Moeller DF6-340 Series User manual

Hardware and Engineering
DF6-340-...
Frequency Inverters
01/02 AWB8230-1413GB
1st edition, 01/2002
© Moeller GmbH, Bonn
Author: Holger Friedrich, Jörg Randermann
Editor: Michael Kämper
Translator: Dominik Kreuzer
All brand and product names are trademarks or registered
trademarks of the owner concerned.
All rights reserved, including those of the translation.
No part of this manual may be reproduced in any form
(printed, photocopy, microfilm or any otherprocess) or processed,
duplicated or distributed by means of electronic systems without
written permission of Moeller GmbH, Bonn.
Subject to alterations without notice.
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I
Before commencing the installation
• Disconnect the power supply of the device.
• Ensure that devices cannot be accidentally restarted.
• Verify isolation from the supply.
• Earth and short circuit the device.
• Cover or enclose any adjacent live components.
• Follow the engineering instructions (AWA) for the
device concerned.
• Only suitably qualified personnel in accordance with
EN 50110-1/-2 (VDE 0105 Part 100) may work on this
device/system.
• Before installation and before touching the device ensure
that you are free of electrostatic charge.
• The functional earth (FE) must be connected to the protective
earth (PE) or the potential equalisation. The system installer is
responsible for implementing this connection.
• Connecting cables and signal lines should be installed so
that inductive or capacitive interference does not impair the
automation functions.
• Install automation devices and related operating elements in
such a way that they are well protected against unintentional
operation.
• Suitable safety hardware and software measures should be
implemented for the I/O interface so that an open circuit on the
signal side does not result in undefined states in the
automation devices.
• Ensure a reliable electrical isolation of the extra-low voltage of
the 24 V supply. Only use power supply units complying with
IEC 60364-4-41 (VDE 0100 Part 410) or HD384.4.41 S2.
• Deviations of the mains voltage from the rated value must
not exceed the tolerance limits given in the specifications,
otherwise this may cause malfunction and dangerous
operation.
• Emergency stop devices complying with IEC/EN 60204-1 must
be effective in all operating modes of the automation devices.
Unlatching the emergency-stop devices must not cause a
restart.
• Devices that are designed for mounting in housings or control
cabinets must only be operated and controlled after they have
been installed and with the housing closed. Desktop or
portable units must only be operated and controlled in
enclosed housings.
• Measures should be taken to ensure the proper restart of
programs interrupted after a voltage dip or failure. This should
not cause dangerous operating states even for a short time.
If necessary, emergency-stop devices should be implemented.
• Wherever faults in the automation system may cause injury or
material damage, external measures must be implemented to
ensure a safe operating state in the event of a fault or
malfunction (for example, by means of separate limit switches,
mechanical interlocks etc.).
• Depending on their degree of protection, frequency inverters
may contain live bright metal parts, moving or rotating
components or hot surfaces during and immediately after
operation.
• Removal of the required covers, improper installation or
incorrect operation of motor or frequency inverter may cause
the failure of the device and may lead to serious injury or
damage.
• The applicable national accident prevention and safety
regulations apply to all work carried on live frequency
inverters.
• The electrical installation must be carried out in accordance
with the relevant regulations (e. g. with regard to cable cross
sections, fuses, PE).
• Transport, installation, commissioning and maintenance work
must be carried out only by qualified personnel (IEC 60364,
HD 384 and national occupational safety regulations).
• Installations containing frequency inverters must be provided
with additional monitoring and protective devices in
accordance with the applicable safety regulations.
Modifications to the frequency inverters using the operating
software are permitted.
Moeller GmbH Safety instructions
Warning!
Dangerous electrical voltage!
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II
• All covers and doors must be kept closed during operation.
• To reduce the hazards for people or equipment, the user must
include in the machine design measures that restrict the
consequences of a malfunction or failure of the drive
(increased motor speed or sudden standstill of motor).
These measures include:
– Other independent devices for monitoring safety-related
variables (speed, travel, end positions etc.).
– Electrical or non-electrical system-wide measures
(electrical or mechanical interlocks).
– Never touch live parts or cable connections of the frequency
inverter after it has been disconnected from the power
supply. Due to the charge in the capacitors, these parts may
still be live after disconnection. Fit appropriate warning
signs.
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01/02 AWB8230-1413GB
1
About this Manual 5
Abbreviations and symbols 5
1 About the DF6 Frequency Inverter 7
System overview 7
Type code 8
Inspecting the package content 9
Layout of the DF6 10
– Features of the frequency inverters 11
Selection criteria 11
Intended use 12
Service and guarantee 12
2 Engineering 13
Performance features of the DF6 13
Connection to the power supply 15
– Mains configurations 15
– Mains voltage, mains frequency 15
– Interaction with p.f. correction equipment 15
– Fuses and cable cross-sections 15
– Protection of persons and domestic animals
with residual-current protective devices 16
– Mains contactor 16
– Current peaks 16
– Mains choke 17
– Mains filters and radio interference filters 17
EMC requirements 18
– EMC interference class 18
3 Installation 19
Installing the DF6 19
– Mounting position 19
– Installation dimensions 19
– Mounting the DF6 20
EMC compliance 21
– EMC-compliant installation 21
– Using the radio interference filter 21
– EMC measures in the control panel 23
– Earthing 24
– Screening 24
Electrical connection 26
– Connecting the power section 28
–Motorcable 37
– Connecting the control signal terminals 38
Contents
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Contents 01/02 AWB8230-1413GB
2
4 Operating the DF6 45
Initial startup 45
Keypad 46
Operation with LCD keypad 46
– Menu overview 47
– Changing display and Basic parameters 48
– Changing the parameters of the extended
parameter groups 48
Display after the supply voltage is applied 49
Connection examples 50
– Operation using an external potentiometer 50
– Operation through an analog setpoint value 50
– Operation with fixed frequencies 51
Operational warnings 52
5 Programming the Control Signal Terminals 53
Overview 53
Analog outputs – AM, AMI and FM 57
– Voltage output (AM) 57
– Current output (AMI) 58
– Frequency output (FM) 58
Analog inputs terminals O, O2 and OI 60
– Frequency setpoint definition 60
– Matching of terminals O, O2 and OI 61
– Analog setpoint value matching 62
Programmable digital inputs 1 to 5 65
– Start/stop 67
– Fixed frequency selection (FF1 to FF4) 68
– Bitwise fixed frequency selection (SF1 to SF7) 70
– Analog input changeover (AT) 72
– Second time ramp (2CH) 73
– Controller inhibit and coasting (free run stop – FRS) 74
– External fault message (EXT) 75
– Unattended start protection (USP) 76
– Reset (RST) 77
– Jog mode (JOG ) 78
– PTC/NTC thermistor input, terminal TH 80
– Software protection (SFT) 81
– Motor potentiometer functions: accelerate (UP) –
decelerate (DWN) – reset frequency (UDC) 82
– Use second parameter set (SET) 84
– Activate DC braking (DB) 85
– Change over current limit (OLR) 87
– Heavy mains starting (CS) 88
– Setpoint value through keypad (OPE) 90
– Three-wire control (STA – STP – F/R) 91
– Activate/deactivate PID control Reset PID and
integral component (PIDC) 92
Programmable relay outputs K11 to K34 93
– Signalling relay terminals K11, K12, K14 93
– Relay outputs K23-K24 and K33-K34 94
– Frequency arrival signal (FA1/FA2/FA3) 94
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01/02 AWB8230-1413GB Contents
3
– Run signal (RUN) 96
–Overloadsignal(OL) 97
– PID control deviation signal (OD) 98
– Fault signal (AL) 99
– Instant stop (IP) and undervoltage (UV) 99
– Running time (RNT) and Mains On time (ONT) 100
– Motor thermal overload (THM) 101
6 Setting Parameters 103
Setting the display parameters 104
Basic functions 105
– Input/display frequency value 105
– Acceleration time 1 105
– Deceleration time 1 106
– Direction of rotation 106
Setting the frequency and start signal parameters 107
– Defined frequency setpoint 107
– Start signal 108
– Base frequency 108
– End frequency 108
Voltage/frequency characteristic and voltage boost 109
–Boost 109
– Voltage/frequency characteristics 109
DC braking (DCB) 112
Operating frequency range 114
Acceleration pause 115
PID control 116
– PID control 116
– Structure and parameters of the PID controller 119
– Example for setting Kpand Ti125
– Application examples 126
Automatic voltage regulation (AVR) 128
Energy-saving mode 128
Time ramps 129
Acceleration and deceleration characteristics 130
Automatic restart after a fault 132
Electronic motor protection 135
– Tripping characteristics with increased
overload protection 135
– Tripping characteristic with normal overload protection 136
– Tripping characteristic at adjustable overload protection 136
Current limit 138
Parameter protection 139
Controlled deceleration 140
Other functions 142
– Inhibit direction 142
– Starting behaviour 142
–Displaymode 143
– Pulse frequency 144
– Initialization 147
– Country version 147
– Frequency factor for display through PNU d007 147
– OFF key disabled 147
– Motor restart after removal of the FRS signal 148
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Contents 01/02 AWB8230-1413GB
4
– Controlling the internal braking transistor
(11 and 15 kW only) 148
– Type of motor stop 149
– Fan control 149
–Debugmode 149
Motor data 149
User-defined parameters – parameter group U 150
7 Messages 151
Fault messages 151
– State of frequency inverter on fault message 151
– Fault message indication 151
– Fault history register 152
Other messages 154
Warnings 155
8 Troubleshooting 157
Appendix 159
Technical Data 159
Weights and dimensions 163
Cables and fuses 164
Mains contactors 165
Mains choke 165
RFI filter 166
Standard form for user defined parameter settings 167
Index 179
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01/02 AWB8230-1413GB
5
About this Manual
This manual describes the DF6 series frequency inverters.
This manual contains information you need to install, configure
and operate the DF6 frequency inverters. The features, parameters
and functions are described in detail, with examples for the most
important applications. All information applies to the specified
hardware and software versions.
Abbreviations and symbols
The following abbreviations and symbols are used in this manual:
All measurements are in millimetres unless otherwise stated.
In some of the illustrations, the enclosure of the frequency inverter
and other components affecting equipment safety have been
omitted for improved clarity. However, the frequency inverter must
always be operated with the enclosure and all necessary
components that affect equipment safety correctly fitted.
Read the manual thoroughly before you install and operate the
frequency inverter. We assume that you have a good knowledge
of engineering fundamentals and that you are familiar with the
electrical systems and the applicable principles and are able to
read, interpret and apply the information contained in technical
drawings.
XIndicates instructions to be followed
To improve legibility, the title of the current section is given at the
top of each left-hand page and the current subsection at the top
of each right-hand page, except on the title page of each section
and the blank pages at the end of each section.
EMC Electromagnetic compatibility
ESD Electrostatic discharge
HF High frequency
IGBT Insulated gate bipolar transistor
PES Positive Earth connection of the cable screen
PNU Parameter number
WE Default setting
hIndicates useful tips and additional information
Caution!
Warns of the possibility of minor material damage.
Warning!
Warns of the possibility of major material damage and
minor injury.
Warning!
Warns of the possibility of major material damage and
serious or fatal injury.
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01/02 AWB8230-1413GB
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01/02 AWB8230-1413GB
7
1 About the DF6 Frequency Inverter
System overview
Figure 1: System overview
aDEX-DEY-10 external keypad
bExpansion module, for example for PROFIBUS-DP connection: DE6-NET-DP
cDF6 frequency inverter
dDE6-LZ... RFI filter
eMains choke
fBraking resistor
a
f
e
d
c
b
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About the DF6 Frequency
Inverter
01/02 AWB8230-1413GB
8
Type code
Type codes and type designations of the DF6 frequency inverters:
Example:
Figure 2: Type codes of the DF6 frequency inverters
DF6-340-11K The DF6 frequency inverters
Three-phase mains supply voltage: 400 V
Assigned motor rating: 11 kW at 400 V
DF6-xxx-yyy
Motor rating code
Incoming supply: EU rated voltage 400 V
Version and model number
0 = basic version
1 = system devices
2 = voltage code suffix
Supply connection, voltage code (EU rated value)
4 = 400 V (342 V – 0 % to 506 V + 0 %)
Supply connection, phase code
3 = three-phase
Series designation:
Drives Frequency inverter, generation 6
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01/02 AWB8230-1413GB Inspecting the package
content
9
Inspecting the package content
The DF6 frequency inverter has been carefully packaged and
prepared for delivery. The device may be transported only in its
original packaging with a suitable transport system (see weight
details). Observe the instructions and the warnings on the side of
the packaging. This also applies after the device is removed from
the package.
Open the packaging with suitable tools and inspect the contents
immediately on delivery to ensure that they are complete and
undamaged. The package must contain the following items:
• One DF6 frequency inverter
• Installation instructions, AWA8230-1937
• One CD containing:
– this manual in PDF format and copies in other languages
– the parameterization software
System requirements: PC with Windows 95, 98, 2000, NT
and DEX-CBL-2M0-PC connecting cable
Figure 3: Package content
hOn the nameplate attached to the frequency inverter,
check to ensure that the frequency inverter is the type
which you have ordered.
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About the DF6 Frequency
Inverter
01/02 AWB8230-1413GB
10
Layout of the DF6
Figure 4: Physical features of the DF6
aKeypad
bFan
cHeat sink
dInterface connector for keypad
eTwo slots for optional modules
fRS 485 interface
gControl signal terminals
hPower terminals
iCable entry points
jScrew for opening the terminal shroud
kTerminal shroud
lCover
a
b
d
e
f
g
h
i
c
l
k
j
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01/02 AWB8230-1413GB Selection criteria
11
Features of the frequency inverters
The DF6 frequency inverters convert the voltage and frequency of
an existing three-phase supply to a DC voltage and use this
voltage to generate a three-phase supply with adjustable voltage
and frequency. This variable three-phase supply allows infinitely
adjustable speed control of three-phase asynchronous motors.
aSupply through an interference suppressor
Mains voltage ULN (EU-rated voltages):
3 AC 400 V, 50/60 Hz
bThe bridge rectifiers convert the AC voltage of the electrical supply to
a DC voltage.
cThe DC link contains a charging resistor, smoothing capacitor and
switched-mode power supply unit. It allows DC link coupling and the
supply of DC current:
DC link voltage (UZK) = W2 xmains voltage (ULN)
dIGBT inverter:
The power inverter converts the DC voltage of the internal DC link to
a variable three-phase alternating voltage with variable frequency.
In conjunction with an external braking resistor, the braking transistor
allows braking of motors with a high moment of inertia or during
extended regenerative operation.
eOutput voltage (U2), motor connection:
three-phase, variable AC voltage, 0 to 100 % of the input voltage
(VLN)
Output frequency (f2):
Variable frequency, 0 to 400 Hz
Output rated current (I2N):
22 to 253 A at about 1.5 times starting current for 60 s, at a switching
frequency of 5 kHz and at an ambient temperature of 40 °C
Motor connection, assigned shaft output (P2):
11 to 132 kW at 400 V
fProgrammable control section with LCD keypad and interface
Selection criteria
Select the frequency inverter according to the rated current of the
motor. The rated output current of the frequency inverter must
however, be greater than or equal to the rated current of the
motor.
The following drive data is assumed to be known:
• Type of motor (three-phase asynchronous motor)
• Mains voltage = supply voltage of the motor (e.g. 3 ~ 400 V)
• Rated motor current (guide value, dependent on the circuit type
and the supply voltage)
• Load torque (quadratic, constant, with 1.5 times the starting
torque)
• Ambient temperature (maximum temperature 40 °C).
The rated output current of the frequency inverter can be found in
the technical data in the appendix from page 159.
Figure 5: Function chart of the frequency inverter
a
bc d
f
e
M
3
˜
h
hIf several motors are connected in parallel to the output of
a frequency inverter, the motor currents are subject to
vector addition, i.e. the active in-phase current and
reactive current components are added separately. When
you select a frequency inverter, make sure that it can
supply the total resulting current.
hIf you connect a motor to an operational frequency
inverter, the motor draws a multiple of its rated current.
When you select a frequency inverter, make sure that the
starting current plus the sum of the currents of the
running motors will not exceed the rated output current of
the frequency inverter.
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About the DF6 Frequency
Inverter
01/02 AWB8230-1413GB
12
Intended use
The DF6 frequency inverters are not domestic appliances. They are
designed only for industrial use as system components.
The DF6 frequency inverters are electrical apparatus for controlling
variable speed drives with three-phase motors. They are designed
for installation in machines or for use in combination with other
components within a machine or system.
After installation in a machine, the frequency inverters must not be
taken into operation until the associated machine has been
confirmed to comply with the safety requirements of Machinery
Safety Directive (MSD) 89/392/EEC and meets the requirements of
EN 60204. The owner/operator of the equipment is responsible for
ensuring that the machine is used in compliance with the relevant
EU Directives.
The CE markings on the DF6 frequency inverter confirm that, when
used in a typical drive configuration, the apparatus complies with
the European Low Voltage Directive (LVD) and the EMC Directives
(Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/
336/EEC, as amended by 93/68/EEC).
In the described system configurations, DF6 frequency inverters
are suitable for use in public and non-public networks. Depending
on their location of use, additional, external filtering may be
necessary.
Connection to IT networks (networks without a ground potential
reference point) is not permitted as the devices internal filter
capacitors connect the network to the ground potential
(enclosure). On earth free networks, this can lead to dangerous
situations or damage the device (isolation monitoring is required).
To the output of the frequency inverter (terminals U, V, W) you
may not:
• connect a voltage or capacitive loads (e.g. phase compensation
capacitor),
• connect multiple frequency inverters in parallel,
• make a direct connection to the input (bypass).
Observe the technical data and terminal requirements. For
additional information, refer to the equipment nameplate or label
and the documentation.
Any other usage constitutes improper use.
Service and guarantee
In the unlikely event that you have a problem with your Moeller
frequency inverter, please contact your local sales office.
Please have the following data and information about your
frequency inverter to hand:
• Exact frequency inverter type designation (anameplate)
• Date of purchase
• Detailed description of the problem which has occurred with the
frequency inverter
If some of the information printed on the nameplate is not legible,
please state only the information which is clearly legible.
Information concerning the guarantee can be found in the Moeller
General Terms and Conditions of Sale.
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01/02 AWB8230-1413GB
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2 Engineering
This section describes the “Performance features of the DF6“ and
the requirements and directives concerning the following:
• Connection to the power supply
• EMC requirements
Performance features of the DF6
Ambient temperatures
Operation1) Ta = –10 to +40 °C with rated current Iewithout derating,
up to +50 °C with reduced pulse frequency of 2 kHz and output current reduced to 80 % Ie
Storage Ta = –20 to +65 °C
Transport Ta = –25 to +70 °C
Permissible environmental conditions
Resistance to vibration Impact and vibration:
• DF6-340-11K to DF6-340-30K: Up to 5.9 m/s2(0.6 g) at 10 to 55 Hz
• From DF6-340-37K: up to 2.94 m/s2(0.3 g) at 10 to 55 Hz
Degree of pollution VDE 0110 Part 2, pollution degree 2
Packaging Dustproof packaging (DIN 4180)
Climatic conditions Class 3K3 according to EN 50178 (non-condensing, average relative humidity 20 to 90 %)
Installation altitude Up to 1000 m above sea level
Mounting position Vertically suspended
Free surrounding areas 100 mm above and below device
Electrical data
Emitted interference IEC/EN 61800-3 (EN 55011 group 1, class B)
Noise immunity IEC/EN 61800-3, industrial environment
Insulation resistance Overvoltage category III according to VDE 0110
Leakage current to PE Greater than 3.5 mA according to EN 50178
Degree of protection IP20
Protection against direct contact Finger and back-of-hand proof (VBG 4)
Protective isolation against switching
circuitry
Safe isolation from the mains. Double basic isolation according to EN 50178
Protective measures Overcurrent, earth fault, overvoltage, undervoltage, overload, over temperature, electronic motor
protection: I2tmonitoring and PTC input (thermistor or temperature contact)
Open-/closed-loop control
Modulation method Pulse width modulation (PWM), V/fcharacteristics control (linear, quadratic)
Switching frequency 5 kHz (default), can be changed between 0.5 and 12 kHz
Torque At start 1.5 xMNfor 60 s at assigned motor rating, every 600 s, 2 xMNfor 0.5 s
Output frequency
Range 0.1 to 400 Hz
Frequency resolution 0.1 Hz, at digital setpoint, maximum frequency/1000 at analog setpoint value
Error limit at 25 °C g10 °C Digital setpoint definition g0.01 % of the maximum frequency
Analog setpoint definition g0.2 % of the maximum frequency
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Engineering 01/02 AWB8230-1413GB
14
Relays
Changeover contacts • Contacts K11-K14
– 250 V AC, 2 A (resistive load)
– 250 V AC, 0.2 A (inductive load, p.f. = 0.4)
– 100 V AC, minimum 10 mA
– 30VDC,8A(resistiveload)
– 30 V DC, 0.6 A (inductive load, p.f. = 0.4)
– 5 V DC, minimum 100 mA
• Contacts K11-K12
– 250 V AC, 1 A (resistive load)
– 250 V AC, 0.2 A (inductive load, p.f. = 0.4)
– 100 V AC, minimum 10 mA
– 30 V DC, 1 A (resistive load)
– 30 V DC, 0.2 A (inductive load, p.f. = 0.4)
– 5 V DC, minimum 100 mA
Make contacts • Contacts K23-K24 and K33-K34
– 250 V AC, 5 A (resistive load)
– 250 V AC, 1 A (inductive load, p.f. = 0.4)
– 30 V DC, 5 A (resistive load)
– 30 V DC, 1 A (inductive load, p.f. = 0.4)
– 5 V DC, minimum 1 mA
Internal voltages
Control 24 V DC, maximum 30 mA
Setpoint definition 10 V DC, maximum 10 mA
Analog and digital actuation
Analog inputs • 1 input, 0 to 10 V, input impedance 10 kO
• 1 input, 4 to 20 mA, load impedance 250 O
• 1 input, +10 to –10 V, input impedance 10 kO
Digital inputs 5 inputs, user-configurable and one input for “start/stop clockwise operation”
Analog outputs • 1 output for motor frequency or current, 10 V, up to 1.2 mA
• 1 output, 0 to 10 V, up to 2 mA, user-configurable
• 1 output, 4 to 20 mA, user-configurable
Relay outputs One changeover contact and two make contacts, user-configurable
Keypad (built-in)
Operation 6 function keys for controlling and parameterizing the DF6
Display Four-digit, 7-segment display and ten LEDs (for status signals)
Potentiometer Setpoint definition (0 to 270°)
1) If the frequency inverter is to be installed in a control panel, enclosure or similar installation, the temperature within the enclosure or control panel is
considered to be ambient temperature Ta. The use of fans should be considered to ensure that the ambient temperature remains within permissible
limits.
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01/02 AWB8230-1413GB Connection to the power
supply
15
Connection to the power supply
The DF6 frequency inverters can not be used in every network
configuration without limitations (network configuration
according to IEC 364-3).
Mains configurations
Networks with earthed centre point (TT/TN networks):
• DF6 frequency inverters can be used without limitations in TT
and TN networks. The ratings of the DF6 frequency inverters
must, however, be observed.
Networks with isolated centre point (IT networks):
• The use of DF6 frequency inverters in IT networks is only
permissible to a limited extent. In this case, a suitable device
(isolation monitor) to monitor earth faults and isolate the
frequency inverter from the mains must be used.
Mains voltage, mains frequency
The ratings of the DF6 frequency inverters cover European and
American standard voltages:
• 400 V, 50 Hz (EU) and 460 V, 60 Hz (USA)
The permissible mains voltage range is:
• 380/480 V: 342 V – 0 % to 528 V + 0 %
The permissible frequency range is 47 Hz – 0 % to 63 Hz + 0 %.
The motor rating to mains voltage assignments are listed in the
appendix, section “Technical Data”, page 159.
Interaction with p.f. correction equipment
The DF6 frequency inverters absorb only a small fundamental
reactive power from the AC supply. A p.f. correction is therefore
not necessary.
Fuses and cable cross-sections
The fuse ratings and cable cross-sections required for the network
connection depend on the rating of the frequency inverter and the
drive’s operating mode.
The recommended fuses and their assignment to the DF6
frequency inverters are listed in the appendix, section “Cables and
fuses”, page 164.
The national and regional standards (e.g. VDE 0113, EN 60204)
must be observed and any required approvals (e.g. UL) at the site
of installation must be fulfilled.
When the device is operated in a UL approved system, only
ULapproved fuses, fuse bases and cables must be used.
The leakage currents to earth (to EN 50178) are greater than
3.5 mA. The connection terminals marked PE and the enclosure
must be connected to the earth circuit.
Caution!
In the event of an earth fault in an IT system, the
capacitors of the frequency inverter which are switched to
earth are subjected to a very high voltage, and safe
operation of the frequency inverter is no longer
guaranteed. To overcome this problem,fit additional
isolating transformer to the frequency inverter’s supply
and earth the transformer’s secondary side at its centre
point to form, in effect, an individual TN network for the
frequency inverter.
Caution!
Operation of DF6 series frequency inverters on the mains
with p.f. correction equipment is only permitted when this
equipment is dampened with chokes.
Caution!
When selecting the cable cross-section, take the voltage
drop under load conditions into account. Compliance to
further standards (e.g. VDE 0113, VDE 0289) is the
responsibility of the user.
Caution!
Observe the specified minimum cross-sections for PE
conductors (EN 50178, VDE 0160) must be observed. Use
a PE conductor whose cross-section is as least as large as
the terminal capacity of the power terminals.
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Engineering 01/02 AWB8230-1413GB
16
Protection of persons and domestic animals with residual-
current protective devices
Residual-current circuit breakers (RCCBs; also called earth-leakage
circuit breakers or ELCBs). Universal current sensitive RCCBs
according to EN 50178 and IEC 755.
The frequency inverter has a built-in mains rectifier. When a frame
fault occurs, a DC fault current can block the trip of the alternating
current sensitive or pulse current sensitive residual-current circuit
breaker, thereby preventing its protective function. We therefore
recommend the use of:
• all-current sensitive RCCBs with a rated fault current
f300 mA.
The approximate fault current values of the DF6 frequency
inverters and their assigned radio interference filters are listed in
the appendix, section “RFI filter”, page 166.
Spurious tripping of a residual-current circuit breaker can be
caused by the following:
• capacitive compensation currents in the cable screens,
particularly with long, screened motor cables,
• simultaneous connection of multiple frequency inverters to the
mains supply,
• the use of additional chokes and filters
(radio interference filters, line filters).
Mains contactor
The mains contactor is connected to the mains side input cables
L1, L2, L3 and allows the DF6 frequency inverter on the supplying
network to be switched on and off during operation and to be
disconnected in the event of a fault.
Mains contactors and their assignment to the DF6 frequency
inverters are listed in the appendix, section “Mains contactors”,
page 165.
Current peaks
In the following cases, a relatively high peak current can occur on
the primary side of the frequency inverter (i.e. on the supply
voltage side), which, under certain conditions, can destroy the
input rectifier of the frequency inverter:
• Imbalance of the voltage supply greater than 3 %.
• The maximum power output of the point of supply must be at
least 10 times greater than the maximum frequency inverter
rating.
• If sudden voltage dips in the supply voltage are to be expected,
for example when:
– a number of frequency inverters are operated on a common
supply voltage
– a thyristor system and a frequency inverter are operated on a
common supply voltage
– power factor correction devices are switched on or off
In these cases, a mains choke with about 3 % voltage drop at
rated operation should be installed.
Identification on the residual-current circuit-breakers
Logo
Model Alternating
current sensitive
(RCCB, Type AC)
Pulse current
sensitive
(RCCB, Type A)
Universal current
sensitive
(RCCB, Type B)
Caution!
Residual-current circuit breakers must be installed only on
the primary side between the incoming supply and the
frequency inverter.
Warning!
To prevent the risk of fire, use only cables, residual-
current circuit breakers and contactors with a suitable
rating.
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01/02 AWB8230-1413GB Connection to the power
supply
17
Mains choke
The mains choke (also called commutating choke or line reactor)
is connected to the mains side input cables L1, L2, L3. It reduces
the harmonics and therefore reduces the apparent mains current
by up to 30 %.
A mains choke also limits any current peaks caused by potential
dips (e.g. caused by p.f. correction equipment or earth faults) or
switching operations on the mains.
The mains choke increases the lifespan of the internal DC link
capacitors and therefore the lifespan of the frequency inverter. Its
use is also recommended:
• with derating (temperatures above +40 °C, sites of installation
more than 1000 m above sea level),
• with parallel operation of multiple frequency inverters on a
single mains supply point,
• with DC link coupling of multiple frequency inverters
(interconnected operation).
Mains chokes and their assignment to the DF6 frequency inverters
are listed in the appendix, section “Mains choke”, page 165.
Mains filters and radio interference filters
Mains filters are a combination of mains chokes and radio
interference filters in a single enclosure. They reduce the current
harmonics and dampen high frequency radio interference levels.
Radio interference filters only dampen high frequency radio
interference levels.
Caution!
The mains phase failure detection (PNU b006) does not
operate correctly when a radio interference filter is
installed.
Caution!
When line filters or radio interference filters are used, the
leakage current to earth of the drive unit increases.
Observe this point when installing residual-current
circuit breakers.
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