Siemens MICROMASTER 440 User manual

MICROMASTER 440
0.12 kW - 250 kW
Operating Instructions Issue 12/02
User Documentation
6SE6400-5AW00-0BP0

MICROMASTER 440 Documentation
Getting Started Guide
Is for quick commissioning with SDP and BOP.
Operating Instructions
Gives information about features of the
MICROMASTER 440, Installation, Commissioning,
Control modes, System Parameter structure,
Troubleshooting, Specifications and available options
of the MICROMASTER 440.
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.

MICROMASTER 440
0.12 kW - 250 kW
Operating Instructions
User Documentation
Issue 12/02
Valid for Issue 12/02
Inverter Type Software Version
MICROMASTER 440 2.0
0.12 kW - 200 kW
Overview 1
Installation 2
Commissioning 3
Using the
MICROMASTER 440
4
System Parameters 5
Troubleshooting 6
Specifications 7
Options 8
Electro-Magnetic
Compatibility
9
Appendices
A
B
C
D
E
F
Index

MICROMASTER 440 Operating Instructions
4 6SE6400-5AW00-0BP0
 
Not all inverters currently have UL approval.
UL listing can be determined by examining the
inverter's Rating Label.
For UL listed products the following UL mark is used:
Note: UL certification is presently in progress!
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 2001. 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: 6SE6400-5AW00-0BP0 Siemens-Aktiengesellschaft

Issue 12/02 Foreword
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 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:
Technical Support Nuremberg
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Monday to Friday: 7:00 am to 5:00 pm (local time)
Internet Home Address
Customers can access technical and general information at:
http://www.siemens.de/micromaster
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.

Definitions and Warnings Issue 12/02
MICROMASTER 440 Operating Instructions
6 6SE6400-5AW00-0BP0
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.
PE = Ground
♦ PE – 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.
♦ - 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.

Issue 12/02 Safety Instructions
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 7
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 440 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 440
Inverter and the equipment you connect to it.
General
WARNING
♦ This 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.
♦ Only 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.
♦ Risk 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.
♦ HP 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
♦ Children and the general public must be prevented from accessing or
approaching the equipment!
♦ This 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.

Safety Instructions Issue 12/02
MICROMASTER 440 Operating Instructions
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NOTICE
♦ Keep these operating instructions within easy reach of the equipment and
make them available to all users
♦ Whenever measuring or testing has to be performed on live equipment, the
regulations of Safety Code BGV A2 must be observed, in particular §8
“Permissible Deviations when Working on Live Parts”. Suitable electronic
tools should be used.
♦ Before 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
♦ Correct transport, storage, erection and mounting, as well as careful
operation and maintenance are essential for proper and safe operation of the
equipment.
CAUTION
♦ Protect the inverter against physical shocks and vibration during transport and
storage. Also be sure to protect it against water (rainfall) and excessive
temperatures (see tableTable 7-1 on page 106).
Commissioning
WARNING
♦ Work 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.
♦ Only permanently-wired input power connections are allowed. This equipment
must be grounded (IEC 536 Class 1, NEC and other applicable standards).
♦ Only type B ELCBs should be used with FSA to FSF. 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 EN50178 section 5.2.11.1).
♦ The following terminals can carry dangerous voltages even if the inverter is
inoperative:
- the power supply terminals L/L1, N/L2, L3 resp. U1/L1, V1/L2, W1/L3
- the motor terminals U, V, W resp. U2/T1, V2/T2, W2/T3
- and depending on the Frame Size, the terminals DC+/B+, DC-, B-, DC/R+
resp. C/L+, D/L-
♦ This 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 2-13 on page 40, to prevent inductive and capacitive
interference from affecting the correct functioning of the inverter.

Issue 12/02 Safety Instructions
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 9
Operation
WARNING
♦ MICROMASTERS operate at high voltages.
♦ When operating electrical devices, it is impossible to avoid applying
hazardous voltages to certain parts of the equipment.
♦ Emergency 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.
♦ Wherever 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.).
♦ Certain parameter settings may cause the inverter to restart automatically
after an input power failure.
♦ Motor parameters must be accurately configured for motor overload
protection to operate correctly.
♦ This 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
PTC (disabled by default P0601).
♦ This equipment is suitable for use in a circuit capable of delivering not more
than 10,000 symmetrical amperes (rms), for a maximum voltage of 230 V /
460 V / 575 V when protected by a H or K type fuse (see Tables starting on
page 109).
♦ This equipment must not be used as an ‘emergency stop mechanism’ (see
EN 60204, 9.2.5.4)
Repair
WARNING
♦ Repairs 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.
♦ Any defective parts or components must be replaced using parts contained in
the relevant spare parts list.
♦ Disconnect the power supply before opening the equipment for access
Dismantling & Disposal
CAUTION
♦ The inverter’s packaging is re-usable. Retain the packaging for future use.
♦ Easy-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.

Safety Instructions Issue 12/02
MICROMASTER 440 Operating Instructions
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Issue 12/02 Table of Contents
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 11
Table of Contents
1Overview ................................................................................................................ 15
1.1 The MICROMASTER 440....................................................................................... 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 ............................................................................................... 31
3Commissioning ..................................................................................................... 41
3.1 Block diagram ......................................................................................................... 43
3.2 Commission modes ................................................................................................ 45
3.3 General operation ................................................................................................... 56
4Using the MICROMASTER 440 ............................................................................ 59
4.1 Frequency setpoint (P1000) ................................................................................... 60
4.2 Command sources (P0700).................................................................................... 61
4.3 OFF and braking functions ..................................................................................... 61
4.4 Control modes (P1300)........................................................................................... 63
4.5 Extended Functions for the MICROMASTER 440.................................................. 64
4.6 Faults and warnings................................................................................................ 64
5System parameters............................................................................................... 65
5.1 Introduction to MICROMASTER system parameters ............................................. 66
5.2 Parameter overview................................................................................................ 67
5.3 Parameter list (short form) ...................................................................................... 68
5.4 Command and Drive Datasets - Overview ............................................................. 84
6Troubleshooting.................................................................................................... 89
6.1 Troubleshooting with the SDP ................................................................................ 90
6.2 Troubleshooting with the BOP ................................................................................ 91
6.3 Fault messages....................................................................................................... 92
6.4 Alarm Messages ..................................................................................................... 99
7MICROMASTER 440 specifications................................................................... 105
8Options ................................................................................................................ 121
8.1 Device-independent options ................................................................................. 121
8.2 Device-dependent options .................................................................................... 121

Table of Contents Issue 12/02
MICROMASTER 440 Operating Instructions
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9Electro-magnetic compatibility (EMC) .............................................................. 123
9.1 Electro-magnetic compatibility .............................................................................. 124
Appendices .............................................................................................................................. 129
AChanging the Operator Panel ............................................................................ 129
BRemoving Front Covers ..................................................................................... 130
B.1 Removing Front Covers, Frame Sizes A .............................................................. 130
B.2 Removing Front Covers, Frame Sizes B and C ................................................... 131
B.3 Removing Front Covers, Frame Sizes D and E ................................................... 132
B.4 Removing Front Covers, Frame Size F ................................................................ 133
B.5 Removing Front Covers, Frame Sizes FX and GX.............................................. 134
CRemoving the I/O Board..................................................................................... 135
DRemoving ‘Y’ Cap ............................................................................................... 136
D.1 Removing ‘Y’ Cap, Frame Size A ......................................................................... 136
D.2 Removing ‘Y’ Cap, Frame Sizes B and C............................................................. 137
D.3 Removing ‘Y’ Cap, Frame Sizes D and E............................................................. 138
D.4 Removing ‘Y’ Cap, Frame Size F ......................................................................... 139
D.5 Removing ‘Y’ Cap, Frame Size FX ....................................................................... 140
D.6 Removing ‘Y’ Cap, Frame Size GX ...................................................................... 141
EApplicable Standards ......................................................................................... 142
FList of Abbreviations .......................................................................................... 143
Index .............................................................................................................................. 146

Issue 12/02 Table of Contents
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 13
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 440 ................................................................................... 25
Figure 2-5 Installation dimensions for MICROMASTER 440 Frame size FX ......................................... 26
Figure 2-6 Installation dimensions for MICROMASTER 440 Frame size GX ........................................ 27
Figure 2-7 Options for the electronic box............................................................................................... 30
Figure 2-8 MICROMASTER 440 Connection Terminals........................................................................ 34
Figure 2-9 MICROMASTER 440 connection drawing – frame size FX.................................................. 35
Figure 2-10 MICROMASTER 440 connection drawing - frame size GX .................................................. 36
Figure 2-11 Motor and Power Connections ............................................................................................. 37
Figure 2-12 Adaptation of fan voltage...................................................................................................... 38
Figure 2-13 Wiring Guidelines to Minimize the Effects of EMI ................................................................. 40
Figure 3-1 Inverter block diagram..........................................................................................................43
Figure 3-2 Configuration of the analogue input as a digital input........................................................... 44
Figure 3-3 Panels available for the MICROMASTER 440 Inverter ........................................................ 45
Figure 3-4 DIP switch ............................................................................................................................ 45
Figure 3-5 Basic operation with SDP ..................................................................................................... 47
Figure 3-6 Buttons on the BOP..............................................................................................................50
Figure 3-7 Changing parameters via the BOP....................................................................................... 51
Figure 3-8 Typical Motor Rating Plate Example (The details given on the rating plate are only
examples)............................................................................................................................. 55
Figure 3-9 Thermal overload protection................................................................................................. 57
Figure 5-1 Parameter Overview............................................................................................................. 67
List of Tables
Table 2-1 Dimensions and Torques of MICROMASTER 440 ............................................................... 28
Table 3-1 Default settings for operation using the SDP........................................................................ 46
Table 3-2 Default settings for operation using the BOP........................................................................ 49
Table 6-1 Inverter conditions indicated by the LEDs on the SDP ......................................................... 90
Table 7-1 MICROMASTER 440 Performance Ratings ....................................................................... 106
Table 7-2 Tightening torques for power terminals .............................................................................. 107
Table 7-3 Current reduction depending on pulse frequency............................................................... 108
Table 7-4 MICROMASTER 440 Specifications .................................................................................. 109
Table 9-1 Permissible harmonic current emissions ............................................................................ 125
Table 9-2 Class 1 - General Industrial ................................................................................................ 126
Table 9-3 Class 2 - Filtered Industrial................................................................................................. 126
Table 9-4 Class 3 - Filtered for Residential, Commercial and Light Industry ...................................... 127
Table 9-5 Compliance Table .............................................................................................................. 128

Issue 12/02 1 Overview
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 15
1 Overview
This Chapter contains:
A summary of the major features of the MICROMASTER 440 range.
1.1 The MICROMASTER 440....................................................................................... 16
1.2 Features.................................................................................................................. 17

1 Overview Issue 12/02
MICROMASTER 440 Operating Instructions
16 6SE6400-5AW00-0BP0
1.1 The MICROMASTER 440
The MICROMASTER 440 are frequency inverters for speed control of three-phase
motors. The various models available cover the performance range from 120 W to
200 kW (for constant torque (CT), alternatively up to 250kW (for variable torque
(VT)).
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.
With the factory default settings, the MICROMASTER 440 is suitable for many
variable speed applications. Using the functionally grouped parameters, the
MICROMASTER 440 can adapted to more demanding applications.
The MICROMASTER 440 can be used in both 'stand-alone' applications as well as
being integrated into 'Automation Systems'.

Issue 12/02 1 Overview
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 17
1.2 Features
Main Characteristics
! Easy installation
! Easy commissioning
! Rugged EMC design
! Can be operated on IT line supplies
! Fast repeatable response time to control signals
! Comprehensive range of parameters enabling configuration for a wide range of
applications
! Simple cable connection
! Output relays
! Analog outputs (0 – 20 mA)
! 6 Isolated and switchable NPN/PNP digital inputs
! 2 Analog inputs:
♦ AIN1: 0 – 10 V, 0 – 20 mA and -10 to +10 V
♦ AIN2: 0 – 10 V, 0 – 20 mA
! The 2 analog inputs can be used as the 7th and 8th digital inputs
! BiCo technology
! Modular design for extremely flexible configuration
! High switching frequencies for low-noise motor operation
! Detailed status information and integrated message functions
! External options for PC communications, Basic Operator Panel (BOP),
Advanced Operator Panel (AOP), PROFIBUS communications module

1 Overview Issue 12/02
MICROMASTER 440 Operating Instructions
18 6SE6400-5AW00-0BP0
Performance Characteristics
! Vector Control
♦ Sensorless Vector Control (SLVC)
♦ Vector Control with encoder (VC)
! V/f Control
♦ Flux Current Control (FCC) for improved dynamic response and motor
control
♦ Multi-point V/f characteristic
! Fast Current Limitation (FCL) for trip-free operation
! Built-in DC injection brake
! Compound braking to improve braking performance
! Built-in braking chopper (Frame Sizes A to F)
! Ramp function generator
♦ With smoothing
♦ Without smoothing
! Technology controller (PID)
! Parameter set switch-over
♦ Motor data sets (DDS)
♦ Command data sets and setpoint sources (CDS)
! Free Function Blocks
! Kinetic Buffering
! Positioning Ramp down
Protection characteristics
! Overvoltage/undervoltage protection
! Overtemperature protection for the inverter
! Ground fault protection
! Short-circuit protection
! i2t thermal motor protection
! PTC/KTY for motor protection

Issue 12/02 2 Installation
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 19
2 Installation
This Chapter contains:
! General data relating to installation
! Dimensions of Inverter
! Wiring guidelines to minimize the effects of EMI
! Details concerning electrical installation
2.1 Installation after a Period of Storage ...................................................................... 21
2.2 Ambient operating conditions ................................................................................. 22
2.3 Mechanical installation............................................................................................ 24
2.4 Electrical installation ............................................................................................... 31

2 Installation Issue 12/02
MICROMASTER 440 Operating Instructions
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WARNING
! Work 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.
! Only permanently-wired input power connections are allowed. This equipment
must be grounded (IEC 536 Class 1, NEC and other applicable standards).
! Only type B ELCBs should be used with FSA to FSF. 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 EN50178 section 5.2.11.1).
! The 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/T1, V2/T2, W2/T3
- and dependeing on the frame size the terminals DC+/B+, DC-, B-, DC/R+
resp. C/L+, D/L-
! Always wait 5 minutes to allow the unit to discharge after switching off before
carrying out any installation work.
! This equipment must not be used as an ‘emergency stop mechanism’ (see EN
60204, 9.2.5.4)
! The minimum size of the earth-bonding conductor must be equal to or greater
than the cross-section of the power supply cables.
! If the front cover (Frame Sizes FX and GX) has been removed, the fan impeller
is exposed. There is danger of injury when the fan is running.
CAUTION
The connection of power, motor and control cables to the inverter must be carried
out as shown in Figure 2-13 on page 40, to prevent inductive and capacitive
interference from affecting the correct functioning of the inverter.