Lust CDD3000-HF User manual

D
CDD3000-HF
Inverter Drive System
2.2 A - 32 A
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Operation Manual

Sizes (BG)
CDD3000-HF Operation Manual
ID No.: 0998.00B.1-00 • 03/2005
We reserve the right to make technical changes.
BG5
24...32A
BG4
14,0...17,0A
BG3
7,8...10,0A
BG2
5,5...5,7A
BG1
2,4...4,0A
CDD32.006-HF
CDD32.008-HF
CDD34.003-HF
CDD34.005-HF
CDD34.006-HF
CDD32.003-HF
CDD32.004-HF CDD34.008-HF
CDD34.010-HF CDD34.014-HF
CDD34.017-HF CDD34.024-HF
CDD34.032-HF
H1H2H3
X4
X2
X3
WARNING
capacitordisscharge
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tempsdedecharge
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ANTRIEBSTECHNIK
SN.:
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X1
L3
U
V
W
RB+
RB
L-
L1
L2
ACHTUNG
Kondensatorent-
ladezeit>3Min.
Betriebsanleitung
beachten!
X5X6X7
H1H2H3
X4
X2
X3
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Payattentionto the
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ANTRIEBSTECHNIK
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X1
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U
V
W
RB+
RB
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L1
L2
ACHTUNG
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Betriebsanleitung
beachten!
X5X6X7
X1
L3
U
V
W
RB+
RB
L-
L1
L2
H1H2H3
X4
X2
X3
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X5X6X7
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X1
L3
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L1
L2
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X5X6X7
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D

CDD3000-HF Operation Manual
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Dear user
Signposts
Step Action Comment
1
This Operation Manual will enable you
to install and commission the
CDD3000-HF drive system very
quickly and easily.
Guide to quick-starting
2
Simply follow the step-by-step tables
in sections 2/3/4.
Experience “Plug 'n Play” with the
CDD3000-HF.
And away you go!
1 Safety
2 Mechanical installation
Appendix: Technical data, Ambient conditions,
Project planning notes A
3 Installation
4 Commissioning
5 Diagnosis / Fault rectification
1
2
3
4
5
Table of contents
Appendix: Index B

CDD3000-HF Operation Manual
Overview
Documentation
If you want more information on the drive solutions presented here and
on the full scope of software features of the drive system, please refer to
the CDD3000 Application Manual. You can order the following
documents from us, or download them free of charge from our website at
www.lust-tec.de:
Pictograms
CDD3000-HF Operation
Manual
CDD3000-HF
Catalogue
Application Manual
CDD3000
Quick and easy initial
commissioning
Selecting and ordering a
drive system
Adaptation of the drive
system to the application
CANLust Communication
Module Manual
CANopen Communication
Module Manual
PROFIBUS-DPCommunication
Module Manual
Project planning,
installation and
commissioning of the
CDD3000-HF on the field
bus
Project planning,
installation and
commissioning of the
CDD3000-HF on the field
bus
Project planning, installation
and commissioning of the
CDD3000-HF on the field bus
D
C
F1
G1
G2
G3
➢ Attention! Misoperation may result in damage to the
drive or malfunctions.
➢ Dangerfromelectricaltension!Improperbehaviour
may endanger human life.
➢ Danger from rotating parts! The drive may start
running automatically.
➢ Note: Useful information.

CDD3000-HF Operation Manual
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1Safety
1.1 Measures for your safety ........................................1-1
1.2 Intended use ............................................................1-2
1.3 Responsibility ..........................................................1-2
2 Mechanical installation
2.1 Notes for operation .................................................2-1
2.2 Mounting variants ...................................................2-1
2.3 Wall mounting .........................................................2-3
2.4 Cold plate ................................................................2-5
2.5 Push-through heat sink (Dx.x) ...............................2-8
3 Installation
3.1 Overview ..................................................................3-2
3.2 Grounding lead connection .....................................3-4
3.3 Motor connection ....................................................3-5
3.3.1 Motor phase connection .......................................3-6
3.3.2 Motor temperature monitoring .............................3-7
3.3.3 Holding brake (if installed) ....................................3-8
3.3.4 production of encoder cables ...............................3-8
3.4 Mains connection ..................................................3-13
3.5 Braking resistor (RB) ............................................3-16
3.6 Control connections ..............................................3-17
3.6.1 Specification of control connections ...................3-18
3.6.2 Standard terminal assignment ...........................3-20
3.6.3 Isolation .............................................................3-21
3.7 EMC compliant installation ...................................3-22
3.8 Encoder simulation - Master encoder input ........3-23
3.8.1 Encoder simulation ............................................3-23
3.8.2 Master encoder ..................................................3-25

CDD3000-HF Operation Manual
4 Commissioning
4.1 Choice of commissioning .......................................4-2
4.2 Serial commissioning ............................................. 4-2
4.2.1 Serial commissioning with DRIVEMANAGER ............ 4-2
4.2.2 Serial commissioning with KEYPAD ...................... 4-4
4.3 Initial commissioning .............................................4-6
4.3.1 Selecting the unit for speed values ...................... 4-8
4.3.2 Selecting preset solution ..................................... 4-9
4.3.3 Setting the motor and encoder ........................... 4-11
4.3.4 Making basic settings ........................................ 4-13
4.3.5 Setting function parameters ............................... 4-14
4.3.6 Safety functions ................................................. 4-15
4.3.7 Motor filter ........................................................ 4-16
4.3.8 Switching frequency .......................................... 4-16
4.3.9 Saving settings .................................................. 4-17
4.4 Test run ................................................................. 4-18
4.5 Operation with DRIVEMANAGER ..............................4-22
4.6 Operation with KEYPAD KP200 ...............................4-24
5 Diagnosis/Fault rectification
5.1 LEDs ........................................................................ 5-1
5.2 Fault response ........................................................5-2
5.3 Error messages ....................................................... 5-3
5.4 Resetting errors ...................................................... 5-4
5.5 User errors in KEYPAD operation ............................. 5-5
5.6 User errors in SMARTCARD operation .......................5-5
5.7 Errors in power switching ...................................... 5-5
5.8 Reset ....................................................................... 5-6

CDD3000-HF Operation Manual
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A Appendix
A.1 Technical data ........................................................ A-2
A.2 Ambient conditions ................................................ A-8
A.3 Project planning notes, “Cold plate” .................... A-9
A.4 Change in system load
through use of a line choke ................................. A-10
A.5 UL approbation ..................................................... A-12
A.6 Layout ................................................................... A-14
B Index

CDD3000-HF Operation Manual

CDD3000-HF Operation Manual 1-1
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1
2
3
4
5
A
1Safety
1.1 Measures for
your safety
The CDD3000-HF servo drives are quick and safe to handle. For your
own safety and for the safe functioning of your device, please be sure to
observe the following points:
Read the Operation Manual first!
• Follow the safety instructions!
Electric drives are dangerous:
• Electrical voltages > 230 V/460 V:
Dangerously high voltages may still be present
10 minutes after the power is cut. You should therefore
always check that no power is being applied!
• Rotating parts
• Hot surfaces
Your qualification:
• In order to prevent personal injury and damage to
property, only personnel with electrical engineering
qualifications may work on the device.
• The qualified personnel must familiarize themselves with
the Operation Manual (refer to IEC364, DIN VDE0100).
• Knowledge of national accident prevention regulations
(e.g. VBG 4 in Germany)
During installation observe the following instructions:
• Always comply with the connection conditions and
technical specifications.
• Comply with the standards for electrical installations,
such as regarding wire cross-section, grounding lead and
ground connections.
• Do not touch electronic components and contacts
(electrostatic discharge may destroy components).

1-2
CDD3000-HF Operation Manual
1 Safety
1.2 Intended use Drive controllers are components for installation into electric systems or
machines.
When installed in machines the commissioning of the drive controller (i. e.
startup of intended operation) is prohibited, unless it has been
ascertained that the machine fully complies with the regulations of the
EC-directive 98/37/EC (Machine Directive); compliance with EN 60204 is
mandatory.
Commissioning (i. e. starting inteded operation) is only permitted when
strictly complying with EMC-directive (89/336/EEC).
For the drive controller the harmonized standards of series EN 50178/
DIN VDE 0160 in connection with EN 60439-1/ VDE 0660 part 500 and
EN 60146/ VDE 0558 are applied.
If the drive controller is used in special applications, e. g. in areas subject
to explosion hazards, the applicable regulations and standards (e. g. in
Ex-environments EN 50014 “General provisions” and EN 50018
“Flameproof housing”) must be strictly observed.
Repairs must only be carried out by authorized repair workshops.
Unauthorised opening and incorrect intervention could lead to physical
injury or material damage. The warranty granted by LUST will become
void.
1.3 Responsibility Electronic devices are never fail-safe. The company setting up and/or
operating the machine or plant is itself responsible for ensuring that the
drive is rendered safe if the device fails.
EN 60204-1/DIN VDE 0113 "Safety of machines", in the section on
"Electrical equipment of machines", stipulates safety requirements for
electrical controls. They are intended to protect personnel and machinery,
and to maintain the function capability of the machine or plant concerned,
and must be observed.
An emergency stop system does not necessarily have to cut the power
supply to the drive. To protect against danger, it may be more beneficial to
keep individual drives running or to initiate specific safety sequences.
Execution of the emergency stop measure is assessed by means of a risk
analysis of the machine or plant, including the electrical equipment in
accordance with DIN EN 1050, and is determined by selecting the circuit
category in accordance with DIN EN 954-1 "Safety of machines - Safety-
related parts of controls".
The CDD3000-HF complies with the low voltage directive 73/
23/EEC

CDD3000-HF Operation Manual 2-1
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1
2
3
4
5
A
2 Mechanical installation
2.1 Notes for operation .................................................2-1
2.2 Mounting variants ...................................................2-1
2.3 Wall mounting .........................................................2-3
2.4 Cold plate ................................................................2-5
2.5 Push-through heat sinks (Dx.x) ..............................2-8
2.1 Notes for
operation
Please ensure that ...
• no damp enters the device
• no aggressive or conductive substances are in the immediate vicinity
• no drill chippings, screws or foreign bodies drop into the device
• the vent openings are not covered over.
The device may otherwise be damaged.
2.2 Mounting
variants
Step Action Comment
1Refer to the name plate to find out the
mounting variant of your drive controller.
The mounting variants differ in
their mode of cooling.
Name plate Mounting and cooling variant Continued
on
CDD3...-HF,Wx.x Wall
mounting Page 2-3
CDD3...-HF,Cx.x Cold plate Page 2-5
CDD3...-HF,Dx.x
Push-
through heat
sink
Page 2-8
Mounting and cooling variants
Cx.x
Dx.x
Wx.x

2-2
CDD3000-HF Operation Manual
2 Mechanical installation
Attention: When mounting drive controller for highspeed drives sizes
BG 1 and BG 2, version C x.x (cold plate) directly on the
switch cabinet wall, a clearance A must be maintained. This
clearance A must be sufficient for the screwdriver to be
inserted.
Note: If the installation prevents the clearance A from being
maintained, the mounting set CDD (order no. 0927.0017) is
available. See Order Catalogue for highspeed drive systems
(order no. 1000.24B.0).
The clearance to devices of different power classes must be
at least 20 mm. The minimum mounting clearance of the
other devices must also be taken into account.
A

CDD3000-HF Operation Manual 2-3
2 Mechanical installation
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1
2
3
4
5
A
2.3 Wall mounting
Figure 2.1 Mounting clearances (see Table 2.1)
Step Action Comment
1
Mark out the position of the tapped holes
on the backing plate.
Cut a tap for each fixing screw in the
backing plate.
Dimensional drawings/hole
spacing see Table 2.1.
The tapping area will provide
you with good, full-area contact.
2Mount the drive controller for highspeed
drives vertically on the backing plate.
Pay attention to the mounting
clearances!
The contact surface must be
metallically bright.
3
Mount the other components, such as the
mains filter, line choke etc., on the
backing plate.
Mains filter max. 20 cm below
the drive controller for
highspeed drives
4Continue with electrical installation in
section 3.
Note the following points:
• Air must be able to flow unhindered through the device.
• The backing plate must be well grounded.
• The best result for effective EMC installation is attained with a
chromated or galvanized backing plate. If backing plates are
varnished, the coating must be removed in the area of the contact
surface!
E
E1 G
FCM-xxxx
FUM-xxxx
38.5
60
30
60
With ventilator grille

2-4
CDD3000-HF Operation Manual
2 Mechanical installation
CDD3...-HF,Wx.x BG12) BG22) BG3 BG4 BG5
Weight [kg] 2.4 3.5 4.4 6.5 7.2
B (width) 70 70 120 170
H (height) 245 270 330
D (depth) 195 220 218
A404080130
C 235 260 320
D∅∅4.8 ∅4.8
Screws 4 x M4 4 x M4
E 3) 0
E1 (with module) 3) 45
F 3) 100
G 3) >300
1) Additionally allow enough space at the bottom for the bending radii of the
connecting cables.
2) Corresponding to cold plate version with accessory heat sink HS3X.xxx
3) Mounting clearances see Figure 2.1.
Table 2.1 Dimensional drawings: Wall mounting (dimensions in mm)
A
C
D∅
B
H
BG3
BG4
BG5
BG6
BG7
BG8
BG1
BG2
T
X5 X6 X7
A
C
D∅
T
B
H
X5 X6 X7
BG3
BG4
BG5
BG6
BG7
BG8

CDD3000-HF Operation Manual 2-5
2 Mechanical installation
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1
2
3
4
5
A
2.4 Cold plate
Figure 2.2 Mounting clearances (see Table 2.2)
Step Action Comment
1
Mark out the positions of the tapped
holes on the backing plate or the cooler.
Cut a tap for each fixing screw in the
backing plate.
Dimensional drawings/hole
spacing see Table 2.2.
The tapping area will provide
you with good, full-area contact.
2
Clean the contact surface and coat it
thinly and evenly with heat transfer
compound.
The contact surface must be
metallically bright.
3
Mount the drive controller for highspeed
drives vertically on the backing plate or
cooler. Tighten all screws to the same
tightness.
Pay attention to the mounting
clearances! Size of cooling
surface see Table 2.3.
4
Mount the other components, such as the
mains filter, line choke etc., on the
backing plate.
Mains filter max. 20 cm below
the drive controller for
highspeed drives
5Continue with electrical installation in
section 3.
F
E
G
FE1
UM-xxxx
CM-xxxx
60
30
With ventilator grille

2-6
CDD3000-HF Operation Manual
2 Mechanical installation
CDD3...-HF,Cx.x BG1 BG2 BG3 BG4 BG5
Weight [kg] 1.6 2.3 3.2 5.2 6.4
B (width) 70 70 100 150 200
H (height) 215 240 300
H (overall height with
ventilator) 235 260 - - -
D (depth) 120 145 150
A 50 85 135 185
C205230 200
C (with mounting set) 230 255 - - -
C1 – 100
D∅∅4.8 ∅5.5
Screws 4 x M4 6 x M5
E 1) 00
E1 (with module) 1) 45 15
F 1) 1002)
G 1) >300
1) Mounting clearances see Figure 2.2.
2) Additionally allow enough space at the bottom for the bending radii of the connecting cables.
Table 2.2 Dimensional drawings: Cold plate (dimensions in mm)
A
B
CH
D∅
T
A
C1
C
D∅
T
B
H
BG3
BG4
BG5
BG1
BG2
X5 X6 X7
X5 X6 X7

CDD3000-HF Operation Manual 2-7
2 Mechanical installation
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1
2
3
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A
Note the following points:
• Cooling can be attained either by a sufficiently large
backing plate (see Table 2.3) or by an additional cooler.
The cooler must be mounted centrally behind the
hottest area (1) of the device. See also “Project
planning notes, “Cold plate”” in Appendix A.3.
• The temperature on the rear panel of the drive
controller for highspeed drives must not exceed 85.0 °C. At a
temperature > 85 °C the device shuts down automatically. It can
only be restarted when it has cooled.
• Required evenness of contact surface = 0.05 mm, maximum
roughness of contact surface = roughness factor 6.3
(1)
Size Device rated
power
drive controller for
highspeed drives
PV[W]
at 4/
8-16 kHz
RthK 3)
[K/W]
Backing plate (unvarnished
steel min. cooling area
Ambient
temperature
BG1 1.0 kVA CDD32.003-HF,Cx.x 49 / 52 W 0.05 None 45°C
1.6 kVA CDD32.004-HF,Cx.x 63 / 70 W 0.05 650x100mm = 0.065m² 45°C1), 40°C2)
BG2
2.2 kVA CDD32.006-HF,Cx.x 90 / 97 W 0.05 650x460mm = 0.3m² 45°C1), 40°C2)
2.8 kVA CDD32.008-HF,Cx.x 110 / 120 W 0.05 650x460mm = 0.3m² 45°C1), 40°C2)
1.5 kVA CDD34.003-HF,Cx.x 70 / 85 W 0.05 None 45°C1), 40°C2)
2.8 kVA CDD34.005-HF,Cx.x 95 / 127 W 0.05 650x460mm = 0.3m² 45°C1), 40°C2)
3.9 kVA CDD34.006-HF,Cx.x 121 / 163 W 0.05
An additional cooler is required to supply
adequate cooling.
For project planning notes see Appendix A.3.
BG3 5.4 kVA CDD34.008-HF,Cx.x 150 / 177 W 0.03
6.9 kVA CDD34.010-HF,Cx.x 187 / 222 W 0.03
BG4 9.7 kVA CDD34.014-HF,Cx.x 225 / 283 W 0.02
11.8 kVA CDD34.017-HF,Cx.x 270 / 340 W 0.02
BG5 16.6 kVA CDD34.024-HF,Cx.x 330 / 415 W 0.015
22.2 kVA CDD34.032-HF,Cx.x 415 / 525 W 0.015
1) With a power stage clock frequency of 4 kHz
2) With a power stage clock frequency of 8/12/16 kHz
3) Thermal resistance between active cooling area and cooler
Table 2.3 Required cooling with cold plate
Note the following points:
• The backing plate must be grounded over a large area.
• The best result for effective EMC installation is attained with a
chromated or galvanized backing plate. If backing plates are
varnished, the coating must be removed in the area of the contact
surface!

2-8
CDD3000-HF Operation Manual
2 Mechanical installation
2.5 Push-through
heat sink (Dx.x)
Step Action Comment
1
Mark out the positions of the tapped
holes and the breakthrough on the
backing plate.
Cut a tap for each fixing screw in the
backing plate and cut out the
breakthrough.
Dimensional drawings/hole
spacing see Table 2.5.
The tapping area will provide you
with good, full-area contact.
2
Mount the drive controller for high-speed
drives vertically on the backing plate.
Tighten all screws to the same tightness.
Pay attention to the mounting
clearances! The mounting seal
must contact flush on the surface.
3
Mount the other components, such as the
mains filter, line choke etc., on the
backing plate.
Mains filter max. 20 cm below the
drive controller for highspeed
drives
4Continue with electrical installation in
section 3.
Note the following points:
• Distribution of power loss:
• The all-round mounting collar must be fitted with a seal. The seal
must fit flush on the surface and must not be damaged.
(1) Seal
(2) Tapped hole for
EMC contact
(3) Outside
(4) Inside
• The backing plate must be well grounded.
• The best result for effective EMC installation is attained with a
chromated or galvanized backing plate. If backing plates are
varnished, the coating must be removed in the area of the contact
surface!
BG3 BG4 BG5
Power loss Outside (3) 70% 75% 80%
Inside (4) 30% 25% 20%
Protection Heat sink side (3) IP54 IP54 IP54
Machine side (4) IP20 IP20 IP20
;;yy
;;yy
(4)
(3)
X5 X6 X7
;y
(1)
(2)

CDD3000-HF Operation Manual 2-9
2 Mechanical installation
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2
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A
Figure 2.3 Mounting clearances (see Table 2.5)
Dimensions of
breakthrough BG3 BG4 BG5
B (width) 75 125 175
H (height) 305 305 305
Table 2.4 Breakthrough for push-through heat sink (dimensions in mm)
F
E
E1
G
F
UM-xxxx
CM-xxxx
B
H
B
H

2-10
CDD3000-HF Operation Manual
2 Mechanical installation
CDD3...-HF,Dx.x BG3 BG4 BG5
Weight [kg] 4.6 6.7 7.4
B (width) 110 160 210
H (height) 340
D (depth) T1 138, T2 80 T1 138, T2 135
A90140 190
A1 – 80 100
C320
C1 200
D∅∅4.8 ∅4.8 ∅4.8
Screws 8 x M4 10 x M4 10 x M4
E 1) 10
E1 (with module) 1) 10
F 1) 100 2)
G 1) >300
1) Mounting clearances, see Figure 2.3
2) Additionally allow enough space at the bottom for the bending radii of the connecting cables.
Table 2.5 Dimensional drawings: push-through heat sink
(dimensions in mm)
A
C1
C
D∅
T1
T2
B
H
BG3
A1
A
C1
C
D∅
B
H
BG4
BG5
X5 X6 X7
For further ambient
conditions,
see appendix A.2