ZIEHL-ABEGG ZETADYN 2 Manual

R-TIA18_02-D-GB 2106 Part.-No. 00163466-D-GB
Retrofit kit
ZETADYN 2 -
ZAdyn4C
Technical Information
Store for future use!

Content
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Application areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Dimensions/minimum clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Ensuring the parameter values of the ZETADYN 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 Replacement of the ZETADYN 2 with the ZAdyn4C . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.3 Assembly on the ZAdyn4C 011-032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.4 Assembly on the ZAdyn4C 040-074 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 Connection of connecting leads running from the retrofit kit on the ZAdyn4C . . . . . . . 11
6.2.1 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2.2 Strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Connection of connecting leads on the retrofit kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3.1 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3.2 Replacement of the connector on the X-K connecting lead . . . . . . . . . . . . . . . . . . 13
6.3.3 Strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4 Connection of connecting leads on the ZAdyn4C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4.1 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4.1.1 Replacement of ZETADYN 2 which has a circuit board produced after March
2001 with the ZAdyn4C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4.1.2 Replacement of ZETADYN 2CF which has a circuit board produced before
March 2001 with the ZAdyn4C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4.2 Replacement of the connector on the X-O connecting lead . . . . . . . . . . . . . . . . . . 19
7 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8 Configuring the ZAdyn4C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.2 Part no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.3 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.4 EU declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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1 Safety instructions
This technical information sheet contains additional information on the ZAdyn4C operating
instructions (R-TBA12_01). Observe the ZAdyn4C operating instructions.
Information
•If the ZETADYN 2 is operated with an EVAC 1C, the EVAC 1C must be replaced with an EVAC 3C.
The EVAC 3C must be connected to the ZAdyn4C as described in the EVAC 3C operating
instructions.
•If the ZETADYN 2 is operated with another evacuation solution, it must be checked whether the
evacuation solution is compatible with the ZAdyn4C.
Danger!
It is forbidden to carry out work on electrically live parts.
In frequency inverters of the ZETADYN type, the intermediate circuit (terminals ZK+ / ZK- or +DC / -
DC) are still under voltage even after switching off.
You must wait at least three minutes.
Danger!
It is not permitted to operate the frequency inverter with the housing covers removed, as exposed live
parts are present inside the device. Failure to observe this provision can lead to serious injury.
Work on electric components may only be carried out by trained electricians or by persons instructed
in electricity under the supervision of an electrician in accordance with electrical engineering regula-
tions.
A second person must always be present when working on energized parts or lines who disconnects
in case of emergency.
Electrical equipment must be checked regularly: Loose connections are to be re-tightened and
damaged lines or cables must be replaced immediately. The switch cabinet and all electrical supply
units must be kept locked at all times. Access is only allowed to authorised persons with a key or
special tool.
2 Product overview
2.1 Application areas
•The retrofit kit is an adapter set that enables easy replacement of the ZETADYN 2 with the
ZAdyn4C. The “X-I”, “X-K”, “encoder output” and “brake monitoring” connecting leads for the
ZETADYN 2 do not have to be rewired.
•The retrofit kit is designed exclusively for installation on the ZAdyn4C.
2.2 Functional description
•Connection of connecting leads that are connected to the ZETADYN 2 to the ZAdyn4C.
•Activation of the ZAdyn4C STO inputs. The relays for controlling the STO function are integrated
into the retrofit kit.
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3 Dimensions/minimum clearances
Retrofit kit dimensions
4 Ensuring the parameter values of the ZETADYN 2
"Note the parameter values of the ZETADYN 2 in the parameter list alongside the parameter names.
"Set the parameter values on the ZAdyn4C after carrying out the mechanical and electrical installa-
tion work.
Parameter list
Some parameter functions have different names in ZAdyn4C to those in ZETADYN 2 - see table
below.
ZETADYN 2 / Interface menu ZAdyn4C / Control system menu
V_ZE1 08:V4
V_ZE2 09:V5
V_ZE3 10:V6
Speed 0 17: v 0
OFF 00:Free
The related parameters are next to each other.
ZETADYN 2 ZAdyn4C
Menu Installation & Motor Value "Motor name plate" menu
M&E (Motor Typ) MOT_TYP
n_NENN (rpm) n
f_NENN (Hz) f
I_NENN (A) I
U_NENN (V) U
P_NENN (kW) P
cos phi cos phi
TYP TYP
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ZETADYN 2 ZAdyn4C
Menu Installation & Motor Value Encoder & BC menu
M&E (Encoder Type) ENC_TYP
ZETADYN 2 ZAdyn4C
Menu INTERFACES Value Encoder & BC menu
GEBER ENC_INC
enter the existing brake chopper or
brake resistor type
BC_TYP
ZETADYN 2 ZAdyn4C
Menu INTERFACES Value Control system menu
Set CONFIG to "00:Free"
CTRL CTRL
01:RF f_I01
04:V1 f_I02
05:V2 f_I03
06:V3 f_I04
07:VZ f_I05
02:RV1-UP f_I06
03:RV2-DOWN f_I07
ZE1 f_I08
ZE3 f_XBR2
ZE2 f_XBR3
ST f_O1
MB_Brake f_O2
SK_1 f_O3
SK_2 f_O4
SK_3 f_O5
V_G1 V_G1
V_G2 V_G2
V_G3 V_G3
Automatic evacuation
In automatic evacuation one of the special inputs ZE1, ZE2 or ZE3 is occupied by the evacuation type
in ZETADYN 2:
•EVA. 3*AC
•EVA.>60VDC
•EVA. 1*AC
•UPS
The digital input used for this function in ZAdyn4C must be configured to the function "12:PARA2".
ZETADYN 2 ZAdyn4C
Menu INTERFACES Control system menu
ZE1 or f_I08 or
12:PARA2
ZE2 or f_XBR2 or
ZE3 f_XBR3
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The evacuation type is set in the menu Parameter set 2.
ZAdyn4C
2nd parameter set
F_PAR2 enter the evacuation type
set at the input ZE1, ZE2
or ZE3 of the ZETADYN 2
ZETADYN 2 ZAdyn4C
Menu INTERFACES Value Monitoring menu
ST MOD_ST
ZETADYN 2 ZAdyn4C
Travelling menu Value Travelling menu
V_ZE1 (m/s) V_4
V_ZE2 (m/s) V_5
V_ZE3 (m/s) V_6
ZETADYN 2 ZAdyn4C
Menu Controller Value Controller menu
K_no leave at default value of the ZA-
dyn4C
SPD_KP
5 Mechanical installation
5.1 General notes
Danger!
It is forbidden to carry out work on electrically live parts.
In frequency inverters of the ZETADYN type, the intermediate circuit (terminals +DC / -DC) is still live
even after switching off.
You must wait at least three minutes.
5.2 Replacement of the ZETADYN 2 with the ZAdyn4C
"Remove all lines connected to the ZETADYN 2.
"Remove ZETADYN 2.
"Install ZAdyn4C. Observe the installation conditions described in the operating instructions!
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5.3 Assembly on the ZAdyn4C 011-032
"Push the mounting plate (2) into the top groove (1) of the ZAdyn4C.
"Screw the M5 x 10 to M5 x 15 screws with washers two turns into the mounting plate.
"Fit the fastening plate in such a way that the M5 screws grips the recesses (3) in the fastening
plate. The chamfer (5) on the fastening plate must be on the right-hand side.
"At the same time, hook in the hooks (2) on the fastening plate into the middle groove on the
ZAdyn4C. In doing so, take care that the washers are located between the screw head and the
fastening plate.
1
2
3
4
5
fastening plate
"Press the fastening plate down so that the M5 screws and the hooks snap in.
"Tighten the M5 screws.
"Hook the with the openings at the side (7) into the top hooks on the fastening plate (6). Press the
down carefully until it is touching.
6
7
"Remove the retrofit kit cover.
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"Tighten M4 screw (8) .
8
"Mount the retrofit kit cover.
5.4 Assembly on the ZAdyn4C 040-074
"Insert the hook (1) of the fastening plate in the openings (2) on the right side of the ZAdyn4C.
Ensure here that the chamfer (3) of the fastening plate is on the right side. The press-in nut (4) of
the fastening plate grips the elongated hole (5) in the side of the ZAdyn4C.
1
4
3
fastening plate
2
5
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"Screw on the fastening plate with the screw M4 (6).
6
"Hook the with the openings at the side (8) into the top hooks on the fastening plate (7). Press the
down carefully until it is touching.
7
8
"Remove the retrofit kit cover.
"Tighten M4 screw (9) .
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9
"Mount the retrofit kit cover.
6 Electrical installation
6.1 General
Danger!
It is forbidden to carry out work on the frequency inverter when it is live.
Even after disconnection, the DC-link ( terminals X2: +DC / X2:-DC ) is still live.
Wait at least 3 minutes before working on the device
Danger!
Operating the ZAdyn4C with the housing covers removed is not permitted, as there are exposed
energized parts inside the frequency inverter. Failure to observe this provision can lead to serious
personal injury.
Attention!
Parts can be destroyed by electrostatic discharge.
Discharge yourself by suitable action before working on electrical components (connectors, etc.). You can do this,
for example, by touching earthed metal parts.
Work on electric components may only be carried out by trained electricians or by persons instructed
in electricity under the supervision of an electrician in accordance with electrical engineering regula-
tions.
A second person must always be present when working on energized parts or lines who disconnects
in case of emergency.
Electrical equipment must be checked regularly: Loose connections are to be re-tightened and
damaged cables must be replaced immediately.
Always keep switch cabinets and all electrical supply facilities locked. Access is only allowed for
authorized persons using a key or special tool.
Never clean electrical equipment with water or similar liquids.
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6.2 Connection of connecting leads running from the retrofit kit on the ZAdyn4C
6.2.1 Connection
•The connecting leads running from the retrofit kit are connected to the ZAdyn4C.
•The connecting leads are labelled.
Lead Connection terminal on
ZAdyn4C
X-IN X-IN
X-MON X-MON, PINs 9-13
X-ENCO, X-EXT X-ENCO, X-EXT
X-STO X-STO
5
4
3
2
1
Connecting leads on ZAdyn4C 011-032
1 X-STO
2 X-EXT
3 X-ENCO
4 X-MON
5 X-IN
6.2.2 Strain relief
Cable ties must be attached to all connecting leads for strain relief. Attach the cable ties to the
recesses provided on the housing of the ZAdyn4C.
The shielding of the X-STO and X-IN connecting leads must be connected to earth potential on the
inverter side. Earthing clips are provided on the ZAdyn4C for this purpose.
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6.3 Connection of connecting leads on the retrofit kit
6.3.1 Connection
Lead Connection terminal on
retrofit kit
X-I X-I
X-K X-K
Encoder output X-2
Brake monitoring BR
1
2
3
4
5
Connecting leads on retrofit kit
1 X-I
2 Brake monitoring
3 X-K, Pins 1-4
4 X-K, Pins 5-13
5 Encoder output
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6.3.2 Replacement of the connector on the X-K connecting lead
Before connection to the retrofit kit, the connector on the X-K connecting cable must be replaced.
"Open the socket for the X-K connector by pressing the two tabs (1) on the sides of the socket
outwards with a screwdriver.
"Loosen the screws for the strain relief (2).
1
2
"Remove the X-K connector socket.
"Using a side cutter, remove the cable protection on the X-K connecting lead.
"Connect wires 1-4 and 5-13 to the connectors supplied (3). The wires are numbered and there are
matching numbers on the connectors. If the wire designations are difficult to read, it is useful to
reconnect the wires individually in turn.
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3
6.3.3 Strain relief
Cable ties must be attached to all connecting leads for strain relief. Attach the cable ties at the
recesses provided on the retrofit kit housing (see figure).
The shielding of the X-I connecting lead must be connected to earth potential on the retrofit kit. An
earthing clip is provided for this purpose (see figure).
7
6
7
7
Connecting leads with strain relief on retrofit kit
6 Earthing clip
7 Cable tie for strain relief
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6.4 Connection of connecting leads on the ZAdyn4C
6.4.1 Connection
Lead Connection terminal on
ZAdyn4C
Power line X1
ENCODER X-ENC8 or X-ENC15
motor X3
Motor temperature monitor-
ing
X-MT
DCP X-DCP
X-O X-OUT
Brake chopper/brake resis-
tor
X2
Temperature monitoring
brake chopper/brake resis-
tor
X-MON
6.4.1.1 Replacement of ZETADYN 2 which has a circuit board produced after March 2001 with the
ZAdyn4C
This section describes what you have to do if a board from the time after March 2001 is installed in the
ZETADYN 2.
Circuit board of ZETADYN 2CF, produced after March
2001
Circuit board of ZETADYN 2SY, produced after March
2001
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"Reconnect the leads from the ZETADYN 2 to the ZAdyn4C as described in the following table.
ZETADYN 2
ZAdyn4C
Pin Mains connection (X1) Pin Mains connection (X1)
L1 L1 -> L1 L1
L2 L2 -> L2 L2
L3 L3 -> L3 L3
Motor connection (X3) Motor connection (X3)
U U -> U U
V V -> V V
W W -> W W
Temperature monitoring of the
motor (X-MT)
Temperature monitoring of the
motor (X-MT)
P1 P1 -> 1 P1
P2 P2 -> 2 P2
Brake chopper (X2) Brake chopper (X2)
ZK+ ZK+ -> +DC +DC
ZK- ZK- -> -DC -DC
Brake resistor (X2) Brake resistor (X2)
ZK+ ZK+ -> +DC +DC
R R -> R R
Temperature monitoring brake
chopper/brake resistor
Temperature monitoring brake
chopper/brake resistor (X-MON)
+24V +24V -> 5 +24V
BC BC -> 6 BC
Encoder connection asynchronous
motors (SUB-D 9-pole)
Encoder connection asynchronous
motors (X-ENC15)
9-pin SUB-D female connector -> 15-pin SUB-D female connector (with
SUB-D adapter for converting 9-pin to
15-pin, art. no.: L-GL-004-HX-ZA-
ASM-9-15) *
Alternatively, the wires of the line of the 9-pin SUB-D male connector can be individually connected to the
impulse encoder connection of the asynchronous motors (X-ENC8).
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ZETADYN 2 ZAdyn4C
Encoder connection asynchronous
motors
Encoder connection asynchronous
motors (X-ENC8)
Track A -> 8 A
Track B -> 6 B
N.C. -> N.C.
Vcc (+ 5 V) -> 4 +5/8V_E
GND -> 3 GND
A/ -> 7 /A
B/ -> 5 /B
N.C. -> N.C.
GND -> N.C.
Shielding
The shielding braid is twisted into a
pigtail.
-> 1
Encoder connection synchronous
motors
Encoder connection synchronous
motors (X-ENC15)
15-pin SUB-D female connector -> 15-pin SUB-D female connector
DCP interface (RS 485) DCP-interface (X-DCP)
1 DATA + (A) -> 1 DCP_A
2 DATA - (B) -> 2 DCP_B
3 GND -> 3 GND_COM
4 PE -> 4
6.4.1.2 Replacement of ZETADYN 2CF which has a circuit board produced before March 2001 with the
ZAdyn4C
This section describes how to proceed when a board dating from before March 2001 is installed in the
ZETADYN 2CF. The board dating from before March 2001 of the ZETADYN 2CF is pictured below.
Circuit board of ZETADYN 2CF, produced before March 2001
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"Reconnect the leads from the ZETADYN 2 to the ZAdyn4C as described in the following table.
ZETADYN 2 ZAdyn4C
Pin Mains connection (X1) Pin Mains connection (X1)
L1 L1 -> L1 L1
L2 L2 -> L2 L2
L3 L3 -> L3 L3
Motor connection (X3) Motor connection (X3)
U U -> U U
V V -> V V
W W -> W W
Brake chopper (X2) Brake chopper (X2)
ZK+ ZK+ -> +DC +DC
ZK- ZK- -> -DC -DC
Temperature monitoring brake
chopper (X-10)
Temperature monitoring brake
chopper (X-MON)
+24V +24V -> 5 +24V
BC BC -> 6 BC
Encoder connection (X-12) Encoder connection (X-ENC8)
1 PE -> 1
2 +24V -> 2 +24V_E
3 GND -> 3 GND
4 +5V -> 4 +5/8V_E
5 /B -> 5 /B
6 B -> 6 B
7 /A -> 7 /A
8 A -> 8 A
PTC thermistor (X-12) Motor temperature monitoring (X-
MT)
P1 P1 -> 1 P1
P2 P2 -> 2 P2
Encoder connection asynchronous
motors (SUB-D 9-pole)
Encoder connection asynchronous
motors (X-ENC15)
9-pin SUB-D female connector -> 15-pin SUB-D female connector (with
SUB-D adapter for converting 9-pin to
15-pin, art. no.: L-GL-004-HX-ZA-
ASM-9-15)
Alternatively, the wires of the line of the 9-pin SUB-D male connector can be individually connected to the
impulse encoder connection of the asynchronous motors (X-ENC8).
Encoder connection asynchronous
motors
Encoder connection asynchronous
motors (X-ENC8)
Track A -> 8 A
Track B -> 6 B
N.C. -> N.C.
Vcc (+ 5 V) -> 4 +5/8V_E
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ZETADYN 2 ZAdyn4C
GND -> 3 GND
A/ -> 7 /A
B/ -> 5 /B
N.C. -> N.C.
GND -> N.C.
Shielding
The shielding braid is twisted into a
pigtail.
-> 1
6.4.2 Replacement of the connector on the X-O connecting lead
•The wires from the X-O lead must be rewired as shown in the following wiring diagram.
•They have to be connected to the connector at the X-OUT terminal on the ZAdyn4C and to the 3-
pin connector supplied.
•Wires 7, 10 and 13 from the X-O connecting lead must be connected to normally closed contacts
on the ZETADYN 2. They cannot be connected to the ZAdyn4C as there are no normally closed
contacts on the ZAdyn4C. They are connected to the 3-pin connector.
•The wires can be connected in any configuration on the 3-pin connector, as it is only used for
insulated storage of the wires that are not used.
•The 3-pin connector should be secured with a cable tie (see figure).
•If the wire designations are difficult to read, it is useful to reconnect the wires individually in turn.
1
Wiring diagram for connection of X-O connecting lead
1 X-O connecting lead
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X-O connecting lead on ZETADYN 2
X-O connecting lead on ZAdyn4C
7 Start-up
7.1 General
For details of commissioning the ZAdyn4C, refer to the “Commissioning” chapter in the ZAdyn4C
operating instructions.
If the absolute value encoder cable length is greater than 5 m, the operating voltage of the absolute
value encoder has to be checked.
Operating voltage Consequence
3.6 - 14 VDC Absolute value encoder can be used.
4.75 - 5.25 VDC Use an absolute value encoder with an operating
voltage of 3.6 - 14 VDC.
8 Configuring the ZAdyn4C
"Parametrise the ZAdyn4C in accordance with the parameter list in the section "Ensuring the
parameter values of the ZETADYN 2".
"Check the following parameter settings:
Menu Parameter Settings
Brake control CONFIG 01:ZA_IO
Monitoring BR Settings according to the number and function of the brake
monitor contacts used (e.g. 1*NC, 2*NC).
Monitoring P1/P2 Settings according to the type of temperature monitoring (e.g.
PTC, TC, KTY).
Technical Information Start-up
R-TIA18_02-D-GB 2106 Part.-No. 00163466-D-GB
20/24