be connected at both ends to the central PE connection. The control
cables must not be longer than 10 m. Check the voltage rating of the screened
cable.
To ensure that the screening is effective, it should not be opened or interrupted.
It should also be laid as close as possible at the cable ends. Connect the
screening of the motor cables to PE in the motor terminal box.

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If the cable between RFI filter and controller is longer than 200 mm, use
screened mains cables. The ground chassis connection should have as low a
resistance and as large a surface as possible.
Type 53x can be used for operation with armature voltage or tacho feedback
(see chapter 4.5 "Connecting diagram").
In case of armature voltage control with "I x R compensation" insert a jumper
between terminal 2 and terminal 4.
Caution!
At terminals 2/4 and 3/4 only the feedback system used must be
connected.
For master voltage operation remove the set-value potentiometer and apply the
master voltage across terminal 7 (-) and terminal 8 (+).
Caution!
The master voltage must be free of mains and ground potential. Several
controllers can only be operated from a master voltage when they are
electrically isolated.
Note for the connection of controller and motor
Lenze controller Motor (acc. to DIN 42017 / VDE 0530 part 8)
Function Terminal Terminal other
designations
Motor type
Armature voltage +
-
Excitation voltage +
-
A
B
I
K
1B1
2B2
F1
F2
A1
B2, A2
E1
E2
DC motor uncompensated
with commutating pole
winding
Armature voltage +
-
Excitation voltage +
-
A
B
I
K
1C1
C2
F1
F2
A1
C2
E1
E2
DC motor compensated
with commutating pole
winding
Armature voltage +
-
A
B
A1
A2
Permanent magnet motor
DC tacho +
-
3
4
2A1
2A2
AC tacho +
with rectification -
3
4
3A1
3A2

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4.2.1 Installation corresponding to EMC
•Controllers cannot be operated on their own. The EMC of controllers on their
own cannot be tested. Only the integration of the controllers into a drive
system allows a test whether the objectives of the EC EMC Directive are met
and whether the device are in compliance with the law about the
electromagnetic compatibility of equipment.
•Lenze has done conformity tests with the controllers of the types 53x in
certain, defined drive systems. These tested drive systems are called "CE-
typical drive system" in the following.
•Therefore, the user of the controller has the choice,
−either to determine the system components and their integration into a
drive system himself and to determine the conformity under his own
responsibility
−or to install the drive system according to the CE-typical drive system as
tested by the manufacturer of the controller and declared to be in
compliance.
•If you observe the following measures you can assume that EMC problems
caused by the drive system will not arise during the operation of the machine
and the EMC Directive and the EMC law are satisfied.
•For any other installation, e.g.
−use of unscreened cables,
−use of collective RFI filters instead of the allocated RFI filters,
−omission of mains chokes
the machine or system must be tested whether it is compliance with the EC
EMC Directive and the EMC limit values are considered.
•The compliance with the EMC Directive in the machine application is
the responsibility of the user.

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4.2.2 CE-typical drive system
Components of a CE-typical drive system
System components Specification
Controller Controller of the types 531 to 534
RFI filter Data and allocation see chapter 3 "Accessories"
Mains choke Data and allocation see chapter 3 "Accessories"
Armature and field cable Screened power cable with tinned E-CU braid with
85 % optical coverage.
Tested maximum length: 50 m
Mains cable between RFI filter and
mains choke and between mains
choke and controller
As from cable length of 200 mm:
screened power cable with tinned E-CU braid with
85 % optical coverage.
Control cables Screened signal cable type LIYCY
Motor DC motor with separate excitation
Lenze series GFQ, GFR or similar
Note:
Controller, RFI filter, and mains choke are located on one mounting plate.
Installation of the CE typical drive system
The electromagnetic compatibility of a drive system depends on the type and
accuracy of the installation.
Take special care with
−filters
−screening
−grounding
Filters
•Only use the RFI filters and mains chokes allocated to the controllers (see
chapter 3 "Accessories").
−RFI filters reduce non-permissible high-frequency interferences to a
permissible value.
−Mains chokes reduce low-frequency interference which depends primarily
on the motor cables and their length.
For motor cables which are longer than 50 m additional measures are
required.
Screening
•Screen all cables from and to the controller.
•Make sure that motor cables are separated from signal and mains cables
when laying the cables.
•Avoid a common terminal board for mains input and motor output.
•The cables must be laid as close as possible to the reference potential.
Dangling cables are like antennas.

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Grounding
•Ground all conductive metal components (controllers, RFI filters, mains
chokes) by suitable cables from a central grounding point
(PE bar).
•Observe the minimum cross-sections prescribed in the safety information.
However, for EMC the surface of the contact is important and not the cross-
section.
Assembly
•Make a contact from controller, RFI filter, and mains chokes to the grounded
mounting plate with as large a surface as possible. Zinc-coated mounting
plates allow long-lasting contacts. For painted plates the paint of the
mounting plates must be removed in all cases.
•If you use several mounting plates:
−Make a conductive connection of the mounting plates with as large a
surface as possible (e.g. using copper bands).
•Connect the screen of the armature and field cable to the mounting plate with
as large a surface as possible:
−Recommendation: Make the large-surface connection of the screens to the
mounting plate with earthing clamps on bare metal mounting surfaces.
•If there are contactors, motor protection switches, or terminals in the
armature cable:
−Contact of the screens of the connected cables to each other and to the
mounting plate with as large a surface as possible.
•In the terminal box, connect the screen of the motor to PE:
−Metal cable glands at the motor terminal box ensure a large-surface
connection of the screen to the motor housing.
•If the total length of the mains cable between RFI filter and mains chokes and
controller exceeds 200 mm:
−Screen mains cables
−Connect the screen of the mains cables to the mounting plate with as large
a surface as possible.
•Connect the screen of the control cables to the mounting plate with as large a
surface as possible.