Lenze 8230 Series User manual

EDB9300UES
00402016
Operating Instructions
Global Drive
Frequency inverters
8230 series
Power range 110 ... 250 kW
23(1
23(1
23(1
23(1
23(1
23(1
23(1
23(1
Show/Hide Bookmarks

Contents
i1
Contents i1
Comments i4
1 Brief description 1
1.1 General 1
1.2 Basic operation 2
1.3 Main features 3
2 Technical Data 5
2.1 Key to types, rating plate 5
2.2 Series of types 6
2.2.1 Technical data at rated current 7
2.2.2 Technical data at basic load current 8
2.2.3 Power loss and cooling air volume 9
2.3 System data 10
2.3.1 Standards, operating conditions and certificates 15
2.3.1.1 Standards applicable 15
2.3.1.2 Certificate 16
2.3.1.3 CE Certificate 16
2.3.2 CE mark 17
2.4 Supply components 19
2.4.1 Components for 3AC supply 19
2.4.1.1 Fuses for 3AC mains connection 19
2.4.1.2 Mains chokes (3-phase chokes) 21
2.4.1.3 Line fuses for operation class gL and cable cross-sections 23
2.4.1.4 Fuse circuit breakers 23
2.4.1.5 Mains contactor 23
2.5 Options 24
2.5.1 Control unit (BDE) 24
2.5.2 Brake chopper and braking resistors 26
2.5.2.1 Brake chopper 27
2.5.2.2 Braking resistors 28
2.5.3 RFI filters 30
2.5.4 Motor filters and output chokes 31
2.5.4.1 Motor filters 31
2.5.4.2 Motor choke 34
2.5.6 Option boards for Alspa MD2000 36
2.5.6.1 Encoder interface 37
2.5.6.2 Operation on a mains supply with no earth 43
2.6 Summary circuit diagrams 44
2.6.1 Summary circuit diagram, 8230 frequency inverter 44
2.7 Connection, terminal wiring 45
2.7.1 Power stack 45
2.7.1.1 3AC supply 45
2.7.2 Electronics section, A10 control board 48
2.7.2.1 Terminal strip wiring :X15 and signal functions 49
2.7.2.2 Description of terminal strip inputs / outputs 54
Show/Hide Bookmarks

Contents
i2
2.8 Dimensions, Installation drawing, weights 58
2.8.1 8230 frequency inverter build-in units 58
2.8.2 Mains chokes for 8230 frequency inverter 60
2.8.3 Installation drawing for control unit 61
2.8.4 Dimensions and installation dimensions Base for semiconductor fuses
of operating class gR with 110 mm length 63
2.8.7 Dimensions and installation dimensions Braking resistor 64
2.8.8 Dimensions and weights motor filters 65
2.8.9 Motor choke 66
2.8.10 Dimensions and weights 67
3 Transport, Installation and Connection 68
3.1 Safety instructions 68
3.2 Storage 69
3.3 Transport 69
3.4 Installation 69
3.5 Connection and wiring 70
3.5.1 Potential separation 77
3.6 Installation and connection instructions for EMC 79
3.7 Specific measures for ensuring electromagnetic compatibility (EMC) 88
4 Operation and Software 90
4.1 Unit operation 90
4.1.1 Control philosophy 92
4.2 Parameter adjustment 93
4.3 Menu 95
4.4 Description of parameters and displays 100
4.4.1 Display 100
4.4.2 Application parameter 101
4.4.3 Configuration parameters 105
4.4.4 Parameters for analog I/O 113
4.4.5 Parameters for digital I/O’s 119
4.4.6 Ratings 123
4.4.7 Control parameters 128
4.4.8 Diagnosis 131
4.4.9 Password 131
4.4.10 Language 133
5 Commissioning 134
5.1 Safety instructions for commissioning 134
5.2 Commissioning sequence diagram, 8230 frequency inverter build-in unit 136
5.3 General 140
5.4 Mains and motor connection 140
5.5 Commissioning Report 141
Show/Hide Bookmarks

Contents
i3
5.6 First commissioning with the 8230 frequency inverter BDE control unit 148
5.6.1 Language Select 148
5.6.2 Ratings 149
5.6.3 Control structure 152
5.6.4 Speed adjustment/speed limit 152
5.6.5 Field weakening 152
5.6.6 Multiple motor operation/Group supply 153
5.6.7 Motor potentiometer function 154
5.7 Terminal strip wiring 154
5.8 Configuring the drive 156
5.9 Demand selection 157
5.10 Control structure 158
5.10.1 Frequency control 158
5.10.2 Control without encoder 158
5.10.3 Control with encoder 159
6 Help in the event of errors 160
6.1 First value log for error messages 160
6.2 Switching sequence on errors 160
6.3 Event log 160
6.4 Events 160
6.5 Error log 163
6.6 Errors 163
7 Maintenance 167
7.1 Battery for RAM and clock 167
7.1.1 Battery change 167
7.1.2 Technical data of battery 167
7.2 Fans 167
7.3 Power connections 167
7.4 Reforming the link capacitors 168
Declaration of Conformity AAS-KE 001/9.95 170
Show/Hide Bookmarks

Comments
i4
Expressions used Note:
A note shows important or additional information separately from the text.
Important!
Important means that the instructions given must be followed precisely in order to
prevent any loss of data or damage.
Warning!
Warning means that the operator may be injured if the relevant instructions are
not followed.
Limitation of liability Unless agreed elsewhere the latest issue of the “General Supply Conditions for
Products and Services of the Electrical Industry” applies accordingly.
We are not obliged to make software updates or upgrades available to users.
Modifications to improve handling and updates for new types of equipment can only
be offered to registered users at preferential prices.
Data, illustrations, amendments Data and illustrations are approximate only and subject to modification without notice.
Please advise if you have any suggestions for improving or otherwise amending the
documentation. A printed form is provided on the last few pages of this document.
Training Lenze GmbH & Co KG offers training seminars to provide additional system
knowledge.
Without prior permission this document may not be duplicated or otherwise made available to third parties. It may not be misused in
any way by the recipient or third parties. Translation into a foreign language is not permitted. All data, dimensions, weights,
illustrations and other technical details may be subject to modification without notice, in particular for further development of our
equipment. The information agreed in an order is final and binding.
Show/Hide Bookmarks

1 Brief description
BA8230 1
1.1 General 8230 frequency inverter are processor-controlled pulse inverters with a field-orientated
control concept for continuous low-loss speed adjustment of AC motors.
The power stack consists of a diode rectifier in a 3-phase bridge circuit on the mains
side and an IGBT inverter on the motor side.
The basic inverter models are designed for standard applications. Through suitable
options (eg. bus couplers, encoder interface) the units can be integrated into
automation systems and can also fulfil highly dynamic requirements.
Operation of all units is identical throughout the entire type range. Easy familiarisation
and operation as well as maximum flexibility were the prime objectives during
development.
The inverters are operated and parameters adjusted by means of a control unit
(BDE).
Connection to automation systems is possible through conventional bus systems (see
field bus coupler options).
With a mains voltage range from 380 to 480 V build-in units cover the power range
from 144 kVA to 330 kVA.
In conjunction with standard asynchronous motors the drive capacities provided are
therefore as follows:
- At unit rated current
110 kW to 200 kW, 400 V
- At unit 1.5 x rated current
132 kW to 250 kW, 400 V
Note:
This operating manual applies to the following units:
8230 frequency inverter
Software version:
V2.0
Important!
8230 frequency inverter are designed as standard for operating on earthed networks.
Show/Hide Bookmarks

Brief description
2BA8230
1.2 Basic operation The link voltage is generated from the mains supply through the mains rectifier. A 3-
phase choke connected to the mains supply reduces harmonic currents and serves to
decouple the unit from other converters (consumers) on the same supply network.
8230 frequency inverter are connected as standard to an earthed network.
The link voltage is smoothed by high quality electrolytic capacitors. With the motor
converter these provide the magnetising reactive power required by the motor and
decouple the converter on the mains side from the inverter on the motor side.
Through optimised pulse width modulation the motor converter generates from the
link voltage a sinusoidal 3-phase system with variable frequency and voltage.
A power dump (option) in conjunction with a braking resistor allows braking energy to
be used in regenerative operation.
Control and regulation of the 8230 frequency inverter are fully digital. Different control
structures such as, frequency control, speed control with or without encoder and
torque control with or without encoder can be selected, depending on the application
requirements. The field-orientated control concept provides control dynamics directly
comparable to those of a DC drive.
In addition, various inputs and outputs can be connected individually according to the
task involved. Thus the drive system can very easily be customised for the
requirements of the specific application.
Fig. 1: Summary circuit diagram, basic layout, operation
Show/Hide Bookmarks

Brief description
BA8230 3
1.3 Main features •Consistent range of Types for drives from 110 kW to 250 kW with
IGBT inverters
•Supply voltage ranges:
- 3AC 380 V ... 460 V +10 %/ -15 % ... 480 V +6 %/ -15 %
•Standard design for connection to earthed networks
•Output frequency range: 0 ... 300 Hz
•120% overload capacity for 60 s related to 1.2 rated controller current
(Applications with medium overload)
•150% overload capacity for 60 s related to 1.5 rated controller current
(Applications with high overload)
•Standard asynchronous motors can be used without power reduction
•High dynamics: Torque rise time: tan = 2 to 8 ms
•8230 frequency inverter units are resistant to idling, short circuit and earth fault
•DC system bus supply for several 8230 frequency inverter through
DC link connection (option)
•4Q operation (option) through power dump with braking resistor
•Mains supply power connections at top and motor connections at foot
•Motor temperature monitoring by thermistor processing electronics (PTC)
•Easy, user-friendly system structure
•Consistent and easily learned operation via control unit (option) with plain
text display (various languages available)
•Extensive additional operating facilities via PC, for example menu control,
user-controlled commissioning, oscilloscope function
•Control structures available:
- Frequency control
- Speed control with or without incremental rotation encoder
- Torque control with or without incremental rotation encoder
Show/Hide Bookmarks

Brief description
4BA8230
•Kinetic back-up on mains failure
Back-up operation of the control electronics using the kinetic energy in the drive
systems at speeds close to zero, also suitable for flow machines
•Capture without torque surge
(the inverter is applied to the de-excited motor while the motor is running)
•Automatic restart facility after mains failure
(Parameter-adjustable up to 15 s as standard)
•Conventional drive through standard terminal strip
- 12 digital potential-separated inputs for control signals (eg. Start, Stop etc.),
of which 3 inputs are parameter-adjustable through selection list
- 4 digital potential-free outputs for messages (On, Ready, Error, free
output parameter-adjustable through selection list, 1 output
"Ready” can be re-assigned via technology)
- 2 free adjustable and scaleable analog outputs
- 2 scaleable analog demand inputs
- 2 parameter sets switchable via control unit or terminal strip
•Expansion of standard terminal strip (I/O interface option)
- 20 configurable digital inputs with separate potential
- 8 configurable digital outputs with separate potential
- 2 configurable analog demand inputs
- 2 configurable analog outputs
•Comprehensive testing and diagnostics facilities:
- Self-test on control electronics and hardware
- Event memory with timings of all binary events with first
value error message and documentation
- Error log with timing details
- Protocol log for documenting all parameter changes
•Comprehensive protection and monitoring facilities.
Show/Hide Bookmarks

2 Technical Data
BA8230 5
2.1 Key to types, The type data includes the following information. An example:
rating plate
Fig. 2: 8230 frequency inverter rating plate
The following details are required for identifying the unit:
- Type No :
-Serial No :

Hans-Lenze-Strasse 1 D-31855 Aerzen
Made in Germany
Global Drive 8230
Type EVF8234BE
029. 206879
00001
00395613
3/PEAC 400/460V 360/430A 50/60Hz
3/PEAC 0-460V 400/483A 200/250kW 0-300Hz
600A / 60s (400V) 520A / 60s (460V)
Id.-No.
Input
Sach.-No.
Ser.-No.
Output
Overload
Show/Hide Bookmarks

Technical Data
6BA8230
2.2 Series of types 8230 frequency inverter for 3-phase AC connection
8230 frequency inverter 150 ... 275 kVA, 3AC 380 ... 480 V
Processor-controlled pulse inverter with field-orientated control concept for continuous
low-loss speed adjustment of standard AC motors.
8230 frequency
inverter Frame size Unit input current, Unit output current
mains current5) 1.2 x rated
current1) 1.5 x rated current2) Max. current 60 s 3) Supply voltage
eff [A] [A] [A] [A]
8231 8 195 (230) 257 216 324 3 AC 50/60Hz
8232 8A 230 (270) 304 257 365 380 ... 460 V
8233 9 290 (360) 396 325 488 +10/-15 %
8234 9A 360 (430) 483 400 600 ...480 V
+6/-15 %
Table 1: 8230 frequency inverter series
1) Rated current with overload capacity 1.2 x rated current
2) Rated current with overload capacity 1.5 x rated current
3) Max. current for max. 60 s overload, cycle time 600 s
4) Mains commutation choke not included in scope of supply.
5) The details for the mains current with the standard mains choke are based on a
mains short circuit capacity in relation to the inverter power of 100 : 1 at unit output
current = rated current. Values in brackets are valid for 1.2 rated current.
Frame size Dimensions Weight
H x W x D [mm] ca. [kg]
8 1049 x 495 x 419 90
8A 1224 x 495 x 419 90
9 1499 x 495 x 419 140
9A 1674 x 495 x 419 140
Table 2: 8230 frequency inverter frame sizes
Scope of supply: Build-in unit, IP20
Show/Hide Bookmarks

Technical Data
BA8230 7
2.2.1 Technical data Overload capacity 1.2 x rated current
at rated current The technical data shown in Table 3 applies at a pulse frequency of fp= 3 kHz,
as supplied ex works, and a maximum air supply temperature up to 40 °C.
8230 frequency
inverter Rated current Max. current 1) for max. 60 s Unit rated current [kVA] at rated current motor rating2) [kW]
[A] [A] 400 V 415 V 460 V 480 V 400 ... 415 V 460 ... 480 V
8231 257 324 178 185 205 214 132 151
8231 304 365 211 218 241 252 160 172
8231 396 488 275 285 316 330 200 230
8231 483 600 335 347 385 400 250 285
Table 3: Technical data at rated current with overload capacity 1.2 x rated current
1) 120 % overload for total max. 60 s on a load cycle of 1 : 10 / cycle time 600 s
2) motor rating based on standard 2, 4 and 6 pole motors at
400 ... 415 V or 460 ... 480 V rated voltage.
Fig. 3 : 8230 frequency inverter Overload capacity 1.2 x rated current
Show/Hide Bookmarks

Technical Data
8BA8230
2.2.2 Technical data Overload capacity 1.5 x rated current
at rated current 1.5 The technical data shown in Table 4 applies at a pulse frequency of fp= 3 kHz
as set ex works, and a maximum air supply temperature up to 50 °C.
8230 frequency
inverter Rated current Max. current 1) for max. 60 s Unit rated current [kVA] at rated current motor rating2) [kW]
[A] [A] 400 V 415 V 460 V 480 V 400 ... 415 V 460 ... 480 V
8231 216 324 150 155 172 180 110 126
8231 325 365 178 185 205 214 132 151
8231 396 488 225 234 259 270 160 184
8231 400 600 275 287 318 333 200 230
Table 4: Technical data at rated current with overload capacity 1.5 x rated current
1) 150 % overload for total max. 60 s on a load cycle of 1 : 10 / cycle time 600 s
2) motor rating based on standard 2, 4 and 6 pole motors at
400 ... 415 V or 460 ... 480 V rated voltage.
Fig. 4: 8230 frequency inverter Overload capacity 1.5 x rated current
Show/Hide Bookmarks

Technical Data
BA8230 9
2.2.3 Power loss and The rise in temperature of the cooling air at rated current is ∆ϑ ≤16 °C for the
cooling air volume cooling air volume stated and when the installation clearances are maintained.
8230 frequency inverter Frame size Cooling air
volume2) Rated current Power loss1) [kW]
at rated current and 3AC supply voltage
[m³/h] [A] 400 V 460 V 480 V
8331 8 580 257 3,73 3,84 3,88
8232 8A 730 304 4,45 4,63 4,70
8233 9 950 396 5,55 5,80 5,88
8234 9A 1100 483 6,50 6,80 6,88
Table 5: Power loss and cooling air volume at rated current
1) The values stated apply to a pulse frequency of fp = 3 kHz
2) The values apply to a static pressure increase of ∆p ≈32 Pa between cooling air
inlet and outlet.
8230 frequency inverter Frame size Cooling air
volume2) Rated current Power loss1) [kW]
at rated current and 3AC supply voltage
[m³/h] [A] 400 V 460 V 480 V
8331 8 580 216 3,14 3,22 3,24
8232 8A 730 257 3,78 3,94 4,00
8233 9 950 325 4,54 4,74 4,83
8234 9A 1100 400 5,60 5,85 5,96
Table 6: Power loss and cooling air volume at 1.5 x rated current
1) The values stated apply to a pulse frequency of fp = 3 kHz
2) The values apply to a static pressure increase of ∆p ≈32 Pa between cooling air
inlet and outlet.
Show/Hide Bookmarks

Technical Data
10 BA8230
2.3 System data •Mains supply voltage 3AC 400 ... 460 V; +10/-15 % ... 480 V; +6/-15 %
•Mains frequency 50 ... 60 Hz ±5 %
•Power factor
- Mains base frequency cos ϕ1> 0.97
- Total at rated current
depending on mains
impedance λN» 0.88 ind - 0.93 ind
•Output voltage 3AC 0 ... Umains
•Approvals prEN50178:1994/VDE0160
CE mark according to low voltage directive
•Efficiency
at rated power ≥0.97
•Overload factor 1.2 for max. 60 s at rated current 1.2
1.5 for max. 60 s at rated current 1.5
cycle time ≥10 min
•Min. operating frequency
With encoder 0 Hz
Without encoder motor: 1 Hz
regenerative: 2.5 Hz
•Max. operating frequency 300 Hz
•Speed adjustment range for speed control
without encoder with encoder
1:50 1) >1:1000
1) The adjustment range is 1:20 in regenerative
operation using the control structure “Speed
control without encoder”
•Speed accuracy for speed control
without encoder with encoder
with digital demand preset
0.5 % 0.05 %
•Torque rise times For speed control
with or without encoder
2 ... 8 ms
•Frequency resolution 10 mHz standard
adjustable with parameter f100
•Frequency stability for
frequency control <0.01 % standard
<0.001 % option, on application
Show/Hide Bookmarks

Technical Data
BA8230 11
•Frequency accuracy for
frequency control <0.01 %
•Temperature response
of analog demand <0.01 %/°C
•Speed encoder incremental encoder
see encoder interface option
•Noise A-weighted sound pressure level
frame size 8 <70 dB(A)
frame size 8A <73 dB(A)
frame size 9 <72 dB(A)
frame size 9A <74 dB(A)
•Overtemperature shutdown frame size 8 at >95 °C
frame size 8A at >105 °C
frame size 9 at >105 °C
frame size 9A at >105 °C
•Ambient temperature
Operation 0 ... +55 °C 1)
Storage -25 °C ... +65 °C
•Cooling corced air cooling
see section 2.2.3 for cooling air volumes
•Coolant temperature 0 ... 40 °C at rated current, overload factor 1.2
for 60 s every 10 minutes
up to max. 55 °C with power reduction 2 % per 1 °K
0 ... 50 °C at rated current, overload factor 1.5
for 60 s every 10 minutes
up to max. 55 °C with power reduction 2 % per 1 °K
•Installation altitude ≤1000 m above MSL, up to max. 2200 m with
power reduction 1.2 % per 100 m
•Storage time Without reforming the capacitors: 2 years, 5 months
of which at temperatures over 40°C
•Protection classes
Build-in units IP20
Cubicle-mounted units IP21 Standard
IP31, IP43, IP54 Option
•Environment class DIN EN 60721 Part 3-3
3K3 / 3M2 / 3C2 2) / 2K2
- Max. relative humidity 85 % at 28 °C, condensation not permitted
- Insulation Contamination Class II to DIN VDE 0110
•Permitted switching Precharging circuit duty cycle = 2 %/180 s,
frequency max. 20 per hour
•Power loss of control ca. 130 W
electronics with control board, no additional options
Show/Hide Bookmarks

Technical Data
12 BA8230
•Mechanical use prEN50178:1994/IPA90 DIN IEC86
(Vibration) T.2-6 10 ... 150 Hz
•Electromagnetic
compatibility3) :
- Interference resistance To IEC1800-3 (IEC22G/21/CDV), EN50082-2,
suitable for use in an industrial environment
- Radiated interference To IEC1800-3 (IEC22G/21/CDV)
- industrial mains supply AC mains choke4)
- public supply network Additional RFI filter4)
EN50081-2, limit to EN55011 Group 1 Class A:
Mains choke and RFI filter4)
EN50081-1, limit to EN55011 Group 1 Class B:
Mains choke, RFI filter and Motor filter4)
1) Adequate convection cooling must be provided for the 8230 frequency inverter control
electronics. No heat build up inside the 8230 frequency inverter.
2) No salt spray mist.
3) Connection to earthed network
4) see section 3.7 for optional measures
•Pulse frequency adjustable
- Standard 3 kHz
- Maximum Up to 6 kHz
For a chopping frequency of fp=6 kHz, a power reduction to 1.5 rated current is
required.
•Servicing Data memory battery replacement required,
see section 7.1
Fan replacement recommended, see section 7.2
Check power connection screws, see section 7.3
Show/Hide Bookmarks

Technical Data
BA8230 13
Power reduction curves
Fig. 5: Power reduction curves (Derating) 8230 frequency inverter
Show/Hide Bookmarks

Technical Data
14 BA8230
Efficiency curves
Fig. 6: 8230 frequency inverter Efficiency curves
The curves in Fig. 6 apply to pulse frequency 3 at a 400 ... 460 V supply voltage.
Show/Hide Bookmarks

Technical Data
BA8230 15
2.3.1 Standards, operating conditions and certificates
2.3.1.1 Standards applicable As per 06.1996
VDE 0100-540 Installation of heavy current systems with rated voltages up to 1000 V; selection and
installation in electrical equipment, earthing, protective conductor, potential
compensation conductor
VDE 0106-100 Protection against electric shock; configuration of actuator components close to parts
which are dangerous to touch
VDE 0110 Insulation coordination for electrical equipment in low voltage systems.
Rating of air gaps and creepage distances
VDE 0160/pr EN50178 Installing electronic equipment on heavy current systems
DIN EN 60146-1-1 (IEC 146-1-1) Semiconductor converters; general requirements and mains-fed converters;
basic requirements (DIN VDE 0558 Part 11: 1994-03)
DIN EN 60146-1-3 (IEC 146-1-3) General requirements and mains-fed converters,
transformers and choke coils (DIN VDE 0558 Part 8: 1994-03)
IEC 1000-4-2 Resistance to electrostatic discharge,
requirements and test methods (conversion IEC 801-2)
IEC 1000-4-3 Resistance to electromagnetic HF fields,
requirements and test methods
IEC 1000-4-4 Resistance to fast electrical transients and bursts (conversion IEC 801-4)
IEC 801-5 Resistance to surge voltages on mains supply cables (surge pulses)
IEC 1000-4-5 Resistance to voltage peaks
DIN EN 55011 Radio interference suppression of electrical plant and equipment;
(VDE 0875 Part 11), limits and test methods for radio interference suppression of
industrial, scientific and medical high frequency equipment
DIN EN 55022 Electromagnetic compatibility of equipment in information processing and
telecommunications technology (VDE 0878 Part 3), limits and test methods for radio
interference suppression on technical information equipment
IEC1800-3/prEN61800-3:1995 EMC product standard for variable speed drives
(IEC22G/21/CDV) EMC interference resistance and radiated interference Anforderungen und
Meßverfahren
DIN EN 50081-1 Electromagnetic compatibility (EMC); specialist basic standard for radiated
interference;
Part 1: Residential, business and light industry
DIN EN 50081-2 Electromagnetic compatibility (EMC); specialist basic standard, radiated interference;
Part 2: Industrial
DIN EN 50082-1 Electromagnetic compatibility (EMC); specialist basic standard, interference
resistance;
Part 1: Residential, business and light industry
DIN EN 50082-2 Electromagnetic compatibility (EMC); specialist basic standard, interference
resistance,
Part 2: Industrial (VDE 0839 Part 82-2)
Show/Hide Bookmarks