Siemens MICROMASTER 440 User manual

MICROMASTER 440
0.12 kW - 250 kW
Operating Instructions Issue 10/06
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 10/06
Valid for Issue 10/06
Inverter Type Software Version
MICROMASTER 440 2.1
0.12 kW - 250 kW
Overview 1
Installation 2
Functions 3
Troubleshooting 4
Specifications 5
Options 6
Electro-Magnetic
Compatibility 7
Appendices
A
B
C
D
E
F
G
Index

MICROMASTER 440 Operating Instructions
4 6SE6400-5AW00-0BP0
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 2001 – 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: 6SE6400-5AW00-0BP0 Siemens-Aktiengesellschaft

Issue 10/06 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:
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: simatic.hotlin[email protected]ns.com
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.

Definitions and Warnings Issue 10/06
MICROMASTER 440 Operating Instructions
6 6SE6400-5AW00-0BP0
Definitions and Warnings
DANGER
indicates an immanently 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 situation
which, if not avoided, may result in minor or moderate injury.
CAUTION
used without safety alert symbol indicates a potentially hazardous situation which,
if not avoided, may result in a property damage.
NOTICE
indicates a potential situation which, if not avoided, may result in an undesirable
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 10/06 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
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.
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, 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.

Safety Instructions Issue 10/06
MICROMASTER 440 Operating Instructions
8 6SE6400-5AW00-0BP0
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 BGV A2 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
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 Table 4-1).
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).
¾Only 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).
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
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 Fig. 2-11 on page 44, to prevent inductive and capacitive
interference from affecting the correct functioning of the inverter.

Issue 10/06 Safety Instructions
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 9
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.
Certain parameter settings may cause the inverter to restart automatically
after an input power failure (e.g. automatic 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.).
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 PTC
or KTY84.
¾This equipment is suitable for use in a circuit capable of delivering not more
than 10,000 (Frame Sizes A to C) or 42,000 (Frame Sizes D to GX)
symmetrical amperes (rms), for a maximum voltage of 230 V / 460 V / 575 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 before opening the equipment for access.
Dismantling & Disposal
CAUTION
¾The inverter’s packaging is re-usable. Retain the packaging for future use.
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.

Electrostatic Sensitive Devices (ESD) Issue 10/06
MICROMASTER 440 Operating Instructions
10 6SE6400-5AW00-0BP0
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

Issue 10/06 Table of Contents
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 11
Table of Contents
1Overview................................................................................................................ 17
1.1 The MICROMASTER 440....................................................................................... 18
1.2 Features.................................................................................................................. 19
2Installation............................................................................................................. 21
2.1 Installation after a Period of Storage ...................................................................... 23
2.2 Ambient operating conditions ................................................................................. 24
2.3 Mechanical installation............................................................................................ 26
2.4 Electrical installation ............................................................................................... 33
3Functions............................................................................................................... 47
3.1 Parameters ............................................................................................................. 51
3.2 Operator panels for MICROMASTER..................................................................... 70
3.3 Block diagram......................................................................................................... 74
3.4 Factory setting ........................................................................................................ 75
3.5 Commissioning ....................................................................................................... 77
3.6 Inputs / outputs ..................................................................................................... 135
3.7 Communications................................................................................................... 144
3.8 Fixed frequencies (FF).......................................................................................... 167
3.9 Motorized potentiometer (MOP) ........................................................................... 170
3.10 JOG....................................................................................................................... 172
3.11 PID controller (technological controller)................................................................ 173
3.12 Setpoint channel................................................................................................... 181
3.13 Free function blocks (FFB) ................................................................................... 191
3.14 Motor holding brake (MHB)................................................................................... 196
3.15 Electronic brakes .................................................................................................. 202
3.16 Automatic restart................................................................................................... 211
3.17 Flying restart......................................................................................................... 213
3.18 Closed-loop Vdc control........................................................................................ 215
3.19 Positioning down ramp ......................................................................................... 219
3.20 Monitoring functions / messages.......................................................................... 221
3.21 Thermal motor protection and overload responses.............................................. 227
3.22 Power module protection...................................................................................... 232
3.23 Open-loop/closed-loop control technique............................................................. 235
4Troubleshooting.................................................................................................. 257
4.1 Troubleshooting with the SDP.............................................................................. 258
4.2 Troubleshooting with the BOP.............................................................................. 259

Table of Contents Issue 10/06
MICROMASTER 440 Operating Instructions
12 6SE6400-5AW00-0BP0
4.3 Fault messages..................................................................................................... 260
4.4 Alarm Messages................................................................................................... 260
5MICROMASTER 440 specifications................................................................... 261
6Options ................................................................................................................ 273
6.1 Inverter-independent options................................................................................ 273
6.2 Inverter-dependent options................................................................................... 274
7Electro-magnetic compatibility (EMC).............................................................. 275
7.1 Electro-magnetic compatibility.............................................................................. 276
Appendices.............................................................................................................................. 281
AChanging the Operator Panel............................................................................ 281
BRemoving Front Covers..................................................................................... 282
B.1 Removing Front Covers. Frame Sizes A.............................................................. 282
B.2 Removing Front Covers. Frame Sizes B and C ................................................... 283
B.3 Removing Front Covers. Frame Sizes D and E ................................................... 284
B.4 Removing Front Covers. Frame Size F................................................................ 285
B.5 Removing Front Covers. Frame Sizes FX and GX.............................................. 286
CRemoving the I/O Board..................................................................................... 287
DRemoving ‘Y’ Cap ............................................................................................... 288
D.1 Removing ‘Y’ Cap. Frame Size A......................................................................... 288
D.2 Removing ‘Y’ Cap. Frame Sizes B and C............................................................. 289
D.3 Removing ‘Y’ Cap. Frame Sizes D and E............................................................. 290
D.4 Removing ‘Y’ Cap. Frame Size F ......................................................................... 291
D.5 Removing ‘Y’ Cap. Frame Size FX....................................................................... 292
D.6 Removing ‘Y’ Cap. Frame Size GX ...................................................................... 293
ERemoving fan...................................................................................................... 294
E.1 Removing fan. Frame Size A................................................................................ 294
E.2 Removing fan. Frame Sizes B and C ................................................................... 295
E.3 Removing fan. Frame Size D and E..................................................................... 296
E.4 Removing fan. Frame Size F................................................................................ 297
E.5 Removing fan. Frame Size F with filter................................................................. 298
E.6 Removing fan. Frame Sizes FX and GX .............................................................. 299
FShort circuit current rating (SCCR)................................................................... 300
GStandards ............................................................................................................ 301
HList of Abbreviations.......................................................................................... 302
Index .............................................................................................................................. 305

Issue 10/06 Table of Contents
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 13
List of Illustrations
Fig. 2-1 Forming................................................................................................................................23
Fig. 2-2 Ambient operating temperature............................................................................................24
Fig. 2-3 Installation altitude................................................................................................................24
Fig. 2-4 Drill pattern for MICROMASTER 440...................................................................................27
Fig. 2-5 Installation dimensions for MICROMASTER 440 Frame size FX.........................................28
Fig. 2-6 Installation dimensions for MICROMASTER 440 Frame size GX ........................................29
Fig. 2-7 Options for the electronic box...............................................................................................32
Fig. 2-8 MICROMASTER 440 Connection Terminals........................................................................37
Fig. 2-9 MICROMASTER 440 connection drawing – frame size FX..................................................38
Fig. 2-10 MICROMASTER 440 connection drawing - frame size GX..................................................39
Fig. 2-11 Motor and Power Connections.............................................................................................40
Fig. 2-12 Adaptation of fan voltage......................................................................................................41
Fig. 2-13 Control terminals of MICROMASTER 440............................................................................42
Fig. 2-14 Wiring Guidelines to Minimize the Effects of EMI.................................................................44
Fig. 3-1 Parameter types...................................................................................................................51
Fig. 3-2 Header line for parameter P0305 .........................................................................................55
Fig. 3-3 Parameter grouping / access................................................................................................56
Fig. 3-4 Binectors ..............................................................................................................................60
Fig. 3-5 Connectors...........................................................................................................................61
Fig. 3-6 BICO connections (examples)..............................................................................................62
Fig. 3-7 Example: Changeover from motor 1 to motor 2....................................................................63
Fig. 3-8 Example: Changing-over between the control and setpoint (frequency) source...................63
Fig. 3-9 Copying from CDS ...............................................................................................................65
Fig. 3-10 Changing-over CDS .............................................................................................................65
Fig. 3-11 Copying from DDS ...............................................................................................................66
Fig. 3-12 Changing-over DDS .............................................................................................................67
Fig. 3-13 Normalization / de-normalization..........................................................................................69
Fig. 3-14 Operator panels....................................................................................................................70
Fig. 3-15 Operator panel keys.............................................................................................................72
Fig. 3-16 Changing parameters using the BOP...................................................................................73
Fig. 3-17 MICROMASTER 440 – block diagram .................................................................................74
Fig. 3-18 Status Display Panel (SDP)..................................................................................................75
Fig. 3-19 Recommended wiring for the factory setting ........................................................................76
Fig. 3-20 Procedure when commissioning...........................................................................................77
Fig. 3-21 DIP switch to change-over between 50/60 Hz......................................................................79
Fig. 3-22 Mode of operation of the DIP50/60 switch in conjunction with P0100..................................79
Fig. 3-23 Motor terminal box................................................................................................................80
Fig. 3-24 Star / delta circuit configurations ..........................................................................................81
Fig. 3-25 V/f characteristic...................................................................................................................82
Fig. 3-26 Equivalent circuit diagram (ECD) .........................................................................................91
Fig. 3-27 Magnetizing characteristic....................................................................................................92
Fig. 3-28 Upread / download using AOP and PC Tools.....................................................................132
Fig. 3-29 Digital inputs.......................................................................................................................135
Fig. 3-30 Digital outputs.....................................................................................................................138
Fig. 3-31 DIP switch and P0756 for ADC current / voltage input.......................................................140

Table of Contents Issue 10/06
MICROMASTER 440 Operating Instructions
14 6SE6400-5AW00-0BP0
Fig. 3-32 Connection example for ADC voltage / current input..........................................................141
Fig. 3-33 ADC channel......................................................................................................................141
Fig. 3-34 Signal output through the D/A converter channel...............................................................142
Fig. 3-35 D/A converter channel........................................................................................................142
Fig. 3-36 Serial communication interfaces - BOP link and COM link.................................................144
Fig. 3-37 Cycle times.........................................................................................................................147
Fig. 3-38 Serial linking of MICROMASTER (slaves) with a higher-level computer (master)..............148
Fig. 3-39 Telegram structure .............................................................................................................149
Fig. 3-40 Assignment of the address byte (ADR) ..............................................................................150
Fig. 3-41 Circulating list (Example of configuration) ..........................................................................151
Fig. 3-42 Cycle time...........................................................................................................................151
Fig. 3-43 Transmit sequence.............................................................................................................152
Fig. 3-44 USS bus topology...............................................................................................................153
Fig. 3-45 Telegram structure .............................................................................................................155
Fig. 3-46 Structure of the PKW and PZD areas.................................................................................155
Fig. 3-47 Connecting the USS bus cable...........................................................................................164
Fig. 3-48 Connecting the RS485 terminator......................................................................................165
Fig. 3-49 Example for directly selecting FF1 via DIN1 and FF2 via DIN2..........................................168
Fig. 3-50 Example for selecting FF1 via DIN1 and FF2 via DIN2 using the binary-coded method....169
Fig. 3-51 Motorized potentiometer.....................................................................................................170
Fig. 3-52 JOG counter-clockwise and JOG clockwise.......................................................................172
Fig. 3-53 Structure of the technology controller.................................................................................174
Fig. 3-54 Structure of the technological controller (PID controller) ....................................................175
Fig. 3-55 PID controller......................................................................................................................176
Fig. 3-56 Example to directly select the PID fixed frequency of fixed frequency 1 via DIN1..............178
Fig. 3-57 PID dancer roll control........................................................................................................179
Fig. 3-58 Structure of the closed-loop PID-dancer roll control...........................................................180
Fig. 3-59 Setpoint channel.................................................................................................................181
Fig. 3-60 Summation.........................................................................................................................182
Fig. 3-61 Modifying the frequency setpoint........................................................................................182
Fig. 3-62 Ramp-function generator....................................................................................................183
Fig. 3-63 Rounding off after an OFF1 command...............................................................................184
Fig. 3-64 OFF1..................................................................................................................................186
Fig. 3-65 OFF2..................................................................................................................................187
Fig. 3-66 OFF3..................................................................................................................................188
Fig. 3-67 Changing-over using the BICO parameters P0810 and P0811..........................................189
Fig. 3-68 Motor holding brake after ON / OFF1.................................................................................196
Fig. 3-69 Motor holding brake after OFF2 .........................................................................................197
Fig. 3-70 Direct motor holding brake connection...............................................................................200
Fig. 3-71 Indirect motor holding brake connection.............................................................................201
Fig. 3-72 Inter-dependency of the electronic brakes..........................................................................202
Fig. 3-73 DC braking after OFF1 / OFF3...........................................................................................203
Fig. 3-74 DC braking after external selection ....................................................................................204
Fig. 3-75 Compound braking.............................................................................................................205
Fig. 3-76 Connecting the chopper (braking) resistor..........................................................................207
Fig. 3-77 Mode of operation of the dynamic braking..........................................................................207

Issue 10/06 Table of Contents
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 15
Fig. 3-78 Load duty cycle – chopper resistors (MICROMASTER Catalog DA51.2)...........................208
Fig. 3-79 Increasing the level of braking energy which can be absorbed..........................................209
Fig. 3-80 Chopper load duty cycle.....................................................................................................209
Fig. 3-81 Automatic restarts ..............................................................................................................211
Fig. 3-82 Flying restart.......................................................................................................................214
Fig. 3-83 Vdc_max controller.............................................................................................................216
Fig. 3-84 Kinetic buffering (Vdc_min controller).................................................................................218
Fig. 3-85 Positioning down ramp.......................................................................................................219
Fig. 3-86 Rotary or linear axis............................................................................................................220
Fig. 3-87 Shaft drive with flat belts.....................................................................................................223
Fig. 3-88 Load torque monitoring (P2181 = 1)...................................................................................223
Fig. 3-89 Frequency/torque tolerance bandwidth ..............................................................................224
Fig. 3-90 Load torque characteristic with minimum permissible load.................................................225
Fig. 3-91 Load torque characteristic with maximum permissible load................................................225
Fig. 3-92 Load torque characteristic with minimum and maximum permissible load.........................226
Fig. 3-93 Thermal motor protection ...................................................................................................228
Fig. 3-94 Connecting a temperature sensor to MICROMASTER.......................................................230
Fig. 3-95 PTC characteristic for 1LG / 1LA motors...........................................................................231
Fig. 3-96 KTY84 characteristic for 1LG / 1LA motors........................................................................231
Fig. 3-97 Operating ranges and characteristics of an induction motor when fed from a drive inverter236
Fig. 3-98 Slip compensation..............................................................................................................239
Fig. 3-99 Effect of V/f resonance damping ........................................................................................240
Fig. 3-100 Imax controller....................................................................................................................242
Fig. 3-101 Current Vector diagram in a steady-state condition............................................................243
Fig. 3-102 Changeover condition for SLVC.........................................................................................245
Fig. 3-103 Starting and passing-through 0 Hz in closed-loop controlled operation..............................246
Fig. 3-104 P0400 and DIP switch on the pulse encoder module.........................................................247
Fig. 3-105 Speed controller.................................................................................................................248
Fig. 3-106 Speed controller with pre-control........................................................................................250
Fig. 3-107 Speed controller with droop................................................................................................252
Fig. 3-108 Closed-loop speed/torque control.......................................................................................253
Fig. 3-109 Torque limits.......................................................................................................................255
List of Tables
Table 2-1 Dimensions and Torques of MICROMASTER 440...............................................................30
Table 3-1 Parameter attributes.............................................................................................................52
Table 3-2 Parameter P0700 .................................................................................................................57
Table 3-3 Parameter P1000 .................................................................................................................58
Table 3-4 Parameter P0719 .................................................................................................................59
Table 3-5 Normalized interfaces...........................................................................................................68
Table 3-6 Normalization functions........................................................................................................68
Table 3-7 Pre-assignment of the digital inputs .....................................................................................75
Table 3-8 Example 1LA7060-4AB10....................................................................................................82
Table 3-9 Possible settings for parameter P0340.................................................................................88
Table 3-10 Calculated parameters .........................................................................................................89
Table 3-11 Parameters P0701 – P0706...............................................................................................136

Table of Contents Issue 10/06
MICROMASTER 440 Operating Instructions
16 6SE6400-5AW00-0BP0
Table 3-12 Parameters P0731 – P0733 (frequently used functions / states)........................................138
Table 3-13 BOP link .............................................................................................................................145
Table 3-14 COM link.............................................................................................................................145
Table 3-15 Minimum start intervals for various baud rates...................................................................152
Table 3-16 Structural data....................................................................................................................153
Table 3-17 Thermal and electrical characteristics ................................................................................154
Table 3-18 Max. number of nodes (devices) depending on the max. data transfer rate.......................154
Table 3-19 Task IDs (master -> drive converter)..................................................................................158
Table 3-20 Response ID (converter -> master)....................................................................................159
Table 3-21 Fault numbers for the response ID "Request cannot be executed"....................................160
Table 3-22 Example for direct coding via digital inputs.........................................................................167
Table 3-23 Example for binary coding via digital inputs........................................................................168
Table 3-24 Mode of operation of the MOP ...........................................................................................171
Table 3-25 Selecting the motorized potentiometer...............................................................................171
Table 3-26 Correspondence between the parameters .........................................................................177
Table 3-27 Important parameters for the PID dancer roll control..........................................................180
Table 3-28 BICO parameters for ramp-function generator...................................................................185
Table 3-29 Examples for settings of parameter P0810.........................................................................190
Table 3-30 Possible settings for parameters P0700 and P1000...........................................................190
Table 3-31 Free function blocks ...........................................................................................................191
Table 3-32 FFB priority table................................................................................................................194
Table 3-33 Settings for parameter P1200.............................................................................................213
Table 3-34 DC link undervoltage – shutdown threshold.......................................................................219
Table 3-35 Partial excerpt of monitoring functions / messages ............................................................222
Table 3-36 Thermal classes .................................................................................................................228
Table 3-37 General protection of the power components.....................................................................232
Table 3-38 V/f characteristic (parameter P1300)..................................................................................236
Table 3-39 Voltage boost .....................................................................................................................238
Table 3-40 Vector control versions.......................................................................................................244
Table 4-1 Inverter conditions indicated by the LEDs on the SDP.......................................................258
Table 5-1 MICROMASTER 440 Performance Ratings.......................................................................262
Table 5-2 Dimensions, required cooling air flow and tightening torques for power terminals.............264
Table 5-3 Current reduction depending on pulse frequency...............................................................265
Table 5-4 Data for braking resistors ...................................................................................................266
Table 5-5 MICROMASTER 440 Specifications ..................................................................................266
Table 7-1 Permissible harmonic current emissions............................................................................277
Table 7-2 General industrial application.............................................................................................278
Table 7-3 With filter, for industrial applications...................................................................................278
Table 7-4 With filter, for residential, commercial and trade applications.............................................279
Table 7-5 Compliance Table ..............................................................................................................280

Issue 10/06 1 Overview
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 17
1 Overview
This Chapter contains:
A summary of the major features of the MICROMASTER 440 range.
1.1 The MICROMASTER 440....................................................................................... 18
1.2 Features.................................................................................................................. 19

1 Overview Issue 10/06
MICROMASTER 440 Operating Instructions
18 6SE6400-5AW00-0BP0
1.1 The MICROMASTER 440
The MICROMASTER 440 are frequency inverters for speed and torque 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 10/06 1 Overview
MICROMASTER 440 Operating Instructions
6SE6400-5AW00-0BP0 19
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:
♦ADC1: 0 – 10 V, 0 – 20 mA and -10 to +10 V
♦ADC2: 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 (drive inverter specific up to 16 kHz) for low-noise
motor operation
¾Internal RS485 interface (port)
¾Detailed status information and integrated message functions

1 Overview Issue 10/06
MICROMASTER 440 Operating Instructions
20 6SE6400-5AW00-0BP0
Performance Characteristics
¾Vector Control
♦Sensorless Vector Control (SLVC)
♦Vector Control with encoder (VC)
¾V/f Control
♦Flux Current Control (FCC) for improved dynamic response and motor
control
♦Multi-point V/f characteristic
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
¾Built-in braking chopper (Frame Sizes A to F) for resistor braking (dynamic
braking)
¾Setpoint input via:
♦Analog inputs
♦Communication interface
♦JOG function
♦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)
¾Free Function Blocks
¾DC link voltage controller
¾Kinetic Buffering
¾Positioning Ramp down
Protection characteristics
¾Overvoltage/undervoltage protection
¾Overtemperature protection for the inverter
¾Ground fault protection
¾Short-circuit protection
¾i
2t thermal motor protection
¾PTC/KTY84 for motor protection
Options
¾Refer to Chapter 5