SEW-Eurodrive MOVITRAC B User manual

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services
MOVITRAC
®
B
Basic unit
O perating I nstructions
GA3A000
Edition 07/2006
11469412 / EN

SEW-EURODRIVE – Driving the world

Operating Instructions Basic Unit – MOVITRAC®B 3
Contents
1 Important notes ................................................................................................. 4
1.1 Explanation of pictograms......................................................................... 4
1.2 Designated use ......................................................................................... 5
1.3 Disposal .................................................................................................... 5
2 Safety notes ....................................................................................................... 6
2.1 Installation and startup .............................................................................. 6
2.2 Operation and service ............................................................................... 7
3 Unit design......................................................................................................... 8
3.1 Sizes 0XS / 0S / 0L ................................................................................... 8
3.2 Sizes 2S / 2............................................................................................... 9
3.3 Size 3 ...................................................................................................... 10
3.4 Size 4 ...................................................................................................... 11
3.5 Unit designation ...................................................................................... 12
4 Installation ....................................................................................................... 13
4.1 Installation notes ..................................................................................... 13
4.2 Deactivate the EMC capacitors (size 0 only) .......................................... 15
4.3 Installation of Cold Plate ......................................................................... 17
4.4 UL compliant installation ......................................................................... 17
4.5 Wiring diagram 230 V 0.37 ... 2.2 kW / 400 V 0.55 ... 4.0 kW................. 18
4.6 Connection braking resistor BW.. / BW..-T ............................................. 19
4.7 Connecting the brake rectifier ................................................................. 20
5 Startup.............................................................................................................. 21
5.1 General startup instructions .................................................................... 21
5.2 Preliminary work and resources basic unit.............................................. 21
5.3 Starting the motor ................................................................................... 21
6 Operation and service..................................................................................... 23
6.1 Device information .................................................................................. 23
6.2 List of errors (F-00 ... F-97) ..................................................................... 24
6.3 Status displays........................................................................................ 27
6.4 SEW Electronics service ......................................................................... 27
6.5 Long term storage ................................................................................... 28
7 Technical data ................................................................................................. 29
7.1 CE marking, UL approval and C-Tick...................................................... 29
7.2 General technical data ............................................................................ 30
7.3 MOVITRAC®B electronics data ............................................................. 31
7.4 MOVITRAC®B technical data ................................................................ 32
Index ................................................................................................................. 43

1Important notes
Explanation of pictograms
4Operating Instructions Basic Unit – MOVITRAC®B
1 Important notes
1.1 Explanation of pictograms
Always follow the safety and warning notes in this publication.
Hazard
Indicates an imminently hazardous situation, which if not avoided, WILL result in death
or serious injury.
Warning
Indicates an imminently hazardous situation caused by the product, which if not
avoided, WILL result in death or serious injury. You will also find this signal to indicate
the potential for damage to property.
Caution
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor
injury or damage to products.
Note
Indicates a reference to useful information, e.g. on startup.
Documentation reference
Indicates a reference to a document, such as operating instructions, catalog, data sheet.
You must adhere to the operating instructions to ensure:
• Fault-free operation
• Fulfillment of any rights to claim under limited warranty
Read the operating instructions before you start working with the unit.
The operating instructions contain important information on servicing. Therefore, keep
the manual close to the unit.

1
Important notes
Designated use
Operating Instructions Basic Unit – MOVITRAC®B 5
1.2 Designated use
The frequency inverters from SEW-EURODRIVE operate AC motors. These motors
must be suitable for operation with frequency inverters. Do not connect any other loads
to the frequency inverters.
Frequency inverters are devices for stationary installation in control cabinets. Adhere to
all instructions referring to the technical data and the permissible conditions where the
unit is operated.
Do not start up the unit (take it into operation in the designated fashion) until you have
verified that:
• The machine complies with the EMC directive 98/37/EC.
• The end product complies with the Machinery Directive 98/37/EC, also with refer-
ence to EN 60204.
1.2.1 Operational environment
The following applications are prohibited unless measures are expressly taken to make
them possible:
• Use in potentially explosive areas.
• Operation in environments with harmful substances to EN 60721, such as oils, acids,
gases, vapors, dusts, radiations.
• Operation with mechanical vibration and shock loads in excess of the regulations
stipulated in EN 61800-5-1.
• If the inverter performs safety functions that have to guarantee the protection of
machinery and people.
1.3 Disposal
Please follow the current regulations: Dispose in accordance with the material structure
and the regulations in force.

2Safety notes
Installation and startup
6Operating Instructions Basic Unit – MOVITRAC®B
2 Safety notes
2.1 Installation and startup
• Never install damaged products or take them into operation. Submit a complaint to
the shipping company immediately in the event of damage.
• Installation, startup and service work on the unit to be performed by trained
personnel only. Such personnel must have undergone accident prevention training
and adhere to the applicable regulations (such as EN 60204, VBG 4, DIN-VDE 0100/
0113/0160).
• Follow the specific instructions during installation and startup of the motor and the
brake!
• The unit meets all requirements for reliable isolation of power and electronics
connections in accordance with EN 61800-5-1. All connected circuits must also
satisfy the requirements for reliable isolation so as to guarantee reliable isolation.
• Take suitable measures to ensure that the connected motor does not start up auto-
matically when the inverter is switched on (for example by disconnecting the elec-
tronics terminal block).
• Preventive measures and protection devices must correspond to the regulations in
force (e.g. EN 60204 or EN 61800-5-1).
The unit must be grounded as a protective measure.
Overcurrent protection devices are a necessary protection device.

2
Safety notes
Operation and service
Operating Instructions Basic Unit – MOVITRAC®B 7
2.2 Operation and service
• Disconnect the unit from power supply before you remove the protective cover.
Dangerous voltages may still be present for up to ten minutes after disconnection
from the power supply source.
• When the unit switch is in the ON position, dangerous voltages are present at the
output terminals as well as any connected cables and motor terminals. Dangerous
voltages may even occur if the unit is inhibited and the motor is at standstill.
• The unit may not necessarily be free from any voltages even if the displays are no
longer illuminated.
• Switch the frequency inverter output with inhibited output stage only.
• Ensure a minimum time of 120 s between two mains activations for AC 230 V /
1-phase units.
• Observe a minimum switch-off time of 10 s for 3-phase units.
• The unit has IP00 enclosure with the protective cover removed. Dangerous voltages
are present at all subassemblies except for the control electronics. The unit must be
closed during operation.
• Safety functions of the unit or mechanical blocking may result in a motor standstill.
Removing the cause of this problem or performing a reset can result in the drive re-
starting on its own. If, for safety reasons, this is not permitted for the driven machine,
disconnect the unit from the mains before correcting the fault.
Risk of burns
Braking resistors have surface temperatures of up to 250 °C.

3Unit design
Sizes 0XS / 0S / 0L
8Operating Instructions Basic Unit – MOVITRAC®B
3 Unit design
3.1 Sizes 0XS / 0S / 0L
[1] Fixing strap
[2] X1: Power supply connection:
3-phase: L1 / L2 / L3
1-phase: L / N
[3] Status LED (visible without optional keypad)
[4] Optional keypad
[5] Connection for optional communication / analog module
[6] X10: Analog input
[7] X12: Binary inputs
[8] X13: Binary outputs
[9] X2: Motor connection U / V / W / Brake connection +R / –R
[10] Shield clamp, fixing strap below
[11] PE connection
[12] Option card slot (cannot be retrofitted / not for BG0XS)
[13] Switch S11 for V-mA toggle analog input
(in size 0XS and 0S behind removable connector)
[11]
[1]
[3]
[4]
[5]
[2]
[12]
[6]
[7]
[8]
[9]
[10]
[13]

3
Unit design
Sizes 2S / 2
Operating Instructions Basic Unit – MOVITRAC®B 9
3.2 Sizes 2S / 2
[1] X1: Mains connection 3-phase: L1 / L2 / L3 / PE screw
[2] Status LED (visible without optional keypad)
[3] Optional keypad
[4] Connection for optional communication / analog module
[5] Option card slot
[6] Switch S11 for V-mA toggle analog input
[7] X10: Analog input
[8] X12: Binary inputs
[9] X13: Binary outputs
[10] X2: Motor connection U / V / W / PE screw
[11] Space for power shield clamp
[12] X3: Braking resistor connection R+ / R– / PE

3Unit design
Size 3
10 Operating Instructions Basic Unit – MOVITRAC®B
3.3 Size 3
[1] X2: PE connection
[2] X1: Mains connection 3-phase: L1 (1) / L2 (2) / L3 (3)
[3] X4: DC link circuit connection (not used)
[4] X2: PE connection
[5] X2: Motor connection U (4) / V (5) / W (6)
[6] X3: Braking resistor connection R+ (8) / R– (9) and PE connection
[7] Status LED (visible without optional keypad)
[8] Optional keypad
[9] Connection for optional communication / analog module
[10] Option card slot
[11] Switch S11 for V-mA toggle analog input
[12] X10: Analog input
[13] X12: Binary inputs
[14] X13: Binary outputs

3
Unit design
Size 4
Operating Instructions Basic Unit – MOVITRAC®B 11
3.4 Size 4
[1] X2: PE connection
[2] X1: Mains connection 3-phase: L1 (1) / L2 (2) / L3 (3)
[3] X4: DC link circuit connection (not used)
[4] X2: PE connection
[5] X2: Motor connection U (4) / V (5) / W (6)
[6] X3: Braking resistor connection R+ (8) / R– (9) and PE connection
[7] Status LED (visible without optional keypad)
[8] Optional keypad
[9] Connection for optional communication / analog module
[10] Option card slot
[11] Switch S11 for V-mA toggle analog input
[12] X10: Analog input
[13] X12: Binary inputs
[14] X13: Binary outputs

3Unit design
Unit designation
12 Operating Instructions Basic Unit – MOVITRAC®B
3.5 Unit designation
MC 07 B0004- 2 B 1- 4- 00
Design 00 = Standard
Quadrants 4 = 4Q (with brake chopper)
Connection type 3 = 3-phase / 1 = 1-phase
Radio interference
suppression
0 = No radio interference
suppression
A = Radio interference
suppression A
B = Radio interference
suppression B
Supply voltage 2 = AC 200 ... 240 V
5 = AC 380 ... 500 V
Recommended motor power 0022 = 2.2 kW
Version B
Series and generation
Type MOVITRAC®

4
Installation
Installation notes
Operating Instructions Basic Unit – MOVITRAC®B 13
4 Installation
4.1 Installation notes
Comply with the safety notes during installation.
Tightening torques Basic unit power terminals:
• Only use genuine connection elements. Note the permitted tightening torques of
MOVITRAC®B power terminals.
– Size 0S / 0L: 0.5 Nm (4.4 lb.in)
Line choke:
• ND020-013: 0.6 ... 0.8 Nm
• ND027-123: 4.0 ... 4.5 Nm
• ND035-073: 4.0 ... 4.5 Nm
• ND010-301: 0.6 Nm
• ND020-151: 1.5 Nm
Line filter:
• NF009-503: 0.6 ... 0.8 Nm
Output filter:
• HF008 / 015 / 022 / 030 / 040-503: 1.6 Nm ± 20 %
Recommended
tools
• Use a screwdriver with a 2.5 mm wide blade for connecting the electronics terminal strip X10 /
X12 / X13.
Minimum
clearance and
mounting position
• Leave 100 mm (4 in) clearance at the top and bottom for optimum cooling. There is no need
for clearance at the sides. You can line up the units directly next to one another. Make sure that
the circulation of air is not disrupted by cables or other installation materials. Prevent the
heated exhaust air from other units from blowing onto this unit. Install the units vertically
only. You must not install them horizontally, tilted or upside down.
Line choke • When more than four 3-phase units or more than one 1-phase unit are connected to a
supply system contactor designed for the total current: Insert a line choke in the circuit to
limit the inrush current.
Separate cable
ducts
• Route power leads and electronics leads in separate cable ducts.
Fuses and earth-
leakage circuit
breaker
•Installinput fuses at the start of the supply system lead after the supply bus junction.
Use D, DO, NH fuse types or power circuit breakers.
Earth-leakage circuit breaker as sole protection device: Only use earth leakage circuit
breakers type B according to EN 61800-5-1.
PE input
connection
• Connect the PE conductor according to the relevant regulations that are applicable in the
specific country.
Connect the protective earth connector of the motor to the PE terminal of the corresponding
inverter.
Ground all units over a large area via short ground connections with large cross-section to a
mutual earthable point or a grounding bar.
Make sure the connection between inverter and earthed metallic installation platform is conduc-
tive (large area metal-on-metal contact between the heat sink and ground, e.g. unpainted
control cabinet mounting panel). Use high-frequency compatible earthing strips if necessary).
Establish a high-frequency equipotential bonding between system / control cabinet and drive /
motor (e. g. by a continuous cable rack).

4Installation
Installation notes
14 Operating Instructions Basic Unit – MOVITRAC®B
Shielding and
earthing
• Shield the control cables and use the shield clamps.
• Connect the shield by the shortest possible route and make sure it is earthed over a wide area
at both ends.
• You can ground one end of the shield via a suppression capacitor (220 nF / 50 V) to avoid
ground loops.
• If using double-shielded cables, ground the outer shield on the inverter end and the inner shield
on the other end.
• Provide high frequency compatible earthing for MOVITRAC®B and all additional units
(wide area metal-on-metal contact between the heat sink and ground with unpainted switch
cabinet mounting panel).
• Any crossovers of control cable and power cables must be at a right angle.
• You can also use earthed sheet-metal ducts or metal pipes to shield the cables.
IT systems • SEW recommends using earth-leakage monitors with pulse code measuring in voltage
supply systems with a non-earthed star point (IT systems). Use of such devices prevents the
earth-leakage monitor mis-tripping due to the earth capacitance of the inverter.
• For size 0, SEW recommends deactivating the interference suppressor filter using the
enclosed insulation discs (see next section).
Contactor • Only use contactors in utilization category AC-3 (EN 60947-4-1).
Cross-sections • Supply system lead: Cross-section according to rated input current IMains at rated load.
Motor cable: Cross-section according to rated output current IN.
Electronics cables: Maximum 1.5 mm2(AWG16) without conductor end sleeves
Maximum 1.0 mm2(AWG17) with conductor end sleeves
Cable lengths for
individual drives
The line lengths depend on the PWM frequency. The permitted motor line lengths are listed in the
"Project Planning" section of the MOVITRAC®B System Manual.
Unit output • Only connect an ohmic/inductive load (motor); do not connect a capacitive load!
Braking resistor
connection
• Cut the lines to the required length.
•Use2 tightly twisted leads or a 2-core shielded power cable. Cross-section according to
the rated output current of the inverter.
• Protect the braking resistor with a bimetallic relay with trip class 10 or 10A (wiring diagram).
Set the trip current according to the technical data of the braking resistor.
• For braking resistors in the BW..-T series, you can connect the integrated thermostat using
a 2-core, shielded cable as an alternative to a bimetallic relay.
•Theflat-design braking resistors have internal thermal overload protection (fuse cannot be
replaced). Install the flat-design braking resistors together with the appropriate touch guard.
Binary outputs • Binary outputs are short-circuit proof and interference-voltage-proof up to 30 V.
Higher external voltages can destroy the binary outputs.
Interference
emission
• Use shielded motor lines for an EMC compliant installation.
Switched
inductances
• Use suppressors to suppress interference on contactors, relays, solenoid valves, etc.
• The minimum distance to the inverter must be 150 mm.

4
Installation
Deactivate the EMC capacitors (size 0 only)
Operating Instructions Basic Unit – MOVITRAC®B 15
4.2 Deactivate the EMC capacitors (size 0 only)
Only electro-technical professionals should carry out any conversions. Once converted,
the unit must be marked with the sticker provided in the accessory bag.
Proceed as follows to deactivate the EMC capacitors for MOVITRAC®B:
• Open the unit:
– Remove all connectors.
– Remove the electronics shield clamp.
– Remove the housing retaining screw in the center of the housing front.
– Remove the housing.
• Remove the two screws [A] securing the circuit board.
• Install the screws in the provided plastic insulations [B].
Line filter MOVITRAC®B frequency inverters have an integrated line filter as standard. They comply with
the following limit value class to EN 55011 on the line side without further measures:
• 1-phase connection: Bcable conducted
• 3-phase connection: A
No EMC limits are specified for interference emission in voltage supply systems
without a grounded star point (IT systems). The effectiveness of line filters is severely
limited.
HD output choke • Install the output choke close to MOVITRAC®B beyond the minimum clearance.
• Always route all 3 phases (not PE!) through the output choke.
• If the cable is shielded, the shield should not be routed through the output choke.
In the case of the HD output choke, the cable must be wrapped
around the choke 5 times.
Only 5 loops are possible if the cable has a large diameter.
To make up for this, 2 or 3 output chokes should be connected
in series. 2 output chokes can be connected in series in case
of 4 windings and 3 output chokes in case of 3 windings.
n = 5
456댷
UVWPE
• Disconnect the inverter from the power. Switch off the 24 V DC and the supply
voltage.
• Take appropriate measures to avoid electrostatic charges (use discharge strap,
conductive shoes, etc.) before removing the cover.
• Touch only the unit frame and heat sink. Do not touch any electronic components.

4Installation
Deactivate the EMC capacitors (size 0 only)
16 Operating Instructions Basic Unit – MOVITRAC®B
• Fasten screws to the unit [C].
• Close the unit.
Deactivating the EMC capacitors stops earth-leakage currents from flowing over the
EMC capacitors.
• Please ensure that the earth-leakage currents are essentially only determined by the
level of the DC link voltage, the PWM frequency, the applied motor line and its length
and the motor used.
The EMC filter is no longer active when the suppression capacitors are deactivated.
[A] [A]
[B]
[C] [C]
IT systems
• No EMC limits are specified for interference emission in voltage supply systems
without a grounded star point (IT systems).

4
Installation
Installation of Cold Plate
Operating Instructions Basic Unit – MOVITRAC®B 17
4.3 Installation of Cold Plate
The dissipation of the frequency inverter power loss can take place via coolers that work
with different cooling media (air, water, oil, etc.).
A good thermal connection to the cooler is important for safe operation of the frequency
inverters:
• The contact area between cooler and frequency inverter has to be the size of the
frequency inverter cooling plate.
• Level contact surface, deviation max. up to 0.05 mm.
• Connect cooler and cooling plate with all necessary screw connections.
• The mounting plate must not exceed 70 °C during operation. This limit must be
ensured by the cooling medium.
• Cold Plate installation is not possible with FHS or FKB.
4.4 UL compliant installation
Please note the following points for UL compliant installation:
• Use only copper cables with the temperature range 60/75 °C as connection lead:
• Necessary tightening torques of MOVITRAC®B power terminals: See installation
notes.
• Operation of inverters on supply systems with a maximum phase-to-earth voltage of
AC 300 V only.
• The inverter can only be operated on IT systems if the phase-to-earth voltage of
AC 300 V cannot be exceeded either during operation or in case of an error.
• The MOVITRAC®B frequency inverter is only allowed to be operated on supply
systems which can supply maximum values in accordance with the following table.
Only use melting fuses. The performance data of the fuses must not exceed the
values in the following table.
4.4.1 Maximum values / fuses
The following maximum values / fuses must be observed for UL compliant installation:
230 V units Max. supply current Max. supply voltage Fuses
0005 / 0008 AC 5000 A AC 240 V 15 A / 250 V
0011 / 0015 / 0022 AC 5000 A AC 240 V 30 A / 250 V
400/500 V units Max. supply current Max. supply voltage Fuses
0005 / 0008 / 0011 / 0015 AC 5000 A AC 500 V 15 A / 600 V
0022 / 0030 / 0040 AC 5000 A AC 500 V 20 A / 600 V
0055 / 0075 AC 5000 A AC 500 V 60 A / 600 V
0110 AC 5000 A AC 500 V 110 A / 600 V
0150 / 0220 AC 5000 A AC 500 V 175 A / 600 V
0300 AC 5000 A AC 500 V 225 A / 600 V
0370 / 0450 AC 10000 A AC 500 V 350 A / 600 V

4Installation
Wiring diagram 230 V 0.37 ... 2.2 kW / 400 V 0.55 ... 4.0 kW
18 Operating Instructions Basic Unit – MOVITRAC®B
4.5 Wiring diagram 230 V 0.37 ... 2.2 kW / 400 V 0.55 ... 4.0 kW
쓔
댷
쓔쓔
Brake released*
→Section "Connection braking
resistor BW.. / BW..-T"
X45 X46
123456HL⊥
FSC11B
MOVITRAC®B
7
}
n13 = n11 + n12
Reference potential
Changeover
s sV
Reference potential for analog signals
Fault reset
CW/Stop
CCW/Stop
Enable/Rapid stop
Supply voltage for
+24V input/output
Reference potential for binary signals
Ready
Reference potential
Relay contact/Fault
Normally open contact relay
Normally closed contact relay
ee
Higher-level
controller
Cut-off in the DC and
AC circuits
Binary input
Binary
outputs
Reference
binary outputs
Cut-off in the DC and
AC circuits
Cut-off in the
AC circuit
eShield clamp
Factory setting
V
VV
ON
OFF
ON
OFF
S1 S2
X44
DO02
GND
REF1
24VIO

4
Installation
Connection braking resistor BW.. / BW..-T
Operating Instructions Basic Unit – MOVITRAC®B 19
4.6 Connection braking resistor BW.. / BW..-T
Overload protection for braking resistors BW:
T2
T1
BW...-...-T
RB2
RB1
X2:
UVW +R-R
BW...
F16
X2:
UVW +R-R
(X3:) (X3:)
PEPE
Has effect
on K11
M
3-phase
Has effect
on K11
When the internal thermostat triggers,
K11 must be opened and DIØØ "Controller
inhibit" must have a "0" signal. The
resistance circuit must not be interrupted!
When the external bimetallic relay (F16)
triggers, K11 must be opened and
DIØØ "controller inhibit" must have a
"0" signal. The resistance circuit must
not be interrupted!
Overload protection
Braking resistor
type
Design
specified
Internal thermostat
(..T)
External bimetallic relay
(F16)
BW... – – Required
BW...-...-T1)
1) Permitted mounting options: On horizontal or vertical surfaces with brackets at the bottom and perforated
sheets at top and bottom. Mounting not permitted: on vertical surfaces with brackets at the top, right or
left.
– One of the two options (internal thermostat / external bimetallic
relay) is required.
BW...-003 / BW...-005 Adequate – Permitted

4Installation
Connecting the brake rectifier
20 Operating Instructions Basic Unit – MOVITRAC®B
4.7 Connecting the brake rectifier
Use contactors of utilization category AC-3 for K11 and K12 only.
Always disconnect the brake in the DC and AC circuits in:
• All hoist applications.
• Drives which require a rapid brake response time.
If the brake rectifier is installed in the control cabinet, route the connecting leads
between the brake rectifier and the brake separately from other power cables. Routing
together with other cables is only permitted if the other cables are shielded.
Note the corresponding connection regulations for brakes without BG/BGE or BME.
Refer to the SEW publication "Drive Engineering – Practical Implementation, volume 4"
for detailed information about this topic.
The connection of the brake rectifier requires a separate supply system cable;
supply from the motor voltage is not permitted!