TWERD Power Electronics AFC200 User manual

TWERD Power Electronics
Frequency converter
AFC200 type
0,37 - 3,0 kW
Single phase supply 230V
User’s manual
Edition 3.3
TWERD
®
www.twerd.pl

Frequency converter
AFC200 type
0,37 - 3,0 kW
Single phase supply 230V
User’s manual
Edition 3.3

Contents
Contents
Technical data of frequency converters AFC2 .............................................7
1. Conditions of safe operation........................................................................9
1.1. Threats and warnings...........................................................................9
1.2. Basic rules.......................................................................................... 1
1.3. Operation list......................................................................................1
1.4. Disposal considerations.....................................................................1
1.5. Environmental conditions...................................................................11
1.6. Limits of responsibility........................................................................11
2. Installation of the frequency converter.......................................................12
2.1. Safety rules........................................................................................12
2.2. Assembly of the frequency converter.................................................14
2.3. Connecting the power circuit..............................................................16
2.4. Connection of control systems...........................................................17
2.5. Using contactors and circuit breakers at the frequency converter
output................................................................................................. 18
3. The control panel.......................................................................................19
4. The first start............................................................................................. 24
4.1. Power circuit connection....................................................................24
4.2. Entering nominal data........................................................................24
5. Configuration of the frequency converter..................................................25
5.1. Control from the control panel............................................................26
5.2. Control from the terminal block..........................................................26
5.3. Shaping the drive dynamics...............................................................29
5.4. Operation in U/f scalar modes............................................................29
5.5. Operation in vector mode...................................................................3
5.6. Analogue inputs.................................................................................31
5.7. Analog output.....................................................................................34
5.8. Constant speeds operation................................................................35
5.9. Motopotentiometer.............................................................................38
5.1 . Elimination of frequencies................................................................4
5.11. Electric motor rotation direction lock.................................................41
5.12. Thermal protections of the motor - Protection by I2t limit..................41
5.13. Operating at frequencies exceeding 5 Hz......................................43
6. PI controller...............................................................................................44
6.1. Turning on and configuration of the PI controller................................44
7. Frequency converter control via RS-485 communication link....................46
7.1. Parameters regarding communication via RS-485.............................47
7.2. Map of registers accessible through RS-485 link...............................48
7.3. Handling communication errors..........................................................51
8. Failures and warnings...............................................................................51
8.1. Messages on failures and warnings on the control panel...................51
8.2. Deleting failure message....................................................................52
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Contents
8.3. Failure log.......................................................................................... 53
9. Restore factory parameters.......................................................................53
1 . Periodic service.......................................................................................54
Appendix A – AFC2 frequency converter parameters table.......................55
Appendix B – Start / Stop control structure....................................................7
Appendix C – Frequency referencing-unit structure.......................................71
Appendix D – EU Declaration of Conformity..................................................72
6 TWERD Power Electronics

Technical data of frequency converters AFC2
Technical data of frequency converters AFC200
Table 0.1. Technical data, common for frequency converters of the AFC200 series
Power su ly Voltage Uin 1-phase: 23 V (-15%, +1 %) / 45..66 Hz;
other voltage levels are available on request
Out ut
Voltage
Frequency
3-phase: ..Uin [V]
, ..32 , Hz – scalar operation mode
, ..9 , Hz – vector operation mode
Frequency
resolution
, 1 Hz
Control
system
Modulator SVPWM
Operation
mode
scalar: U/f (linear or quadratic),
Vector without sensor
Frequency-
Shift Keying
4/8/16 kHz
Rotation speed
setting
Analogue inputs, control panel, motopotentiometer,
PI controller, RS485 port.
Resolution .1% for analog inputs or . 1 Hz/1rpm
for control panel and RS
Control:
in uts /
out uts
Analogue
inputs
2 analogue inputs AI1 and AI2:
AI1: voltage mode (2) .. 1 V, Rin ≥ 47 kΩ;
accuracy .5% of the full range
AI2: current mode (4) .. 2 mA, Rin = 5 Ω;
accuracy .5% of the full range
Digital inputs 6 digital inputs separated by / (15..24) V,
Rin ≥ 8kΩ
Analogue
outputs
1 current output AO1 : (4)..2 mA - configuration
by parameters, accuracy: .5% of the full range
Digital outputs 2 relay outputs (K1, K2) - breaking capacity: 25 V/
1A AC
Communica-
tion
Connectors RS-485 with optoisolation
Communication
protocol
MODBUS RTU. Function 3 (Read Register);
Function 6 (Write Register)
Transmission
speed 96 or 192 bit/s
Application Remote operation control and programming of all
the frequency converter parameters.
S ecial
functions
PI controller
Selection of referencing-unit signal source and
feedback signal source, possibility of inverting
polarity of control error signal, output erasing on
STOP signal, limitation of an output value.
Restoring
factory
parameters
Possibility of quick restoration of factory
parameters of frequency converter
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Technical data of frequency converters AFC2
Protections
Short-circuit Short-circuit at the system output
Over-current Instantaneous value 3,5 In;; effective value 2,5 In
Thermal:
converter
Heatsink temperature sensor
Thermal: motor I2t limit
Communication
control via RS-
485
Established permissible time of connection
absence
Control of
analog inputs
Checking the absence of “living null” in modes
2..1 V and 4..2 mA
Table 0.2. Technical data of frequency converters of the AFC200 series, depending on
a type
Type of a
frequency
converter:
AFC200/...
Constant-torque load
( ermissible overload
= 1.5 In)
Pn [kW] In [A]
Variable-torque load
( ermissible overload
= 1.1 In2)1)
Pn2 [kW] In2 [A]
I
[A]
,37 kW ,37 2,2 ,55 3, 3,3
,55 kW ,55 3, ,75 4, 4,5
,75 kW ,75 4, 1,1 5,5 6,
1,1 kW 1,1 5,5 1,5 7, 8,3
1,5 kW 1,5 7, 2,2 9,5 1 ,5
2,2 kW 2,2 9,5 3, 13, 14,5
3, kW 3, *)13, *)3, 13, 14,5
Pn – nominal power with permissible overload current Ip of ~1.5 In
In – nominal output current at Pn
Pn2 – nominal power with permissible overload current Ip of ~1.1 In2 (pumps,
fans)
In2 – nominal output current at Pn2
IP – output over-current: for 6 seconds every 1 minutes
*) Caution: The AFC2 /3. kW converter is intended for fan/pump applications and
cannot be loaded with a current greater than 1.1In.
1) For ambient temperature <35 C
8 TWERD Power Electronics

Section 1: Conditions of safe operation
1. Conditions of safe o eration
Ignorance of these instructions can result in serious injury or death to
personnel or damage to the frequency converter.
1.1. Threats and warnings
Incorrect installation or use of the AFC2 frequency converter may cause a
risk to life, human health or irreparable damage to the device.
RISK OF ELECTRIC SHOCK
•Installation, operation, maintenance and repair of the device must be
performed only by properly qualified and authorized personnel.
•Before switching on the power supply voltage, make sure that the
frequency converter has been correctly installed and all housing
elements have been properly assembled.
•It is forbidden to touch the voltage terminals of the frequency converter
connected to the power supply voltage.
•After connecting the converter to the power supply voltage, its internal
components (except for the control terminals) are on the power supply
potential. Touching these components can cause an electric shock.
•When the converter is connected to the power supply voltage, dangerous
voltage occurs at its output U, V, W terminals even when the motor is not
running.
•Externally supplied control circuits may carry dangerous voltage even
when the input power supply voltage of the frequency converter is
switched off.
•After disconnecting the device from the power supply voltage, the
dangerous voltage is still present for about 5 minutes.
•Don’t make any changes to the connections when the converter AFC2
is connected to the power supply voltage.
•Before working with the frequency converter, electric motor cable or
electric motor, wait minimum 5 minutes after disconnecting the power
supply voltage and make sure that there is no dangerous voltage at the
connection terminals.
Attention! The lack of the voltage at the connection terminals is not
synonymous with the lack of dangerous voltage in the internal DC circuit
of the frequency converter.
•The frequency converter is not designed to be installed in a
flammable/explosive environment as it may cause a fire/explosion.
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Section 1: Conditions of safe operation
1.2. Basic rules
•Don’t connect the supply voltage to the U, V, W output terminals.
•Don’t measure the voltage endurance of any unit devices.
• It is necessary to disconnect cables from the frequency converter to
measure their insulation.
•Don’t repair the frequency converter yourself. All repairs can only be
carried out by the manufacturer's authorized service centre. Any attempt
at unauthorised repairs will void your warranty.
•Don't connect any capacitor banks to the output (motor) cables to
improve cos φ.
•The voltage at the output terminals U, V, W should be measured with an
electromagnetic voltmeter (measurement ith a digital voltmeter ithout
a lo -pass filter is incorrect).
•The frequency converter is not designed to operate with periodically
switched on/off supply voltage. Don't turn on the power supply voltage
more than once every 5 minutes because this will damage the frequency
converter.
1.3. O eration list
The operations applied at installation and the first start-up of the
frequency converter
✔After unpacking the frequency converter, it is necessary to check up
visually presence of damages which could arise during transport.
✔Check whether the delivery is in accordance with the order - check the
nameplate.
✔Check up the correspondence between the conditions in which the
frequency converter will be used and conditions of an environment for
which it is designed (section 1.5).
✔Installation of the frequency converter should be made due to the
principles of safety and EMC rules listed in section 2.
✔Perform the configuration of frequency converter in accordance with
sections 4 and 5.
1.4. Dis osal considerations
Equipment containing electrical and electronic components can
not be removed into municipal waste containers. Such equip-
ment must be separated from other wastes and attached to
electrical and electronic waste in accordance with applicable
local regulations.
1 TWERD Power Electronics