Lenze i410 Quick start guide

Inverter
Inverter i410 Cabinet 0.25 ... 2.2 kW
Commissioning EN

Contents
1About this document 9
1.1 Document descripon 9
1.1.1 Further documents 9
1.2 Notaons and convenons 10
2Safety instrucons 11
2.1 Basic safety instrucons 11
2.2 Applicaon as directed 12
2.3 Handling 12
2.4 Residual hazards 13
3Product informaon 14
3.1 Idencaon of the products 14
4Commissioning 15
4.1 Important notes 15
4.2 Inial switch-on and funconal test 16
4.3 Operang interfaces 18
4.3.1 Keypad 18
4.3.2 Engineering tool »EASY Starter« 19
4.3.2.1 Generate a connecon between inverter and »EASY Starter« 20
4.4 General informaon on parameter seng 22
4.4.1 Addressing of the parameters 22
4.4.2 Structure of the parameter descripons 23
4.4.3 Parameter overview lists 23
4.4.4 Favorites 24
4.4.4.1 Accessing the "Favorites" with the keypad 24
4.4.4.2 Favorites parameter list (default seng) 25
4.4.4.3 Conguring the "Favorites" 26
4.5 Saving the parameter sengs 29
4.5.1 Save parameter sengs with keypad 29
4.5.2 Save parameter sengs with »EASY Starter« 29
4.5.3 Automac storage in the memory module 29
5Basic seng 30
5.1 Device name 30
5.2 Mains voltage 31
5.3 Frequency limits 32
5.4 Start behavior 33
5.5 Stop behavior 36
5.6 Funcon assignment of the inputs and outputs (default seng) 38
5.7 Motor data 39
5.7.1 Select motor from motor catalog 40
5.7.2 Manual seng of the motor data 41
5.8 Motor control mode 42
Contents
3

6 Start, stop and rotang direcon commands 43
6.1 Control selecon 43
6.1.1 Flexible I/O conguraon 45
6.1.2 Keypad control 46
6.1.3 Keypad full control 47
6.2 Flexible I/O conguraon of the start, stop and rotang direcon commands 48
6.2.1 Trigger list 52
6.2.2 Example: Start/stop (1 signal) and reversal 54
6.2.3 Example: Quick stop 55
6.2.4 Example: Enable inverter 56
6.2.5 Example: Jog forward/Jog reverse 57
6.3 Control/restrict direcon of rotaon of the motor 59
6.4 Changing the control source during operaon 60
6.4.1 Example: Change-over from terminal control to keypad control 62
7Conguring the frequency control 64
7.1 Basic seng 64
7.1.1 Standard setpoint source 65
7.1.2 Ramp mes 66
7.2 Congure setpoint sources 68
7.2.1 Keypad 68
7.2.2 Setpoint presets 69
7.2.3 Motor potenometer (MOP) 71
7.2.4 Sequencer 73
7.2.4.1 Segment conguraon 75
7.2.4.2 Sequence conguraon 85
7.2.4.3 Sequencer basic sengs 89
7.2.4.4 Sequencer control funcons 92
7.2.4.5 Sequencer diagnoscs 96
7.3 Conguring the process controller 98
7.3.1 Basic seng 99
7.3.2 Process controller sleep mode 105
7.3.3 Process controller rinse funcon 107
7.3.4 Process controller funcon selecon 107
7.3.5 Process controller diagnoscs 109
7.4 Changing the setpoint source during operaon 111
7.4.1 Example: Change-over from keypad setpoint to AI1/AI2 setpoint 114
7.4.2 Example: Change-over from AI1 setpoint to keypad setpoint 116
7.4.3 Example: Change-over from keypad setpoint to preset 1 ... 7 118
7.4.4 Example: Change-over from AI1 setpoint to MOP setpoint 121
7.5 Change over to ramp 2 during operaon 123
7.6 "Switch-o posioning" stop mode 126
7.7 Setpoint diagnoscs 128
Contents
4

8Conguring the torque control 129
8.1 Basic seng 130
8.1.1 Standard setpoint source 131
8.1.2 Torque limits 132
8.1.3 Speed limitaon 134
8.1.4 Ramp me 136
8.2 Congure setpoint sources 137
8.2.1 Keypad 137
8.2.2 Setpoint presets 138
8.2.3 Motor potenometer (MOP) 138
8.3 Process input data (CiA 402 objects) 139
8.4 Process output data (CiA 402 objects) 139
8.5 Setpoint diagnoscs 139
Contents
5

9Conguring the motor control 140
9.1 Sensorless vector control (SLVC) 141
9.1.1 Required commissioning steps 141
9.1.2 Expert sengs 142
9.2 V/f characterisc control for asynchronous motor (VFC open loop) 143
9.2.1 Required commissioning steps 143
9.2.2 Basic seng 143
9.2.3 Dene V/f characterisc shape 144
9.2.3.1 Linear V/f characterisc 145
9.2.3.2 Square-law V/f characterisc 146
9.2.4 Set voltage boost 147
9.2.5 Set slip compensaon 148
9.2.6 Set oscillaon damping 150
9.2.7 Opmising the stalling behaviour 151
9.2.8 Torque limitaon seng 153
9.2.9 Flying restart circuit 154
9.3 Parameterisable motor funcons 156
9.3.1 Skip frequencies 156
9.3.2 DC braking 158
9.3.2.1 Example: Automac DC braking when starng the motor 159
9.3.2.2 Example: Automac DC braking when stopping the motor 160
9.3.2.3 Acvang DC braking manually 162
9.3.2.4 Migraon of Lenze Inverter Drives 8200/8400 164
9.3.3 Holding brake control 165
9.3.3.1 Basic seng 166
9.3.3.2 "Automac" brake mode (automac operaon) 167
9.3.3.3 Brake holding load 168
9.3.3.4 Brake closing threshold 170
9.3.3.5 Manual release of the holding brake 172
9.3.4 Load loss detecon 174
9.4 Opons for opmizing the control loops 175
9.4.1 Automac motor idencaon (energized) 178
9.4.2 Automac motor calibraon (non-energized) 179
9.4.3 Tuning of the motor and the speed controller 180
9.4.4 Inverter characterisc 181
9.4.4.1 Extended sengs for idencaon 181
9.4.5 Motor equivalent circuit diagram data 181
9.4.6 Motor control sengs 183
9.4.6.1 Speed controller 184
9.4.6.2 Current controller 185
9.4.6.3 ASM eld controller 185
9.4.6.4 ASM eld weakening controller 185
9.4.6.5 ASM eld weakening controller (extended) 186
9.4.6.6 Imax controller 187
9.4.6.7 Flying restart controller 188
9.4.6.8 SLVC controller 188
Contents
6

9.5 Motor protecon 189
9.5.1 Motor overload monitoring (i²*t) 190
9.5.2 Overcurrent monitoring 194
9.5.3 Motor phase failure detecon 195
9.5.4 Motor speed monitoring 196
9.5.5 Motor torque monitoring 197
9.5.6 Maximum overload current of the inverter 199
9.5.7 Heavy load monitoring 201
10 I/O extensions and control connecons 203
10.1 Congure digital inputs 203
10.2 Congure analog inputs 205
10.2.1 Analog input 1 205
10.2.1.1 Example: Input range 0 ... 10 V = seng range 0 ... 50 Hz 207
10.2.1.2 Example: Input range 0 ... 10 V = seng range -40 ... +40 Hz 208
10.2.1.3 Example: Error detecon 208
10.2.2 Analog input 2 209
10.3 Congure digital outputs 211
10.3.1 Relay output 211
10.3.2 Digital output 1 215
10.4 Congure analog outputs 216
10.4.1 Analog output 1 216
10.4.1.1 Example: Output voltage 0 ... 10 V = output frequency 0 ... 100 Hz 217
10.4.1.2 Example: Output voltage 2 ... 10 V = output frequency 30 ... 60 Hz 218
11 Device funcons 219
11.1 Opcal device idencaon 219
11.2 Reset parameters to default 220
11.3 Saving/loading the parameter sengs 221
11.4 Switching frequency changeover 224
11.5 Device overload monitoring (i*t) 225
11.6 Heatsink temperature monitoring 225
11.7 Automac restart aer a fault 226
11.8 Update device rmware 227
11.8.1 Firmware download with »EASY Starter (rmware loader)« 227
12 Addional funcons 228
12.1 Brake energy management 228
12.1.1 Stopping the deceleraon ramp funcon generator 229
12.1.2 Inverter motor brake 230
12.2 Parameter change-over 231
12.2.1 Example: Selecve control of several motors with one inverter 232
12.2.1.1 232
12.2.2 Parameter set conguraon 233
12.2.3 Device commands for parameter change-over 234
12.2.4 Funcons for parameter change-over 236
12.2.4.1 Example: Acvaon via command (only when disabled) 238
12.2.4.2 Example: Acvaon via command (immediately) 239
12.2.4.3 Example: Acvaon if the selecon is changed (only if the inverter is disabled) 240
12.2.4.4 Example: Acvaon if the selecon is changed (immediately) 241
12.3 Trigger acon if a frequency threshold is exceeded 242
Contents
7

13 Using accessories 244
13.1 Keypad 244
13.1.1 Keypad operang mode 245
13.1.1.1 Keypad status display 245
13.1.1.2 Funcon of keypad keys in operang mode 246
13.1.1.3 Error reset with keypad 247
13.1.2 Keypad parameterisaon mode 248
13.1.2.1 Parameter groups 248
13.1.2.2 Funcon of the keypad keys in the parameterisaon mode 249
13.1.2.3 Save parameter sengs with keypad 250
13.1.2.4 Display of status words on keypad 251
13.1.2.5 Keypad parameter list 252
13.1.3 Keypad sengs 265
13.1.3.1 Select language 265
13.1.3.2 Change setpoint increment 265
13.1.3.3 Congure status display 265
13.1.3.4 Congure R/F and CTRL keys 266
14 Diagnoscs and fault eliminaon 268
14.1 LED status display 268
14.2 Logbook 269
14.3 Error history buer 270
14.4 Diagnosc parameters 273
14.4.1 Inverter diagnoscs 274
14.4.2 I/O diagnoscs 278
14.4.2.1 Digital inputs and outputs 278
14.4.2.2 Analog inputs and outputs 279
14.4.3 Service life diagnoscs 280
14.4.4 Device idencaon 281
14.4.5 CiA 402 objects 282
14.5 Error handling 284
14.5.1 Error types 285
14.5.1.1 Timeout for error response 286
14.5.2 Error conguraon 287
14.5.3 Error reset 287
14.6 Error codes, causes and remedies 290
15 Technical data 308
15.1 Standards and operang condions 308
15.1.1 Conformies/approvals 308
15.1.2 Protecon of persons and device protecon 308
15.1.3 EMC data 308
15.1.4 Motor connecon 309
15.1.5 Environmental condions 309
15.1.6 Electrical supply condions 309
15.2 1-phase mains connecon 230/240 V 310
15.2.1 Rated data 310
16 Appendix 311
16.1 Parameter aribute list 311
16.2 Glossary 333
Contents
8

1 About this document
WARNING!
Read this documentaon carefully before starng any work.
▶Please observe the safety instrucons!
1.1 Document descripon
1.1.1 Further documents
For certain tasks, informaon is available in further documents.
Document Contents/topics
Conguraon document Basic informaon on conguring and ordering the product
Commissioning document Basic informaon on installing and commissioning the product
Quick Reference Card Brief informaon on the operaon and device properes of the product
For certain tasks, informaon is available in other forms.
Form Contents/topics
Engineering Tools For commissioning
AKB arcles Applicaon Knowledge Base with addional technical informaon for users
CAD data Exports in dierent formats
EPLAN macros Project planning, documentaon and management of projects for P8.
•Data reference via Lenze or EPLAN data portal
Informaon and tools with regard to the Lenze products can be found on the
Internet: hp://www.lenze.com à Downloads
About this document
Document descripon
Further documents
9

1.2 Notaons and convenons
This document uses the following convenons to disnguish dierent types of informaon:
Numeric notaon
Decimal separator Point The decimal point is always used.
Example: 1 234.56
Warning
UL warning UL Are used in English and French.
UR warning UR
Text
Engineering tools » « Soware
Example: »Engineer«, »EASY Starter«
Icons
Page reference ¶Reference to another page with addional informaon
Example: ¶ 16 = see page 16
Documentaon reference ,Reference to another documentaon with addional informaon
Example: , EDKxxx = see documentaon EDKxxx
Layout of the safety instrucons
DANGER!
Indicates an extremely hazardous situaon. Failure to comply with this instrucon will result
in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situaon. Failure to comply with this instrucon may result
in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situaon. Failure to comply with this instrucon may result in slight to
medium injury.
NOTICE
Indicates a material hazard. Failure to comply with this instrucon may result in material
damage.
About this document
Notaons and convenons
10

2 Safety instrucons
Disregarding the following basic safety measures and safety informaon may lead to severe
personal injury and damage to property!
Observe all specicaons of the corresponding documentaon supplied. This is the
precondion for safe and trouble-free operaon and for obtaining the product features
specied.
Please observe the specic safety informaon in the other secons!
2.1 Basic safety instrucons
DANGER!
Danger to life due to electrical voltage!
The product's power connecons can sll be carrying voltage when the mains supply has been
switched o.
Possible consequences: Death, severe injury, or burns
▶Do not touch the power connecons immediately.
▶Take note of the corresponding warning plates on the product.
▶Check power terminals for isolaon from supply.
DANGER!
Dangerous electrical voltage
Possible consequences: Death or severe injuries from electric shock
▶Any work on the device must only be carried out in a deenergized state.
▶Aer switching o the mains voltage, observe the signs on the product.
DANGER!
Incorrect sengs during commissioning may cause unexpected and dangerous motor and
system movements.
Possible consequences: death, severe injuries or damage to property
▶Clear hazardous area.
▶Observe safety instrucons and safety clearances.
Personnel
The product must only be used by qualied personnel. IEC 60364 or CENELEC HD 384 dene
the skills of these persons:
•They are familiar with installing, mounng, commissioning, and operang the product.
•They have the corresponding qualicaons for their work.
•They know and can apply all regulaons for the prevenon of accidents, direcves, and
laws applicable at the place of use.
Process engineering
The procedural notes and circuit details described are only proposals. It is up to the user to
check whether they can be adapted to the parcular applicaons. Lenze does not take any
responsibility for the suitability of the procedures and circuit proposals described.
Safety instrucons
Basic safety instrucons
11

2.2 Applicaon as directed
•The product must only be operated under the operang condions prescribed in this
documentaon.
•The product meets the protecon requirements of 2014/35/EU: Low-Voltage Direcve.
•The product is not a machine in terms of 2006/42/EU: Machinery Direcve.
•Commissioning or starng the operaon as directed of a machine with the product is not
permied unl it has been ensured that the machine meets the regulaons of the EU
Direcve 2006/42/EU: Machinery Direcve; observe EN 60204−1.
•Commissioning or starng operaon as directed is only permissible if the EMC Direcve
2014/30/EU is complied with.
•The harmonised standard EN 61800−5−1 is applied.
•The product is not a household appliance, but is only designed as a component for
commercial or professional use in terms of EN 61000−3−2.
•The product can be used according to the technical data if drive systems have to comply
with categories according to EN 61800−3.
In residenal areas, the product may cause EMC interferences. The operator is responsible
for taking interference suppression measures.
•The product must only be actuated with motors that are suitable for the operaon with
inverters.
-Lenze L-force motors meet the requirements
-Excepon: m240 motors are designed for mains operaon only.
2.3 Handling
•Never commission the product in the event of visible damage.
•The product must never be technically modied.
•Never commission the product before assembly has been completed.
•The product must never be operated without required covers.
•Establish, separate and change all electrical connecons only in deenergised state!
Safety instrucons
Handling
12

2.4 Residual hazards
DANGER!
Danger to life due to electrical voltage!
The product's power connecons can sll be carrying voltage when the mains supply has been
switched o.
Possible consequences: Death, severe injury, or burns
▶Do not touch the power connecons immediately.
▶Take note of the corresponding warning plates on the product.
▶Check power terminals for isolaon from supply.
Product
Observe the warning labels on the product!
Icon Descripon
Electrostac sensive devices:
Before working on the product, the sta must ensure to be free of electrostac charge!
Dangerous electrical voltage
Before working on the product, make sure there is no voltage applied to the power terminals!
Aer mains disconnecon, the power terminals will sll carry the hazardous electrical voltage for the me given next to the
symbol!
High leakage current:
Carry out xed installaon and PE connecon in compliance with EN 61800−5−1 or EN 60204−1!
Hot surface:
Use personal protecve equipment or wait unl the device has cooled down!
Motor protecon
With some sengs of the inverter, the connected motor can be overheated.
•E. g. by longer operaon of self-venlated motors at low speed.
•E. g. by longer operaon of the DC-injecon brake.
Protecon of the machine/system
Drives can reach dangerous overspeeds.
•E. g. by seng high output frequencies in connecon with motors and machines not
suitable for this purpose.
•The inverters do not provide protecon against such operang condions. For this
purpose, use addional components.
Switch contactors in the motor cable only if the controller is inhibited.
•Switching while the inverter is enabled is only permissible if no monitoring funcons are
acvated.
Motor
If there is a short circuit of two power transistors, a residual movement of up to 180°/number
of pole pairs can occur at the motor! (e. g. 4-pole motor: residual movement max. 180°/2 =
90°).
Degree of protecon - protecon of persons and device protecon
•Informaon applies to the mounted and ready-for-use state.
•Informaon does not apply to the wire range of the terminals.
-Terminals that are not assigned only have a low protecon against contact.
Safety instrucons
Residual hazards
13

3 Product informaon
3.1 Idencaon of the products
Product code
I 4 1 A E □□
□□ 1 X □ □ □ □□□□
Product type Inverter I
Product family i400 4
Product i410 1
Product generaon Generaon 1 A
Mounng type Control cabinet installaon E
Rated power [W]
(Examples)
0.25 kW 125
0.75 kW 175
2.2 kW 222
Mains voltage and connecon type 1/N/PE AC 230/240 V B
Motor connecons Single axis 1
Integrated funconal safety Without 0
Degree of protecon IP20 0
IP20, coated V
Interference suppression Without 0
Integrated RFI lter 1
Design types Global type 50 Hz 0
Basic I/O without network 000S
Example:
Product code Meaning
I41AE215B10010000S Inverter i410 Cabinet, 1.5 kW, single-phase, 230V/240 V
IP20, integrated RFI lter, 50-Hz version
Basic I/O without network
Product informaon
Idencaon of the products
14

4 Commissioning
The purpose of commissioning is to adapt the inverter as part of a machine with a variable-
speed drive system to its drive task.
4.1 Important notes
DANGER!
Incorrect wiring can cause unexpected states during the commissioning phase.
Possible consequences: death, severe injuries or damage to property
Ensure the following before switching on the mains voltage:
▶Wiring must be complete and correct.
▶Wiring must be free of short circuits and earth faults.
▶The motor circuit conguraon (star/delta) must be adapted to the inverter output voltage.
▶The motor must be connected in-phase (direcon of rotaon).
▶The "emergency o" funcon of the overall system must operate correctly.
DANGER!
Incorrect sengs during commissioning may cause unexpected and dangerous motor and
system movements.
Possible consequences: death, severe injuries or damage to property
▶Clear hazardous area.
▶Observe safety instrucons and safety clearances.
Commissioning
Important notes
15

4.2 Inial switch-on and funconal test
Drive behavior by default
By default, the V/f characterisc control with a linear characterisc is preset as motor control
for asynchronous motors. The V/f characterisc control is a motor control for convenonal
frequency inverter applicaons. It is based on a simple and robust control mode for the
operaon of asynchronous motors with a linear or are-law load torque characterisc (e. g.
fan). Because of the minimal parameterizaon eort, such applicaons can be commissioned
easily and quickly.
The default sengs of the parameters ensure that the inverter is ready for operaon
immediately and the motor works adequately without further parameterizaon if an
inverter and an asynchronous motor* with matching performances are assigned to each
other.
* Device/mains frequency 50-Hz asynchronous motor.
Funconal test
Target: the motor connected to the inverter should rotate as quickly as possible.
Requirements:
•The connected motor matches the inverter in terms of power.
•The parameter sengs correspond to the state upon delivery.
1.Preparaon
1. Wire the power connecons. See the mounng and switch-on instrucon for more
details.
2. Wire digital inputs X3/DI1 (start/stop), X3/DI3 (reversal) and X3/DI4 (frequency preset
20 Hz).
3. Do not connect terminal X3/AI1 (analog setpoint selecon) or connect it to GND.
Start/
Stop
1 DI 3 DI 4 DI
24V
X3
20 Hz
2.Switch on mains and check readiness for operaon
1. Switch on mains voltage.
2. Observe LED status displays "RDY" and "ERR" on the front of the inverter:
a) If the blue "RDY" LED is blinking and the red "ERR" LED does not light up, the inverter
is ready for operaon. The controller is inhibited.
You can now start the drive.
b) If the red "ERR" LED is lit permanently, a fault is pending.
Eliminate the fault before you carry on with the funconal test.
Commissioning
Inial switch-on and funconal test
16

Carry out funconal test
1.Start drive
1. Start inverter: X3/DI1 = HIGH.
2. Acvate frequency preset 1 (20 Hz) as speed setpoint: X3/DI4 = HIGH.
The drive rotates with 20 Hz.
3. Oponal: acvate the funcon for the reversal of rotaon direcon.
a) X3/DI3 = HIGH.
The drive rotates at 20 Hz in the opposite direcon.
b) Deacvate the funcon for the reversal of rotaon direcon again: X3/DI3 = LOW.
Speed characterisc (example)
t
0
50
60
20
5 s 5 s
-20
t
DI3 t
DI4 t
AI1 [V]
0
10
t
DI1 Drive follows frequency setpoint
Speed setpoint selection via X3/ 1 activeAI
(In this example X3/ 1 is connected to )AI GND
Preset frequency
setpoint 1 (20 Hz)
Invert rotation active
f [Hz]
set
Preset frequency setpoint 1 active
2.Stop drive
1. Deacvate frequency preset 1 again: X3/DI4 = LOW.
2. Stop inverter again: X3/DI1 = LOW.
The funconal test has been completed.
Related topics
4Funcon assignment of the inputs and outputs (default seng)^ 38
4LED status display^ 268
4Error codes, causes and remedies^ 290
Commissioning
Inial switch-on and funconal test
17

4.3 Operang interfaces
Depending on the inverter, there are one or several opons for accessing the device
parameters that are available for customizing the drive task.
Simple access to the device parameters is provided by the Lenze Engineering
Tool »EASY Starter«. Connecon X16 is used as an interface for an engineering PC in this case.
4.3.1 Keypad
The keypad is an easy means for the local operaon, parameterizaon, and diagnoscs of the
inverter.
Funcon of keypad keys in operang mode
Key Actuaon Condion Acon
Briey Local keypad control acve.
Display "LOC"
Run motor.
Remote control acve
Display "REM"
Display "KSTOP"
Deacvate keypad triggered stop.
The motor remains at standsll.
Display changes from "KSTOP" to "STOP".
Briey No Jog operaon Stop motor.
Display "KSTOP"
Briey Operang mode Change to parameterisaon mode.
4Keypad parameterisaon mode ^ 248
Longer than 3 s None (anyme possible) Save parameter sengs in the user memory of the memory
module.
Briey During operaon Scroll through informaon in the above status line.
Briey Manual setpoint selecon via keypad
acve.
Display "MAN"
Change frequency setpoint.
CTRL
Briey Operang mode Acvate full keypad control
Display "ON?" à Conrm with
Control and setpoint selecon can now only be carried out via
keypad.
Renewed clicking: Exit full keypad control.
Display "OFF?" à Conrm with
4Keypad full control ^ 47
RF
Briey Local keypad control acve.
Display "LOC"
Reversal of rotaon direcon.
Display "REV?" à Conrm with
4Congure R/F and CTRL keys ^ 266
Detailed informaon on the keypad can be found in the Chapter "Using accessories".
4Keypad ^ 244
Commissioning
Operang interfaces
Keypad
18

4.3.2 Engineering tool »EASY Starter«
The »EASY Starter« is a PC soware that is especially designed for the commissioning and
diagnoscs of the inverter.
•»EASY Starter« Download
Sample screenshot:
Commissioning
Operang interfaces
Engineering tool »EASY Starter«
19

4.3.2.1 Generate a connecon between inverter and »EASY Starter«
For commissioning the inverter with the »EASY Starter«, a wired communicaon link with the
inverter is required.
Precondions
•A USB module and a USB 2.0 cable (A plug on Micro-B plug) are required for wired
communicaon.
Commissioning
Operang interfaces
Engineering tool »EASY Starter«
20