Siemens MICROMASTER 440 User manual

MICROMASTER 440
Operating Instructions Issue B1
User Documentation

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.
Reference Manual
The Reference Manual gives detailed information
about engineering communication troubleshooting
and maintenance.
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
Operating Instructions
User Documentation
Issue B1
Valid for Issue 10/01
Converter Type Control Version
MICROMASTER 440 1.6
Overview 1
Installation 2
Commissioning 3
Using the
MICROMASTER 440 4
System Parameters 5
Troubleshooting 6
MICROMASTER 440
Specifications 7
Available options 8
Electro-Magnetic
Compatibility 9
Appendices A
B
C
D
E
F
G
H
I
J
K
L
Index

MICROMASTER 440 Operating Instructions
46SE6400-5AC00-0BP0
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. 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: 6SE6400-5AC00-0BP0 Siemens-Aktiengesellschaft

Issue B1 Foreword
MICROMASTER 440 Operating Instructions
6SE6400-5AC00-0BP0 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 B1
MICROMASTER 440 Operating Instructions
66SE6400-5AC00-0BP0
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 B1 Safety Instructions
MICROMASTER 440 Operating Instructions
6SE6400-5AC00-0BP0 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.
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 VBG 4.0 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.

Safety Instructions Issue B1
MICROMASTER 440 Operating Instructions
86SE6400-5AC00-0BP0
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 on page 82).
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).
♦If 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 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.
- the motor terminals U, V, W, DC+/B+, DC-, B- and DC/R+
♦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 2-7 on page 31, to prevent inductive and capacitive
interference from affecting the correct functioning of the inverter.

Issue B1 Safety Instructions
MICROMASTER 440 Operating Instructions
6SE6400-5AC00-0BP0 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
230V/460V/575V when protected by a H or K type fuse (see Tables starting
on page 81).
♦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 qualified 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 or
return it to the manufacturer.
♦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 B1
MICROMASTER 440 Operating Instructions
10 6SE6400-5AC00-0BP0

Issue B1 Table of Contents
MICROMASTER 440 Operating Instructions
6SE6400-5AC00-0BP0 11
Table of Contents
1 Overview ................................................................................................................15
1.1 The MICROMASTER 440 ....................................................................................... 16
1.2 Features .................................................................................................................. 16
2 Installation .............................................................................................................19
2.1 General.................................................................................................................... 21
2.2 Ambient operating conditions.................................................................................. 21
2.3 Mechanical installation ............................................................................................ 23
2.4 Electrical installation................................................................................................ 26
3 Commissioning .....................................................................................................33
3.1 Block diagram.......................................................................................................... 35
3.2 Commission modes................................................................................................. 36
3.3 General operation.................................................................................................... 46
4 Using the MICROMASTER 440.............................................................................49
4.1 Frequency setpoint (P1000).................................................................................... 50
4.2 Command sources (P0700) .................................................................................... 51
4.3 OFF and braking functions...................................................................................... 51
4.4 Control modes (P1300) ........................................................................................... 53
4.5 Faults and warnings ................................................................................................ 54
5 System parameters...............................................................................................55
5.1 Introduction to MICROMASTER system parameters.............................................. 56
5.2 Parameter overview ................................................................................................ 57
5.3 Parameter list (short form) ...................................................................................... 58
6 Troubleshooting....................................................................................................71
6.1 Troubleshooting with the SDP................................................................................. 72
6.2 Troubleshooting with the BOP ................................................................................ 73
6.3 Fault messages ....................................................................................................... 74
6.4 Alarm messages...................................................................................................... 78
7 MICROMASTER 440 specifications.....................................................................81
8 Options...................................................................................................................93
8.1 Device-independent options.................................................................................... 93
8.2 Device-dependent options ...................................................................................... 93
9 Electro-magnetic compatibility (EMC) ................................................................95
9.1 Electro-magnetic compatibility ................................................................................ 96

Table of Contents Issue B1
MICROMASTER 440 Operating Instructions
12 6SE6400-5AC00-0BP0
Appendices...............................................................................................................................101
A Changing the Operator Panel ............................................................................101
B Removing Covers Frame Size A........................................................................102
C Removing Covers Frame Sizes B and C...........................................................103
D Removing Covers Frame Size D and E.............................................................104
E Removing Covers Frame Size F ........................................................................105
F Removing the I/O Board .....................................................................................106
G Removing ‘Y’ Cap Link Frame Size A................................................................107
H Removing ‘Y’ Cap Link Frame Sizes B and C...................................................108
I Removing ‘Y’ Cap Link Frame Sizes D and E...................................................109
J Removing ‘Y’ Cap Link Frame Sizes F..............................................................110
K Applicable Standards..........................................................................................111
L List of Abbreviations...........................................................................................112
Index ...............................................................................................................................113

Issue B1 Table of Contents
MICROMASTER 440 Operating Instructions
6SE6400-5AC00-0BP0 13
List of Illustrations
Figure 2-1 Forming.................................................................................................................................21
Figure 2-2 Ambient operating temperature ............................................................................................21
Figure 2-3 Installation altitude ................................................................................................................22
Figure 2-4 Drill pattern for MICROMASTER 440....................................................................................24
Figure 2-5 MICROMASTER 440 Connection Terminals ........................................................................28
Figure 2-6 Motor and Power Connections..............................................................................................29
Figure 2-7 Wiring Guidelines to Minimize the Effects of EMI .................................................................31
Figure 3-1 Inverter block diagram ..........................................................................................................35
Figure 3-2 Panels available for the MICROMASTER 440 Inverter.........................................................36
Figure 3-3 DIP switch.............................................................................................................................36
Figure 3-4 Basic operation with SDP .....................................................................................................38
Figure 3-5 Buttons on the BOP ..............................................................................................................41
Figure 3-6 Changing parameters via the BOP .......................................................................................42
Figure 3-7 Typical Motor Rating Plate Example.....................................................................................45
Figure 3-8 Motor Overload PTC Connection..........................................................................................47
Figure 5-1 Parameter Overview .............................................................................................................57
List of Tables
Table 2-1 Dimensions and Torques of MICROMASTER 440 ...............................................................23
Table 3-1 Default settings for operation using the SDP ........................................................................37
Table 3-2 Default settings for operation using the BOP........................................................................40
Table 6-1 Inverter conditions indicated by the LEDs on the SDP .........................................................72
Table 7-1 MICROMASTER 440 Performance Ratings .........................................................................82
Table 7-2 Tightening torques for power terminals................................................................................83
Table 7-3 MICROMASTER 440 Specifications.....................................................................................83
Table 9-1 Permissible harmonic current emissions ..............................................................................97
Table 9-2 Class 1 - General Industrial ..................................................................................................98
Table 9-3 Class 2 - Filtered Industrial ...................................................................................................98
Table 9-4 Class 3 - Filtered for Residential, Commercial and Light Industry ........................................99
Table 9-5 Compliance Table...............................................................................................................100

Table of Contents Issue B1
MICROMASTER 440 Operating Instructions
14 6SE6400-5AC00-0BP0

Issue B1 1 Overview
MICROMASTER 440 Operating Instructions
6SE6400-5AC00-0BP0 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 .................................................................................................................. 16

1 Overview Issue A2
MICROMASTER 440 Operating Instructions
16 6SE6400-5AC00-0BP0
1.1 The MICROMASTER 440
The MICROMASTER 440s are a range of frequency inverters for controlling the
speed of three phase AC motors. The various models available range from the 120
W single-phase input to the 75 kW three phase input.
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.
The MICROMASTER 440 with its default factory settings is ideal for a large range
of simple motor control applications. The MICROMASTER 440 can also be used
for more advanced motor control applications via its comprehensive functionality.
The MICROMASTER 440 can be used in both 'stand-alone' applications as well as
being integrated into 'Automation Systems'.
1.2 Features
Main Characteristics
ØEasy installation
ØEasy commissioning
ØRugged EMC design
ØCan be operated on IT line supplies
ØFast repeatable response time to control signals
ØComprehensive range of parameters enabling configuration for a wide range of
applications
ØSimple cable connection
ØOutput relays
ØAnalog outputs (0 – 20 mA)
Ø6 Isolated and switchable NPN/PNP digital inputs
Ø2 Analog inputs:
♦AIN1: 0 – 10 V, 0 – 20 mA and -10 to +10 V
♦AIN2: 0 – 10 V, 0 – 20 mA
ØThe 2 analog inputs can be used as the 7th and 8th digital inputs
ØBiCo technology
ØModular design for extremely flexible configuration
ØHigh switching frequencies for low-noise motor operation
ØDetailed status information and integrated message functions
ØExternal options for PC communications, Basic Operator Panel (BOP),
Advanced Operator Panel (AOP), PROFIBUS communications module

Issue B1 1 Overview
MICROMASTER 440 Operating Instructions
6SE6400-5AC00-0BP0 17
Performance Characteristics
ØSensorless Vector Control
ØFlux Current Control (FCC) for improved dynamic response and motor control
ØFast Current Limitation (FCL) for trip-free operation
ØBuilt-in DC injection brake
ØCompound braking to improve braking performance
ØAcceleration/deceleration times with programmable smoothing
ØClosed-loop control using PID (Proportional, Integral and Differential) control
loop function, with auto-tuning
ØBuilt-in braking chopper
ØSelectable up and down ramps
Ø4-point ramp smoothing
ØMulti-point V/f characteristic
Øparameter sets which can be switched, allowing one inverter to control several
alternative processes
Protection characteristics
ØOvervoltage/undervoltage protection
ØOvertemperature protection for the inverter
ØGround fault protection
ØShort-circuit protection
Øi
2t thermal motor protection
ØPTC/KTY for motor protection

1 Overview Issue A2
MICROMASTER 440 Operating Instructions
18 6SE6400-5AC00-0BP0

Issue B1 2 Installation
MICROMASTER 440 Operating Instructions
6SE6400-5AC00-0BP0 19
2 Installation
This Chapter contains:
ØGeneral data relating to installation
ØDimensions of Inverter
ØWiring guidelines to minimize the effects of EMI
ØDetails concerning electrical installation
2.1 General.................................................................................................................... 21
2.2 Ambient operating conditions.................................................................................. 21
2.3 Mechanical installation ............................................................................................ 23
2.4 Electrical installation................................................................................................ 26

2 Installation Issue A2
MICROMASTER 440 Operating Instructions
20 6SE6400-5AC00-0BP0
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).
♦If 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 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.
- the motor terminals U, V, W, DC+/B+, DC-, B- and DC/R+
♦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.
CAUTION
The connection of power, motor and control cables to the inverter must be carried
out as shown in Figure 2-7 on page 31, to prevent inductive and capacitive
interference from affecting the correct functioning of the inverter.