Siemens MICROMASTER 430 User manual

MICROMASTER 430
7.5 kW - 250 kW
Operating Instructions Issue 10/06
User Documentation
6SE6400-5AE00-0BP0
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MICROMASTER 430 Documentation
Getting Started Guide
Is for quick commissioning with SDP and BOP-2.
Operating Instructions
Gives information about features of the
MICROMASTER 430, Installation, Commissioning,
Control modes, System Parameter structure,
Troubleshooting, Specifications and available options
of the MICROMASTER 430.
Parameter List
The Parameter List contains the description of all
Parameters structured in functional order and a
detailed description. The Parameter list also includes
a series of function plans.
Catalogues
In the catalogue you will find all the necessary
information to select an appropriate inverter, as well
as filters, chokes, operator panels and
communication options.
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Overview 1
Installation 2
Commissioning 3
MICROMASTER 430
Functions 4
System Parameters 5
Troubleshooting 6
Specifications 7
Available options 8
Electro-Magnetic
Compatibility 9
Appendices
A
B
C
D
E
F
G
Index
MICROMASTER 430
7.5 kW - 250 kW
Operating Instructions
User Documentation
Issue 10/06
Valid for Issue 10/06
Converter Type Software Version
MICROMASTER 430 V2.1
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MICROMASTER 430 Operating Instructions
4 6SE6400-5AE00-0BP0
Further information can be obtained from Internet
website:
http://www.siemens.de/micromaster
Approved Siemens Quality for Software and Training
is to DIN ISO 9001, Reg. No. 2160-01
The reproduction, transmission or use of this document,
or its contents is not permitted unless authorized in
writing. Offenders will be liable for damages. All rights
including rights created by patent grant or registration of a
utility model or design are reserved.
© Siemens AG 2002, 2005, 2006. All Rights Reserved.
MICROMASTER® is a registered trademark of Siemens
Other functions not described in this document may be
available. However, this fact shall not constitute an
obligation to supply such functions with a new control, or
when servicing.
We have checked that the contents of this document
correspond to the hardware and software described.
There may be discrepancies nevertheless, and no
guarantee can be given that they are completely identical.
The information contained in this document is reviewed
regularly and any necessary changes will be included in
the next edition. We welcome suggestions for
improvement.
Siemens handbooks are printed on chlorine-free paper
that has been produced from managed sustainable
forests. No solvents have been used in the printing or
binding process.
Document subject to change without prior notice.
Order number: 6SE6400-5AE00-0BP0 Siemens-Aktiengesellschaft
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Issue 10/06 Foreword
MICROMASTER 430 Operating Instructions
6SE6400-5AE00-0BP0 5
Foreword
User Documentation
WARNING
Before installing and commissioning the inverter, you must read all safety
instructions and warnings carefully including all the warning labels attached to the
equipment. Make sure that the warning labels are kept in a legible condition and
replace missing or damaged labels.
Information is also available from:
Regional Contacts
Please get in touch with your contact for Technical Support in your Region for
questions about services, prices and conditions of Technical Support.
Central Technical Support
The competent consulting service for technical issues with a broad range of
requirements-based services around our products and systems.
Europe / Africa
Tel: [phone]
Fax: [phone]
Email: [email protected]
America
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Asia / Pazific
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Online Service & Support
The comprehensive, generally available information system over the Internet, from
product support to service & support to the support tools in the shop.
http://www.siemens.com/automation/service&support
Contact address
Should any questions or problems arise while reading this manual, please contact
the Siemens office concerned using the form provided at the back this manual.
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Definitions and Warnings Issue 10/06
MICROMASTER 430 Operating Instructions
6 6SE6400-5AE00-0BP0
Definitions and Warnings
DANGER
indicates an immiently hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING
indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
used with the safety alert symbol indicates a potentially hazardous situationwhich,
if not avoided, may result in minor or moderate injury.
CAUTION
used without safety alert symbol indicates a potentially hzardous situation which, if
not avoided, may result in a property demage.
NOTICE
indicates a potential situation which, if not avoided, may result in an undesireable
result or state.
NOTE
For the purpose of this documentation, "Note" indicates important information
relating to the product or highlights part of the documentation for special attention.
Qualified personnel
For the purpose of this Instruction Manual and product labels, a "Qualified person"
is someone who is familiar with the installation, mounting, start-up and operation of
the equipment and the hazards involved.
He or she must have the following qualifications:
1. Trained and authorized to energize, de-energize, clear, ground and tag circuits
and equipment in accordance with established safety procedures.
2. Trained in the proper care and use of protective equipment in accordance with
established safety procedures.
3. Trained in rendering first aid.
¾PE – Protective Earth uses circuit protective conductors sized for short circuits
where the voltage will not rise in excess of 50 Volts. This connection is normally
used to ground the inverter.
¾- Is the ground connection where the reference voltage can be the same as
the Earth voltage. This connection is normally used to ground the motor.
Use for intended purpose only
The equipment may be used only for the application stated in the manual and only
in conjunction with devices and components recommended and authorized by
Siemens.
PE = Ground
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Issue 10/06 Safety Instructions
MICROMASTER 430 Operating Instructions
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Safety Instructions
The following Warnings, Cautions and Notes are provided for your safety and as a
means of preventing damage to the product or components in the machines
connected. This section lists Warnings, Cautions and Notes, which apply generally
when handling MICROMASTER 430 Inverters, classified as General, Transport &
Storage, Commissioning, Operation, Repair and Dismantling & Disposal.
Specific Warnings, Cautions and Notes that apply to particular activities are
listed at the beginning of the relevant chapters and are repeated or supplemented
at critical points throughout these sections.
Please read the information carefully, since it is provided for your personal
safety and will also help prolong the service life of your MICROMASTER 430
Inverter and the equipment you connect to it.
General WARNING
¾This equipment contains dangerous voltages and controls potentially dangerous
rotating mechanical parts. Non-compliance with Warnings or failure to follow
the instructions contained in this manual can result in loss of life, severe
personal injury or serious damage to property.
¾Only suitable qualified personnel should work on this equipment, and only after
becoming familiar with all safety notices, installation, operation and
maintenance procedures contained in this manual. The successful and safe
operation of this equipment is dependent upon its proper handling, installation,
operation and maintenance.
¾Risk of electric shock. The DC link capacitors remain charged for five minutes
after power has been removed. It is not permissible to open the equipment
until 5 minutes after the power has been removed.
¾The following terminals can carry dangerous voltages even if the inverter is
inoperative:
♦the power supply L/L1, N/L2, L3 resp. U1/L1, V1/L2, W1/L3
♦the motor terminals U, V, W resp. U2, V2, W2
♦and depending on the frame size the terminals DC+/B+, DC-, B-, DC/R+
resp. DCPS, DCNS, DCPA, DCNA
¾HP ratings are based on the Siemens 1LA motors and are given for guidance
only; they do not necessarily comply with UL or NEMA HP ratings.
CAUTION
¾Children and the general public must be prevented from accessing or
approaching the equipment!
¾This equipment may only be used for the purpose specified by the
manufacturer. Unauthorized modifications and the use of spare parts and
accessories that are not sold or recommended by the manufacturer of the
equipment can cause fires, electric shocks and injuries.
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Safety Instructions Issue 10/06
MICROMASTER 430 Operating Instructions
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NOTICE
¾Keep these operating instructions within easy reach of the equipment and make
them available to all users
¾Whenever measuring or testing has to be performed on live equipment, the
regulations of Safety Code VBG 4.0 must be observed, in particular §8
“Permissible Deviations when Working on Live Parts”. Suitable electronic tools
should be used.
¾Before installing and commissioning, please read these safety instructions and
warnings carefully and all the warning labels attached to the equipment. Make
sure that the warning labels are kept in a legible condition and replace missing
or damaged labels.
Transport & Storage
WARNING
¾Correct transport, storage, erection and mounting, as well as careful operation
and maintenance are essential for proper and safe operation of the equipment.
CAUTION
¾Protect the inverter against physical shocks and vibration during transport and
storage. Also be sure to protect it against water (rainfall) and excessive
temperatures (see table on page 80).
Commissioning
WARNING
¾Work on the device/system by unqualified personnel or failure to comply with
warnings can result in severe personal injury or serious damage to material.
Only suitably qualified personnel trained in the setup, installation,
commissioning and operation of the product should carry out work on the
device/system.
¾Only permanently-wired input power connections are allowed. This equipment
must be grounded (IEC 536 Class 1, NEC and other applicable standards).
¾If a Residual Current-operated protective Device (RCD) is to be used, it must be
an RCD type B. Machines with a three-phase power supply, fitted with EMC
filters, must not be connected to a supply via an ELCB (Earth Leakage Circuit-
Breaker - see DIN VDE 0160, section 5.5.2 and EN 50178 section 5.2.11.1).
¾The following terminals can carry dangerous voltages even if the inverter is
inoperative:
- the power supply L/L1, N/L2, L3 resp. U1/L1, V1/L2, W1/L3
- the motor terminals U, V, W resp. U2, V2, W2
- and dependeing on the frame size the terminals DC+/B+, DC-, B-, DC/R+
resp. DCPS, DCNS, DCPA, DCNA
¾This equipment must not be used as an ‘emergency stop mechanism’ (see EN
60204, 9.2.5.4)
CAUTION
The connection of power, motor and control cables to the inverter must be carried
out as shown in Figure 2-14 on page 40, to prevent inductive and capacitive
interference from affecting the correct functioning of the inverter.
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Issue 10/06 Safety Instructions
MICROMASTER 430 Operating Instructions
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Operation WARNING
¾MICROMASTERS operate at high voltages.
¾When operating electrical devices, it is impossible to avoid applying hazardous
voltages to certain parts of the equipment.
¾Emergency Stop facilities according to EN 60204 IEC 204 (VDE 0113) must
remain operative in all operating modes of the control equipment. Any
disengagement of the Emergency Stop facility must not lead to uncontrolled or
undefined restart.
¾Wherever faults occurring in the control equipment can lead to substantial
material damage or even grievous bodily injury (i.e. potentially dangerous
faults), additional external precautions must be taken or facilities provided to
ensure or enforce safe operation, even when a fault occurs (e.g. independent
limit switches, mechanical interlocks, etc.).
¾Certain parameter settings may cause the inverter to restart automatically after
an input power failure.
¾Motor parameters must be accurately configured for motor overload protection
to operate correctly.
¾This equipment is capable of providing internal motor overload protection in
accordance with UL508C section 42. Refer to P0610 and P0335, i2t is ON by
default. Motor overload protection can also be provided using an external
KTY84 or PTC.
¾This equipment is suitable for use in a circuit capable of delivering not more
than 10,000 (Frame Size C) or 42,000 (Frame Sizes D to GX) symmetrical
amperes (rms), for a maximum voltage of 460 V when protected by an H, J or K
type fuse, a circuit breaker or self-protected combination motor controller (for
more details see Appendix F).
¾This equipment must not be used as an ‘emergency stop mechanism’ (see EN
60204, 9.2.5.4)
Repair WARNING
¾Repairs on equipment may only be carried out by Siemens Service, by repair
centers authorized by Siemens or by authorized personnel who are
thoroughly acquainted with all the warnings and operating procedures contained
in this manual.
¾Any defective parts or components must be replaced using parts contained in
the relevant spare parts list.
¾Disconnect the power supply across all poles before opening the equipment for
access.
Dismantling & Disposal
CAUTION
¾The inverter’s packaging is re-usable. Retain the packaging for future use or
return it to the manufacturer.
¾Easy-to-release screw and snap connectors allow you to break the unit down
into its component parts. You can then re-cycle these component parts, dispose
of them in accordance with local requirements or return them to the
manufacturer.
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Electrostatic Sensitive Devices (ESD) Issue 10/06
MICROMASTER 430 Operating Instructions
10 6SE6400-5AE00-0BP0
Electrostatic Sensitive Devices (ESD)
The device contains components which can be destroyed by electrostatic
discharge. These components can be easily destroyed if not carefully handled.
Before opening the cabinet/enclosure in which the device is located, you must
electrically discharge your body and apply the appropriate ESDS protective
measures. The cabinet/enclosure should be appropriately labeled.
If you have to handle electronic boards, please observe the following:
•Electronic boards should only be touched when absolutely necessary.
•The human body must be electrically discharged before touching an electronic
board.
•Boards must not come into contact with highly insulating materials - e.g. plastic
parts, insulated desktops, articles of clothing manufactured from man-made
fibers.
•Boards must only be placed on conductive surfaces.
•Boards and components should only be stored and transported in conductive
packaging (e.g. metalized plastic boxes or metal containers).
•If the packing material is not conductive, the boards must be wrapped with a
conductive packaging material, e.g. conductive foam rubber or household
aluminium foil.
The necessary ESD protective measures are clearly shown again in the following
diagram:
•a = Conductive floor surface
•b = ESD table
•c = ESD shoes
•d = ESD overall
•e = ESD chain
•f = Cubicle ground connection
Sitting
a
b
e
d
c
d
a
c
d
b
ca
e
f
ff f f
Standing Standing / Sitting
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Issue 10/06 Table of Contents
MICROMASTER 430 Operating Instructions
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Table of Contents
1Overview................................................................................................................ 15
1.1 The MICROMASTER 430....................................................................................... 16
1.2 Features.................................................................................................................. 17
2Installation............................................................................................................. 19
2.1 Installation after a Period of Storage ...................................................................... 21
2.2 Ambient operating conditions ................................................................................. 22
2.3 Mechanical installation............................................................................................ 24
2.4 Electrical installation ............................................................................................... 30
3Commissioning..................................................................................................... 43
3.1 Block diagram ......................................................................................................... 45
3.2 Commission modes ................................................................................................ 47
3.3 General operation ................................................................................................... 58
4MICROMASTER 430 functions ............................................................................ 61
4.1 Frequency set point (P1000) .................................................................................. 63
4.2 Command sources (P0700).................................................................................... 63
4.3 OFF and brake function .......................................................................................... 64
4.4 Control modes (P1300)........................................................................................... 65
4.5 MICROMASTER 430 operating modes .................................................................. 66
4.6 Free Function Blocks (P2800 ff) ............................................................................. 70
4.7 Faults and Alarms ................................................................................................... 70
5System parameters............................................................................................... 71
5.1 Introduction to MICROMASTER system parameters ............................................. 72
5.2 Parameter overview................................................................................................ 73
6Troubleshooting.................................................................................................... 75
6.1 Troubleshooting with the SDP ................................................................................ 76
6.2 Troubleshooting with the BOP-2............................................................................. 77
6.3 Fault messages....................................................................................................... 78
6.4 Alarm Messages ..................................................................................................... 78
7MICROMASTER 430 specifications..................................................................... 79
8Options .................................................................................................................. 87
8.1 Device-independent options ................................................................................... 87
8.2 Device-dependent options ...................................................................................... 87
9Electro-magnetic compatibility (EMC)................................................................ 89
9.1 Electro-magnetic compatibility ................................................................................ 90
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Table of Contents Issue 10/06
MICROMASTER 430 Operating Instructions
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Appendices................................................................................................................................ 95
AChanging the Operator Panel.............................................................................. 95
BRemoving Front Covers....................................................................................... 96
B.1 Removing Front Covers Frame Size C................................................................... 96
B.2 Removing Front Covers Frame Sizes D and E ...................................................... 97
B.3 Removing Covers Frame Size F............................................................................. 98
B.4 Removing Front Covers Frame Sizes FX and GX.................................................. 99
CRemoving the I/O Board..................................................................................... 100
DRemoving ‘Y’ Cap ............................................................................................... 101
D.1 Removing ‘Y’ Cap Frame Size C .......................................................................... 101
D.2 Removing ‘Y’ Cap Frame Sizes D and E.............................................................. 102
D.3 Removing ‘Y’ Cap Frame Sizes F......................................................................... 103
D.4 Removing ‘Y’ Cap Frame Sizes FX ...................................................................... 104
D.5 Removing ‘Y’ Cap Frame Sizes GX...................................................................... 105
EApplicable Standards......................................................................................... 106
FShort circuit current rating (SCCR)................................................................... 107
GList of Abbreviations.......................................................................................... 108
Index .............................................................................................................................. 111
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Issue 10/06 Table of Contents
MICROMASTER 430 Operating Instructions
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List of Illustrations
Figure 2-1 Forming ................................................................................................................................ 21
Figure 2-2 Ambient operating temperature ............................................................................................ 22
Figure 2-3 Installation altitude................................................................................................................ 22
Figure 2-4 Drill pattern for MICROMASTER 430 Frame Sizes C to F ................................................... 25
Figure 2-5 Installation dimensions for MICROMASTER 430 Frame size FX ......................................... 26
Figure 2-6 Installation dimensions for MICROMASTER 430 Frame size GX ........................................ 27
Figure 2-7 Installation of options for the electronic box.......................................................................... 29
Figure 2-8 MICROMASTER 430 Connection Terminals, Frame Sizes C to F ....................................... 33
Figure 2-9 MICROMASTER 430 connection drawing – frame size FX.................................................. 34
Figure 2-10 MICROMASTER 430 connection drawing – frame size GX ................................................. 35
Figure 2-11 Motor and Power Connections ............................................................................................. 36
Figure 2-12 Adaptation of fan voltage...................................................................................................... 37
Figure 2-13 Control terminals of MICROMASTER 430............................................................................ 38
Figure 2-14 Wiring Guidelines to Minimize the Effects of EMI ................................................................. 40
Figure 3-1 Inverter block diagram..........................................................................................................45
Figure 3-2 Configuration of the analogue input as a digital input........................................................... 46
Figure 3-3 Panels available for the MICROMASTER 430 Inverter ........................................................ 47
Figure 3-4 DIP switch ............................................................................................................................ 47
Figure 3-5 Recommended wiring for the factory setting ........................................................................ 49
Figure 3-6 Buttons on the BOP-2........................................................................................................... 52
Figure 3-7 Changing parameters via the BOP-2.................................................................................... 53
Figure 3-8 Typical Motor Rating Plate Example .................................................................................... 57
Figure 3-9 Thermal overload protection................................................................................................. 59
Figure 4-1 Bypass circuit ....................................................................................................................... 66
Figure 4-2 Belt Failure Detection ........................................................................................................... 67
Figure 4-3 Motor Staging ....................................................................................................................... 68
Figure 4-4 Energy Saving Mode ............................................................................................................ 69
Figure 5-1 Parameter Overview............................................................................................................. 73
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Table of Contents Issue 10/06
MICROMASTER 430 Operating Instructions
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List of Tables
Table 2-1 Dimensions and Torques of MICROMASTER 430............................................................... 28
Table 3-1 Default settings for operation using the SDP........................................................................ 48
Table 3-2 Default settings for operation using the BOP-2 .................................................................... 51
Table 6-1 Inverter conditions indicated by the LEDs on the SDP ......................................................... 76
Table 7-1 MICROMASTER 430 Performance Ratings ......................................................................... 80
Table 7-2 Dimensions, required cooling air flow and tightening torques for power terminals ............... 81
Table 7-3 Current reduction depending on pulse frequency................................................................. 82
Table 7-4 MICROMASTER 430 Specifications .................................................................................... 83
Table 9-1 General Industrial ................................................................................................................. 91
Table 9-2 Filtered Industrial.................................................................................................................. 91
Table 9-3 Filtered for Residential, Commercial and Light Industry ....................................................... 92
Table 9-4 Compliance Table ................................................................................................................93
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Issue 10/06 1 Overview
MICROMASTER 430 Operating Instructions
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1 Overview
This Chapter contains:
A summary of the major features of the MICROMASTER 430 range.
1.1 The MICROMASTER 430....................................................................................... 16
1.2 Features.................................................................................................................. 17
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1 Overview Issue 10/06
MICROMASTER 430 Operating Instructions
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1.1 The MICROMASTER 430
The MICROMASTER 430s are a range of 3AC-frequency inverters for controlling
the speed of three phase AC motors. The various models available range from the
7,5 kW input to the 250 kW input.
The MICROMASTER 430 is especially well suited for use with pumps and
ventilators when used with its factory set functions and settings.
The inverters are microprocessor-controlled and use state-of-the-art Insulated Gate
BipoIar Transistor (IGBT) technology. This makes them reliable and versatile. A
special pulse-width modulation method with selectable Pulse frequency permits
quiet motor operation. Comprehensive protective functions provide excellent
inverter and motor protection.
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Issue 10/06 1 Overview
MICROMASTER 430 Operating Instructions
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1.2 Features
Main Characteristics
¾Easy installation
¾Easy commissioning
¾Rugged EMC design
¾Can be operated on IT line supplies
¾Fast repeatable response time to control signals
¾Comprehensive range of parameters enabling configuration for a wide range of
applications
¾Simple cable connection
¾Output relays
¾Analog outputs (0 – 20 mA)
¾6 Isolated and switchable NPN/PNP digital inputs
¾2 Analog inputs:
♦AIN1: 0 – 10 V, 0 – 20 mA and -10 to +10 V
♦AIN2: 0 – 10 V, 0 – 20 mA
¾The 2 analog inputs can be used as the 7th and 8th digital inputs
¾BiCo technology
¾Modular design for extremely flexible configuration
¾High switching frequencies for low-noise motor operation
¾Detailed status information and integrated message functions
¾External options for PC communications, Basic Operator Panel (BOP-2) and
PROFIBUS communications module
¾Pump & Fan Features:
♦Motor Staging (Control of additional drives via output relay)
♦Energy Saving Mode
♦Hand / Auto (manual / automatic) with BOP-2
♦Belt failure detection (e.g. detects if pumps have run dry)
♦Bypass
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1 Overview Issue 10/06
MICROMASTER 430 Operating Instructions
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Performance Characteristics
¾U/f control
♦Linear U/f control with flux current control (FCC)for improved dynamic
response and motor control
♦Multiple point U/f control
¾Automatic restart
¾Flying restart
¾Slip compensation
¾Fast Current Limitation (FCL) for trip-free operation
¾Motor holding brake
¾Built-in DC injection brake
¾Compound braking to improve braking performance
¾Setpoint input via:
♦Analog inputs
♦Communication interface
♦Motorized potentiometer
♦Fixed frequencies
¾Ramp function generator
♦With smoothing
♦Without smoothing
¾Technology controller (PID)
¾parameter set switch-over
♦Motor data sets (DDS)
♦Command data sets and setpoint sources (CDS)
¾Rating for operation with variable torque (VT)
¾Free Function Blocks
Protection characteristics
¾Overvoltage/undervoltage protection
¾Overtemperature protection for the inverter
¾Ground fault protection
¾Short-circuit protection
¾i
2t thermal motor protection
¾PTC/KTY for motor protection
Options
Refer to Chapter 8
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Issue 10/06 2 Installation
MICROMASTER 430 Operating Instructions
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2 Installation
This Chapter contains:
¾General data relating to installation
¾Dimensions of Inverter
¾Wiring guidelines to minimize the effects of EMI
¾Details concerning electrical installation
2.1 Installation after a Period of Storage ...................................................................... 20
2.2 Ambient operating conditions ................................................................................. 22
2.3 Mechanical installation............................................................................................ 24
2.4 Electrical installation ............................................................................................... 29
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