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
TWERD Power Electronics 5

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
TWERD Power Electronics 7

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.
TWERD Power Electronics 9

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

Section 1: Conditions of safe operation
1.5. Environmental conditions
Degree of ollution
During design, the second degree of pollution has been assumed, at which
there is normally only non-conducting pollution. However, there is a probability
of temporary conductivity caused by a condensation when the converter is not
running.
In case the environment in which the frequency converter will work contains
pollution, which can influence its safety, it is necessary to apply appropriate
counteraction, using, for example, additional cases, air channels, filters etc.
Climatic conditions
Table 1.1. Installation climatic conditions: requirements
Installation site During warehousing During
transport
Tem erature
from -1 °C to +5 °C1) -25°C to +55°C -25°C to
+7 °C
In protective packaging
Relative
humidity
from 5% to 95% from 5% to 95% Max 95%
Short-term, insignificant condensation on the external side of
the converter case is permitted only when converter isn’t
running.
Air ressure from 86 kPa to 1 6
kPa
from 86 kPa to 1 6 kPa from 7 kPa
to 1 6 kPa
1.6. Limits of res onsibility
•Despite all the efforts and due diligence, TWERD Power Electronics does
not guarantee that the published data is error-free.
•The User is obliged to read the information contained in this Manual be-
fore using the device.
•The TWERD logo is a registered trademark of Zakład Energoelektroniki
TWERD Sp. z o.o.
•In case of any doubts or questions, please contact us.
1) For nominal load temperature 4 oC was assumed; however, for lower loads higher
temperatures are acceptable.
TWERD Power Electronics 11

Section 2: Installation of the frequency converter
2. Installation of the frequency converter
2.1. Safety rules
Protective earthing connections
The protection against indirect contact consists in the automatic shutdown of
the power supply voltage by special short-circuit (or differential-current) pro-
tection or voltage limitation to a level not exceeding the permissible values in
case of an insulation failure.
Due to the operation of the intermediate circuit, a ground fault at the fre-
quency converter output cannot be detected by short-circuit protection. Al-
though the protection against interpolar and ground faults at the frequency
converter output is provided, it is based on IGBT transistors blocking which
does not meet the requirements of electric shock protection. For these reas-
ons, to ensure the safety of personnel, local protective connections must be
made accordingly.
The frequency converter provides terminals, appropriately marked and protec-
ted against corrosion, for connecting protective conductors.
Protections
The frequency converter is equipped with protections: against electrical motor
overload, thermal motor (I2t limit), under- or over voltage in the converter inter-
mediate circuit, short-circuit at the converter output (it only protects the con-
verter!).
The usage of differential-current protection to prevent electric shock can ap-
pear unfavourable since it can trigger due to temporary or constant leakage
current of the power drive system, operating under normal conditions. If a dif-
ferential-current device is used, due to the different nature of the differential
current, only circuit breakers of a B type are permitted.
12 TWERD Power Electronics

Section 2: Installation of the frequency converter
Disconnecting device
In order to comply with EU directives, according to PN-EN 6 2 4-1:2 1 ,
power drive, which consists of a frequency converter and electrical machine,
should be supplied with a device for disconnecting power supply voltage. This
device should be one of listed below:
•separator (with or without fuses), category of usage AC-23B fulfilling
the requirements EN 6 947-3,
•disconnector (with or without) fuses, disconnecting a load circuit
before opening main contacts, conforming the EN 6 947-3
requirements,
•circuit breaker, in accordance with EN 6 947-2.
A user is obliged to fulfil these requirements.
Emergency sto
In order to comply with the European Union Directive, according to PN - EN
6 2 4-1:2 1 , for the safety of personnel and equipment, it is necessary to
use an emergency stop switch, the operation of which takes precedence over
other functions, irrespective of operating mode. The key STOP on the oper-
ator panel cannot be treated as an emergency stop switch, because it doesn't
disconnect a frequency converter from power supply voltage.
A user is obliged to fulfill this requirement.
Housing
The housing conforms to the requirements of an IP2 protection degree. The
surface, on which the operator's control panel is located, meets the require-
ments of an IP4 protection degree. The housing has been designed so that it
cannot be removed without the use of tools.
Ca acitors discharging
There is a capacitor battery with relatively high capacity in a DC link circuit of
the frequency converter. Despite switching off the power supply voltage of the
converter, dangerous voltage may remain on the terminals for a specified
period of time. It is necessary to wait 5 minutes before switching on the power
strip of the frequency converter. The information about danger of such voltage
is also placed on the terminal block cover.
TWERD Power Electronics 13

Section 2: Installation of the frequency converter
2.2. Assembly of the frequency converter
To ensure appropriate air circulation, the converter must be mounted vertically
with a free space around the device: 1 cm from the top and the bottom and
3 cm on both sides of the device.
The dimensions of the AFC2 frequency converters are presented in figure
2.1.
1 cm
1 cm
3 cm 3 cm
Fig. 2.1. The required free space around the device
14 TWERD Power Electronics

Section 2: Installation of the frequency converter
C
c
A
a
B
M4
Ø
Ø
A1
Fig. 2.2. The dimensions of the AFC200 frequency converters
Table 2.1. The dimensions of the AFC200 frequency converters
Ty e:
AFC200/...
Size
[mm]
A A1 a B C c Ø
Weight
[kg]
,37 kW
,55 kW
,75 kW
1,1 kW
168 134 151 7 133 6 7
,8
,8
,8
,85
1,5 kW
2,2 kW
3, kW
195 162 174 73 169 74 7
1,3
1,35
1,4
TWERD Power Electronics 15

Section 2: Installation of the frequency converter
2.3. Connecting the ower circuit
•The AFC2 frequency converter is powered by a single phase voltage
23 VAC, 5 Hz.
•Connect the frequency converter to electric motor using the shortest pos-
sible symmetrical shielded cable.
•Do not use contactors and circuit breakers on the output side of the con-
verter that would disconnect the system during operation - see section
2.5.
•Figure 2.3 shows the scheme of power circuits connections.
Figure 2.3. Connection of po er circuits to AFC200 frequency converter
Table 2.2 can be used to select the cross-sections of power cables. The final
selection of cable cross-sections must com ly with the a licable
standards.
Table 2.2. Conductor cross-sections selected for long-term load capacity in
accordance ith PN-IEC 60364-5-523:2001 for Cu PVC multicore cables laid in pipes
or strips on alls, alls or floors; design ambient temperature: 250 C.
AFC200/... Iin
[A]
Iz
[A]
L,N,PE
[mm2]
U,V,W,PE
[mm2]
,37 kW 4,5 6 3 x 1,5 4 x 1,5
,55 kW 6,9 1 3 x 1,5 4 x 1,5
,75 kW 8,9 1 3 x 1,5 4 x 1,5
1,1 kW 13,5 16 3 x 1,5 4 x 1,5
1,5 kW 17,7 2 3 x 2,5 4 x 1,5
2,2 kW 28,8 32 3 x 4, 4 x 2,5
3, kW 28,8 32 3 x 4, 4 x 2,5
Iin – the highest RMS value of input current
Iz – the maximum permissible nominal protection current;
the protection can be a gG fuse or a "B" type circuit breaker.
16 TWERD Power Electronics
AFC200
Overcurrent protectionSwitch
L
N
PE
* Do not use any contactors between converter
output and motor!
* Output voltage can be measured correctly only with
an electromagnetic voltmeter!
NOTE: The terminals are for illustration only
and do not correspond to their actual location
on the inverter.
M
3~
U
V
W
L
N
PE
PE

Section 2: Installation of the frequency converter
2.4. Connection of control systems
Fig. 2.4 shows a view of terminal blocks of the frequency converter control
block together with a simplified internal block diagram. Tables 2.3 and 2.4 de-
scribe the functions of the individual terminals.
Figure 2.4. Vie of control system terminal blocks (X1, X2) and an exemplary connec-
tion configuration
Table 2.3. Control terminal block X1 – inputs and outputs
No Name Descri tion Note
X1:1 B Interface RS-485, line B Terminator/bias are connected
with J25/J26 jumpers
X1:2 A Interface RS-485, line A The same
X1:3 AGND Analog Ground Use only for connecting analog
inputs/outputs signals
X1:4 AO1 Analog Output 1 (current
mode)
X1:5 AGND Analog Ground Use only for connecting analog
inputs/outputs signals
X1:6 AI1 Analog input 1 (voltage
mode)
Input impedance:
 47 kOhm
X1:7 AI2 Analog input 2 (current
mode)
Input impedance:
= 5 Ohm
TWERD Power Electronics 17
16 15141312111987654321
A
B
AO1 +10V AGND
AGND
AI1 AI2 GND DI6 DI5 DI4 DI3 DI2 DI1 +24V
X1
Modbus
master
RS-485
P
–I
654321
K1, K2 - relay outputs.
Can be used e.g. to control signal
lights at 23 V
A
NO
K2K1
NC
COM
X2
NO NC
COM
X2
J26 J25
Terminal jumpers of RS-485 interface.
J25 and J26 should be closed when
the frequency converter is the last
device on the communication line.
X1
Analog inputs:
AI1 – voltage
AI2 – current
Current
analog
output
AO1
RS-485
Digital inputs DI1..DI6
U –/~
Passive current
source
Input
+24V
Output
An example of connecting the
equipment with a passive
current source to the AI2 input
+

Section 2: Installation of the frequency converter
No Name Descri tion Note
X1:8 +1 V Power supply of external
systems, i.e. potentiometer of
a referencing-unit
Load ca acity of the source:
100 mA
X1:9 GND Digital Inputs Ground
X1:1 DI1 Digital input 1 Input impedance: 8 kOhm
X1:11 DI2 Digital input 2 The same
X1:12 DI3 Digital input 3 The same
X1:13 DI4 Digital input 4 The same
X1:14 DI5 Digital input 5 The same
X1:15 DI6 Digital input 6 The same
X1:16 +24V Power supply for digital
inputs and external systems
Load ca acity of the source:
200 mA
Table 2.4. Control terminal block X2 – inputs and outputs
No Name Descri tion Note
X2:1 K1
(NO)
Relay output K1, contact NO (normally
open)
Load capacity of
contacts: 1A / 25 V
AC
X2:2 K1
(COM)
Relay output K1, contact COM
(common)
The same
X2:3 K1
(NC)
Relay output K1, contact NC (normally
closed)
The same
X2:4 K2
(NO)
Relay output K2, contact NO (normally
open)
The same
X2:5 K2
(COM)
Relay output K2, contact COM
(common)
The same
X2:6 K2
(NC)
Relay output K2, contact NC (normally
closed)
The same
Note:
Control circuit cables should be routed separately from power circuit cables.
2.5. Using contactors and circuit breakers at the frequency converter
out ut
If it is necessary to use contactors or circuit breakers between the frequency
converter and the electric motor, the switching of the contactor (circuit
breaker) must absolutely(!) be carried out in the voltageless state, when the
converter is stopped (STOP state). Otherwise, there will be damage to the
converter not covered by the warranty.
18 TWERD Power Electronics

Section 3: The control panel
3. The control anel
Fig. 3.1 shows the view of the converter control panel with a description of
each function of the keys and the display.
Fig. 3.1. The control panel, the basic functions of the keys and the display
The control panel is used for continuous monitoring of the process parameters
(e. g. output frequency, electric motor current), system operation control
(START/STOP, change of referencing-unit value, reset of failure report) and
for reviewing and changing the frequency converter parameters. The panel is
equipped with an LED display. When the system is connected to the mains,
the control panel is activated in the Basic Mode.
The functions of the keys, changing the panel modes and the way of changing
the values displayed on the panel are shown schematically in fig. 3.2, 3.3, 3.4,
3.5.
The parameters in group (read only) allow to view the process variables,
such as present output currents of the frequency converter, the heat sink tem-
perature, input and output status and other important parameters of the con-
verter.
The parameters placed in the following groups are responsible for:
•group 1: drive configuration,
•group 2: referencing-units and control,
•group 3: failures,
•group 4: access codes, settings of RS communication and the dis-
play.
Editing any parameter from groups 1 ... 4 takes place according to the
scheme shown in fig. 3.3.
TWERD Power Electronics 19
REF
Hz
r m
RUN
REV
FAULT
START to the left or right
when the control is set from
the Panel
- Stopping the electric motor
- Failure reset
- Changing the value of the current
referencing-unit
- changing the current parameter in
the parameter preview mode
- changing the parameter value in the
parameter edition mode
- Changing the preview size
(quick preview mode)
- entering the parameter edition mode
- confirmation (saving) of the parameter
value in the parameter editing mode
- Exit from quick preview mode
- Preview of parameter groups
- Resignation from parameter change
- Deleting a warning
Indication of operation
LEFT direction of rotation
(minus "-")
Failure indication
Display of the referencing-unit value
Unit: Hz
Unit: RPM

Section 3: The control panel
Control panel operation diagram
Connecting the system to the mains
Fig. 3.2. Control panel operation diagram
2 TWERD Power Electronics
↑
↓
CHANGING
THE VALUES OF THE
REFERENCING-UNIT
REF.- NIT [Hz]
CURRENT [A]
VOLTAGE [V]
TEMPERATURE
REVOLUTIONS
FREQ ENCY [Hz]
THE QUICK
PREVIEW
*
*
*
*
*
*
PAR. GROUP
↔
PAR. GROUP 1
↔
PAR. GROUP 2
↔
PAR. GROUP 3
↔
PAR. GROUP 4
↔
↔
↔
↔
↔
↔
↔
Parameters mode
*
Basic Mode
The referencing-unit value
can be changed when one
of the panel referencing-
units is active.