Lenze i55AE125B User manual

Inverter
Inverter i550 Cabinet 0.25 ... 90 kW
Commissioning | EN

Contents
1 General informaon 15
1.1 Read rst, then start 15
2 Safety instrucons 16
2.1 Basic safety measures 16
2.2 Residual hazards 17
2.3 Applicaon as directed 17
3 Mechanical installaon 18
3.1 Dimensions 18
4 Electrical installaon 28
4.1 Important notes 28
4.2 Mains connecon 29
4.2.1 1-phase mains connecon 120 V 29
4.2.1.1 Connecon plan 29
4.2.1.2 Fusing and terminal data 30
4.2.2 1-phase mains connecon 230/240 V 32
4.2.2.1 Connecon plan 32
4.2.2.2 Fusing and terminal data 34
4.2.3 3-phase mains connecon 230/240 V 37
4.2.3.1 Connecon plan 37
4.2.3.2 Fusing and terminal data 39
4.2.4 3-phase mains connecon 400 V 41
4.2.4.1 Connecon plan 41
4.2.4.2 Fusing and terminal data 42
4.2.5 3-phase mains connecon 400 V "light duty" 47
4.2.5.1 Connecon plan 47
4.2.5.2 Fusing and terminal data 48
4.2.6 3-phase mains connecon 480 V 52
4.2.6.1 Connecon plan 52
4.2.6.2 Fusing and terminal data 53
4.2.7 3-phase mains connecon 480 V "Light Duty" 58
4.2.7.1 Connecon plan 58
4.2.7.2 Fusing and terminal data 59
4.3 Control connecons 63
4.4 Networks 64
4.4.1 CANopen 64
4.4.2 Modbus RTU 65
4.4.3 Modbus TCP 66
4.4.4 PROFIBUS 67
4.4.5 EtherCAT 68
4.4.6 EtherNet/IP 68
4.4.7 PROFINET 69
4.4.8 POWERLINK 70
4.5 Connecon of the safety module 70
Contents
3

5 Commissioning 71
5.1 Important notes 71
5.2 Operang interfaces 72
5.2.1 Keypad 72
5.2.2 Engineering tool »EASY Starter« 73
5.2.2.1 Generate a connecon between inverter and »EASY Starter« 74
5.3 Parameter seng 76
5.3.1 General notes on parameters 77
5.3.2 Basic inverter sengs 78
5.3.3 Basic motor sengs 81
5.3.4 Funcon assignment of the inputs and outputs 82
5.4 Keypad parameter list 85
5.5 Save parameter sengs in the memory module 107
5.5.1 Save parameter sengs with keypad 107
5.5.2 Save parameter sengs with »EASY Starter« 107
6Diagnoscs and fault eliminaon 108
6.1 LED status display 108
6.2 Diagnoscs parameter 109
6.2.1 Logbook 110
6.2.2 Error history buer 111
6.2.3 Inverter diagnoscs 114
6.2.4 Network diagnoscs 118
6.2.4.1 CANopen diagnoscs 119
6.2.4.2 Modbus diagnoscs 122
6.2.4.3 PROFIBUS diagnoscs 122
6.2.4.4 EtherNet/IP diagnoscs 125
6.2.4.5 PROFINET diagnoscs 126
6.2.4.6 EtherCAT diagnoscs 127
6.2.4.7 POWERLINK diagnoscs 128
6.2.5 Diagnoscs of the inputs and outputs 129
6.2.5.1 Digital inputs and outputs 129
6.2.5.2 Analog inputs and outputs 130
6.2.6 Wireless-LAN diagnoscs 132
6.2.7 Setpoint diagnosc 133
6.2.8 Process controller status 133
6.2.9 Sequencer diagnoscs 134
6.2.10 Device idencaon 135
6.2.11 Device overload monitoring (i*t) 136
6.2.12 Heatsink Temperature Monitoring 137
6.2.13 Life-diagnosis 137
6.3 Error handling 139
6.3.1 Error types 139
6.3.2 Error conguraon 140
6.3.3 Error reset 140
6.3.4 Keypad error messages 140
6.4 Data handling 141
Contents
4

7 Basic seng 143
7.1 Mains voltage 144
7.2 Inverter load characterisc 146
7.3 Control source selecon 147
7.4 Selecon of setpoint source 148
7.4.1 Keypad setpoint default seng 151
7.5 Starng/stopping performance 153
7.5.1 Starng performance 153
7.5.2 Stopping performance 155
7.6 Frequency limits and ramp mes 156
7.7 Quick stop 159
7.8 S-shaped ramps 161
7.9 Opcal device idencaon 162
Contents
5

8 Motor control 163
8.1 Motor data 164
8.1.1 Manual seng of the motor data 164
8.2 Motor control selecon 165
8.2.1 V/f characterisc control (VFC) 166
8.2.1.1 Linear V/f characterisc 167
8.2.1.2 Square-law V/f characterisc 168
8.2.1.3 User-denable V/f characterisc 169
8.2.1.4 V/f characterisc control - energy-saving (VFC Eco) 170
8.2.2 V/f characterisc control (VFC closed loop) 172
8.2.3 Sensorless vector control (SLVC) 173
8.2.4 Servo control for asynchronous motors (SC-ASM) 176
8.2.5 Sensorless control for synchronous motors (SL-PSM) 178
8.2.5.1 Stall monitoring 181
8.3 Opmisaon of motor control 182
8.3.1 V/f voltage boost 183
8.3.2 Skip frequencies 184
8.3.3 Opmising the stalling behaviour 186
8.3.4 Slip compensaon 188
8.3.5 Oscillaon damping 190
8.3.6 Pole posion idencaon without movement 191
8.4 Opmisaon of the control loops 193
8.4.1 Opons for opmized motor tuning 196
8.4.1.1 Motor selecon from motor catalogue 197
8.4.1.2 Tuning of the motor and the speed controller 198
8.4.1.3 Automac motor idencaon (energized) 199
8.4.1.4 Automac motor calibraon (non-energized) 200
8.4.2 Inverter Characteriscs 200
8.4.3 Motor equivalent circuit diagram data 201
8.4.4 Motor controller sengs 202
8.4.4.1 Current controller 202
8.4.4.2 Field controller 203
8.4.4.3 Field weakening controller 203
8.4.4.4 Field weakening controller (advanced) 203
8.4.4.5 Imax controller 204
8.4.4.6 Flying restart controller 205
8.4.4.7 SLVC controller 205
8.4.4.8 Torque control w/ freq. limit 206
8.4.4.9 Slip controller 210
8.4.5 Speed controller 211
8.5 Motor rotang direcon 212
8.6 Switching frequency changeover 213
Contents
6

8.7 Motor protecon 214
8.7.1 Motor overload monitoring (i²*t) 215
8.7.2 Motor temperature monitoring 219
8.7.3 Current limits 220
8.7.4 Overcurrent monitoring 222
8.7.5 Motor phase failure detecon 223
8.7.6 Motor speed monitoring 224
8.7.7 Motor torque monitoring 224
Contents
7

9Conguring the network 226
9.1 General network sengs 227
9.2 Predened process data words 246
9.2.1 Device prole CiA 402 247
9.2.2 AC Drive Prole 248
9.2.3 Lenze LECOM prole 249
9.2.4 Further process data 251
9.2.5 Parameter access monitoring (PAM) 257
9.2.6 Process data handling in case of error 258
9.3 Acyclic data exchange 258
9.4 CANopen 259
9.4.1 Introducon 259
9.4.2 Node address seng 260
9.4.3 Baud rate seng 261
9.4.4 Congure device as mini master 262
9.4.5 Diagnoscs 263
9.4.6 Emergency telegram 264
9.4.7 Heartbeat protocol 264
9.4.8 Process data objects 266
9.4.9 Data mapping 271
9.4.10 Service data objects 274
9.4.11 Error responses 275
9.4.12 Diagnosc counter 276
9.4.13 LED status displays 277
9.4.14 Restart communicaon 278
9.4.15 Short setup 279
9.5 Modbus RTU 282
9.5.1 Introducon 282
9.5.2 Node address seng 282
9.5.3 Baud rate seng 283
9.5.4 Data format seng 283
9.5.5 Time-out monitoring 284
9.5.6 Diagnoscs 284
9.5.7 Funcon codes 287
9.5.8 Data mapping 289
9.5.9 LED status displays 290
9.5.10 Restart communicaon 291
9.5.11 Response me seng 291
9.5.12 Short setup 292
Contents
8

9.6 PROFIBUS 294
9.6.1 Introducon 294
9.6.2 Communicaon me seng 294
9.6.3 Staon address seng 295
9.6.4 Baud rate seng 296
9.6.5 Monitoring 296
9.6.6 LED status displays 298
9.6.7 Diagnoscs 298
9.6.8 Funcons 299
9.6.9 Data mapping 300
9.6.10 Parameter data transfer 303
9.6.11 Read parameter data 305
9.6.12 Write parameter data 308
9.6.13 Error codes for parameter data transfer 311
9.6.14 Restart communicaon 312
9.6.15 Short setup 313
9.7 EtherNet/IP 316
9.7.1 Basic sengs 317
9.7.2 Monitoring 320
9.7.3 LED status displays 322
9.7.4 Diagnoscs 322
9.7.5 Objects 324
9.7.6 Restart communicaon 331
9.7.7 Process data transfer 332
9.7.7.1 Customer specic conguraons 337
9.7.8 Parameter data transfer 342
9.7.9 Short setup 346
9.8 Modbus TCP 348
9.8.1 Introducon 348
9.8.2 Basic sengs 349
9.8.3 Time-out behaviour 351
9.8.4 LED status displays 352
9.8.5 Diagnoscs 353
9.8.6 Funcon codes 355
9.8.7 Data mapping 360
9.8.8 Short setup 362
9.8.9 Restart communicaon 363
9.8.10 Baud rate seng 363
9.9 PROFINET 365
9.9.1 Introducon 365
9.9.2 Basic sengs 366
9.9.3 LED status displays 368
9.9.4 Diagnoscs 368
9.9.5 Monitoring 370
9.9.6 Data mapping 371
9.9.7 Parameter data transfer 375
9.9.8 Short setup 377
Contents
9

9.10 EtherCAT 383
9.10.1 Device idencaon 384
9.10.2 EtherCAT conguraon 385
9.10.3 LED status displays 386
9.10.4 Diagnoscs 386
9.10.5 Monitoring 387
9.10.6 Objects 388
9.10.7 Process data transfer 389
9.10.8 Parameter data transfer 393
9.10.9 Short setup 394
9.11 POWERLINK 396
9.11.1 Introducon 396
9.11.2 Basic sengs 397
9.11.3 LED status displays 398
9.11.4 Diagnoscs 399
9.11.5 Process data transfer 399
9.11.6 Monitoring 400
9.11.7 Error response 400
9.11.8 Supported objects 400
9.11.9 Short setup 406
10 Conguring the process controller 407
10.1 Basic process controller sengs 408
10.2 Process controller - idle state and rinse funcon 414
10.2.1 Process controller idle state 414
10.2.2 Process controller rinse funcon 416
Contents
10

11 Addional funcons 417
11.1 Device Commands 418
11.1.1 Reset parameters to default 418
11.1.2 Saving/loading the parameter sengs 419
11.1.3 Device commands for parameter change-over 421
11.1.4 Delete logbook 421
11.2 Keypad 422
11.2.1 Keypad language selecon 422
11.2.2 Keypad setpoint increment 422
11.2.3 Keypad scaling of speed display 422
11.2.4 Keypad status display 422
11.2.5 Keypad - Conguraon of R/F and CTRL buons 423
11.3 Wireless LAN (WLAN) 426
11.3.1 WLAN LED status displays 426
11.3.2 WLAN basic sengs 427
11.3.2.1 Reseng WLAN sengs to default seng 429
11.3.3 WLAN access point mode 430
11.3.3.1 Establishing a direct WLAN connecon between smartphone and inverter 431
11.3.3.2 Using the smartphone as "Smart Keypad" 432
11.3.3.3 Establishing a direct WLAN connecon between Engineering PC and inverter 433
11.3.4 WLAN client mode 435
11.4 DC braking 437
11.4.1 Example 1: Automac DC braking when the motor is started 439
11.4.2 Example 2: Automac DC braking when the motor is stopped 440
11.4.3 Migraon of Lenze Inverter Drives 8200/8400 442
11.5 Brake energy management 443
11.5.1 Use of a brake resistor 445
11.5.2 Stopping the deceleraon ramp funcon generator 447
11.5.3 Inverter motor brake 448
11.6 Load loss detecon 449
11.7 Access protecon 450
11.7.1 Write access protecon 450
11.7.1.1 Write access protecon in the »EASY Starter« 452
11.7.1.2 Write access protecon in the keypad 455
11.8 Favorites 459
11.8.1 Accessing the "Favorites" with the keypad 459
11.8.2 Favorites parameter list (default seng) 460
11.8.3 Conguring the "Favorites" 461
11.9 Parameter change-over 464
11.9.1 Example: Selecve control of several motors with one inverter 467
11.10 Device prole CiA 402 469
11.11 Holding brake control 472
11.11.1 Basic seng 473
11.11.2 "Automac" brake mode (automac operaon) 474
11.11.3 Brake holding load 476
11.11.4 Brake closing level 478
11.11.5 Manual release of the holding brake 480
11.12 Flying restart circuit 481
11.13 Timeout für fault reacon 483
Contents
11

11.14 Automac restart 484
11.15 Mains failure control 485
11.15.1 Acvang the mains failure control 487
11.15.2 Restart protecon 488
11.15.3 Fast mains recovery 488
11.15.4 Commissioning the mains failure control 489
11.16 UPS operaon 490
11.17 Process data 493
11.17.1 Posion counter 493
11.18 Encoder sengs 495
11.18.1 HTL encoder 496
11.18.2 Encoder monitoring 498
11.19 Firmware download 501
11.19.1 Firmware download with »EASY Starter (Firmware loader)« 501
11.20 Addive voltage impression 502
11.20.1 Example: Using the funcon with a 400-V inverter 503
12 Sequencer 504
12.1 Segment conguraon 506
12.2 Sequence conguraon 516
12.3 Sequencer basic sengs 520
13 Safety funcons 523
13.1 Safe torque o (STO) 523
Contents
12

14 Flexible I/O conguraon 525
14.1 Control source change-over 526
14.1.1 Example 1: Change-over from terminal control to keypad control 529
14.1.2 Example 2: Change-over from terminal control to network control 530
14.2 Start / stop motor 531
14.2.1 Example 1: Start/stop (1 signal) and reversal 537
14.2.2 Example 2: Start forward/start reverse/stop (edge-controlled) 538
14.2.3 Example 3: Run forward/Run reverse/stop (status-controlled) 540
14.2.4 Example 4: Quick stop 542
14.2.5 Example 5: Jog forward/Jog reverse 543
14.2.6 Example 6: Enable inverter 545
14.3 Setpoint change-over 546
14.3.1 Priority of the setpoint sources 548
14.3.2 Analog input setpoint source 548
14.3.3 Keypad setpoint source 551
14.3.4 Network setpoint source 553
14.3.5 Setpoint source of preset setpoints 554
14.3.6 Motor potenometer setpoint source (MOP) 559
14.3.7 Setpoint source segment setpoints 563
14.3.8 HTL input setpoint source 565
14.3.8.1 Example 1: Input range 10 ... 85 kHz ≡ seng range 0 ... 50 Hz 569
14.3.8.2 Example 2: Input range 10 ... 85 kHz ≡ seng range -50 ... 50 Hz 569
14.4 Reset error 570
14.5 Acvang DC braking manually 572
14.6 Releasing holding brake manually 574
14.7 Acvang ramp 2 manually 576
14.8 Triggering a user-dened fault 578
14.9 Funcons for parameter change-over 579
14.9.1 Example 1: Acvaon via command (only when disabled) 581
14.9.2 Example 2: Acvaon via command (immediately) 582
14.9.3 Example 3: Acvaon if the selecon is changed (only if the inverter is disabled) 583
14.9.4 Example 4: Acvaon if the selecon is changed (immediately) 584
14.10 Process controller funcon selecon 585
14.11 Sequencer control funcons 588
14.12 Frequency threshold for "Frequency threshold exceeded" trigger 593
14.13 Conguraon of digital inputs 594
14.14 Conguraon of analog inputs 597
14.14.1 Analog input 1 597
14.14.1.1 Example 1: Input range 0 ... 10 V ≡ seng range 0 ... 50 Hz 599
14.14.1.2 Example 2: Input range 0 ... 10 V ≡ seng range -40 ... +40 Hz 599
14.14.1.3 Example 3: Input range -10 ... +10 V ≡ seng range -40 ... +40 Hz 600
14.14.1.4 Example 4: Error detecon 600
14.14.2 Analog input 2 601
Contents
13

14.15 Conguraon of digital outputs 603
14.15.1 Relay 603
14.15.2 Digital output 1 607
14.15.3 Digital output 2 608
14.15.4 NetWordOUT1 status word 609
14.15.5 HTL output 612
14.15.5.1 Example 1: Pulse train 0 ... 10 kHz ≡ output frequency 0 ... 100 Hz 615
14.15.5.2 Example 2: Pulse train 2 ... 10 kHz ≡ output frequency 30 ... 60 Hz 616
14.16 Conguraon of analog outputs 617
14.16.1 Analog output 1 617
14.16.1.1 Example 1: Output voltage 0 ... 10 V ≡ output frequency 0 ... 100 Hz 619
14.16.1.2 Example 2: Output voltage 2 ... 10 V ≡ output frequency 30 ... 60 Hz 619
14.16.2 Analog output 2 620
15 Technical data 622
15.1 Standards and operang condions 622
15.1.1 Conformies/approvals 622
15.1.2 Protecon of persons and device protecon 622
15.1.3 EMC data 622
15.1.4 Motor connecon 623
15.1.5 Environmental condions 623
15.1.6 Electrical supply condions 623
15.2 1-phase mains connecon 120 V 624
15.2.1 Rated data 624
15.3 1-phase mains connecon 230/240 V 625
15.3.1 Rated data 625
15.4 3-phase mains connecon 230/240 V 626
15.4.1 Rated data 626
15.5 3-phase mains connecon 400 V 627
15.5.1 Rated data 627
15.6 3-phase mains connecon 400 V "light duty" 628
15.6.1 Rated data 628
15.7 3-phase mains connecon 480 V 629
15.7.1 Rated data 629
15.8 3-phase mains connecon 480 V "Light Duty" 630
15.8.1 Rated data 630
16 Appendix 631
16.1 Operate and parameterise the inverter with keypad 631
16.1.1 Keypad operang mode 632
16.1.1.1 Keypad status display 632
16.1.1.2 Funcon of keypad keys in operang mode 633
16.1.1.3 Error reset with keypad 634
16.1.2 Keypad parameterisaon mode 635
16.1.2.1 Parameter groups 635
16.1.2.2 Funcon of the keypad keys in the parameterisaon mode 636
16.1.2.3 Save parameter sengs with keypad 637
16.1.2.4 Display of status words on keypad 638
16.2 Error codes 639
16.3 Parameter aribute list 659
Contents
14

1 General informaon
1.1 Read rst, then start
WARNING!
Read this documentaon thoroughly before carrying out the installaon and commissioning.
▶Please observe the safety instrucons!
Informaon and tools with regard to the Lenze products can be found on the
Internet:
hp://www.lenze.com à Download
General informaon
Read rst, then start
15

2 Safety instrucons
2.1 Basic safety measures
Disregarding the following basic safety measures may lead to severe personal injury and dam-
age to material assets!
The product
•must only be used as directed.
•must never be commissioned if they display signs of damage.
•must never be technically modied.
•must never be commissioned if they are not fully mounted.
•must never be operated without required covers.
Connect/disconnect all pluggable terminals only in deenergised condion.
Only remove the product from the installaon in the deenergised state.
Insulaon resistance tests between 24V control potenal and PE: According to EN 61800−5−1,
the maximum test voltage must not exceed 110 V DC.
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.
The procedural notes and circuit details described in this document 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 descri-
bed.
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.
Please observe the specic notes in the other chapters!
Notes used:
DANGER!
This note refers to an imminent danger which, if not avoided, may result in death or serious
injury.
WARNING!
This note refers to a danger which, if not avoided, may result in death or serious injury.
CAUTION!
This note refers to a danger which, if not avoided, may result in minor or moderate injury.
NOTICE
This note refers to a danger which, if not avoided, may result in damage to property.
Safety instrucons
Basic safety measures
16

2.2 Residual hazards
The user must take the residual hazards menoned into consideraon in the risk assessment
for his/her machine/system.
If the above is disregarded, this can lead to severe injuries to persons and damage to material
assets!
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, check if no voltage is applied to the power terminals!
Aer mains disconnecon, the power terminals carry the hazardous electrical voltage given on the product!
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 devices have cooled down!
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! (For 4-pole motor: residual movement max. 180°/2 =
90°).
2.3 Applicaon as directed
•The product must only be operated under the operang condions prescribed in this doc-
umenta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/EC: 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 EC
Direcve 2006/42/EC: Machinery Direcve; observe EN 60204−1.
•Commissioning or starng the operaon as directed is only allowed when there is compli-
ance with the EMC Direcve 2014/30/EU.
•The harmonised standard EN 61800−5−1 is used for the inverters.
•The product is not a household appliance, but is only designed as component for commer-
cial 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.
Safety instrucons
Applicaon as directed
17

3 Mechanical installaon
3.1 Dimensions
0.25 kW ... 0.37 kW
The dimensions in mm apply to:
0.25 kW I55AE125B I55AE125D
0.37 kW I55AE137B I55AE137D I55AE137F
Mechanical installaon
18

0.25 kW ... 0.37 kW
The dimensions in mm apply to:
0.25 kW I55AE125A
0.37 kW I55AE137A
Mechanical installaon
Dimensions
19

0.55 kW ... 0.75 kW
The dimensions in mm apply to:
0.55 kW I55AE155B I55AE155D I55AE155F
0.75 kW I55AE175B I55AE175D I55AE175F
Mechanical installaon
Dimensions
20