Lenze 8400 StateLine C User manual

EDS84ASC552
.A4K
Ä.A4Kä
Hardware Manual
8400 0.25 ... 22 kW
l
E84Axxxx StateLine C/HighLine C
8400 frequency inverter
L−force Drives
efesotomasyon.com - Lenze

0Fig. 0Tab. 0
efesotomasyon.com - Lenze

Contents i
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EDS84ASC552 EN 6.0
1 About this documentation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Document history 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Conventions used 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Terms and abbreviations used 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Notes used 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety instructions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General safety and application notes for Lenze controllers 11. . . . . . . . . . . . . . . . . .
2.2 General safety and application instructions for Lenze motors 14. . . . . . . . . . . . . . . .
2.3 Residual hazards 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Product description 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Device features 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Overview of standard devices 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Overview of control terminals 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Identification 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Type code 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Technical data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 General data and operating conditions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Rated data 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Overview 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Operation at rated mains voltage 230 V 30. . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.3 Operation at rated mains voltage 400 V 34. . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.4 Operation at rated mains voltage 500 V 40. . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Current characteristics 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Overcurrent operation 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Terminal description 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Overview 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 StateLine C control terminals 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 External supply voltage 24 V 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.2 Analog inputs 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.3 Analog outputs 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.4 Digital inputs 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.5 Digital outputs 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.6 Relay output connection 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.7 HighLine C control terminals 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.1 External supply voltage 24 V 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2 Analog inputs 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.3 Analog outputs 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.4 Digital inputs 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.5 Digital outputs 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.6 Relay output connection 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.7 Motor holding brake connection 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Mechanical installation 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Important notes 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Standard devices in the power range 0.25 ... 2.2 kW 62. . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Assembly in built−in technique (standard) 62. . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Assembly in push−through technique (thermal separation) 68. . . . . . . . . .
5.2.3 Mounting in "cold plate" technique 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Standard devices in the power range 3 ... 22 kW 71. . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 Assembly in built−in technique (standard) 71. . . . . . . . . . . . . . . . . . . . . . . .
5.3.2 Assembly in push−through technique (thermal separation) 77. . . . . . . . . .
5.3.3 Mounting in "cold plate" technique 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Electrical installation 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Important notes 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 Electrical isolation 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.2 Device protection 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.3 Maximum motor cable length 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.4 Motor protection 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.5 Interaction with compensation equipment 87. . . . . . . . . . . . . . . . . . . . . . .
6.1.6 Safety notes for the installation according to UL or UR 88. . . . . . . . . . . . .
6.2 Installation according to EMC (installation of a CE−typical drive system) 90. . . . . . .
6.2.1 Shielding 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2 Mains connection, DC supply 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.3 Motor cables 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.4 Control cables 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.5 Installation in the control cabinet 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.6 Wiring outside the control cabinet 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.7 Detecting and eliminating EMC interferences 99. . . . . . . . . . . . . . . . . . . . .
6.3 Devices in the power range 0.25 ... 2.2 kW (1/N/PE AC 230 V) 100. . . . . . . . . . . . . . . .
6.3.1 Example circuits 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.2 Terminal assignment of the power connections 103. . . . . . . . . . . . . . . . . . .
6.4 Devices in the power range 0.37 ... 22 kW (3/PE AC 400 V) 110. . . . . . . . . . . . . . . . . . .
6.4.1 Example circuits 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.2 Terminal assignment of the power connections 112. . . . . . . . . . . . . . . . . . .
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6.5 Common control terminals 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.1 Important notes 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.2 System bus connection (CANopen) 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.3 Relay output connection 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.4 Diagnostics 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 StateLine C control terminals 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.1 External supply voltage 24 V 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.2 Analog inputs and outputs 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.3 Digital inputs and outputs 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 HighLine C control terminals 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.1 External supply voltage 24 V 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.2 Analog inputs and outputs 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.3 Digital inputs and outputs 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.4 Motor holding brake connection 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Commissioning 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Before switching on 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Quick commissioning 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1 Keypad control 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2 Terminal control 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Braking operation 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Braking operation without additional measures 149. . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Braking operation with external brake resistor 150. . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.1 Operation at rated mains voltage 230 V 150. . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2 Operation at rated mains voltage 400 V 151. . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.3 Operation at rated mains voltage 500 V 152. . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.4 Selection of the brake resistors 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.5 Rating for Lenze brake resistors 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.6 Wiring of brake resistor 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Operation with spring−applied brake 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1 Introduction 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2 Rated data 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.3 Wiring 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Diagnostics 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 Display of operating data, diagnostics 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.1 Status display via LEDs at the controller 163. . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.2 Drive diagnostics via keypad 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contentsi
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10 Safety engineering 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Introduction 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Important notes 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.1 Hazard and risk analysis 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.2 Standards 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Overview of sensors 170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Operating mode 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5 Technical data 172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6 Electrical installation 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7 Certification 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Accessories (overview) 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1 Overview 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 Mains chokes 176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3 RFI filters 177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4 Sinusoidal filters 178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.5 External brake resistors 179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.6 Memory module 180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.7 Communication modules 181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.8 Keypad 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.9 Power supply units 183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Appendix 184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1 Total index 184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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About this documentation
Document history
1
l7
EDS84ASC552 EN 6.0
1 About this documentation
Contents
The Hardware Manual contains the complete information on the intended use of the 8400
controllers in the StateLine C and HighLine C versions.
Validity
Type Type designation From hardware version From software version
8400 StateLine C E84AVSCxxxxx0 VA 01.00
8400 HighLine C E84AVHCxxxxx0 VA 01.00
Target group
This Hardware Manual is intended for all persons who design, install, commission, and
adjust controllers of the 8400 Inverter Drives product range.
ITip!
Documentation and software updates for further Lenze products can be found
on the Internet in the "Services & Downloads" area under
http://www.Lenze.com
1.1 Document history
Material number Version Description
13234980 1.0 02/2008 TD14 First edition
13252301 2.0 05/2008 TD14 Complete revision
13255657 2.1 06/2008 TD14 Supplements to the chapter "Electrical Installation"
13261567 3.0 07/2008 TD31 Supplemented by devices in the HighLineversion
13277975 4.0 11/2008 TD36 Supplemented by devices of device size 5 (7 ... 15kW)
13296844 5.0 04/2009 TD37 Supplemented by push−through and cold plate
technique for devices in device size 5
.A4K 6.0 11/2009 TD36 Supplemented by devices of device size 6
(18.5 ... 22kW)
Error corrections
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About this documentation
Conventions used
1
l
8 EDS84ASC552 EN 6.0
1.2 Conventions used
This documentation uses the following conventions to distinguish between different
types of information:
Type of information Writing Examples/notes
Notation of numbers
Decimal separator Point The decimal point is always used.
For example: 1234.56
Warnings
UL warnings JAre only given in English.
UR warnings O
Text font style
Program name » « Lenze software
For example: »Engineer«
Symbols
Cross−reference ^ Refers to additional information. For
example ^16 = see page 16.
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About this documentation
Terms and abbreviations used
1
l9
EDS84ASC552 EN 6.0
1.3 Terms and abbreviations used
Term Meaning
Device size Used as generic term for a group of devices which have the same dimensions
(depth, height and width) but different power ratings.
Standard device Used as generic term when actions and features are described which are very
similar or the same for different versions or device sizes, e.g.
mechanical installation or
power terminals
Abbreviation Meaning
Cat. Category according to EN ISO 13849−1
OSSD Output Signal Switching Device, tested signal output
PWM Pulse width modulation
SIL Safety Integrity Level according to IEC 61508
SU Safety Unit
OFF state Signal status of the safety sensors when safety sensors are activated or respond
ON state Signal status of the safety sensors during normal operation
STO Safe Torque Off
Former designation: safe standstill
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About this documentation
Notes used
1
l
10 EDS84ASC552 EN 6.0
1.4 Notes used
The following pictographs and signal words are used in this documentation to indicate
dangers and important information:
Safety instructions
Structure of safety instructions:
}Danger!
(characterises the type and severity of danger)
Note
(describes the danger and gives information about how to prevent dangerous
situations)
Pictograph and signal word Meaning
{Danger!
Danger of personal injury through dangerous electrical voltage.
Reference to an imminent danger that may result in death or
serious personal injury if the corresponding measures are not
taken.
}Danger!
Danger of personal injury through a general source of danger.
Reference to an imminent danger that may result in death or
serious personal injury if the corresponding measures are not
taken.
(Stop!
Danger of property damage.
Reference to a possible danger that may result in property
damage if the corresponding measures are not taken.
Application notes
Pictograph and signal word Meaning
)Note! Important note to ensure troublefree operation
ITip! Useful tip for simple handling
,Reference to another documentation
Special safety instructions and application notes for UL and UR
Pictograph and signal word Meaning
JWarnings!
Safety or application note for the operation of a UL−approved
device in UL−approved systems.
Possibly the drive system is not operated in compliance with UL
if the corresponding measures are not taken.
OWarnings!
Safety or application note for the operation of a UR−approved
device in UL−approved systems.
Possibly the drive system is not operated in compliance with UL
if the corresponding measures are not taken.
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Safety instructions
General safety and application notes for Lenze controllers
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EDS84ASC552 EN 6.0
2 Safety instructions
2.1 General safety and application notes for Lenze controllers
(in accordance with Low−Voltage Directive 2006/95/EC)
For your personal safety
Disregarding the following safety measures can lead to severe injury to persons and
damage to material:
ƒOnly use the product as directed.
ƒNever commission the product in the event of visible damage.
ƒNever commission the product before assembly has been completed.
ƒDo not carry out any technical changes on the product.
ƒOnly use the accessories approved for the product.
ƒOnly use original spare parts from Lenze.
ƒObserve all regulations for the prevention of accidents, directives and laws
applicable on site.
ƒTransport, installation, commissioning and maintenance work must only be carried
out by qualified personnel.
– Observe IEC 364 and CENELEC HD 384 or DIN VDE 0100 and IEC report 664 or
DIN VDE 0110 and all national regulations for the prevention of accidents.
– According to this basic safety information, qualified, skilled personnel are persons
who are familiar with the assembly, installation, commissioning, and operation of
the product and who have the qualifications necessary for their occupation.
ƒObserve all specifications in this documentation.
– This is the condition for safe and trouble−free operation and the achievement of
the specified product features.
– The procedural notes and circuit details described in this documentation are only
proposals. It’s up to the user to check whether they can be transferred to the
particular applications. Lenze Drives GmbH does not accept any liability for the
suitability of the procedures and circuit proposals described.
ƒDepending on their degree of protection, some parts of the Lenze controllers
(frequency inverters, servo inverters, DC speed controllers) and their accessory
components can be live, moving and rotating during operation. Surfaces can be hot.
– Non−authorised removal of the required cover, inappropriate use, incorrect
installation or operation, creates the risk of severe injury to persons or damage to
material assets.
– For more information, please see the documentation.
ƒHigh amounts of energy are produced in the controller. Therefore it is required to
wear personal protective equipment (body protection, headgear, eye protection, ear
protection, hand guard).
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Safety instructions
General safety and application notes for Lenze controllers
2
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12 EDS84ASC552 EN 6.0
Application as directed
Controllers are components which are designed for installation in electrical systems or
machines. They are not to be used as domestic appliances, but only for industrial purposes
according to EN 61000−3−2.
When controllers are installed into machines, commissioning (i.e. starting of the operation
as directed) is prohibited until it is proven that the machine complies with the regulations
of the EC Directive 98/37/EC (Machinery Directive); EN 60204 must be observed.
Commissioning (i.e. starting of the operation as directed) is only allowed when there is
compliance with the EMC Directive (2004/108/EC).
The controllers meet the requirements of the Low−Voltage Directive 2006/95/EC. The
harmonised standard EN 61800−5−1 applies to the controllers.
The technical data and supply conditions can be obtained from the nameplate and the
documentation. They must be strictly observed.
Warning: Controllers are products which can be installed in drive systems of category C2
according to EN 61800−3. These products can cause radio interferences in residential areas.
In this case, special measures can be necessary.
Transport, storage
Please observe the notes on transport, storage, and appropriate handling.
Observe the climatic conditions according to the technical data.
Installation
The controllers must be installed and cooled according to the instructions given in the
corresponding documentation.
The ambient air must not exceed degree of pollution 2 according to EN 61800−5−1.
Ensure proper handling and avoid excessive mechanical stress. Do not bend any
components and do not change any insulation distances during transport or handling. Do
not touch any electronic components and contacts.
Controllers contain electrostatic sensitive devices which can easily be damaged by
inappropriate handling. Do not damage or destroy any electrical components since this
might endanger your health!
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Safety instructions
General safety and application notes for Lenze controllers
2
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EDS84ASC552 EN 6.0
Electrical connection
When working on live controllers, observe the applicable national regulations for the
prevention of accidents (e.g. VBG 4).
The electrical installation must be carried out according to the appropriate regulations
(e.g. cable cross−sections, fuses, PE connection). Additional information can be obtained
from the documentation.
This documentation contains information on installation in compliance with EMC
(shielding, earthing, filter, and cables). These notes must also be observed for CE−marked
controllers. The manufacturer of the system is responsible for compliance with the limit
values demanded by EMC legislation. The controllers must be installed in housings (e.g.
control cabinets) to meet the limit values for radio interferences valid at the site of
installation. The housings must enable an EMC−compliant installation. Observe in
particular that e.g. the control cabinet doors have a circumferential metal connection to
the housing. Reduce housing openings and cutouts to a minimum.
Lenze controllers can cause a DC current in the PE conductor. If a residual current device
(RCD) is used for protection in the event of direct or indirect contact, a residual current
device (RCD) of type B must be used on the supply side of the controller in case of a
three−phase controller supply. Otherwise, a different protective measure must be taken,
e.g. separation from the environment through double or reinforced insulation or
separation from the supply system by means of a transformer.
Operation
If necessary, systems including controllers must be equipped with additional monitoring
and protection devices according to the valid safety regulations (e.g. law on technical
equipment, regulations for the prevention of accidents). The controllers can be adapted to
your application. Please observe the corresponding information given in the
documentation.
After the controller has been disconnected from the supply voltage, all live components
and power connections must not be touched immediately because capacitors can still be
charged. Please observe the corresponding stickers on the controller.
All protection covers and doors must be shut during operation.
Notes for UL−approved systems with integrated controllers: UL warnings are notes that
only apply to UL systems. The documentation contains special UL notes.
Safety functions
Special controller variants support safety functions (e.g. "safe torque off", formerly "safe
standstill") according to the requirements of appendix I No. 1.2.7 of the EC Directive
"Machinery" 98/37/EC, EN 954−1 category 3 and EN 1037. Strictly observe the notes on the
safety functions given in the documentation on the respective variants.
Maintenance and servicing
The controllers do not require any maintenance if the prescribed operating conditions are
observed.
Disposal
Recycle metal and plastic materials. Ensure professional disposal of assembled PCBs.
The product−specific safety and application notes given in these instructions must be
observed!
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Safety instructions
General safety and application instructions for Lenze motors
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14 EDS84ASC552 EN 6.0
2.2 General safety and application instructions for Lenze motors
(According to: Low−Voltage Directive 2006/95/EC)
General
Low−voltage machines have hazardous live and rotating parts and possibly also hot
surfaces.
Synchronous machines induce voltages at open terminals during operation.
All operations concerning transport, connections, commissioning and maintenance must
be carried out by qualified, skilled personnel (EN 50110−1 (VDE 0105−100) and IEC 60364
must be observed). Inappropriate use creates the risk of severe injury to persons and
damage to material assets.
Low−voltage machines may only be operated under the conditions that are indicated in the
section "Application as directed".
The conditions at the place of installation must comply with the data given on the
nameplate and in the documentation.
Application as directed
Low−voltage machines are intended for commercial installations. They comply with the
harmonised standards of the series EN60034 (VDE 0530). Their use in potentially
explosive atmospheres is prohibited unless they are expressly intended for such use
(follow additional instructions).
Low−voltage machines are components for installation into machines as defined in the
Machinery Directive 98/37/EC. Commissioning is prohibited until the conformity of the
end product with this directive has been established (follow i. a. EN 60204−1).
Low−voltage machines with IP23 protection or less are only intended for outdoor use when
applying special protective features.
The integrated brakes must not be used as safety brakes. It cannot be ruled out that factors
which cannot be influenced, such as oil ingress due to a defective A−side shaft seal, cause
a brake torque reduction.
Transport, storage
Damage must be reported immediately to the forwarder upon receipt; if required,
commissioning must be excluded. Tighten screwed−in ring bolts before transport. They are
designed for the weight of the low−voltage machines, do not apply extra loads. If
necessary, use suitable and adequately dimensioned means of transport (e. g. rope
guides).
Remove transport locking devices before commissioning. Reuse them for further
transport. When storing low−voltage machines, ensure a dry, dust−free and low−vibration
(veff 0.2 mm/s) environment (bearing damage while being stored).
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Safety instructions
General safety and application instructions for Lenze motors
2
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EDS84ASC552 EN 6.0
Installation
Ensure an even surface, solid foot/flange mounting and exact alignment if a direct clutch
is connected. Avoid resonances with the rotational frequency and double mains frequency
which may be caused by the assembly. Turn rotor by hand, listen for unusual slipping
noises. Check the direction of rotation when the clutch is not active (observe section
"Electrical connection").
Use appropriate means to mount or remove belt pulleys and clutches (heating) and cover
them with a touch guard. Avoid impermissible belt tensions.
The machines are half−key balanced. The clutch must be half−key balanced, too. The visible
jutting out part of the key must be removed.
If required, provide pipe connections. Designs with shaft end at bottom must be protected
with a cover which prevents the ingress of foreign particles into the fan. Free circulation of
the cooling air must be ensured. The exhaust air − also the exhaust air of other machines
next to the drive system − must not be taken in immediately.
Electrical connection
All operations must only be carried out by qualified and skilled personnel on the
low−voltage machine at standstill and deenergised and provided with a safe guard to
prevent an unintentional restart.This also applies to auxiliary circuits (e. g. brake, encoder,
blower).
Check safe isolation from supply!
If the tolerances specified in EN 60034−1; IEC 34 (VDE 0530−1) − voltage ±5 %, frequency
±2 %, waveform, symmetry − are exceeded, more heat will be generated and the
electromagnetic compatibility will be affected.
Observe the data on the nameplate, operating notes, and the connection diagram in the
terminal box.
The connection must ensure a continuous and safe electrical supply (no loose wire ends);
use appropriate cable terminals. The connection to the PE conductor must be safe. The
plug−in connectors must be bolted tightly (to stop).
The clearances between blank, live parts and to earth must not fall below 8 mm at
Ur550 V, 10 mm at Ur725 V, 14 mm at Ur1000 V.
The terminal box must be free of foreign particles, dirt and moisture. All unused cable
entries and the box itself must be sealed against dust and water.
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Safety instructions
General safety and application instructions for Lenze motors
2
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16 EDS84ASC552 EN 6.0
Commissioning and operation
Before commissioning after longer storage periods, measure insulation resistance. In the
case of values 1 kper volt of rated voltage, dry winding.
For trial run without output elements, lock the featherkey. Do not deactivate the
protective devices, not even in a trial run.
Check the correct operation of the brake before commissioning low−voltage machines
with brakes.
Integrated thermal detectors do not provide full protection for the machine. If necessary,
limit the maximum current. Parameterise the controller so that the motor will be switched
off with I > Irafter a few seconds of operation, especially at the risk of blocking.
Vibrational severities veff 3.5 mm/s (Pr15 kW) or 4.5 mm/s (Pr> 15 kW) are acceptable if
the clutch is activated.
If deviations from normal operation occur, e.g. increased temperatures, noises, vibrations,
find the cause and, if required, contact the manufacturer. In case of doubt, switch off the
low−voltage machine.
If the machine is exposed to dirt, clean the air paths regularly.
Shaft sealing rings and roller bearings have a limited service life.
Regrease bearings with relubricating devices while the low−voltage machine is running.
Only use the grease recommended by the manufacturer. If the grease drain holes are
sealed with a plug, (IP54 drive end; IP23 drive and non−drive end), remove plug before
commissioning. Seal bore holes with grease. Replace prelubricated bearings (2Z bearing)
after approx. 10,000 h − 20,000 h, at the latest however after 3 − 4 years.
The product−specific safety and application notes given in these instructions must be
observed!
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Safety instructions
Residual hazards
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EDS84ASC552 EN 6.0
2.3 Residual hazards
Protection of persons
ƒBefore working on the controller, check that no voltage is applied to the power
terminals, because
– depending on the controller − the power terminals U, V, W, +UG, −UG, Rb1 and Rb2
carry hazardous voltages for up to 3 to 20 minutes after mains disconnection.
– the power terminals L1, L2, L3; U, V, W, +UG, −UG, Rb1 and Rb2 carry hazardous
voltages when the motor is stopped.
Device protection
ƒConnect/disconnect all pluggable terminals only in deenergised condition!
ƒDetach the controllers from the installation, e.g. from the rear panel of the control
cabinet, only in deenergised condition!
Motor protection
ƒDepending on the controller settings, the connected motor can be overheated by:
– For instance, longer DC−braking operations.
– Longer operation of self−ventilated motors at low speed.
Protection of the machine/system
ƒDrives can reach dangerous overspeeds (e.g. setting of high output frequencies in
connection with motors and machines unsuitable for such conditions):
– The controllers do not offer any protection against such operating conditions. Use
additional components for this purpose.
Parameter set transfer
ƒDuring the parameter set transfer, control terminals of the controllers can adopt
undefined states!
– Therefore, it is absolutely necessary to remove control terminal X4 (digital input
signals for devices in StateLine C design) or control terminal X5 (digital input
signals for devices in HighLine C design). This ensures that the controller is
inhibited and all control terminals have the firmly defined "LOW" status.
ƒSwitch contactors in the motor cable only if the controller is inhibited.
When switching contactors in the motor cable while the controller is enabled, you can
activate monitoring functions of the controller. If no monitoring function is activated,
switching is permissible.
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Product description
Device features
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18 EDS84ASC552 EN 6.0
3 Product description
3.1 Device features
Features
Version
StateLine C HighLine C
Power range from 250 W to 22 kW  
Interfaces for communication modules and
diagnostic adapters  
Integrated interference suppression according to
EN 61800−3
 
Integrated DC−bus connection for devices with
400 V mains connection  
Flying restart circuit  
Integrated brake management  
Integrated brake chopper  
Optional: drive−based safety "Safe torque off
(STO)"  
Operating modes:
 
– VFCplus: V/f open loop, linear and
square−law
– SLVC: sensorless vector control
(torque/speed)
– VFCplus: V/f closed loop for speed−controlled
applications
– SC: servo control (torque/speed) − 
S−shaped ramps for smooth acceleration and
deceleration  
200 % overload current (3 s)  
Usability on IT system  
Protection against restart for cyclic mains
switching
 
CANopen baud rate up to 500 kbit/s up to 1000 kbit/s
Incremental encoder evaluation: two−track 10 kHz 10 kHz and 100 kHz
Point−to−point positioning −
Digital output 2.5 A with integrated spark
suppressor, e.g. for the direct control of a 24 V
motor holding brake
−
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Product description
Overview of standard devices
3
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EDS84ASC552 EN 6.0
3.2 Overview of standard devices
Standard device in device size GG 1 ... 3 Standard device in device size GG 4 ... 6
8400HLC058 8400HLC057
Connection Information
Pos. Description 230 V 400 V
X80 Terminal strip for the integrated safety unit ^167
X100
Mains/DC−bus voltage (for 400V devices)
– For devices in device size 6 (18.5 ... 22 kW) the terminal strip
is not pluggable.
^105
^117
X101 Relay output ^125
X105
Motor/external brake resistor
– For devices in device size 6 (18.5 ... 22 kW) the terminal strip
is not pluggable.
^109
^118
X106 Motor temperature monitoring ^108 ^119
IT Contact screw for interference suppression (on the supply
side/on the motor side) ^106 ^116
MCI Slot for communication module (Module Communication
Interface) ^181
3Sticker with warning ^61
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Product description
Overview of control terminals
3
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20 EDS84ASC552 EN 6.0
3.3 Overview of control terminals
Control terminals for devices in the StateLine version Control terminals for devices in the HighLine version
8400HLC080a 8400HLC081a
Connection Information
Pos. Description StateLine C HighLine C
X1 CANopen connection ^124
S1 CANopen settings
X3 analog inputs/outputs; 10V reference voltage ^129 ^135
X4
Digital inputs; controller enable
^128
−
24V supply of the control electronics
Digital outputs ^138
24V voltage output
X5
Digital inputs; controller enable
−^137
External 24V supply of the control electronics; internal 24V supply
fused via PTC
X6 (DIAG) Diagnostic interface ^127
x107
24 V brake supply;
−^140
+ BD1 Connection for DC brake coil
− BD2
MMI Slot for memory module (Memory Module Interface) ^180
2Icon Description
{Long discharge time: All power terminals remain live for a few minutes after mains
disconnection! The duration is given under the warning symbol on the device.
}High discharge current: Carry out fixed installation and PE connection according to
EN 61800−5−1!
'Electrostatic sensitive devices: Before working on the device, the personnel must be free of
electrostatic charge!
|Hot surface: Risk of burns! Hot surfaces should not be touched without wearing protective
gloves.
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