Weq 6 A User manual

User's Guide Frequency Inverter
Guía del Usuario Convertidor de Frecuencia
Manual do Usuário Inversor de Freqüência

02/2008
Series: CFW-11
Language: English
Document: 10000063093 / 02
Models: 6...105 A / 200...240 V
3,6...88 A / 380...480 V
FREQUENCY
INVERTER
MANUAL

2
Revision Description Chapter
1 First Edition -
2 General Revision -
Summary of Revisions

Index
CHAPTER 1
Safety Instructions
1.1 Safety Warnings in the Manual.....................................................................................................1-1
1.2 Safety Warnings in the Product.....................................................................................................1-1
1.3 Preliminary Recommendations ....................................................................................................1-2
CHAPTER 2
General Instructions
2.1 About the Manual ......................................................................................................................2-1
2.2 Terms and Definitions..................................................................................................................2-1
2.3 About the CFW-11 .....................................................................................................................2-4
2.4 Identification Labels for the CFW-11.............................................................................................2-7
2.5 Receiving and Storage ................................................................................................................2-9
CHAPTER 3
Installation and Connection
3.1 Mechanical Installation ...............................................................................................................3-1
3.1.1 Installation Environment.....................................................................................................3-1
3.1.2 Mounting Considerations...................................................................................................3-1
3.1.3 Cabinet Mounting ............................................................................................................3-4
3.1.4 Access to the Control and Power Terminal Strips...................................................................3-5
3.2 Electrical Installation ...................................................................................................................3-7
3.2.1 Identification of the Power and Grounding Terminals ............................................................3-7
3.2.2 Power / Grounding Wiring and Fuses..................................................................................3-8
3.2.3 Power Connections..........................................................................................................3-12
3.2.3.1 Input Connections ..............................................................................................3-12
3.2.3.1.1 IT Networks ........................................................................................3-12
3.2.3.2 Dynamic Braking................................................................................................3-14
3.2.3.2.1 Sizing the Braking Resistor....................................................................3-14
3.2.3.2.2 Installation of the Braking Resistor.........................................................3-16
3.2.3.3 Output Connections ...........................................................................................3-17
3.2.4 Grounding Connections ..................................................................................................3-19
3.2.5 Control Connections .......................................................................................................3-20
3.2.6 Typical Control Connections.............................................................................................3-24
3.3 Installation According to the European Directive of Electromagnetic Compatibility .........................3-27
3.3.1 Conformal Installation .....................................................................................................3-27
3.3.2 Standard Definitions ........................................................................................................3-28
3.3.3 Emission and Immunity Levels...........................................................................................3-29

Index
CHAPTER 4
KEYPAD AND DISPLAY
4.1 Integral Keypad - HMI-CFW11 ....................................................................................................4-1
4.2 Parameters Organization.............................................................................................................4-4
CHAPTER 5
First Time Power-Up and Start-Up
5.1 Prepare for Start-Up....................................................................................................................5-1
5.2 Start-Up.....................................................................................................................................5-2
5.2.1 Password Setting in P0000 .................................................................................................5-2
5.2.2 Oriented Start-up ..............................................................................................................5-3
5.2.3 Setting Basic Application Parameters ...................................................................................5-5
5.3 Setting Date and Time.................................................................................................................5-8
5.4 Blocking Parameters Modification ................................................................................................5-8
5.5 How to Connect a PC .................................................................................................................5-9
5.6 FLASH Memory Module ..............................................................................................................5-9
CHAPTER 6
Troubleshooting and Maintenance
6.1 Operation of the Faults and Alarms..............................................................................................6-1
6.2 Faults, Alarms, and Possible Causes .............................................................................................6-2
6.3 Solutions for the Most Frequent Problems......................................................................................6-6
6.4 Information for Contacting Technical Support................................................................................6-7
6.5 Preventive Maintenance...............................................................................................................6-7
6.5.1 Cleaning Instructions .........................................................................................................6-9
CHAPTER 7
Option Kits and Accessories
7.1 Option Kits ................................................................................................................................7-1
7.1.1 RFI Filter...........................................................................................................................7-1
7.1.2 Safety Stop According to EN 954-1 Category 3 (Pending Certification) ..................................7-1
7.1.3 24 Vdc External Control Power Supply.................................................................................7-3
7.2 Accessories ................................................................................................................................7-4
CHAPTER 8
Technical Specifications
8.1 Power Data ................................................................................................................................8-1
8.2 Electrical / General Specifications................................................................................................8-6
8.2.1 Codes and Standards ........................................................................................................8-7
8.3 Mechanical Data........................................................................................................................8-8
8.4 Conduit Kit ..............................................................................................................................8-12

Safety Instructions
1-1
1
SAFETY INSTRUCTIONS
This manual provides information for the proper installation and
operation of the CFW-11 frequency inverter.
Only trained and qualified personnel should attempt to install,
start-up, and troubleshoot this type of equipment.
1.1 SAFETY WARNINGS IN THE MANUAL
The following safety warnings are used in this manual:
DANGER!
Failure to follow the recommended procedures listed in this warning may result in death, serious
injury, and equipment damage.
ATTENTION!
Failure to follow the recommended procedures listed in this warning may result in equipment
damage.
NOTE!
This warning provides important information for the proper understanding and operation of the
equipment.
1.2 SAFETY WARNINGS IN THE PRODUCT
The following symbols are attached to the product and require special attention:
Indicates a high voltage warning.
Electrostatic discharge sensitive components.
Do not touch them.
Indicates that a ground (PE) must be connected securely.
Indicates that the cable shield must be grounded.
Indicates a hot surface warning.

Safety Instructions
1-2
1
1.3 PRELIMINARY RECOMMENDATIONS
DANGER!
Only trained personnel, with proper qualifications, and familiar with the CFW-11 and associated
machinery shall plan and implent the installation, starting, operation, and maintenance of this
equipment.
The personnel shall follow all the safety instructions described in this manual and/or defined by the
local regulations.
Failure to comply with the safety instructions may result in death, serious injury, and equipment
damage.
NOTE!
For the purpose of this manual, qualified personnel are those trained and able to:
1. Install, ground, power-up, and operate the CFW-11 according to this manual and to the current
legal safety procedures;
2. Use the protection equipment according to the established regulations;
3. Provide first aid.
DANGER!
Always disconnect the main power supply before touching any electrical device associated with the
inverter.
Several components may remain charged with high voltage and/or in movement (fans), even after
the AC power supply has been disconnected or turned off.
Wait at least 10 minutes to guarantee the fully discharge of capacitors.
Always connect the equipment frame to the ground protection (PE).
ATTENTION!
The electronic boards contain components sensitive to electrostatic discharges. Do not touch the
components and terminals directly. If needed, touch first the grounded metal frame or wear an
adequate ground strap.
NOTE!
Frequency inverters may cause interference in other electronic devices. Follow the recommendations
listed in Chapter 3 – Installation and Connection, to minimize these effects.
NOTE!
Fully read this manual before installing or operating the inverter.
Do not perform a withstand voltage test on any part of the inverter!
If needed, please, consult WEG.

General Instructions
2-1
2
GENERAL INSTRUCTIONS
2.1 ABOUT THE MANUAL
The purpose of this manual is to provide you with the basic
information needed to install, start-up in the V/f control mode
(scalar), and troubleshoot the most common problems of the
CFW-11 frequency inverter series.
It is also possible to operate the CFW-11 in the following control modes: V V W, Sensorless Vector and Vector with
Encoder. For further details on the inverter operation with other control modes, refer to the Software Manual.
For information on other functions, accessories, and communication, please refer to the following manuals:
Software Manual, with a detailed description of the parameters and advanced functions of the CFW-11.
Incremental Encoder Interface Module Manual.
I/O Expansion Module Manual.
RS-232/RS-485 Serial Communication Manual.
CANopen Slave Communication Manual.
Anybus-CC Communication Manual.
These manuals are included on the CD supplied with the inverter or can be downloaded from the WEG website
at - www.weg.net.
2.2 TERMS AND DEFINITIONS
Normal Duty Cycle (ND): Inverter duty cycle that defines the maximum continuous operation current (IRAT-ND) and
the overload current (110 % for 1 minute). The ND cycle is selected by setting P0298 (Application) = 0 (Normal
Duty (ND)). This duty cycle shall be used for the operation of motors that are not subjected to high torque loads
(with respect to the motor rated torque) during its operation, starting, acceleration, or deceleration.
IRAT-ND:Inverter rated current for use with the normal duty (ND) cycle.
Overload: 1.1 x IRAT-ND/ 1 minute.
Heavy Duty Cycle (HD): Inverter duty cycle that defines the maximum continuous operation current (IRAT-HD)
and the overload current (150 % for 1 minute). The HD cycle is selected by setting P0298 (Application) = 1
(Heavy Duty (HD)). This duty cycle shall be used for the operation of motors that are subjected to high torque
(with respect to the motor rated torque) during its operation, starting, acceleration, or deceleration.
IRAT-HD:Inverter rated current for use with the heavy duty (HD) cycle.
Overload: 1.5 x IRAT-HD / 1 minute.
Rectifier: Input circuit of inverters that transforms the AC input voltage in DC voltage. It is composed of power
diodes.
Pre-charge Circuit: Charges the DC bus capacitors with limited current, which avoids higher peak currents
at the inverter power-up.

General Instructions
2-2
2
DC Bus: Inverter intermediate circuit; DC voltage obtained from the rectification of the AC input voltage or
from an external power supply; feeds the output inverter bridge with IGBTs.
Power modules U, V, and W: Set of two IGBTs of the inverter output phases U, V, and W.
IGBT: Insulated Gate Bipolar Transistor; basic component of the output inverter bridge. The IGBT works as an
electronic switch in the saturated (closed switch) and cut-off (open switch) modes.
Braking IGBT: Works as a switch to activate the braking resistors. It is controlled by the DC bus voltage
level.
PTC: Resistor which resistance value in ohms increases proportionally to the temperature increase; used as a
temperature sensor in electrical motors.
NTC: Resistor which resistance value in ohms decreases proportionally to the temperature increase; used as a
temperature sensor in power modules.
Keypad: Device that allows controlling the motor, and viewing/editing inverter parameters. It is composed of
motor control keys, navigation keys, and a graphic LCD display.
FLASH memory: Non-volatile memory that can be electronically written and erased.
RAM memory: Random Access Memory (volatile).
USB: Universal Serial Bus; is a serial bus standard that allows devices to be connected using the ”Plug and
Play” concept.
PE: Protective Earth.
RFI Filter: Radio-Frequency Interference Filter for interference reduction in the Radio-Frequency range.
PWM: Pulse Width Modulation; pulsed voltage that feeds the motor.
Switching frequency: Frequency of the IGBTs switching in the inverter bridge, normally expressed in kHz.
General enable: When activated, this function accelerates the motor via acceleration ramp set in the inverter.
When deactivated, this function immediately blocks the PWM pulses. The general enable function may be
controlled through a digital input set to this function or via serial communication.
Start/Stop: When enabled in the inverter (start), this function accelerates the motor via acceleration ramp up
to the speed reference. When disabled (stop), this function decelerates the motor via deceleration ramp up to
the complete motor stop; at this point, the PWM pulses are blocked. The start/stop function may be controlled
through a digital input set for this function or via serial communication. The operator keys and of the
keypad work in a similar way:
=Start, =Stop.
Heatsink: Metal device designed to dissipate the heat generated by the power semiconductors.

General Instructions
2-3
2
Amp, A: Ampères.
°C: celsius degree.
AC: Alternated Current.
DC: Direct Current.
CFM: Cubic Feet per Minute; unit of flow.
hp: Horse Power = 746 Watts (unit of power, used to indicate the mechanical power of electrical motors).
Hz: hertz.
l/s: liters per second.
kg: kilogram = 1000 grams.
kHz: kilohertz = 1000 Hertz.
mA: miliampère = 0.001 Ampère.
min: minute.
ms: millisecond = 0.001 seconds.
Nm: newton meter; unit of torque.
rms: "Root mean square"; effective value.
rpm: revolutions per minute; unit of speed.
s: second.
V: volts.
: ohms.

General Instructions
2-4
2
2.3 ABOUT THE CFW-11
The CFW-11 frequency inverter is a high performance product designed for speed and torque control of three-
phase induction motors. The main characteristic of this product is the “Vectrue” technology, which has the
following advantages:
Scalar control (V/f), V V W, or vector control programmable in the same product;
The vector control may be programmed as “sensorless” (which means standard motors without using
encoders) or as “vector control” with the use of an encoder;
The “sensorless” control allows high torque and fast response, even in very low speeds or at the starting;
The “vector with encoder” control allows high speed precision for the whole speed range (even with a
standstill motor);
“Optimal Braking” function for the vector control: allows the controlled braking of the motor, eliminating
the additional braking resistors in some applications;
“Self-Tuning” feature for vector control. It allows the automatic adjustment of the regulators and control
parameters from the identification (also automatic) of the motor parameters and load.
2

General Instructions
2-5
2
Figure 2.1 - Block diagram for the CFW-11
Analog
Inputs
(AI1 and AI2)
FLASH
Memory
Module
Digital
Inputs
(DI1 to DI6)
Control power supply and interfaces
between power and control
USB
PC
POWER
CONTROL
Rectifier
Motor
Inverter
with IGBT
transistors
Mains Power
Supply
c= DC bus connection
= Braking resistor connection
d
Pre-
charge
SuperDrive G2 Software
WLP Software
Capacitor
Bank
RFI Filter
Keypad
CC11
Control
Board with
a 32 bits
"RISC"
CPU
Analog
Outputs
(AO1 and AO2)
Digital Outputs
DO1 (RL1) to
DO3 (RL3)
Keypad (remote)
DC BUS Feedback:
- voltage
- current
PE
PE
COMM 2
(anybus) (Slot 4 )
COMM 1
(Slot 3 - green)
Encoder Interface
(Slot 2 - yellow)
I/O Expansion
(Slot 1 - white)
Accessories
2

General Instructions
2-6
2
A – Mounting supports
(for through the wall mounting)
B – Heatsink
C – Top cover
D – Fan with mounting support
E – COMM 2 module (anybus)
F – Option board / accessory module
G – FLASH memory module
H – Front cover
I – Keypad
Figure 2.2 - Main components of the CFW-11
USB Connector
USB LED
Off: No USB connection
On/Flashing: USB communication is active
STATUS LED
Green: Normal operation with no fault or alarm
Yellow: Alarm condition
Flashing red: Fault condition
Figure 2.3 - LEDs and USB connector
1
2
3

General Instructions
2-7
2
Figure 2.5 - Location of the nameplates
Nameplate affixed to the
side of the heatsink
Nameplate under the keypad
1
2
2.4 IDENTIFICATION LABELS FOR THE CFW-11
There are two nameplates on the CFW-11: one complete nameplate is affixed to the side of the inverter and
a simplified one is located under the keypad. The nameplate under the keypad allows the identification of the
most important characteristics of the inverter even if they are mounted side-by-side.
Figure 2.4 - Nameplates
D1DPHSODWHDIÀ[HGWRWKHVLGHRIWKHLQYHUWHU
E1DPHSODWHORFDWHGXQGHUWKHNH\SDG
WEG part number
Serial number
CFW11 model number
Hardware revision
Manufacturing date (day/month/year)
2
1
O W O W G G WK N
BRCFW110058T4SZ
417107525
#000020
R00
01/06/06
Rated output data (voltage, number of power
phases, rated currents for use with Normal
Duty (ND) and Heavy Duty (HD) cycles,
overload currents for 1 min and 3 s, and
frequency range)
Rated input data (voltage, number of power pha-
ses, rated currents for use with Normal Duty (ND)
and Heavy Duty (HD) cycles, frequency)
PHSODWH DIÀ[HG WR WKH VLGH RI WKH LQY
Maximum surrounding air temperature
Current specifications for use with the
Heavy Duty (HD) cycle
Current specifications for use with the
Normal Duty (ND) cycle
Manufacturing date (day-month-year)
Hardware revision
CFW11 model number
Serial number
WEG part number
Inverter net weight

General Instructions
2-8
2
INVERTER MODEL AVAILABLE OPTION KITS (CAN BE INSTALLED IN THE PRODUCT FROM THE FACTORY)
Refer to chapter 8 for a list of models for the CFW11 series
and for a complete inverter's technical specification Refer to chapter 8 to check option kit availability for each inverter model
Example BR CFW11 0016 T 4 S _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Z
Field description
Market identification (defines the manual language and the factory settings)
WEG CFW-11 frequency inverter series
Rated output current for use with the Normal Duty (ND) cycle
Number of power phases
Power supply voltage
Option kit Enclosure
type
Keypad Braking RFI filter Safety stop 24 Vdc external
power supply for control
Special hardware
Special software
Character that identifies the code end
Available options
2 characters S=single-phase
power supply T=three-phase power supply B=single or three-phase power supply
2=200...240 V 4=380...480 V
S=standard product O=product with option kit
Blank= standard c N1=Nema1 21=IP21
Blank= standardd IC=no keypad (blind cover)
Blank= standard e
Blank= standard FA=class 3 internal RFI filter
Blank=standard (safety stop function is not available) Y=safety stop according to EN-954-1 category 3
Blank=standard (not available) W=24 Vdc external power supply for control
Blank= standard H1=special hardware #1
Blank= standard S1=special software #1
HOW TO CODIFY THE CFW-11 MODEL (SMART CODE)
cStandard for frames A, B, and C: IP21;
Standard for frame D: Nema1 / IP20;
dStandard keypad (HMI-CFW11); eStandard: Braking transistor (IGBT) incorporated in all models of frames A, B, C, and D.

General Instructions
2-9
2
2.5 RECEIVING AND STORAGE
The CFW-11 is packaged and shipped in a cardboard box for models of frames A, B, and C. The bigger frame
models are packaged and shipped in a wood crate.
The same nameplate affixed to the CFW-11 inverter is affixed to the outside of the shipping container.
Follow the instructions below to remove the CFW-11 models above frame C from the package:
1- Put the shipping container over a flat and stable area with the assistance of another two people;
2- Open the wood crate;
3- Remove all the packing material (the cardboard or styrofoam protection) before removing the inverter.
Check the following items once the inverter is delivered:
Verify that the CFW-11 nameplate corresponds to the model number on your purchase order;
Inspect the CFW-11 for external damage during transportation.
Report any damage immediately to the carrier that delivered your CFW-11 inverter.
If CFW-11 is to be stored for some time before use, be sure that it is stored in a clean and dry location that
conforms to the storage temperature specification (between -25 °C and 60 °C (-13 °F and 140 °F)). Cover the
inverter to prevent dust accumulation inside it.
ATTENTION!
Capacitor reforming is required if drives are stored for long periods of time without power. Refer to
the procedures in item 6.5 - table 6.3.

General Instructions
2-10
2

Installation and Connection
3-1
3
INSTALLATION AND CONNECTION
This chapter provides information on installing and wiring the CFW-11.
The instructions and guidelines listed in this manual shall be followed
to guarantee personnel and equipment safety, as well as the proper
operation of the inverter.
3.1 MECHANICAL INSTALLATION
3.1.1 Installation Environment
Avoid installing the inverter in an area with:
Direct exposure to sunlight, rain, high humidity, or sea-air;
Inflammable or corrosive gases or liquids;
Excessive vibration;
Dust, metallic particles, and oil mist.
Environment conditions for the operation of the inverter:
Temperature: -10 ºC to 50 ºC (14 °F to 122 °F) – standard conditions (surrounding the inverter).
From 50 ºC to 60 ºC (122 °F to 140 °F) - 2 % of current derating for each Celsius degree above 50 ºC (122 °F).
Humidity: from 5 % to 90 % non-condensing.
Altitude: up to 1000 m (3,300 ft) - standard conditions (no derating required).
From 1000 m to 4000 m (3,300 ft to 13,200 ft) - 1 % of current derating for each 100 m (330 ft) above
1000 m (3,300 ft) altitude.
Pollution degree: 2 (according to EN50178 and UL508C) with non-conductive pollution. Condensation shall
not originate conduction through the accumulated residues.
3.1.2 Mounting Considerations
Consult the inverter weight at the table 8.1.
Mount the inverter in the upright position on a flat and vertical surface.
External dimensions and fixing holes position according to the figure 3.1. Refer to the section 8.3 for more
details.
First mark the mounting points and drill the mouting holes. Then, position the inverter and firmly tighten the screws
in all four corners to secure the inverter.
Minimum mounting clearances requirements for proper cooling air circulation are specified in figures 3.2 and 3.3.
Inverters of frames A, B, and C can be arranged side-by-side with no clearance required between them. In this
case, the top cover must be removed as shown in figure 3.3 (b).
Do not install heat sensitive components right above the inverter.
ATTENTION!
When arranging two or more inverters vertically, respect the minimum clearance A + B (figure 3.2) and
provide an air deflecting plate so that the heat rising up from the bottom inverter does not affect the
top inverter.

Installation and Connection
3-2
3
ATTENTION!
Provide conduit for physical separation of the signal, control, and power conductors (refer to item
3.2 - Electrical Installation).
Figure 3.1 - Mechanical installation details
D6XUIDFH0RXQWLQJ E)ODQJH0RXQWLQJ
Max. 3 mm
(0.12 in)
Air flow Air flow
Tolerances for dimensions d3 and e3: +1.0 mm (+0.039 in)
Tolerances for remaining dimensions: ±1.0 mm (±0.039 in)
(*) Recommended torque for the inverter mounting (valid for c2 and c3)
Model
A1 B1 C1 D1 E1 a2 b2 c2 a3 b3 c3 d3 e3 Torque (*)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in) Mmm (in)
mm
(in) Mmm (in)
mm
(in)
N.m
(lbf.in)
Frame A 145
(5.71)
247
(9.73)
227
(8.94)
70
(2.75)
270
(10.61)
115
(4.53)
250
(9.85) M5 130 (5.12)
240
(9.45) M5 135 (5.32)
225
(8.86)
5.0
(44.2)
Frame B 190
(7.46)
293
(11.53)
227
(8.94)
71
(2.78)
316
(12.43)
150
(5.91)
300
(11.82) M5 175 (6.89)
285
(11.23) M5 179 (7.05)
271
(10.65)
5.0
(44.2)
Frame C 220
(8.67)
378
(14.88)
293
(11.52)
136
(5.36)
405
(15.95)
150
(5.91)
375
(14.77) M6 195
(7.68)
365
(14.38) M6 205 (8.08)
345
(13.59)
8.5
(75.2)
Frame D 300
(11.81)
504
(19.84)
305
(12.00)
135
(5.32)
550
(21.63)
200
(7.88)
525
(20.67) M8 275 (10.83)
517
(20.36) M8 285 (11.23)
485
(19.10)
20.0
(177.0)

Installation and Connection
3-3
3
Figure 3.3 - Minimum side clearance requirements for inverter ventilation
D0LQLPXPVLGHFOHDUDQFHUHTXLUHPHQWV
Figure 3.2 - Minimum top, bottom, and front clearance requirements for air circulation
Tolerance: ±1.0 mm (±0.039 in)
Model
ABC
mm
(in)
mm
(in)
mm
(in)
Frame A 25
(0.98)
25
(0.98)
10
(0.39)
Frame B 40
(1.57)
45
(1.77)
10
(0.39)
Frame C 110
(4.33)
130
(5.12)
10
(0.39)
Frame D 110
(4.33)
130
(5.12)
10
(0.39)
E)UDPHV$%DQG&VLGHE\VLGHPRXQWLQJ1RFOHDUDQFHUHTXLUHGEHWZHHQLQYHUWHUVLIWRSFRYHULVUHPRYHG
* Dimensions in mm [in]