Santerno Sinus Penta User manual
•15P0102B1 •
SINUS PENTA
MULTIFUNCTION AC DRIVE
USER MANUAL
- Installation Guide -
Issued on 25/09/2013
R.06.2
Elettronica Santerno S.p.A.
Via della Concia, 7 – 40023 Castel Guelfo (BO) Italy
Tel. +39 0542 489711 – Fax +39 0542 489722
santerno.com [email protected]
• This manual is integrant and essential to the product. Carefully read the instructions contained herein
as they provide important hints for use and maintenance safety.
•
This device is to be used only for the purposes it has been designed to. Other uses should be
considered improper and dangerous. The manufacturer is not responsible for possible damages caused
by improper, erroneous and irrational uses.
• Elettronica Santerno is responsible for the device in its original setting.
• Any changes to the structure or operating cycle of the device must be performed or authorized by
Elettronica Santerno.
• Elettronica Santerno assumes no responsibility for the consequences resulting by the use of non-
original spare-parts.
• Elettronica Santerno reserves the right to make any technical changes to this manual and to the
device without prior notice. If printing errors or similar are detected, the corrections will be included in
the new releases of the manual.
• The information contained herein is the property of Elettronica Santerno and cannot be reproduced.
Elettronica Santerno enforces its rights on the drawings and catalogues according to the law.
English
SINUS PENTA
INSTALLATION GUIDE
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REVISION INDEX
The following subjects covered in this User Manual (Installation Instructions) R.06.2 have been added,
changed or suppressed in respect to revision R.06.
The User Manuals mentioned in this manual have been added below.
The following sections: Nameplate, Transport and Handling, Unpacking, Scheduled Maintenance have been
added.
Warnings concerning Motor and bearings insulation protection, Sensors integrated in the motor, Critical
torsional speeds, Transient torque analysis have been added.
Notes concerning Installation clearance, Touch current in the ground conductor, Decisive voltage class
according to IEC 61800-5-1 for terminal boards have been added.
A section covering additional safety standards for permanent magnets motors has been added.
In the Modular IP00 STAND-ALONE Models (S64–S90) section, Partial dimensions, Partial weights and
Partial power dissipation have been removed (only Overall dimensions, Overall weights and Overall power
dissipation are now mentioned).
The noise levels (db(A)) for stand-alone models and modular models have been added. No noise levels have
been added for the Box and Cabinet models.
The phrase “The precharge circuit of DC-bus capacitors is not present” has been better explained and
replaced with “The precharge circuit of DC-bus capacitors is not present (in S64, S74 and S84 ) or upstream
of the DC power supply terminals (in S41, S42, S51, S52, S60)”.
The phrase “DC current power supply” has been replaced with “DC voltage power supply”.
The term “reactor” has been replaced with “inductor”.
The IP54 models, S05 0020 2T and S14 0032 5T/6T, have been removed because unavailable.
Maximum surrounding air temperature increased to 55°C following the Type Tests required by DNV Marine
Certification.
SANTERNO USER MANUALS MENTIONED IN THIS
INSTALLATION GUIDE
The following Santerno User Manuals are mentioned throughout this Installation Guide:
- 15R0102B1 Sinus Penta - Programming Guide
- 15N0102B1 Sinus Penta - ES821 Spare User Manual
- 15Q0102B00 Sinus Penta - Guide to the Regenerative Application
- 15Q0102B10 Sinus Penta - Guide to the Multipump Application
- 15Q0102B200 Sinus Penta - Guide to the Synchronous Motor Application
- 15P0101B1 Sinus Penta - Assembly Instructions for Modular Inverters
- 15G0010B1 PROFIdrive COMMUNICATIONS BOARD - Installation and Programming Instructions
- 15G0851B100 DATA LOGGER ES851 - Programming Instructions
- 16B0901B1 Remote Drive DRIVE REMOTE CONTROL - User Manual
- 15M0102B10 Sinus Penta - Guide for Capacitor Reforming
INSTALLATION GUIDE
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0. TABLE OF CONTENTS
REVISION INDEX .............................................................................................................................................. 2
SANTERNO USER MANUALS MENTIONED IN THIS INSTALLATION GUIDE ............................................ 2
0. TABLE OF CONTENTS ............................................................................................................................ 3
0.1. Index of Figures .............................................................................................................................. 10
1. GENERAL DESCRIPTION ..................................................................................................................... 15
1.1. Feature List .................................................................................................................................... 16
1.2. Special Applications Available on Sinus Penta .............................................................................. 17
2. SAFETY STATEMENTS ......................................................................................................................... 18
2.1. Installing and Operating the Equipment ......................................................................................... 18
2.2. Permanent Magnet Motors ............................................................................................................. 20
3. EQUIPMENT DESCRIPTION AND INSTALLATION .............................................................................. 21
3.1. Products Covered in this Manual ................................................................................................... 21
3.2. Delivery Check ............................................................................................................................... 22
3.2.1. Nameplate ............................................................................................................................. 23
3.2.2. Transport and Handling ......................................................................................................... 25
3.2.3. Unpacking .............................................................................................................................. 25
3.3. Installing the Equipment ................................................................................................................. 27
3.3.1. Environmental Requirements for the Equipment Installation, Storage and Transport .......... 27
3.3.2. Air Cooling ............................................................................................................................. 29
3.3.3. Scheduled Maintenance ........................................................................................................ 32
3.3.4. Air Filters ............................................................................................................................... 32
3.3.5. Heat Sink and Ambient Temperature Check ......................................................................... 34
3.3.5.1. Control Board .................................................................................................................... 34
3.3.5.2. Cleaning the Heat Sink ..................................................................................................... 34
3.3.6. Cooling Fans .......................................................................................................................... 34
3.3.6.1. Replacing the Cooling Fans .............................................................................................. 34
3.3.7. Capacitors .............................................................................................................................. 34
3.3.7.1. Capacitor Reforming ......................................................................................................... 34
3.3.7.2. Replacing a Capacitor ....................................................................................................... 34
3.3.8. Bypass Contactor .................................................................................................................. 35
3.3.8.1. Replacing the Bypass Contactor ....................................................................................... 35
3.3.9. Size, Weight, Dissipated Power, Noise Level ....................................................................... 36
3.3.9.1. IP20 and IP00 STAND-ALONE Models (S05–S60) Class 2T .......................................... 36
3.3.9.2. IP20 and IP00 STAND-ALONE Models (S05–S60) Class 4T .......................................... 37
3.3.9.3. IP20 and IP00 STAND-ALONE Models (S12–S52) Class 5T-6T ..................................... 38
3.3.9.4. Modular IP00 STAND-ALONE Models (S64–S90) ........................................................... 39
3.3.9.5. IP54 STAND-ALONE Models (S05–S30) Class 2T .......................................................... 44
3.3.9.6. IP54 STAND-ALONE Models (S05–S30) Class 4T .......................................................... 45
3.3.9.7. IP54 STAND-ALONE Models (S12–S32) Class 5T-6T ..................................................... 46
3.3.9.8. IP54 BOX Models (S05–S20) Class 2T ............................................................................ 47
3.3.9.9. IP54 BOX Models (S05–S20) Class 4T ............................................................................ 48
3.3.9.10. IP24 and IP54 Cabinet Models (S15–S90) ................................................................... 49
3.3.10. Standard Mounting and Piercing Templates (IP20 and IP00 Stand-Alone Models S05–S60) .
............................................................................................................................................... 51
3.3.11. Through-Panel Assembly and Piercing Templates (IP20 and IP00 Stand-Alone Models S05–
S52) ............................................................................................................................................... 53
3.3.11.1. Sinus Penta S05 ........................................................................................................... 53
3.3.11.2. Sinus Penta S12 ........................................................................................................... 54
3.3.11.3. Sinus Penta S14 ........................................................................................................... 55
3.3.11.4. Sinus Penta S15–S20–S30 .......................................................................................... 56
3.3.11.5. Sinus Penta S22–S32 ................................................................................................... 57
3.3.11.6. Sinus Penta S41–S42–S51–S52 .................................................................................. 59
3.3.12. Standard Mounting and Piercing Templates (IP00 Modular Models S64–S90) .................... 61
3.3.12.1. Installation and Lay-out of the Connections of a Modular Inverter (S65) ..................... 63
3.3.13. Standard Mounting and Piercing Templates (IP54 Stand-Alone Models S05–S32) ............. 64
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3.4. Power Connections ........................................................................................................................ 65
3.4.1. Wiring Diagram for inverters S05–S60 .................................................................................. 67
3.4.2. Wiring Diagram for Modular Inverters S64–S90 .................................................................... 69
3.4.2.1. External Connections for Modular Inverters S65 and S70 ................................................ 69
3.4.2.2. External Connections for Modular Inverters S64 .............................................................. 70
3.4.2.3. External Connections for Modular Inverters S74, S75 and S80 ....................................... 71
3.4.2.4. External Connections for Modular inverters S84 and S90 ................................................ 71
3.4.2.5. 12-pulse Connection for Modular Inverters ....................................................................... 71
3.4.2.6. Internal Connections for Modular Inverters S65 and S70 ................................................. 73
3.4.2.7. Internal Connections for Modular Inverters S64 ............................................................... 80
3.4.2.8. Internal Connections for Modular Inverters S74, S75 and S80 ........................................ 84
3.4.2.9. Internal Connections for Modular Inverters S84 and S90 ................................................. 84
3.4.3. Power Terminals for S05–S52 ............................................................................................... 85
3.4.4. Power Terminals Modified for a DC Inductor ........................................................................ 88
3.4.5. Connection Bars for S60 Inverters ........................................................................................ 89
3.4.6. Connection Bars for Modular Inverters S64–S70 .................................................................. 90
3.4.7. Connection Bars for Modular Inverters S74–S80 .................................................................. 91
3.4.8. Connection Bars for Modular Inverters S84–S90 .................................................................. 92
3.4.9. Auxiliary Power Supply Terminals ......................................................................................... 93
3.4.10. Cross-sections of the Power Cables and Sizes of the Protective Devices ........................... 93
3.4.10.1. 2T Voltage Class ........................................................................................................... 94
3.4.10.2. UL-approved Fuses - 2T Voltage Class ........................................................................ 95
3.4.10.3. UL-approved Surge Protective Devices (SPDs) - 2T Voltage Class ............................ 96
3.4.10.4. 4T Voltage Class ........................................................................................................... 97
3.4.10.5. UL-approved Fuses - 4T Voltage Class ...................................................................... 100
3.4.10.6. 5T and 6T Voltage Classes ........................................................................................ 101
3.4.10.7. UL-approved Fuses - 5T and 6T Voltage Classes ..................................................... 103
3.4.11. Inverter and Motor Ground Connection ............................................................................... 104
3.5. Control Terminals ......................................................................................................................... 105
3.5.1. Main Features ...................................................................................................................... 105
3.5.1.1. Gaining Access to Control Terminals and Power Terminals in IP20 and IP00 Models .. 107
3.5.1.2. Gaining Access to Control Terminals and Power Terminals in IP54 Models .................. 108
3.5.1.3. Grounding Shielded Cable Braiding ................................................................................ 109
3.5.2. Control Board Signals and Programming ............................................................................ 110
3.5.2.1. Display and Indicator LEDs ............................................................................................. 111
3.5.2.2. DIP-switches ................................................................................................................... 114
3.5.2.3. Configuration Jumpers .................................................................................................... 116
3.5.3. Digital Inputs (Terminals 14 to 21)....................................................................................... 117
3.5.3.1. START (Terminal 14) ...................................................................................................... 117
3.5.3.2. ENABLE (Terminal 15) .................................................................................................... 118
3.5.3.3. RESET (Terminal 16) ...................................................................................................... 118
3.5.3.4. Connecting the Encoder and Frequency Input (Terminals 19 to 21) .............................. 119
3.5.3.5. Technical Sheet for Digital Inputs ................................................................................... 120
3.5.4. Analog Inputs (Terminals 1 to 9) ......................................................................................... 121
3.5.4.1. REF Single-ended Reference Input (Terminal 2) ............................................................ 122
3.5.4.2. Differential Auxiliary Inputs (Terminals 5–8) ................................................................... 123
3.5.4.3. Motor Thermal Protection Input (PTC, Terminals 7-8) .................................................... 125
3.5.4.4. Technical Sheet for Analog Inputs .................................................................................. 127
3.5.5. Digital Outputs (Terminals 24 to 34) .................................................................................... 128
3.5.5.1. Push-Pull Output MDO1 and Wiring Diagrams (Terminals 24 to 26) ............................. 128
3.5.5.2. Open-collector MDO2 Output and Wiring Diagrams (Terminals 27-28) ......................... 130
3.5.5.3. Relay Outputs (Terminals 29..34) ................................................................................... 131
3.5.5.4. Technical Sheet for Digital Outputs ................................................................................. 132
3.5.6. Analog Outputs (Terminals 10 to 13) .................................................................................. 133
3.5.6.1. Technical Sheet for Analog Outputs ............................................................................... 133
3.6. Operating and Remoting the Keypad ........................................................................................... 134
3.6.1. Indicator LEDs on the Display/Keypad ................................................................................ 134
3.6.2. Function Keys ...................................................................................................................... 135
3.6.3. Setting the Operating Mode ................................................................................................. 136
3.6.3.1. Adjusting the Display Contrast ........................................................................................ 136
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3.6.3.2. Adjusting the Display Contrast, Back-light and Buzzer ................................................... 136
3.6.4. Remoting the Display/Keypad ............................................................................................. 137
3.6.5. Using the Display/Keypad for Parameter Transfer .............................................................. 140
3.7. Serial Communications ................................................................................................................ 141
3.7.1. General Features ................................................................................................................. 141
3.7.2. Direct Connection ................................................................................................................ 142
3.7.3. Multidrop Network Connection ............................................................................................ 142
3.7.3.1. Connection ...................................................................................................................... 142
3.7.3.2. Line Terminators ............................................................................................................. 144
3.7.4. How to Use Isolated Serial Board ES822 (Optional) ........................................................... 145
3.7.5. The Software ....................................................................................................................... 145
3.7.6. Serial Communication Ratings ............................................................................................ 145
3.8. Auxiliary Power Supply ................................................................................................................. 146
4. START UP ............................................................................................................................................ 147
4.1. “IFD” Motor Control ...................................................................................................................... 148
4.2. “VTC” Motor Control ..................................................................................................................... 150
4.3. “FOC” Motor Control ..................................................................................................................... 152
4.4. “SYN” Motor Control ..................................................................................................................... 155
5. TECHNICAL SPECIFICATIONS ........................................................................................................... 156
5.1. Choosing the Product ................................................................................................................... 158
5.1.1. LIGHT Applications: Overload up to 120% (60/120s) or up to 144% (3s) .......................... 161
5.1.1.1. Technical Sheet for 2T and 4T Voltage Classes ............................................................. 161
5.1.1.2. Technical Sheet for 5T and 6T Voltage Classes ............................................................. 163
5.1.2. STANDARD Applications: Overload up to 140% (60/120s) or up to 168% (3s) ................. 164
5.1.2.1. Technical Sheet for 2T and 4T Voltage Classes ............................................................. 164
5.1.2.2. Technical Sheet for 5T and 6T Voltage Classes ............................................................. 166
5.1.3. HEAVY Applications: Overload up to 175% (60/120s) or up to 210% (3s) ......................... 167
5.1.3.1. Technical Sheet for 2T and 4T Voltage Classes ............................................................. 167
5.1.3.2. Technical Sheet for 5T and 6T Voltage Classes ............................................................. 169
5.1.4. STRONG Applications: Overload up to 200% (60/120s) or up to 240% (3s) ...................... 170
5.1.4.1. Technical Sheet for 2T and 4T Voltage Classes ............................................................. 170
5.1.4.2. Technical Sheet for 5T and 6T Voltage Classes ............................................................. 172
5.2. Carrier Frequency Setting ............................................................................................................ 173
5.2.1. IP20 and IP00 Models – Class 2T-4T ................................................................................. 173
5.2.2. IP20 and IP00 Models – Class 5T-6T ................................................................................. 175
5.2.3. IP54 Models – Class 2T-4T ................................................................................................. 176
5.2.4. IP54 Models – Class 5T-6T ................................................................................................. 177
5.3. Operating Temperatures Based On Application Category ........................................................... 178
6. ACCESSORIES .................................................................................................................................... 181
6.1. Resistive Braking .......................................................................................................................... 181
6.1.1. Braking Resistors ................................................................................................................ 182
6.1.1.1. Applications with DUTY CYCLE 10% - Class 2T ............................................................ 182
6.1.1.2. Applications with DUTY CYCLE 20% - Class 2T ............................................................ 183
6.1.1.3. Applications with DUTY CYCLE 50% - Class 2T ............................................................. 184
6.1.1.4. Applications with DUTY CYCLE 10% - Class 4T ............................................................ 185
6.1.1.5. Applications with DUTY CYCLE 20% - Class 4T ............................................................ 186
6.1.1.6. Applications with DUTY CYCLE 50% - Class 4T ............................................................ 187
6.1.1.7. Applications with DUTY CYCLE 10% - Class 5T ............................................................ 188
6.1.1.8. Applications with DUTY CYCLE 20% - Class 5T ............................................................ 189
6.1.1.9. Applications with DUTY CYCLE 50% - Class 5T ............................................................ 190
6.1.1.10. Applications with DUTY CYCLE 10% - Class 6T ....................................................... 191
6.1.1.11. Applications with DUTY CYCLE 20% - Class 6T ....................................................... 192
6.1.1.12. Applications with DUTY CYCLE 50% - Class 6T ....................................................... 193
6.2. Braking Unit (BU200) for S60 ....................................................................................................... 194
6.2.1. Delivery Check..................................................................................................................... 194
6.2.1.1. Nameplate for BU200 ...................................................................................................... 195
6.2.2. Operation ............................................................................................................................. 196
6.2.2.1. Configuration Jumpers .................................................................................................... 196
6.2.2.2. Adjusting Trimmers ......................................................................................................... 197
6.2.2.3. Indicator LEDs ................................................................................................................. 198
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6.2.3. Ratings ................................................................................................................................. 198
6.2.4. Installing the Braking Unit .................................................................................................... 199
6.2.4.1. Environmental Requirements for the Braking Unit Installation, Storage and Transport . 199
6.2.4.2. Cooling System and Dissipated Power ........................................................................... 199
6.2.4.3. Mounting .......................................................................................................................... 200
6.2.4.4. Lay-Out of Power Terminals and Signal Terminals ........................................................ 201
6.2.4.5. Wiring .............................................................................................................................. 202
6.2.4.6. Master – Slave Connection ............................................................................................. 203
6.2.5. Braking Resistors for BU200 2T .......................................................................................... 204
6.2.5.1. Applications with DUTY CYCLE 10% - Class 2T ............................................................ 204
6.2.5.2. Applications with DUTY CYCLE 20% - Class 2T ............................................................ 205
6.2.5.3. Applications with DUTY CYCLE 50% - Class 2T ............................................................ 205
6.2.6. Braking Resistors for BU200 4T .......................................................................................... 206
6.2.6.1. Applications with DUTY CYCLE 10% - Class 4T ............................................................ 206
6.2.6.2. Applications with DUTY CYCLE 20% - Class 4T ............................................................ 207
6.2.6.3. Applications with DUTY CYCLE 50% - Class 4T ............................................................ 207
6.3. Braking Units for S41–S51 (BU700 2T-4T) and S42–S52 (BU600 5T-6T) .................................. 208
6.3.1. Delivery Check..................................................................................................................... 208
6.3.1.1. Nameplate for BU600 ...................................................................................................... 208
6.3.2. Operating Mode ................................................................................................................... 209
6.3.3. Specifications ....................................................................................................................... 211
6.3.4. Installing the Braking Unit .................................................................................................... 211
6.3.4.1. Environmental Requirements for the Braking Unit Installation, Storage and Transport . 211
6.3.4.2. Mounting the Braking Unit ............................................................................................... 212
6.3.4.3. Lay-Out of Power Terminals and Signal Terminals ........................................................ 213
6.3.4.4. Wiring Diagram ................................................................................................................ 216
6.3.5. Braking Resistors for BU700 2T-4T..................................................................................... 217
6.3.5.1. Applications with DUTY CYCLE 10% - Class 2T ............................................................ 217
6.3.5.2. Applications with DUTY CYCLE 20% - Class 2T ............................................................ 217
6.3.5.3. Applications with DUTY CYCLE 50% - Class 2T ............................................................ 218
6.3.5.4. Applications with DUTY CYCLE 10% - Class 4T ............................................................ 218
6.3.5.5. Applications with DUTY CYCLE 20% - Class 4T ............................................................ 219
6.3.5.6. Applications with DUTY CYCLE 50% - Class 4T ............................................................ 219
6.3.6. Braking Resistors for BU600 5T-6T..................................................................................... 220
6.3.6.1. Applications with DUTY CYCLE 10% - Class 5T ............................................................ 220
6.3.6.2. Applications with DUTY CYCLE 20% - Class 5T ............................................................ 220
6.3.6.3. Applications with DUTY CYCLE 50% - Class 5T ............................................................ 221
6.3.6.4. Applications with DUTY CYCLE 10% - Class 6T ............................................................ 221
6.3.6.5. Applications with DUTY CYCLE 20% - Class 6T ............................................................ 222
6.3.6.6. Applications with DUTY CYCLE 50% - Class 6T ............................................................ 222
6.4. Braking Unit BU1440 for Modular Inverters ................................................................................. 223
6.4.1. Delivery Check..................................................................................................................... 223
6.4.1.1. Nameplate for BU1440 .................................................................................................... 223
6.4.2. Operation ............................................................................................................................. 224
6.4.3. Ratings ................................................................................................................................. 224
6.4.4. Installing the Braking Unit .................................................................................................... 224
6.4.4.1. Environmental Requirements for the Braking Unit Installation, Storage and Transport . 224
6.4.4.2. Mounting the Braking Unit ............................................................................................... 225
6.4.4.3. Wiring Diagram ................................................................................................................ 226
6.4.5. Braking Resistors for BU1440 4T ........................................................................................ 231
6.4.5.1. Applications with DUTY CYCLE 10% - Class 4T ............................................................ 231
6.4.5.2. Applications with DUTY CYCLE 20% - Class 4T ............................................................ 232
6.4.5.3. Applications with DUTY CYCLE 50% - Class 4T ............................................................ 232
6.4.6. Braking Resistors for BU1440 5T-6T .................................................................................. 233
6.4.6.1. Applications with DUTY CYCLE 10% - Class 5T ............................................................ 233
6.4.6.2. Applications with DUTY CYCLE 20% - Class 5T ............................................................ 234
6.4.6.3. Applications with DUTY CYCLE 50% - Class 5T ............................................................ 234
6.4.6.4. Applications with DUTY CYCLE 10% - Class 6T ............................................................ 235
6.4.6.5. Applications with DUTY CYCLE 20% - Class 6T ............................................................ 235
6.4.6.6. Applications with DUTY CYCLE 50% - Class 6T ............................................................ 236
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6.4.7. Available Braking Resistors ................................................................................................. 237
6.4.7.1. 350W Models (IP55)........................................................................................................ 237
6.4.7.2. 1300W Models (IP33)...................................................................................................... 238
6.4.7.3. IP55 Models from 1100W to 2200W ............................................................................... 239
6.4.7.4. IP20 Models from 4kW-8kW-12kW ................................................................................. 241
6.4.7.5. IP23 Boxes from 4kW to 64kW ....................................................................................... 243
6.5. Keypad Remoting Kits .................................................................................................................. 248
6.5.1. Remoting the Keypad on the Cabinet ................................................................................. 248
6.5.2. Remoting a Keypad Controlling Multiple Inverters .............................................................. 248
6.5.2.1. Kit Component Parts ....................................................................................................... 248
6.5.2.2. Operating Conditions....................................................................................................... 249
6.5.2.3. Connecting the Keypad ................................................................................................... 249
6.5.2.4. The Communications Protocol ........................................................................................ 250
6.5.2.5. Connection ...................................................................................................................... 251
6.6. Inductors ....................................................................................................................................... 252
6.6.1. Input Inductors ..................................................................................................................... 252
6.6.2. Output Inductors (DU/DT Filters) ......................................................................................... 255
6.6.3. Applying the Inductor to the Inverter ................................................................................... 256
6.6.3.1. Class 2T – AC and DC Inductors .................................................................................... 256
6.6.3.2. Class 4T – AC and DC Inductors .................................................................................... 257
6.6.3.3. Class 5T-6T – AC and DC Inductors ............................................................................... 258
6.6.4. Inductance Ratings .............................................................................................................. 260
6.6.4.1. Class 2T-4T – AC 3-Phase Inductors ............................................................................. 260
6.6.4.2. Class 5T-6T – AC 3-Phase Inductors ............................................................................. 260
6.6.4.3. Class 2T-4T – DC Inductors ............................................................................................ 262
6.6.4.4. Class 5T-6T – DC Inductors ............................................................................................ 262
6.6.4.5. Class 2T, 4T, 5T, 6T – 3-Phase DU/DT Inductors .......................................................... 264
6.6.5. Class 2T – 3-Phase AC Inductors in IP54 Cabinet ............................................................. 265
6.6.6. Class 4T – 3-Phase AC Inductors in IP54 Cabinet ............................................................. 266
6.6.7. Class 5T-6T – 3-Phase AC Inductors In IP54 Cabinet ........................................................ 267
6.6.8. Output Single-Phase Inductors for Modular Inverters S75, S80, S90 ................................. 269
6.6.8.1. AC single-phase Inductors – Class 4T-5T-6T ................................................................. 269
6.6.9. Sinusoidal Filters ................................................................................................................. 270
6.7. ES836/2 Encoder Board (Slot A) ................................................................................................. 271
6.7.1. Identification Data ................................................................................................................ 271
6.7.2. Environmental Requirements .............................................................................................. 271
6.7.3. Electrical Specifications ....................................................................................................... 272
6.7.4. Installing ES836/2 Encoder Board on the Inverter (Slot A) ................................................. 273
6.7.5. Terminals in Encoder Board ................................................................................................ 274
6.7.6. Configuration DIP-switches ................................................................................................. 274
6.7.7. Jumper Selecting the Type of Encoder Supply ................................................................... 275
6.7.8. Adjusting Trimmer ............................................................................................................... 276
6.7.9. Encoder Wiring and Configuration....................................................................................... 276
6.7.10. Wiring the Encoder Cable .................................................................................................... 281
6.8. ES913 Line Driver Encoder Board (Slot A) .................................................................................. 282
6.8.1. Identification Data ................................................................................................................ 282
6.8.2. Environmental Requirements .............................................................................................. 282
6.8.3. Electrical Specifications ....................................................................................................... 283
6.8.4. Installing the Line Driver Board on the Inverter (Slot A) ...................................................... 284
6.8.5. Terminals in the Line Driver Encoder Board ....................................................................... 285
6.8.6. Configuration DIP-switches ................................................................................................. 285
6.8.7. Encoder Supply Selection Jumper ...................................................................................... 286
6.8.8. Adjusting Trimmer ............................................................................................................... 287
6.9. ES822 Isolated Serial Board (Slot B) ........................................................................................... 288
6.9.1. Identification Data ................................................................................................................ 288
6.9.2. Environmental Requirements .............................................................................................. 288
6.9.3. Electrical Features ............................................................................................................... 289
6.9.4. Installing ES822 Board on the Inverter (Slot B) ................................................................... 290
6.9.5. Setting ES822 Board ........................................................................................................... 291
6.9.5.1. Jumper for RS232/RS485 Selection ............................................................................... 291
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6.9.5.2. DIP-switch for RS485 Terminator ................................................................................... 292
6.10. Optional Boards For Fieldbus (Slot B) ......................................................................................... 293
6.10.1. Identification Data ................................................................................................................ 294
6.10.2. Installing the Fieldbus Board on the Inverter (Slot B) .......................................................... 294
6.10.3. Fieldbus PROFIBUS-DP® Board ......................................................................................... 297
6.10.3.1. Profibus® Fieldbus Connector .................................................................................... 298
6.10.3.2. Configuration of the Profibus-DP Communications Board ......................................... 298
6.10.3.3. Connection to the Fieldbus ......................................................................................... 300
6.10.4. PROFIdrive® Fieldbus Board ............................................................................................... 301
6.10.5. DeviceNet® Fieldbus Board ................................................................................................. 301
6.10.5.1. DeviceNet® Fieldbus Terminals .................................................................................. 302
6.10.5.2. Board Configuration .................................................................................................... 302
6.10.5.3. Connection to the Fieldbus ......................................................................................... 303
6.10.6. CANopen® Fieldbus Board .................................................................................................. 305
6.10.6.1. CANopen® Fieldbus Connector .................................................................................. 306
6.10.6.2. Board Configuration .................................................................................................... 306
6.10.6.3. Connection to the Fieldbus ......................................................................................... 307
6.10.7. Ethernet Board..................................................................................................................... 308
6.10.7.1. Ethernet Connector ..................................................................................................... 309
6.10.7.2. Connection to the Network ......................................................................................... 309
6.10.7.3. Board Configuration .................................................................................................... 311
6.10.8. Status LEDs ......................................................................................................................... 316
6.10.8.1. LEDs for Fieldbus Interface CPU Diagnostics ............................................................ 316
6.10.8.2. LEDs for PROFIBUS-DP® Board Diagnostics ............................................................ 317
6.10.8.3. LEDs for DeviceNet® Board Diagnostics .................................................................... 317
6.10.8.4. LEDs for CANopen® Board Diagnostics ..................................................................... 318
6.10.8.5. LEDs for Ethernet Board Diagnostics ......................................................................... 318
6.10.9. Environmental Requirements Common to All Boards ......................................................... 318
6.11. ES919 Communications Board (Slot B) ....................................................................................... 319
6.11.1. Identification Data ................................................................................................................ 319
6.11.2. Environmental Requirements Common to All Boards ......................................................... 319
6.11.3. Electrical Features Common to All Boards .......................................................................... 319
6.11.4. Installing ES919 Board on the Inverter (Slot B) ................................................................... 320
6.11.5. ES919 Board for Metasys® N2 ............................................................................................ 321
6.11.5.1. Configuration ............................................................................................................... 321
6.11.5.2. RS485 Connector ....................................................................................................... 321
6.11.5.3. LEDs on the ASP485 ProtoCessor Module ................................................................ 322
6.11.5.4. Baud Rate DIP-switches ............................................................................................. 322
6.11.5.5. Address DIP-Switches ................................................................................................ 322
6.11.6. ES919 Board for BACnet/Ethernet ...................................................................................... 323
6.11.6.1. Ethernet Connector ..................................................................................................... 323
6.11.6.2. LEDs on the FFP485 ProtoCessor Module ................................................................ 324
6.11.6.3. Troubleshooting Tips .................................................................................................. 324
6.11.6.4. Board Configuration .................................................................................................... 325
6.11.7. ES919 Board for BACnet/RS485......................................................................................... 326
6.11.7.1. RS485 Connector ....................................................................................................... 326
6.11.7.2. Board Configuration .................................................................................................... 327
6.12. ES851 Datalogger Board (Slot B) ................................................................................................ 328
6.12.1. Identification Data ................................................................................................................ 329
6.12.2. Installing ES851 Board on the Inverter (Slot B) ................................................................... 329
6.12.3. Connectivity ......................................................................................................................... 331
6.12.3.1. Wiring RS232 Serial Links .......................................................................................... 332
6.12.3.2. Wiring RS485 Serial Link ............................................................................................ 333
6.12.3.3. COM1 Configuration and Wiring ................................................................................. 335
6.12.3.4. COM2 Configuration and Wiring ................................................................................. 337
6.12.3.5. Types of Ethernet Connections .................................................................................. 338
6.12.3.6. Ethernet Port Wiring .................................................................................................... 340
6.13. ES851-RTC Real Time Clock (Slot B) ......................................................................................... 341
6.13.1. Identification Data ................................................................................................................ 341
6.13.2. Installing ES851-RTC Board on the Inverter (Slot B) .......................................................... 342
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6.13.2.1. DIP-switch Configuration ............................................................................................ 342
6.14. ES847 I/O Expansion Board (Slot C) ........................................................................................... 343
6.14.1. Signal Conditioning and I/O Expansion Board .................................................................... 343
6.14.2. Identification Data ................................................................................................................ 344
6.14.3. Installing ES847 Board on the Inverter (Slot C) .................................................................. 344
6.14.4. ES847 Board Terminals ...................................................................................................... 346
6.14.5. Configuration DIP-switches ................................................................................................. 348
6.14.6. Possible Settings for DIP-switches SW1 and SW2 ............................................................. 349
6.14.7. Wiring Diagrams .................................................................................................................. 351
6.14.7.1. Connection of “Fast” Differential Analog Inputs .......................................................... 351
6.14.7.2. Connection of “Fast” Current Inputs ........................................................................... 352
6.14.7.3. Connecting “Slow” Analog Inputs to Voltage Sources ................................................ 352
6.14.7.4. Connecting “Slow” Analog Inputs to Current Sources ................................................ 353
6.14.7.5. Connecting “Slow” Analog Inputs to Thermistor PT100 ............................................. 353
6.14.7.6. Connecting Isolated Digital Inputs .............................................................................. 354
6.14.7.7. Connection to an Encoder or a Frequency Input ........................................................ 355
6.14.7.8. Connection to Isolated Digital Outputs ....................................................................... 356
6.14.8. Environmental Requirements .............................................................................................. 357
6.14.9. Electrical Ratings ................................................................................................................. 358
6.14.9.1. Analog Inputs .............................................................................................................. 358
6.14.9.2. Digital Inputs ............................................................................................................... 360
6.14.9.3. Digital Outputs ............................................................................................................ 361
6.14.9.4. Supply Outputs ........................................................................................................... 361
6.15. ES870 Relay I/O Expansion Board (Slot C) ................................................................................. 362
6.15.1. Identification Data ................................................................................................................ 362
6.15.2. Installing ES870 Board on the Inverter (Slot C) .................................................................. 363
6.15.3. ES870 Board Terminals ...................................................................................................... 364
6.15.3.1. Connection to an Encoder or a Frequency Input ....................................................... 365
6.16. ES914 Power Supply Unit Board ................................................................................................. 366
6.16.1. Identification Data ................................................................................................................ 368
6.16.2. Wiring ES914 Board ............................................................................................................ 368
6.17. “Loc-0-Rem” Key Selector Switch And Emergency Push-Button for IP54 Models ...................... 373
6.17.1. Wiring IP54 Inverters with Optional “LOC-0-REM” Key Selector Switch and Emergency
Push-button ........................................................................................................................................... 374
6.18. ES860 SIN/COS Encoder Board (Slot A) ..................................................................................... 375
6.18.1. Identification Data ................................................................................................................ 376
6.18.2. Installing ES860 Board on the Inverter (Slot A) ................................................................... 376
6.18.2.1. Sin/Cos Encoder Connector ....................................................................................... 378
6.18.3. ES860 Configuration and Operating Modes ........................................................................ 379
6.18.3.1. Configuring and Adjusting the Encoder Supply Voltage ............................................. 380
6.18.4. Connecting the Encoder Cable ............................................................................................ 381
6.18.5. Environmental Requirements .............................................................................................. 382
6.18.6. Electrical Ratings ................................................................................................................. 382
6.19. ES861 Resolver and Incremental Encoder Board (Slot C) .......................................................... 384
6.19.1. Identification Data ................................................................................................................ 385
6.19.2. Installing ES861 Board on the Inverter (Slot C) .................................................................. 385
6.19.2.1. Resolver Connector .................................................................................................... 388
6.19.2.2. Incremental Encoder and Digital Lines Connectors ................................................... 389
6.19.3. ES861 Configuration and Operating Modes ........................................................................ 390
6.19.3.1. Configuring and Adjusting the Encoder Supply Voltage ............................................. 390
6.19.4. Connecting the Resolver Cable ........................................................................................... 392
6.19.5. Environmental Requirements .............................................................................................. 393
6.19.6. Electrical Ratings ................................................................................................................. 393
6.20. ES950 BiSS/EnDat Encoder Board (Slot C) ................................................................................ 395
6.20.1. Identification Data ................................................................................................................ 396
6.20.2. Installing ES950 Board on the Inverter (Slot C) .................................................................. 397
6.20.2.1. BiSS/EnDat Encoder Connector ................................................................................. 399
6.20.2.2. Incremental Encoder and Digital Line Connectors ..................................................... 400
6.20.3. ES950 Configuration and Operating Modes ........................................................................ 401
6.20.3.1. BiSS Operating Mode ................................................................................................. 402
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6.20.3.2. EnDat Operating Mode ............................................................................................... 402
6.20.3.3. Configuring and Adjusting the Encoder Supply Voltage ............................................. 402
6.20.4. Connecting the Encoder Cable ............................................................................................ 404
6.20.5. Environmental Requirements .............................................................................................. 406
6.20.6. Electrical Ratings ................................................................................................................. 406
6.21. Encoder Board Hiperface ES966 (Slot C) ................................................................................... 408
6.21.1. Part Number ........................................................................................................................ 408
7. NORMATIVE REFERENCES ............................................................................................................... 409
7.1. Electromagnetic Compatibility Directive ....................................................................................... 409
7.1.1. RADIOFREQUENCY DISTURBANCE ................................................................................ 412
7.1.1.1. The Power Supply Mains ................................................................................................ 413
7.1.1.2. Output Toroid Filters........................................................................................................ 413
7.1.1.3. The Cabinet ..................................................................................................................... 413
7.1.1.4. Input and Output Filters ................................................................................................... 416
7.2. Low Voltage Directive ................................................................................................................... 416
8. INDEX ................................................................................................................................................... 417
0.1. Index of Figures
Figure 1: Packaging of the Sinus Penta .......................................................................................................... 22
Figure 2: Example of a nameplate affixed on the drive metal enclosure ........................................................ 23
Figure 3: Example of a nameplate ................................................................................................................... 23
Figure 4: Lifting the packing from underneath ................................................................................................. 25
Figure 5: How to open the packaging .............................................................................................................. 25
Figure 6: “This side up” pictogram ................................................................................................................... 26
Figure 7: The Sinus Penta is unpacked ........................................................................................................... 26
Figure 8: Sinus Penta packing box with the internal protective elements ....................................................... 26
Figure 9: Clearance to be observed between two inverters ............................................................................ 29
Figure 10: Clearance to allow when installing the Inverter/Power supply unit modules ................................. 30
Figure 11: Piercing template for STAND-ALONE models from S05 to S52 included ..................................... 51
Figure 12: Piercing template for size S60........................................................................................................ 52
Figure 13: Fittings for through-panel assembly for Sinus Penta S05 .............................................................. 53
Figure 14: Piercing templates for through-panel assembly for Sinus Penta S05 ............................................ 53
Figure 15: Fittings for through-panel assembly for Sinus Penta S12 .............................................................. 54
Figure 16: Piercing template for through-panel assembly for Sinus Penta S12 .............................................. 54
Figure 17: Fittings for through-panel assembly for Sinus Penta S14 .............................................................. 55
Figure 18: Piercing template for through-panel assembly for Sinus Penta S14 .............................................. 55
Figure 19: Through-panel assembly and piercing template for Sinus Penta S15, S20 and S30 .................... 56
Figure 20: Fittings for through-panel assembly for Sinus Penta S22 and S32 ............................................... 57
Figure 21: Piercing template for through-panel assembly for Sinus Penta S22 and S32 ............................... 58
Figure 22: Mechanical parts for the through-panel assembly for Sinus Penta S41, S42, S51 and S52 ......... 59
Figure 23: Piercing templates for the through-panel assembly for Sinus Penta S41, S42, S51 and S52 ...... 60
Figure 24: Piercing templates for modular units .............................................................................................. 62
Figure 25: Piercing templates for control unit (stand-alone model) ................................................................. 62
Figure 26: Installation example for Sinus Penta S65 (in cabinet) ................................................................... 63
Figure 27: Piercing template for IP54 inverter ................................................................................................. 64
Figure 28: Wiring diagram ............................................................................................................................... 67
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Figure 29: External connections for modular inverters S65-S70 ..................................................................... 69
Figure 30: External connections for modular inverters S64 ............................................................................ 70
Figure 31: Layout of 12-pulse connection ....................................................................................................... 71
Figure 32: Single optical fibre connector ......................................................................................................... 73
Figure 33: Double optical fibre connector ........................................................................................................ 74
Figure 34: Internal wiring for Sinus Penta S65-S70 ........................................................................................ 76
Figure 35: ES840 Supply Board ...................................................................................................................... 77
Figure 36: ES841 Inverter Module Gate Unit Board ........................................................................................ 77
Figure 37: ES843 Bus-bar Voltage Acquisition Board ..................................................................................... 78
Figure 38: Position of the fastening screws in the terminal board cover and the control unit ......................... 78
Figure 39: ES842 Control Unit ......................................................................................................................... 79
Figure 40: Single optical-fibre connector ......................................................................................................... 80
Figure 41: Double optical-fibre connector........................................................................................................ 81
Figure 42: Internal wiring for inverters S64...................................................................................................... 83
Figure 43: Connection bars in S41–S42–S51–S52 ......................................................................................... 87
Figure 44: S60 Connection bars ...................................................................................................................... 89
Figure 45: Connection bars for S64-S70 ......................................................................................................... 90
Figure 46: Connection bars for S74-S80 ......................................................................................................... 91
Figure 47: Connection bars for S84-S90 ......................................................................................................... 92
Figure 48: Control terminals .......................................................................................................................... 106
Figure 49: Gaining access to the control terminals ....................................................................................... 107
Figure 50: Clamping a signal shielded cable ................................................................................................. 109
Figure 51: Control board: signals and programming ..................................................................................... 110
Figure 52: Gaining access to DIP-switches SW1 and SW2 .......................................................................... 114
Figure 53: Gaining access to DIP-switch SW3 and connector RS485 (Sinus Penta S05 to S22) ................ 114
Figure 54: Position of DIP-switch SW3 and connector RS485 (Sinus Penta S30 to S60) ............................ 115
Figure 55: PNP command (active to +24V) ................................................................................................... 117
Figure 56: Connecting an incremental encoder ............................................................................................ 119
Figure 57: Signal sent from a push-pull, +24V output ................................................................................... 120
Figure 58: Potentiometer linked to the REF Input ......................................................................................... 122
Figure 59: Wiring of a PLC analog output, axis control board, etc. ............................................................... 123
Figure 60: Wiring of unipolar remote potentiometer 0 ÷ REF max ................................................................ 124
Figure 61: 4 ÷ 20 mA Sensor wiring .............................................................................................................. 124
Figure 62: Standard pattern of the thermistor resistor for the motor thermal protection ............................... 125
Figure 63: PNP output wiring for relay control ............................................................................................... 128
Figure 64: NPN output wiring for relay control .............................................................................................. 129
Figure 65: Cascade connection: frequency output → frequency input ......................................................... 129
Figure 66: PNP output wiring for relay control ............................................................................................... 130
Figure 67: NPN output wiring for relay control .............................................................................................. 130
Figure 68: Display/keypad ............................................................................................................................. 134
Figure 69: Removing the display/keypad module ......................................................................................... 138
Figure 70: Front/rear view of the display/keypad and its shell. ..................................................................... 139
Figure 71: Example of multidrop and direct connection ................................................................................ 141
Figure 72: Pin lay-out of serial link 1 connector ............................................................................................ 143
Figure 73: Recommended wiring diagram for “2-wire” MODBUS connection ............................................... 143
Figure 74: Nameplate for BU200 ................................................................................................................... 195
Figure 75: Positions of BU200 configuration jumpers ................................................................................... 196
Figure 76: Positions of BU200 adjusting trimmers ........................................................................................ 197
Figure 77: Position of the Indicator LEDs ...................................................................................................... 198
Figure 78: Dimensions and fixing points of BU200 ....................................................................................... 200
Figure 79: Terminals in BU200 ...................................................................................................................... 201
Figure 80: Connecting one BU200 to the inverter ......................................................................................... 202
Figure 81: Master – Slave multiple connection ............................................................................................. 203
Figure 82: Nameplate for BU600 ................................................................................................................... 208
Figure 83: BRAKE connector supplied with the Sinus Penta ........................................................................ 209
Figure 84: Cable connecting the Sinus Penta to braking unit BU600 ........................................................... 209
Figure 85: Diagnostic LEDs ........................................................................................................................... 210
Figure 86: Dimensions and fixing points of BU600/BU700 ........................................................................... 212
Figure 87: Power terminals ............................................................................................................................ 213
Figure 88: Signal terminals ............................................................................................................................ 215
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Figure 89: Wiring diagram for S41-S51/S42-S52 with braking unit BU600/700............................................ 216
Figure 90: Nameplate for BU1440 ................................................................................................................. 223
Figure 91: Dimensions and fixing points of BU1440 ..................................................................................... 225
Figure 92: External power connections for modular inverters S65-S70 provided with braking unit BU1440 226
Figure 93: External power connections for modular inverters S75-S80 provided with braking unit BU1440 227
Figure 94: ES841 Unit gate board for the braking unit .................................................................................. 228
Figure 95: Connection points on ES842 for the braking unit optical fibres ................................................... 229
Figure 96: Internal wiring of inverters S65-S70 provided with a braking unit ................................................ 230
Figure 97: Overall dimensions, resistor 56-100Ω/350W ............................................................................... 237
Figure 98: Overall dimensions and ratings for braking resistor 75Ω/1300W ................................................. 238
Figure 99: Overall dimensions and mechanical features for braking resistors from 1100W to 2200W ........ 239
Figure 100: Overall dimensions for braking resistors 4kW, 8kW, 12kW ....................................................... 241
Figure 101: Overall dimensions of IP23 Box resistors .................................................................................. 243
Figure 102: Position of electrical connections in box resistors ...................................................................... 243
Figure 103: Wiring diagram of the keypad remoting kit controlling multiple inverters ................................... 250
Figure 104: Wiring diagram for optional inductors ......................................................................................... 252
Figure 105: Amplitude of harmonic currents (approximate values) ............................................................... 254
Figure 106: Output inductor wiring ................................................................................................................ 255
Figure 107: Mechanical features of a 3-phase inductor ................................................................................ 261
Figure 108: Mechanical features of a DC inductor ........................................................................................ 263
Figure 109: Mechanical features of the 3-phase du/dt inductors .................................................................. 264
Figure 110: Mechanical features of a 3-phase inductor for Class 2T-4T in IP54 cabinet ............................. 268
Figure 111: Mechanical features of a single-phase output inductor .............................................................. 269
Figure 112: Sinusoidal filter ........................................................................................................................... 270
Figure 113: Encoder board (ES836/2) ........................................................................................................... 271
Figure 114: Position of slot A for the installation of the encoder board ......................................................... 273
Figure 115: Encoder board fastened to its slot .............................................................................................. 273
Figure 116: Positions of DIP-switches and their factory-setting .................................................................... 274
Figure 117: LINE DRIVER or PUSH-PULL encoder with complementary outputs ....................................... 277
Figure 118: PUSH-PULL encoder with single-ended outputs ....................................................................... 278
Figure 119: PNP or NPN encoder with single-ended outputs and load resistors with external wiring .......... 279
Figure 120: PNP or NPN encoder with single-ended outputs and internal load resistors ............................. 280
Figure 121: Wiring the encoder cable ............................................................................................................ 281
Figure 122: ES913 Encoder board ................................................................................................................ 282
Figure 123: Position of slot A for the installation of the encoder board ......................................................... 284
Figure 124: Encoder board fastened to its slot .............................................................................................. 284
Figure 125: Position of the configuration DIP-switches ................................................................................. 285
Figure 126: Location of the jumpers selecting the encoder supply voltage .................................................. 287
Figure 127: ES822 board .............................................................................................................................. 288
Figure 128: Position of the slot for the installation of the serial isolated board ............................................. 290
Figure 129: Jumper setting RS232/RS485 .................................................................................................... 291
Figure 130: Configuration of terminator DIP-switch for line RS485 .............................................................. 292
Figure 131: Location of the slot B inside the terminal board cover of the Sinus PENTA inverters ............... 295
Figure 132: Checking contacts in the slot B .................................................................................................. 295
Figure 133: Fastening the communications board to slot B .......................................................................... 296
Figure 134: PROFIBUS-DP® fieldbus communications board ...................................................................... 297
Figure 135: Example of a Profibus network (the correct setting of the line terminators is highlighted) ........ 299
Figure 136: Example of the rotary-switch position to set Profibus address “19” ........................................... 299
Figure 137: DeviceNet® Fieldbus communications board ............................................................................. 301
Figure 138: Outline of the topology of a DeviceNet trunk line ....................................................................... 303
Figure 139: CANopen® fieldbus communications board ............................................................................... 305
Figure 140: Example of the position of the rotary-switches for 125kbits/s and Device Address 29 ............. 306
Figure 141: Ethernet Fieldbus Communications Board ................................................................................. 308
Figure 142: Cable of Cat. 5 for Ethernet and standard colour arrangement in the connector ...................... 309
Figure 143: Setting a computer for a point-to-point connection to the inverter ............................................. 312
Figure 144: Setting the DIP-switches to set the IP address 192.168.0.2. ..................................................... 313
Figure 145: Example of the ping command to the IP address of the inverter interface board ...................... 314
Figure 146: Anybus IP config utility ............................................................................................................... 314
Figure 147: Setting ModScan for a Modbus/TCP connection ....................................................................... 315
Figure 148: Display of the output variables of the inverter through the Modbus/TCP protocol ..................... 315
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Figure 149: Position of indicator LEDs on the board ..................................................................................... 316
Figure 150: Position of the slot for ES919 board ........................................................................................... 320
Figure 151: ES919 Board for Metasys® N2 ................................................................................................... 321
Figure 152: ES919 Board for BACnet/Ethernet ............................................................................................. 323
Figure 153: BACnet LEDs ............................................................................................................................. 324
Figure 154: BACnet IP Configuration ............................................................................................................ 325
Figure 155: ES919 Board for BACnet/RS485 ............................................................................................... 326
Figure 156: BACnet MSTP Configuration...................................................................................................... 327
Figure 157: ES851 DataLogger Board .......................................................................................................... 328
Figure 158: Position of the slot for the installation of ES851 DataLogger board .......................................... 329
Figure 159: ES851 DataLogger fitted into slot B ........................................................................................... 330
Figure 160: Recommended wiring diagram for the connection of 2-wire MODBUS devices ........................ 333
Figure 161: Cable of Cat. 5 for Ethernet and standard colour arrangement in the connector ..................... 338
Figure 162: Location of the Ethernet port ...................................................................................................... 340
Figure 163: Wiring of the Ethernet cable ....................................................................................................... 340
Figure 164: Real Time Clock ES851-RTC Board .......................................................................................... 341
Figure 165: Signal conditioning and additional I/Os board (ES847) ............................................................. 343
Figure 166: Removing the inverter cover; location of slot C.......................................................................... 344
Figure 167: Fitting the strips inside ES847 board and fixing the board on slot C ......................................... 345
Figure 168: Connection of a bipolar voltage source to a differential input .................................................... 351
Figure 169: Connection of 0÷20mA (4÷20mA) sensors to “fast” current inputs ............................................ 352
Figure 170: Connecting a voltage source to a “slow” analog input ............................................................... 352
Figure 171: Connecting thermoresistors PT100 to analog channels XAIN8–11 / T1–4 ............................... 353
Figure 172: PNP input wiring ......................................................................................................................... 354
Figure 173: Connecting the incremental encoder to fast inputs XMDI7 and XMDI8 ..................................... 355
Figure 174: Signal sent from a 24V, Push-pull frequency output .................................................................. 355
Figure 175: Connection of a PNP output for relay control ............................................................................. 356
Figure 176: Connection of an NPN output for relay control ........................................................................... 356
Figure 177: Relay I/O expansion board ES870 ............................................................................................. 362
Figure 178: Removing the inverter cover; location of slot C.......................................................................... 363
Figure 179: ES914 Power supply unit board ................................................................................................. 366
Figure 180: Basic wiring diagram for ES914 board ....................................................................................... 367
Figure 181: Block-diagram with 3-zone insulation ......................................................................................... 367
Figure 182: Position of the LEDs and DIP-switches in ES914 board ............................................................ 372
Figure 183: Wiring diagram for IP54 inverters ............................................................................................... 374
Figure 184: ES860 Sin/Cos Encoder board .................................................................................................. 375
Figure 185: Location of Slot A inside the terminal board covers in Sinus PENTA inverters. ........................ 376
Figure 186: Fitting the ES860 board inside the inverter. ............................................................................... 377
Figure 187: Pin layout on the high density connector ................................................................................... 378
Figure 188: DIP-switch SW1 setting in three-channel mode ......................................................................... 379
Figure 189: DIP-switch SW1 setting for five-channel mode .......................................................................... 379
Figure 190: Position of the jumper and voltage adjusting trimmer. ............................................................... 380
Figure 191: Recommended dual shielded connection for encoder cable. .................................................... 381
Figure 192: ES861 Incremental Encoder and Resolver expansion board .................................................... 384
Figure 193: Location of slot C inside the terminal board cover of the Sinus Penta inverter ......................... 386
Figure 194: Terminal strips inserted into SLOT C ......................................................................................... 386
Figure 195: Fitting the ES861 board inside the inverter. ............................................................................... 387
Figure 196: Pin layout on the D-sub 9-pin female connector. ....................................................................... 388
Figure 197: Input-output signal terminal boards ............................................................................................ 389
Figure 198: Jumpers and trimmer for power supply configuration. ............................................................... 390
Figure 199: Recommended dual shielded connection for resolver cable. .................................................... 392
Figure 200: ES950 encoder BiSS/EnDat board. ........................................................................................... 395
Figure 201: Location of slot C inside the terminal board cover in Sinus PENTA inverters. .......................... 397
Figure 202: Terminal strips inserted into SLOT C ......................................................................................... 398
Figure 203: Fitting the ES950 board inside the inverter ................................................................................ 398
Figure 204: Pin layout on CN7 D-sub 15-pin female connector. ................................................................... 399
Figure 205: Input-output signal terminal board .............................................................................................. 400
Figure 206: Block diagram for ES950 board interface. ................................................................................. 401
Figure 207: Jumpers and trimmer for power supply configuration ................................................................ 403
Figure 208: Recommended dual shielded connection for encoder cable ..................................................... 405
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Figure 209: Disturbance sources in a power drive system equipped with an inverter .................................. 412
Figure 210: Example of correct wiring of an inverter inside a cabinet ........................................................... 415
Figure 211: Wiring the toroid filter for the inverters of the Sinus Penta series .............................................. 416
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1. GENERAL DESCRIPTION
Inverters are electronic devices capable of powering an AC electric motor and of imposing speed and torque
values. The inverters of the PENTA series manufactured by Elettronica Santerno SpA allow adjusting speed
and torque values of three-phase asynchronous and synchronous motors and brushless, permanent-magnet
AC motors by way of several control modes. Control modes may be user-defined and allow obtaining the
best performance in terms of fine-tuning and energy saving for any industrial application.
The PENTA inverters provided with the standard firmware feature the control modes below:
-
IFD control mode: voltage / frequency scalar control for asynchronous motors,
-
VTC control mode: sensorless vector control for asynchronous motors.
-
FOC control mode: vector control with encoder feedback for asynchronous motors,
The following applications are also available by re-programming the firmware (this can be done by the user
as well):
-
SYN control mode: vector control with feedback from encoder for PMSM synchronous motors;
-
Specific applications featuring the most popular automation functions.
See Special Applications Available on Sinus Penta for more details.
Available Sinus Penta models range from 1.5kW to 3MW.
AVAILABLE Sinus Penta MODELS
NOTE
Products may have different ratings and/or appearance than the ones shown in
the picture above. The proportion of on
e enclosure to the other is shown as an
example and is not binding.
SINUS PENTA
INSTALLATION GUIDE
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1.1. Feature List
• One product, multiple functions:
vector-modulation IFD function for general-purpose applications (V/f pattern);
sensorless, vector VTC function for high torque demanding performance (direct torque control);
vector FOC function with an encoder for accurate torque requirements and wide speed range;
SYN function for synchronous motors (see Special Applications Available on Sinus Penta);
RGN AFE (Active Front End) function for power exchange with the mains, with unitary power
factor and very low harmonic current (see Special Applications Available on Sinus Penta);
special optional functions for any application (such as MUP function for Multipump) (see Special
Applications Available on Sinus Penta).
• Wide range of supply voltage values (200 VAC ÷ 690 VAC) both for stand-alone models and cabinet
models.
• Standard DC power supply, 280 to 970 VDC.
• Wide power range from 1.5kW a 3MW.
• Wide range of voltage values and power values for the electric motors to be connected to any
inverter model.
MODEL
LIGHT
STANDARD
HEAVY
STRONG
Sinus Penta 0025 4TBA2X2
22kW 18.5kW 15kW 11kW
• Built-in filters for the whole Sinus Penta range in compliance with regulation EN
61800-3, issue 2 concerning emission limits.
• The new hardware configuration is standard supplied with a safety
system including redundant contacts for the inhibition of firing pulses
in the power circuit, in compliance with the latest requirements of the safety
regulations in force, EN 61800-5-1/EN 61800-5-2. (However, respect the specific
rules of the field of application).
• Compact and light, the new series of Sinus Penta models may be installed in
cabinets and offers a better price/performance ratio.
• Detection of the heat sink temperatures and control component temperatures.
• Automatic control of the cooling system. The ventilation system activates only when required. This
ensures greater energy saving, minor wear of the cooling fans and reduced noise; In case of
equipment failure, it is possible to adjust the system speed in order not to stop the equipment and to
limit dissipated power.
• Built-in braking module up to Size S32 included.
• Noiseless operation ensured by high modulation frequency programmable up to 16 kHz.
• Motor thermal protection to be integrated both through thermal relay function and PTC
input (in compliance with DIN44081/2).
• Remotable control panel with a 12-key LCD display showing full words for easier
managing and programming of the displayed measures. Five languages available.
• Function parameter saving to remotable display/keypad and possibility of data transfer
to multiple inverters.
• Four access levels to the operation parameters and preset parameters for the most common
applications.
• PC interface for WINDOWS environment with the RemoteDrive software available in six foreign
languages.
• RS485 MODBUS RTU Serial communication for serial links to PCs, PLCs and control interfaces.
• Fieldbuses with internal optional interface boards.
INSTALLATION GUIDE
SINUS PENTA
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1.2. Special Applications Available on Sinus Penta
Beside basic parameterization, Sinus Penta drives also implement operating modes and optional functional
modes named APPLICATIONS, which can be obtained through firmware updating and additional external
components.
Optional operating modes available for the inverters of the PENTA series are multipump control
application, regenerative inverter control application and synchronous motor control application.
In the future, additional optional operating modes will be available, which include application software,
instruction manual and dedicated interface board (if any). They implement the most common automation
applications, thus replacing PLCs or dedicated control board, and they reduce to a minimum the electric
equipment required, thus ensuring lower maintenance costs.
NOTE In order to upload and install your application SW and upda
te the firmware
packets of your Sinus Penta, you can use our Remo
teDrive software. Refer to
the User Manual related to each individual application for detailed instructions.
The Multipump application (MUP) allows obtaining a divided pumping plant, with pressure delivery control,
flow control or level control; this application does not need any PLC, because the inverter is capable of
controlling multiple pumps at a time.
The Regenerative application (RGN) allows PENTA inverters to be used as AC/DC converters for the DC
supply of multiple inverters. When operating as an AC/DC converter, the PENTA operates as a bidirectional
mains interface both to power connected inverters and to regenerate the braking powers of the connected
motors. Mains power supply always provides sinusoidal currents and a unitary power factor, thus avoiding
using braking resistors, power factor correction capacitor banks and damping systems of the harmonics
delivered to the mains.
The Synchronous Motor application (SYN) allows PENTA inverters to control permanent magnet
synchronous motors (PMSM). Optional boards are required, which are described later on in this manual.
Any detail concerning functionality is given in the User Manuals related to each individual application.
SINUS PENTA
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2. SAFETY STATEMENTS
This section contains safety statements. The non-observance of these safety instructions may cause serious
injury or death and equipment failure. Carefully read the instructions below before installing, starting and
operating the inverter.
Only competent personnel must carry out the equipment installation.
SYMBOLS:
DANGER
Indicates operating procedures that, if not correctly performed, may cause
serious injury or death due to electric shock.
CAUTION Indicates operating procedure
s that, if not carried out, may cause serious
equipment failure.
NOTE Indicates important hints concerning the equipment operation.
2.1. Installing and Operating the Equipment
NOTE
Always read this instruction manual before starting the equipment.
The ground connection
of the motor casing should follow a separate path to
avoid possible interferences.
DANGER
ALWAYS PROVIDE PROPER GROUNDING OF THE MOTOR CASING AND
THE INVERTER FRAME.
If a differential relay against electric
shocks is intended to be used, this must be
a “B-type” differential relay.
The inverter may generate an output frequency up to 1000 Hz; this may cause a
motor rotation speed up to 20 (twenty) times the rated motor speed—
for 50Hz
motors: never use the mo
tor at a higher speed than the max. allowable speed
stated on the motor nameplate.
ELECTRIC SHOCK HAZARD –
Never touch the inverter electrical parts when
the inverter is on; always wait at least 20 minutes after switching off the inverter
before operating on the inverter.
Never perform any operation on the motor when the inverter is on.
Do not perform electrical connections on the motor or the inverter if the inverter
is on. Electric shock
hazard exists on output terminals (U,V,W) and resistive
braking module terminals (+, –, B) even when the inverter is disabled.
Wait at
least 20 minutes
after switching off the inverter before operating on the electrical
connection of the motor or the inverter.
MECHANICAL MOTION – The inverter determines mechanical motion.
It is the
operator's responsibility to ensure that this does not give rise to any dangerous
situation.
EXPLOSION AND FIRE – Explosion and fire hazard exists if the equipment is
installed in presence of flammable fumes. Do not install the inv
erter in places
exposed to explosion and fire hazard, even if the motor is installed there.
INSTALLATION GUIDE
SINUS PENTA
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CAUTION
Do not connect supply voltages exceeding the equipment rated voltage to avoid
damaging the internal circuits.
If the inverter is installed in envi
ronments exposed to flammable and/or explosive
substances (zones AD according to standards IEC 64-2), please refer to IEC 64-
2, EN 60079-10 and related standards.
Do not connect the equipment power supply to the output terminals (U,V,W), to
the resistive braking module terminals (+, –, B) and to the control terminals. The
equipment power supply must be connected only to terminals R,S,T.
Do not short-circuit terminals (+) and (–
) and terminals (+) and (B); do not
connect any braking resistors with lower ratings than the required ratings.
Do not start or stop the motor using a contactor over the inverter power supply.
If a contactor is installed between the inverter and the motor, make sure that it is
switched over only when the inverter is disabled.
Do not connect any power
factor correction capacitor to the motor.
Operate the inverter only if a proper grounding is provided.
If an alarm trips, a comprehensive review of the Diagnostic section in the Sinus
Penta’s Programming Guide
is recommended; restart the equipment only after
removing the cause responsible for the alarm trip.
Do not perform any insulation test between the power terminals
or the control
terminals.
Make sure that the fastening screws of the control terminal board and the power
terminal board are properly tightened.
Prior to install the product, check the tightening of the factory-made link between
power terminals 47/D and 47/+ in the models where this link is provided.
Do not connect single-phase motors.
Always use a motor thermal protection
(use the inverter motor thermal model or
a thermoswitch installed in the motor).
Respect the environmental requirements for the equipment installation.
The bearing surface of the inverter must be capable of withstanding high
temperatures (up to 90°C).
The inverter electronic boards contain components which may be affected by
electrostatic discharges. Do not touch them unless it is strictly necessary. Always
be very careful so as to prevent any damage caused by electrostatic discharges.
Before programming and starting the inverter, make sure that the connected
motor and all the controlled devices can be used fo
r the whole speed range
allowed by the converter.
The inverter may be programmed to control the motor
at higher or lower rpm in respect to the speed obtained
by connecting the motor
directly to the power supply line.
SINUS PENTA
INSTALLATION GUIDE
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CAUTION
Motor insulation and bearing protection
Regardless of the output frequency, the inverter output includes impulses of
approx. 1.35 times the equivalent grid voltage with a very short rise time. This
applies to all inverters based on IGBT technology.
The impulse voltage may be approx. twofold
at the motor terminals, based on
the reflection and attenuation of the terminals and motor cable.
This may cause
additional stress to the motor and the motor insulation cable.
The variable speed drives characterized by rapid rise voltage impulses a
nd by
high switching frequen
cies may cause current impulses through the motor
bearings, that could gradually wear the housings of the bearings
and the rolling
parts.
The motor insulation stress may be avoided by adopting optional du/dt filters
(see section Output Inductors (DU/DT Filters)). The du/dt
filters also reduce the
shaft currents.
Sensors integrated into the motor
For the electrical and insulation specifications, please refer to the Control
Terminals
section and/or to the optional boards which those sensors are
connected to.
Critical torsional speed
If required, set up the critical torsional speed of the connected motor (see
Prohibit Speeds menu in the Sinus Penta’s Programming Guide).
Transient torque analysis
If required, limit the transient torque of the connected motor (see Limits m
enu in
the Sinus Penta’s Programming Guide).
2.2. Permanent Magnet Motors
This section covers additional safety statements concerning Sinus Penta drives used with permanent magnet
motors. The non-observance of the safety instructions below may cause serious injuries or death and
equipment failure.
DANGER
Do not operate on the converter when the permanent magnet motor is rotating.
Even if the power supply is cut out and the inverter is stopped, the permanent
magnet motor, when rotating, powers the DC-link of the converter, and voltage is
applied to the power supply links.
Do the following prior to install and service the inverter:
• Stop the motor.
• Make sure that the motor cannot rotate when operating on the equipment.
• Make sure that no voltage is applied to the power terminals in the converter.
DANGER
Do not exceed the motor rated rpm.
Exceeding the motor rpm may cause
overvoltage leading to damage or explosion of the converter DC-Link.
The permanen
t magnet motor control is made possible only by using the
application firmware “PS”
of the Sinus Penta for permanent magnet synchronous
motors.
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