SycoTec e@syDrive 4624 User manual

Operating Manual EN
HF Inverter e@syDrive 4624, 4625, 4626

EN
Table of Contents
1.0 User Information 5
1.1 Symbols Used 5
1.2 Important Definitions 5
1.3 Abbreviations 6
2.0 Scope of Supply and Accessories 7
2.1 Scope of Supply 7
2.2 Accessories 7
3.0 Safety Instructions and Warnings 8
3.1 Appropriate Use 9
3.2 Installation, Commissioning and Operation 9
3.3 Operation 10
3.4 Transport, Storage, Maintenance and Disposal 10
3.5 EMC 11
4.0 Technical Data 12
4.1 Type Plate 12
4.2 Performance Data 13
Frequency inverter e@syDrive 4624 13
Frequency inverter e@syDrive 4625 13
Frequency inverter e@syDrive 4626 13
Nominal and Overload Conditions 13
4.3 Inverter Dimensions 14
Frequency inverter e@syDrive 4624 14
Frequency inverter e@syDrive 4625 and 4626 15
4.4 General 15
Configuration 15
FW button 16
Operation 16
Display 16
Standards 16
Overload situation 16
Protection category 17
Appliance class 17
Weight 17
Ambient conditions 17
Storage and transport conditions 17
4.5 Description of Functions 17
3-phase asynchronous motor (ASM 3-phase) 17
Permanent-magnet synchronous motor without sensors (PMSM) 17
Selection of target value 18
Start/Stop 18
Block diagram 20
5.0 Mounting and Installation 21
5.1 Mounting Frequency Inverter e@syDrive 4624 21
5.2 Mounting Frequency Inverter e@syDrive 4625 and 4626 22
6.0 Connector Pin Assignment 23
6.1 Electrical Installation 23
Wiring guidelines for compliance with the EMC standards 23
Access to the electrical connections 23
Installation electrical connections 24
6.2 Connectors 24
Data of the PCB terminal blocks 25
Data of the PCB connectors 25
6.3 Terminal 1…3 28
Mains connection –Terminal 1…3 28
6.4 Terminal 10…13 28
Motor connection –Terminal 10…13 28

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6.5 Terminal 20…27 29
Safe Torque Off –Terminal 20…27 29
6.6 Terminal 30…35 30
Relay 1 and Relay 2 –Terminal 30…35 30
6.7 Terminal 40…59 31
Motor temperature sensor –.Terminal 40...41 31
Frequency output –Terminal 42…43 31
Analog input 0…10 V – Terminal 44…46 32
Analog input 0…20 mA – Terminal 47…48 32
Analog output 0…10 V – Terminal 49 32
Digital PLC input –Terminal 50…51 33
Digital inputs –Terminal 52...59 33
6.8 Terminal 60…63 34
CAN bus connection –Terminal 60…63 34
6.9 Mini USB connector 35
6.10 Micro SD card 35
7.0 Switch-on Sequence 36
8.0 Status Report / Malfunctions / Error Correction 37
8.1 Status Report 37
8.2 Description of LEDs 37
8.3 Warnings 38
8.4 Errors 39
8.0 Operating Software and Programming 40
Warranty Conditions 40
CE Declaration of Conformity 40

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1.0 User Information
1.1 Symbols Used
Operating Manual / Unit
DANGER
Indicates a hazardous situation that can directly cause death or serious injury.
WARNING
Indicates a hazardous situation that can cause damage to property or
moderate
to serious injuries.
ATTENTION
Indicates a hazardous situation that can cause damage to property or mild
to moderate injuries.
Risk of injury due to electric shock. After electric devices have been
switched off, touch volltages may occure.
Important information for operator and engineer
Information on protection category
Information on disposal
CE mark (Communauté Européenne)
Packaging
Fragile
Keep dry
Transport upright with the arrows pointing upwards.
Stacking restrictions
Temperature range
Air pressure
Humidity
Quantity
1.2 Important Definitions
PC operation: The frequency inverter is configured and, if required, operated using a standard PC.
Micro step With a micro step start-up, the PMSM motor is operated as a synchronous motor with
–Start-up: constant current. In this case, the output frequency is slowly increased from 0 Hz to the
start-up frequency, after which the system switches to controlled motor running. With a
micro step start-up, it is possible to start up sensor less PMSM motors with large
centrifugal masses (such as vacuum pumps), which would otherwise fail to start due to the
large moment of inertia.
Ready for If no error occurs after the inverter switches on, then the green LED 1 lights up.
operation: This machine state is referred to as ready for operation.
Configuration: Configuration refers to the operating process that allows the settings of the frequency inverter
to be configured in relation to the motor data of the connected motor as well as the inputs and
outputs. The settings of the frequency inverter are configured with the help of the SycoDrive
operating software, which is available free of charge from the website www.sycotec.eu.
(A more detailed description of the SycoDrive operating software can be found in Chapter 9.0.)

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Qualified staff: For the purposes of these instructions for use, these are persons who are familiar with and
have been properly trained in the installation, assembly, commissioning and operation of the
product and the possible hazards and risks associated with the electrical current.
Galvanic Galvanic isolation ensures that two electrical circuits are physically separated from one
isolation: another. This means that the two circuits have no direct connection with each other.
Electrical energy is transferred from one conductor to another electro-magnetically and
without contact, with the help of an inductive coupling element, for example. This also
ensures that the potentials are separated from each other.
1.3 Abbreviations
A
Ampere
AC
Alternating current
AIN
Analog input
Aout
Analog output
ASM 3-phase
3-phase asynchronous motor
AWG
American Wire Gaude
°C
Degrees Celsius
CAN
Bus system (Controller Area Network)
CANH
CAN bus high-level
CANL
CAN bus low-level
CB
Circuit breaker
COM
Common connection relay
CUL
UL for Canada
DC
Direct current
DIN
Digital input
DIN EN
German Industrial Standards / European Standards
EEPROM
Electrically erasable programmable read-only memory
EMC
Electromagnetic compatibility
EMF
Electromotive force
°F
Degrees Fahrenheit
FRQout
Frequency output
FW
Firmware
GB
Gigabyte
GND
Ground/earth
GR
Rectifier –Block Diagram
GS
Direct current –Block Diagram
HF
High frequency
hPa
Hectopascal
Hz
Hertz
ID
Identification
I
Input
INV
Inverter
IP
Protection category
kg
Kilogram
kOhm
Kiloohm
LED
Light-emitting diode
m
Meter
mA
Milliampere
max.
Maximal
min.
Minimal
mm
Millimeter
mm²
Square millimeter
ms
Millisecond
NC
Normally closed contact
NN
Geographical reference height (Normal Null)
NO
Normally open contact
NTC
Negative temperature coefficient
O
Output
PAM
Pulse-amplitude modulation
PC
Personal computer
PCB
Printed-circuit board
PDO
Process data object
PE
Protective earth conductor

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PFHA
Propability of a Dangerous Failure per Hour
PLC
Programmable logic controller
PMSM
Permanent-magnet synchronous motor without rotor position sensor
PTC
Positive temperature coefficient
RMS
Root Mean Square
SD card
Secure digital memory card
SDO
Service data object
SN
Serial number
STO
Safe Torque Off
T
Motor temperature
U
Motor phase U
Ueff
RMS voltage
UL
Underwriters Laboratories (Organisation that tests and certifies products for their safety)
USB
Universal Serial Bus
V
Volt
V
Motor phase V
V/Hz
Voltage-frequency ratio
VA
Volt-ampere
W
Watt
W
Motor phase W
2.0 Scope of Supply and Accessories
2.1 Scope of Supply
Frequency inverter e@syDrive 4624 Material no. 2.002.1053
Frequency inverter e@syDrive 4625 Material no. 2.002.1054
Frequency inverter e@syDrive 4626 Material no. 2.002.1055
Mini USB cable (1.8 m) Material no. 2.002.2675
Operating Manual SycoDrive Operating Software Material no. 2.002.2669
Operating Manual e@syDrive 4626, 4625, 4626 Material no. 2.002.1912
Micro SD card (2GB) Material no. 2.002.5831
Check that all parts are present.
2.2 Accessories
The following power supply modules from SycoTec are specially designed for use with frequency
inverters e@syDrive 4624, 4625, 4626 and are therefore recommended:
Power supply e@syDrive 4428 Material no. 1.001.2770
Power supply e@syDrive 4429 Material no. 1.002.2515
Alternative options are:
Transformer 4425 –360 VA Material no. 2.000.6843
Transformer 550 VA Material no. 2.001.9835
Transformer 4426 –1.100 VA Material no. 2.001.0922
Transformer 1.300 VA Material no. 2.002.4336
DANGER
When using a transformer or different mains adapter, double isolation must be maintained between the
secondary voltage and mains voltage. This means that the frequency inverter supply voltage must be
galvanically separated from the mains.
Ensure that the supply voltage is equipped with an overcurrent protection device.

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3.0 Safety Instructions and Warnings
These safety instructions contain important information for your safety.
Before installing and operating this device, these safety instructions and warnings must be read
carefully and all of the warning signs on the device must be payed attention to.
This document is intended for machine manufacturers and persons responsible for putting into service
and operating the frequency inverter.
ATTENTION
The operating manual must be read by the user/operator before starting up the unit for the first time in
order to avoid incorrect operation and other damage. Duplication and distribution of the operating
manual require SycoTec’s prior consent.
Safe operation and protection of the device can only be assured if the device is used as intended, in
accordance with the instructions for use, and using only approved tools. The following must also be
observed:
•The occupational health and safety regulations
•The accident prevention regulations
Also note the following directives:
-Low-Voltage Directive 2014/35/EU
-EMC Directive 2014/30/EU
-RoHS Directive 2011/65/EG
All specifications, information and properties of the product described in the operating manual
correspond to the status on going to press.
Modifications and improvements to the product as a result of new technical developments are possible.
This does not imply any right to retrofitting of existing units.
SycoTec assumes no responsibility for damage arising through:
•external influences (poor quality of the media or faulty installation, natural phenomenons, etc.)
•use of incorrect information
•improper use
•improperly performed repairs
DANGER
•The frequency inverters e@syDrive 4624, 4625, 4626 operate dangerously rotating mechanical parts.
Failure to follow the instructions provided in these instructions for use could result in serious damage
to property, personal injury or death.
•Hazard-free operation of this device is dependent on the proper installation, handling and operation of
the device.
•Only properly qualified personnel must commission, service and work on this device. Only qualified
staff is permitted to connect up and commission the device and to rectify faults.
•This device must not be used as an "emergency stop mechanism" (see EN 60204).
•The device must be used only for the purpose intended by the manufacturer. Unauthorized alterations
and the use of auxiliary equipment that is not recommended by the manufacturer could cause fires,
electric shocks and injuries.
ATTENTION
For safety reasons, the frequency inverter supplied has been configured to operating mode "no motor".
Since it is not known which motor will be connected, an incorrect configuration could damage or destroy
the motor or the frequency inverter.
In order to configure the frequency inverter, please see chapter 8.0.
Modifications to and in the device may only be performed after prior agreement with SycoTec.

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3.1 Appropriate Use
The SycoTec frequency inverters e@syDrive 4624, 4625, 4626 have been specially developed for driving
HF 3-phase asynchronous motors (ASM 3-phase) and permanent-magnet synchronous motors (PMSM).
They are used in spindles, for grinding, milling and drilling machines on machine tools, for example.
They can also be used to operate motors that are made up of motor elements, and are used, for example,
as drives for test stands or other physical-technical equipment (such as vacuum pumps, centrifuges,
optical systems etc.).
The pulse-amplitude modulation (PAM) used ensures smooth and gentle operation of the motors.
The following types of motor can be operated:
•3-phase asynchronous motor (ASM 3-phase)
•Parallel operation of ASM 3-phase is possible according to user’s requirements (please contact
SycoTec’s technical support team regarding configuration of the inverter).
•Permanent-magnet synchronous motors without sensors (PMSM)
Integrated load compensation offers consistent speed regulation and –by ensuring low currents in idle
operation –prevents unnecessary heating of the connected motors.
When the stop command is given, the connected motor is braked with the deceleration ramp.
A PC can be connected via the USB interface and used to operate and configure the system and to update
the firmware.
The frequency inverter can be operated entirely via remote control. Various inputs and outputs are freely
programmable.
3.2 Installation, Commissioning and Operation
The installation must only be carried out by qualified personnel with electrotechnical training.
The commissioning must only be carried out be specialist personnel with sufficient knowledge in the
fields of electrical engineering and drive technology.
Electrostatically sensitive components must not be touched.
The following requirements must be considered for the installation and operation of the devices:
Pollution: Clean air according to IEC 60664-1, dirt level 2
Max. operating altitude: 1,000.m (5,231 ft)
Ambient temperature: +5 to +40°C (41 to 104°F) according to EN 61800-2
Relative humidity: 5 to 85% (no condensation)
The inverter must be mounted in the control cabinet.
The protection against harmful gas, oil vapor and salty air must be ensured.
The ambient air must not contain aggressive, grinding, electrically conductive, highly flammable
substances or dust.
A sudden change in temperature and / or humidity must be avoided.
For devices with a fan sufficient spaces for the suction and discharge of cooling air must be provided to
ensure effective cooling.
Incorrect installation may result in damage of material and / or serious injury of persons.
The applicable accident prevention regulations must be followed to avoid serious injuries when working
on energized devices.
The system must be properly grounded in order to prevent serious injuries due to high currents.
The electrical installation must be carried out in according to the relevant electrical codes (appropriate
wire gauges, connections of ground conductors, etc.).
The frequency inverter supply voltage must be electrically isolated from the mains.
Ensure that the supply voltage must be equipped with an overcurrent protective device.

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The device does not have a power switch. The device must be completely disconnected from the power
supply before work is carried out on the opened device. The power supply may only be available after the
work on the device has been completed.
The values of a presetting performed by SycoTec must be checked by the user for correctness.
3.3 Operation
DANGER
During the operation of the product, there is a risk of serious injury to persons and property caused by
moving of flying parts or by unauthorized use.
It must be ensured that all accesses to the moving parts of the system are kept closed during operation.
It must be ensured that all the mounting screws and tools have been adequately fastened.
It must be ensured that the products are used as intended.
A correct operation of the products must be ensured.
It must be ensured that the applicable safety regulations of the respective system are complied with.
The relevant instructions in the operating manual must be followed.
3.4 Transport, Storage, Maintenance and Disposal
The frequency inverter must not be subjected to an unacceptable load. The following factors must be
considered:
Protection against mechanical damage during transportation, handling, etc. must be ensured!
Protection against contamination and moisture must be ensured!
Protection against contact with electronic components must be ensured!
The following storage conditions must be met, if necessary by appropriate measures:
Pollution: Clean air according to IEC 60664-1, dirt level 2
Storage temperature: -25 to +55°C (-14 to 104°F) according to EN 61800-2
Relative humidity (storage location): 5 to 95% (no condensation)
A sudden change in temperature and / or humidity must be avoided.
Depending on the ambient conditions, the frequency inverter must be inspected of for cleanliness and
function at regular intervals.
The safety function STO must be checked by being triggered at regular intervals by qualified staff. This
can be done, for example, by opening the safety switch with the motor running or the attempt of starting
the motor with the safety switch open. If required, the test report according to DIN EN 61800-5-2 can be
made available.
The safety function STO has been tested in accordance with DIN EN 61800-5-2 and compliance with the
underlying standard has been confirmed and documented.
Repair and maintenance work, apart from the activities described in this operating manual, must be
performed only by qualified staff.
ATTENTION
•In the event of modifications by third parties, the licenses become null and void.
•Use only SycoTec original parts and spare parts.
Before disposing of the frequency inverter, the battery must be removed.
The battery must be disposed of separately.