Lust CDA3000 User manual

C
CDA3000
The easy route
to your drive solution
EN
EN
FR
ES
Engineering
Guide
Inverter drive system
to 90 kW
With drive engineering
formula bank

Overview of documentation
Engineering Guide CDA3000
ID no.: 0840.25B.1-00 Sheets for Engineering Guide
Date: December 1999
We reserve the right to make technical changes.
Before purchase
With shipment
(depending on supply
pakkage)
C
CDA3000 Catalogue Engineering Guide
CDA3000
Selecting and ordering a
drive system
Dimensioning a drive
system
CDA3000 Operation
Manual
User Manual
DRIVEMANAGER and KEYPAD
Application Manual
Traction and lifting
drives, Rotational drives
Quick and easy initial
commissioning
Operation via
DRIVEMANAGER and KEYPAD
Adaptation of the drive
system to the application
CANLust Communication
Module Manual
CANopen Communica-
tion Module Manual
PROFIBUS-DP Communi-
cation Module Manual
Project planning, installa-
tion and commissioning of
the CDA3000 on the field
bus
Project planning, installa-
tion and commissioning of
the CDA3000 on the field
bus
Project planning, installa-
tion and commissioning of
the CDA3000 on the field
bus
C
D
E
F1
G1
G2
G3

Engineering Guide CDA3000
DE
EN
FR
About this manual This guide is intended for users looking for background information
relating to the engineering of inverter drives.
The term “engineering” (or “project planning”) in this context covers the
design and configuration of complex technical systems through to receipt
of the order to implement. General project planning tasks including:
➢ Analysis of the task
➢ Concept design of the system
➢ Design of the system components
➢ Selection of the best solution to be implemented.
How to use this
manual
1 Analysis of task
2 Definition of drive
Appendix: Formula bank, Copy templates
Bibliography and index
Table of contents A
3 Selection of inverter module
4 Selection of user and communication
modules
5 Selection of supplementary components
6 Tips for system installation
1
2
3
4
5
6
System overview, Revision history
Project planning process

Engineering Guide CDA3000
Project planning
flowchart
STEPS SECTION
1. Record movement task in
processing process
➢ Basics - see section 1
➢ Checklist for recording
the task - see section 2.1
2. Calculate drive variables,
such as power output, torque,
speed, etc. ➢ See sections 2.2 to 2.4
3. Select motor, transmission gear
and gearing ➢ See sections 2.5 to 2.6
4. Select inverter module and
software performance
➢ See section 3
➢ See section 6
5. Select user
and/or communication
modules ➢ See section 4
6. Select supplementary
components such as filters,
line choke, etc. ➢ See section 5

Engineering Guide CDA3000
DE
EN
FR
Drive system layout
System modules Section
(1) Inverter module See section 3
(2) DRIVEMANAGER PC user software See section 4.1.4
(3) KEYPAD control unit See section 4.1.3
(4) Line choke See section 6.1
(5) Software performance - Preset solutions See section 4.2
(6) I/O terminal expansion See section 4
(7) CANLust, CANopen,
Profibus-DP bus interface See section 5.3
(8) Braking resistor See section 6.3
(9) Motor chokes See section 6.2
(10) HF spindle See section 2.5.5
(11) Asynchronous servomotor See section 2.5.2
(12) IEC standard motor See section 2.5.1
(13) Geared motor See section 2.5
,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,@@ÀÀ ,,yy
12
12
12
34567 89
10 11 12
12 16 17 18 19 20
34567 8910
11 12
12 16 17 18 19 20
D
RIVE
M
ANAGER
Netz/ Main
SMART
CARD
SMART
CARD
SMART CARD
start
enter stop
return
H1 H2 H3
X4
X2
X1 X3
ACHTUNG
Kondensatorent-
ladezeit >3 Min.
Betriebsanleitung
beachten!
WARNING
capacitor disscharge
time >3 minutes.
Pay attention to the
operation manual!
ATTENTION
temps de decharge
du condensteur
>3 min. observer le
mode dèmploi!
!
ANTRIEBSTECHNIK
SN.:
000.000.00000000
Typ:
Netz:
Ausg.:
D-35633Lahnau
m2
(5)
(1)
(2)
(3) (6)
(7)
(8)
(9)
(4)
(10)
(11)
(12)
(13)

Engineering Guide CDA3000
1 Analysis of task
1.1 Systematic thinking ................................................1-2
1.1.1 Inverter system .................................................... 1-2
1.1.2 System environment ............................................1-3
1.2 Process analysis ..................................................... 1-4
1.2.1 Example of a process analysis in comparison
with functional analysis .......................................1-4
1.3 Characteristic values of machinery .......................1-9
1.3.1 Movement requirement .......................................1-9
1.3.2 Moment of inertia ..............................................1-12
1.3.3 Manipulating range and accuracy ...................... 1-13
1.3.4 Load torque .......................................................1-19
2 Drive definition
2.1 Recording of movement task .................................2-2
2.2 Drive definition via normogram ............................. 2-6
2.2.1 Example of solution with four-pole motor ............ 2-7
2.2.2 Example of solution with six-pole motor ............. 2-8
2.3 Drive definition via power rating ............................2-9
2.3.1 Example 1: Traction drive ..................................2-10
2.3.2 Example 2: Lifting drive .....................................2-12
2.4 Drive definition via LUDRIVE PC PROGRAM ...............2-13
2.4.1 Example 1: Trolley drive for gantry crane ...........2-15
2.4.2 Example 2: Belt turning station for truck engine
distribution ........................................................2-20
2.5 Selection of motor ................................................2-24
2.5.1 Characteristic values of standard three-phase
AC motors .........................................................2-26
2.5.2 Characteristic values of asynchronous
servomotors ASx ...............................................2-35
2.5.3 Characteristic values of reluctance motors ........ 2-41
2.5.4 Characteristic values of synchronous motors .....2-44
2.5.5 Characteristic values of high-frequency motors .2-47

Engineering Guide CDA3000
DE
EN
FR
2.6 Selection of gearing ..............................................2-48
2.6.1 Transmission gear .............................................2-48
2.6.2 Characteristic values of standard gears ..............2-49
2.6.3 Characteristic values of planetary gears .............2-49
3 Selection of inverter module
3.1 Technical data .........................................................3-3
3.1.1 Acceptance tests .................................................3-5
3.1.2 Ambient conditions ..............................................3-6
3.1.3 Installation and cooling methods ..........................3-7
3.2 Extreme operating conditions ..............................3-14
3.2.1 Mains side/system condition ..............................3-16
3.2.2 Loading on the supply system ............................3-20
3.2.3 General points on the mains connection .............3-21
3.2.4 Operation of fault current breakers .....................3-23
3.2.5 Switching at the inverter input ...........................3-24
3.2.6 High-voltage test/Insulation test .........................3-24
3.2.7 Forming of the DC-link capacitors ......................3-25
3.2.8 Direction of rotation and terminal designation ....3-27
3.2.9 Switching at the inverter output .........................3-28
3.2.10 Short-circuit and ground fault proofing ...............3-29
3.2.11 Motor cable length .............................................3-29
3.2.12 Voltage load on the motor winding .....................3-31
3.2.13 Motor protection possibilities .............................3-31
3.2.14 Power reduction .................................................3-33
3.2.15 Calculation of effective inverter capacity
utilization ...........................................................3-55
3.2.16 Measurement on the inverter module .................3-58
3.3 Special applications ..............................................3-60
3.3.1 Project planning for three-phase AC motors .......3-60
3.3.2 Efficiency of the motor control methods .............3-62
3.3.3 Standard inverter operation ................................3-67
3.3.4 70 Hz characteristic with 25% field weakening ..3-69
3.3.5 87 Hz characteristic / Expanded manipulating
range .................................................................3-73
3.3.6 Multi-motor operation on one inverter ................3-76
3.3.7 DC network operation ........................................3-79
3.3.8 Design of the braking resistor ............................3-83
3.3.9 Power failure bridging ........................................3-87

Engineering Guide CDA3000
4 Software functions
4.1 User interface and data structure ..........................4-2
4.1.1 Data structure .....................................................4-2
4.1.2 Initial commissioning ........................................... 4-6
4.1.3 Operation via KEYPAD KP200 ..............................4-11
4.1.4 Operation via DRIVEMANAGER .............................. 4-12
4.2 Device and terminal view .....................................4-15
4.2.1 Specification of control terminals ....................... 4-16
4.2.2 Isolation method and connection tips ................. 4-19
4.3 Preset solutions .................................................... 4-20
4.3.1 Traction and lifting drive .................................... 4-24
4.3.2 Rotational drive ................................................. 4-39
4.3.3 Field bus operation ............................................4-49
4.3.4 Master/Slave operation ......................................4-56
5 Communication and user modules
5.1 Principle of function ............................................... 5-2
5.2 User module ............................................................ 5-3
5.3 CAN-BUS ................................................................. 5-4
5.3.1 Interconnection of inverter modules on the
CAN bus ..............................................................5-6
5.3.2 Communication via CANLUST .................................5-8
5.3.3 Communication via CANopen ..............................5-12
5.4 PROFIBUS-DP ........................................................5-13
5.4.1 Interconnection of LUST drive units with the
PROFIBUS-DP Gateway ...................................... 5-14
5.4.2 Interconnection via the PROFIBUS-DP module ....5-17
5.4.3 Communication via PROFIBUS-DP .....................5-18

Engineering Guide CDA3000
DE
EN
FR
6 Selection of supplementary components
6.1 Line choke ...............................................................6-2
6.1.1 Effect of the line choke ........................................6-2
6.1.2 Operation with reactive current compensation
system .................................................................6-4
6.1.3 Technical data of line chokes LR3x.xxx ................6-6
6.1.4 Assignment of line choke to inverter module ........6-7
6.2 Motor choke ............................................................6-8
6.2.1 Technical data of the motor chokes .....................6-8
6.2.2 Assignment to the inverter modules ...................6-10
6.3 Braking resistors ...................................................6-12
6.3.1 Technical data of series BRxxx, xx-xx ................6-12
6.3.2 Assignment to inverter modules CDA3000 .........6-13
6.4 Radio interference suppression filter ...................6-14
6.4.1 Technical data of RFI filters EMC34.xxx ..............6-14
6.4.2 Permissible motor cable length with internal
RFI filter .............................................................6-15
6.4.3 Permissible motor cable length with internal
and external RFI filter .........................................6-16
6.4.4 Permissible motor cable length with external
RFI filter .............................................................6-16
7 System installation
7.1 Heat discharge from the switch cabinet ................7-2
7.1.1 Basic terms for calculation ...................................7-2
7.1.2 Effective switch cabinet surface ...........................7-3
7.1.3 Calculation of filter fans .......................................7-4
7.1.4 Calculation of heat exchangers ............................7-5
7.2 Heat transfer by heat conductance ........................7-7
A Formula bank
A.1 Mathematical symbols ........................................... A-2
A.1.1 SI units ................................................................A-2

Engineering Guide CDA3000
A.1.2 Important units ....................................................A-4
A.2 Drive engineering equations ..................................A-5
A.2.1 Basic physical equations .....................................A-5
A.2.2 Power ..................................................................A-6
A.2.3 Torques .............................................................A-11
A.2.4 Work .................................................................A-12
A.2.5 Friction ..............................................................A-14
A.2.6 Effective motor torque/power output ..................A-15
A.2.7 Choice of max. acceleration ...............................A-17
A.2.8 Mass moments of inertia ...................................A-20
A.2.9 V/t diagram ........................................................A-27
A.2.10 Efficiencies, coefficients of friction and density ..A-30
A.2.11 Motor lists .........................................................A-34
A.3 Protection ..............................................................A-40
A.3.1 Protection to IEC/EN ...........................................A-40
A.3.2 Protection to EEMAC and Nema .........................A-43
B Practical working aids for the project
engineer
C Bibliography and source reference
D Index

Engineering Guide CDA3000 1-1
DE
EN
FR
1
2
3
4
5
6
7
A
1 Analysis of task
1.1 Systematic thinking ................................................1-2
1.1.1 Inverter system ....................................................1-2
1.1.2 System environment ............................................1-3
1.2 Process analysis .....................................................1-4
1.2.1 Example of a process analysis in comparison with
functional analysis ...............................................1-4
1.3 Characteristic values of machinery .......................1-9
1.3.1 Movement requirement ........................................1-9
1.3.2 Moment of inertia ..............................................1-12
1.3.3 Manipulating range and accuracy ......................1-13
1.3.4 Load torque .......................................................1-19
Take your time, especially at
the beginning
Please note: The more complex the task, the more important is the analy-
sis. A “better” analysis can identify impending failures in good time.
"Good" "Better"
Complexity Complexity
Analysis Analysis
Intuition/experience
Intuition/experience
Decision
Decision
Time and
cost saving

1-2
Engineering Guide CDA3000
1 Analysis of task
1.1 Systematic
thinking
efore beginning your project planning you should read through this
section - it will help you identify how to attain the new solutions you
need.
What can we learn from system analysis? The term "system" in this
context means:
Thinking differently
[leads to]
Belief
[in turn resulting in]
Acting differently
➢ a unified whole, distinct from its surroundings
➢ comprising individual elements
➢ between which fixed relationships exist
➢ and which perform specific functions.
The starting point for any system analysis is to record, understand and
order the existing inter-relationships within a system. To this end, the sys-
tem is split down into its subsidiary areas (components) such that all the
individual components are distinct from each other and the relations
between them become visible.
1.1.1 Inverter system An inverter system comprises the following individual components and
modules:
The chain is only as strong as
its weakest link
Figure 1.1 Inverter system
B
• Inverter module • Motor choke
• Operator module • Braking resistor
• User module • Cable
• Communication module • Motors
• Software modules •Gearing
• Line choke •etc.
• Mains filter
Software
modules
Inverter
module
User
module Motor
Comm.
module
Braking
resistor Line choke
Services
Gearing
Interface
to the
System
environment

Engineering Guide CDA3000 1-3
1 Analysis of task
DE
EN
1
2
3
4
5
6
7
A
In summary: An inverter system is a combination of standalone
products and services which create new usable drive
system properties with added value.
1.1.2 System
environment
Analysis of the system environment of inverter drives reveals four inter-
faces which outline that environment:
1. Interface to the processing process
2. Interface to the automation process
3. Interface to the surrounding environment and installation conditions
4. Interface to the requirements arising from standards, regulations and
safety concerns
Figure 1.2 System environment
This section deals with the interface to the “processing process”. The
other interfaces are dealt with in the subsequent sections of the guide.
Processing process
ML= f (n, s, )
Automation
process Standards,
regulations
and safety
Environmental
and installation
conditions
Software
modules
Inverter
module
User
module Motor
Comm.
module
Braking
resistor Line choke
Services
Gearing

1-4
Engineering Guide CDA3000
1 Analysis of task
1.2 Process analysis irst find out what processing process1the drive solution is to be used
for. Apply the principles of process analysis, because process analy-
sis will provide you with a non-solution-specific view of the task at hand.
Do not perform a functional analysis at the beginning of an analysis,
because the functions used always describe the specific solution.
The functional analysis is derived from the value analysis. Its main role is
to eliminate dual functions and to cut the cost per function.2
1.2.1 Example of a
process analysis
in comparison
with functional
analysis
Standard screw-type extruder
➢ An extruder is a machine which takes in solid to liquid (synthetic)
molding compounds and presses them out of an opening, for the
most part continuously.
It compresses, mixes, plasticizes and homogenizes the compound in
the process.
The screw-type extruder shown (see Figure 1.3) principally comprises a
drive unit and a plasticizer unit. The plasticizer unit consists of a screw
cylinder, a screw, a material funnel, and heating and cooling zones.
Figure 1.3 Schematic of an extruder
1. Processing process: Process in the course of which energy, information and/or material is transformed
and conveyed
2. The value analysis method was developed in 1948 by the Purchasing department of General Electric.
Literature: DIN 69910 and VDI 2801.
F
(1) Screw
(2) Cylinder
(3) Heater
(4) Funnel
(5) Gearing
(6) Motor
(1) (2) (3) (4) (5)
(6)

Engineering Guide CDA3000 1-5
1 Analysis of task
DE
EN
1
2
3
4
5
6
7
A
The drive unit is formed by a regulated DC drive, gearing and the screw
return thrust bearing, which absorbs the forces occurring during convey-
ing and plasticizing.
Figure 1.4 Load characteristic of the plastics extruder
Task for a new drive unit
In order to provider a higher degree of machine availability, the drive is to
be switched from DC to three-phase AC. The DC drive used to date has a
speed manipulating range of 1:1000 and an overload capacity to 200%.
ML= f (n)
P = f (n)
(1) DC controller
(2) DC motor
(3) Tacho
(4) Gearing
(5) Screw return thrust bearing
Figure 1.5 Old solution with DC drive
n
ML,
P
PML
M
M
1~
T
(1) (2)
(4) (5)
(3)

1-6
Engineering Guide CDA3000
1 Analysis of task
Functional analysis
In a functional analysis each component which performs a function must
merely be replaced by another one. In this case this means:
• the DC motor is replaced by an AC motor
• the tacho is replaced by a digital encoder and
• the DC controller is replaced by an inverter with field-oriented regula-
tion.
Figure 1.6 Solution from functional analysis
The functional analysis produces a solution with speed feedback - See
Table 1.1.
(1) Inverter with field-oriented regulation
(2) AC motor
(3) Encoder
(4) Gearing
(5) Screw return thrust bearing
DC drive Three-phase AC drive
1 DC controller 1 Inverter with field-oriented regulation
2 DC motor 2 AC motor
3 Tacho 3 Encoder
4 Gearing 4 Gearing
5 Screw return thrust bearing 5 Screw return thrust bearing
Old solution Functional analysis (NEW 1)
Table 1.1 Comparison between old solution and solution from functional
analysis
~M
3~
M
1~
(1) (2)
(4) (5)
(3)
~

Engineering Guide CDA3000 1-7
1 Analysis of task
DE
EN
1
2
3
4
5
6
7
A
Process analysis
A process analysis establishes what demands the processing process
places on the drive.
Questions to be answered:
1. What is the movement requirement for processing?
2. Moment of inertia of the processing machine, referred to the motor
shaft?
3. What manipulating range is required for the processing process?
4. What load torque needs to be overcome?
Answer the questions in this example:
1. Continuous material flow.
2. Is of no significance in applications with continuous material flow.
3. Speed manipulating range of 1:10.
4. No overload necessary, because the screw of the extruder would
otherwise be damaged. When the screw has become clogged, it is
drawn forward out of the extruder for cleaning.
The answers supplied in the process analysis deliver a solution with a
standard inverter without speed feedback. This means a substantial cost
reduction.
Figure 1.7 Solution from process analysis
~M
3~
~

1-8
Engineering Guide CDA3000
1 Analysis of task
Comparison of solutions:“Functional analysis / Process analysis”
In summary: Always analyze the processing process! Because just
because something is
known does not necessarily
mean it is recognized !
Solution from functional analysis Solution from process analysis
NEW 1
Inverter with field-oriented regulation
NEW 2
Inverter with VFC
Figure 1.8 Comparison of solutions
~M
3~
M
1~
~
$
~M
3~
M
1~
~
$

Engineering Guide CDA3000 1-9
1 Analysis of task
DE
EN
1
2
3
4
5
6
7
A
1.3 Characteristic
values of
machinery
ou do not usually need to take account of the detailed structure of the
machinery for drive project planning. It can be adequately described
by:
1. the movement requirement for processing
2. the moment of inertia of the processing machine, referred to the
motor shaft
3. the manipulating range and accuracy of the torque, speed and posi-
tion
4. the characteristic over time of the load torque
1.3.1 Movement
requirement
The movement requirement for processing is roughly divided into three
groups.
Y
Movement requirements
for processing
Continuous Discontinuous
Continuous material flow
Paper machinery
Textile machinery
Batch processes
Stirrers
Mills
Unit processes
Packaging machinery
Optical machinery
Continuous material flow Material flow not continuous or irregular

1-10
Engineering Guide CDA3000
1 Analysis of task
Traction and mechanical function
The movement solution in the processing process in most cases involves
a traction function and a mechanical function. The mechanical function
usually generates a non-linear movement. The processing process coun-
teracts this movement with a specific load torque.
Figure 1.9 Movement solution in the processing process
Processing
material Processing
process
ML=f(n,s, j )Product
Mechanical
function
X(n2(t))
n2n1
n2
n1
M
3~
=
~~
Drive function with frequency inverter Drive function with servocontroller
Movement solution
X
Reference
Energy