Professional Documents
Culture Documents
C
EN
FR
ES ing
e n g ineer
drive
CDA3000 With rmula b
f o
ank
Engineering
Guide
Inverter drive system
to 90 kW
Before purchase
C
Application Manual
CDA3000 Operation User Manual
Traction and lifting
Manual DRIVEMANAGER and KEYPAD
drives, Rotational drives
With shipment
(depending on supply
pakkage)
D E F1
G1 G2 G3
1 Analysis of task 1
2 Definition of drive 2
DE
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Engineering Guide CDA3000 FR
Project planning
flowchart
STEPS SECTION
Select user
5. and/or communication ➢ See section 4
modules
Select supplementary
6. components such as filters, ➢ See section 5
line choke, etc.
Netz/ Main
m2
yy
ÀÀ
@@
,,
T
R
A D
M R
(4)
S A
C
T
RD
AR
(5)
SM
CA
SMART
CARD
H1 H2 H3
(3)
1
2
ANTRIEBSTECHNIK
3
D-35633 Lahnau
1
start stop
(6)
4
enter return
5
6
Typ:
7
4
8
Netz:
9
6
Ausg.: X4
10
7
11
8
SN.:
12
9
000.000.00000000
10
16
11
17
1
12
18
2
19
16
1
20
17
2
(7)
18
D RIVE
1
19
2
20
M ANAGER !
ACHTUNG
(2)
Kondensatorent-
ladezeit >3 Min.
Betriebsanleitung
beachten!
WARNING
capacitor disscharge
time >3 minutes.
Pay attention to the
operation manual!
ATTENTION X2
temps de decharge
(1) X1
du condensteur
>3 min. observer le
mode dèmploi!
X3
(8)
(9)
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Engineering Guide CDA3000 FR
1 Analysis of task
1.1 Systematic thinking ................................................ 1-2
1.1.1 Inverter system .................................................... 1-2
1.1.2 System environment ............................................ 1-3
1.2 Process analysis ..................................................... 1-4
1.2.1 Example of a process analysis in comparison
with functional analysis ....................................... 1-4
1.3 Characteristic values of machinery .......................1-9
1.3.1 Movement requirement ....................................... 1-9
1.3.2 Moment of inertia .............................................. 1-12
1.3.3 Manipulating range and accuracy ...................... 1-13
1.3.4 Load torque ....................................................... 1-19
2 Drive definition
2.1 Recording of movement task .................................2-2
2.2 Drive definition via normogram ............................. 2-6
2.2.1 Example of solution with four-pole motor ............ 2-7
2.2.2 Example of solution with six-pole motor ............. 2-8
2.3 Drive definition via power rating ............................2-9
2.3.1 Example 1: Traction drive .................................. 2-10
2.3.2 Example 2: Lifting drive ..................................... 2-12
2.4 Drive definition via LUDRIVE PC PROGRAM ...............2-13
2.4.1 Example 1: Trolley drive for gantry crane ........... 2-15
2.4.2 Example 2: Belt turning station for truck engine
distribution ........................................................ 2-20
2.5 Selection of motor ................................................2-24
2.5.1 Characteristic values of standard three-phase
AC motors ......................................................... 2-26
2.5.2 Characteristic values of asynchronous
servomotors ASx ............................................... 2-35
2.5.3 Characteristic values of reluctance motors ........ 2-41
2.5.4 Characteristic values of synchronous motors ..... 2-44
2.5.5 Characteristic values of high-frequency motors . 2-47
7 System installation
7.1 Heat discharge from the switch cabinet ................7-2
7.1.1 Basic terms for calculation ...................................7-2
7.1.2 Effective switch cabinet surface ...........................7-3
7.1.3 Calculation of filter fans .......................................7-4
7.1.4 Calculation of heat exchangers ............................7-5
7.2 Heat transfer by heat conductance ........................7-7
A Formula bank
A.1 Mathematical symbols ........................................... A-2
A.1.1 SI units ................................................................A-2
DE
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Engineering Guide CDA3000 FR
A.1.2 Important units ....................................................A-4
A.2 Drive engineering equations ..................................A-5
A.2.1 Basic physical equations ..................................... A-5
A.2.2 Power ..................................................................A-6
A.2.3 Torques .............................................................A-11
A.2.4 Work ................................................................. A-12
A.2.5 Friction .............................................................. A-14
A.2.6 Effective motor torque/power output ..................A-15
A.2.7 Choice of max. acceleration ...............................A-17
A.2.8 Mass moments of inertia ................................... A-20
A.2.9 V/t diagram ........................................................A-27
A.2.10 Efficiencies, coefficients of friction and density ..A-30
A.2.11 Motor lists ......................................................... A-34
A.3 Protection ..............................................................A-40
A.3.1 Protection to IEC/EN ........................................... A-40
A.3.2 Protection to EEMAC and Nema ......................... A-43
D Index
2
1 Analysis of task
3
1.1 Systematic thinking ................................................1-2
1.1.1 Inverter system ....................................................1-2
1.1.2 System environment ............................................1-3
4
1.2 Process analysis .....................................................1-4
1.2.1 Example of a process analysis in comparison with 5
functional analysis ...............................................1-4
1.3 Characteristic values of machinery .......................1-9
1.3.1 Movement requirement ........................................1-9 6
1.3.2 Moment of inertia ..............................................1-12
1.3.3 Manipulating range and accuracy ......................1-13
1.3.4 Load torque .......................................................1-19
7
Take your time, especially at Please note: The more complex the task, the more important is the analy-
the beginning sis. A “better” analysis can identify impending failures in good time.
A
"Good" "Better"
Complexity Complexity
Analysis
Analysis
Intuition/experience
Intuition/experience
Decision
Time and
cost saving
Decision
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Engineering Guide CDA3000 1-1 FR
1 Analysis of task
1.1 Systematic efore beginning your project planning you should read through this
thinking B section - it will help you identify how to attain the new solutions you
need.
What can we learn from system analysis? The term "system" in this
context means:
Thinking differently ➢ a unified whole, distinct from its surroundings
[leads to]
➢ comprising individual elements
Belief
[in turn resulting in] ➢ between which fixed relationships exist
Acting differently ➢ and which perform specific functions.
The starting point for any system analysis is to record, understand and
order the existing inter-relationships within a system. To this end, the sys-
tem is split down into its subsidiary areas (components) such that all the
individual components are distinct from each other and the relations
between them become visible.
1.1.1 Inverter system An inverter system comprises the following individual components and
modules:
User Motor
module
Comm. Software
module Gearing
modules
Services
1.1.2 System Analysis of the system environment of inverter drives reveals four inter- 2
environment faces which outline that environment:
1. Interface to the processing process
2. Interface to the automation process 3
3. Interface to the surrounding environment and installation conditions
4. Interface to the requirements arising from standards, regulations and
safety concerns
4
Inverter
6
module
User Motor
module
Comm. Software
Gearing
7
module modules
Braking
resistor Line choke
Services
Standards,
A
Automation
process regulations
and safety
This section deals with the interface to the “processing process”. The
other interfaces are dealt with in the subsequent sections of the guide.
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Engineering Guide CDA3000 1-3
1 Analysis of task
The functional analysis is derived from the value analysis. Its main role is
to eliminate dual functions and to cut the cost per function.2
(6)
1. Processing process: Process in the course of which energy, information and/or material is transformed
and conveyed
2. The value analysis method was developed in 1948 by the Purchasing department of General Electric.
Literature: DIN 69910 and VDI 2801.
The drive unit is formed by a regulated DC drive, gearing and the screw
return thrust bearing, which absorbs the forces occurring during convey-
ing and plasticizing. 1
P ML ML = f (n)
P = f (n)
2
ML,
P
3
4
n
7
(4) (5)
(1) (2)
A
M
M
T
1~ (3)
(1) DC controller
(2) DC motor
(3) Tacho
(4) Gearing
(5) Screw return thrust bearing
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Engineering Guide CDA3000 1-5
1 Analysis of task
Functional analysis
In a functional analysis each component which performs a function must
merely be replaced by another one. In this case this means:
• the DC motor is replaced by an AC motor
• the tacho is replaced by a digital encoder and
• the DC controller is replaced by an inverter with field-oriented regula-
tion.
(4) (5)
(1) (2)
~ M
~ 3~
M
1~
(3)
Process analysis
A process analysis establishes what demands the processing process
places on the drive. 1
Questions to be answered:
1. What is the movement requirement for processing?
2. Moment of inertia of the processing machine, referred to the motor
2
shaft?
3. What manipulating range is required for the processing process?
4. What load torque needs to be overcome? 3
7
~ M
~ 3~ A
Figure 1.7 Solution from process analysis
DE
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Engineering Guide CDA3000 1-7
1 Analysis of task
~ M ~ M
~ 3~ ~ 3~
M M
1~ 1~
$
$
NEW 1 NEW 2
Inverter with field-oriented regulation Inverter with VFC
1.3 Characteristic
values of Y
by:
ou do not usually need to take account of the detailed structure of the
machinery for drive project planning. It can be adequately described
1
machinery
1. the movement requirement for processing
2. the moment of inertia of the processing machine, referred to the
motor shaft 2
3. the manipulating range and accuracy of the torque, speed and posi-
tion
4. the characteristic over time of the load torque
3
1.3.1 Movement The movement requirement for processing is roughly divided into three
requirement groups.
Movement requirements
for processing
4
Continuous Discontinuous
5
Continuous material flow Batch processes Unit processes
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Engineering Guide CDA3000 1-9
1 Analysis of task
Processing
material Processing
process Product
ML=f(n,s,j)
Mechanical
function
X(n2(t))
n2
M
Movement solution
Drive function with
frequency inverter
3~
Energy
~ =
Reference ~
Figure 1.9 Movement solution in the processing process
Movement solution 1
x y
t x y(x(t))
2
t x
ϕ 4
S0
S
Figure 1.10 Movement solution split into traction and mechanical function 5
v/t diagram
The processing cycle of a machine or plant is typically described by the
6
velocity/time profile, also termed the v/t diagram. From that diagram the
acceleration/deceleration time and the startup and shutdown frequency
can be determined. This repetition rate of the startup and shutdown
process determines the 7
➢ motor rating 2 2 2
M1 ⋅ t 1 + M 2 ⋅ t 2 + Mn ⋅ t n
Meff = -----------------------------------------------------------------
T A
➢ current load of the 2 2 2
inverter module I1 ⋅ t1 + I2 ⋅ t2 + In ⋅ tn
Ieff = -------------------------------------------------------
-
T
➢ and the braking 2 2 2
chopper design P1 ⋅ t 1 + P 2 ⋅ t2 + Pn ⋅ t n
P eff = -------------------------------------------------------------
T
For more information on the subject of the v/t diagram refer to the formula
bank in See Appendix A.2.9.
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Engineering Guide CDA3000 1-11
1 Analysis of task
1.3.2 Moment of The moment of inertia of a machine or a machining process is kept as low
inertia as possible. However, the room for maneuver in terms of dimensioning is
very low as a result of the pressure for technological optimization.
The moment of inertia of motors is of great significance for the overall
drive design in cases of frequent and rapid changes of speed, while in
rotational drives, such as a sugar centrifuge or a continuous winding
drive, a reduction in the moment of inertia of the motor has little or no
effect on the overall drive design.
For more information on this subject refer to the formula bank in section
A.2.8 and section 2.
1.3.3 Manipulating The desired torque rise time, the speed manipulating range and the posi-
range and tioning accuracy are likewise determined by the technological processing
accuracy
process. 1
In the following some terms are defined more closely, in order to avoid
misunderstandings between you - the customer - and the drive manu-
facturer.
2
Definition of terms Torque rise time
The torque rise time is the time which elapses after a reference step from
0 to MN until the actual value of the torque in the motor has reached 95%
of the nominal value. 3
The torque rise time is dependent on the control methods applied and on
the electrical parameters of the motor used. As the speed increases the
voltage reserve for injection of a current falls, causing the torque rise time 4
to increase.
(1) (2)
5
100%
6
M(t) 95 %
TA t A
TA= Torque rise time
(1) Reference
(2) Actual
Figure 1.11 Torque rise time
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Engineering Guide CDA3000 1-13
1 Analysis of task
MN
fmin fN f (n)
nmin nN
Nf nN
Manipulating range = -------- = ---------
-
f min n min
fN Rated frequency in Hz
fmin Minimum frequency in Hz
nN Nominal speed in rpm
nmin Minimum speed in rpm
2
(3)
(1)
3
n
4
t
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Engineering Guide CDA3000 1-15
1 Analysis of task
(1)
(3)
(2) (1)
(2) (3)
n n
t t
SF = Vmax . tRF 2
Vmax. SF = Positioning error
in mm
3
(4) Vmax = Velocity
in mm/s
5
(1) Scan cycle of control terminals on inverter (tRF=response error)
(2) Destination position 1 (stop signal comes together with read-in
of control signals on inverter)
(3) Destination position 2 (Stop signal comes directly after read-in of 6
control signals on inverter)
(4) Slip range (depending on control mode the braking ramp
is slipdependent)
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Engineering Guide CDA3000 1-17
1 Analysis of task
ua ub uc
ia
Calculation
of flux and
mactual ib
momentum
εRS M
3~
nactual Angle of
rotation
xactual G
and speed
recording Encoder
Figure 1.16 Positioning with reference generator and position control in the
controller
Reference generator
The reference generator generates the characteristic over time of the
reference position.
Position controller
The position controller ensures that the reference position is maintained
as closely as possible.
Speed controller
The speed controller in turn ensures that the reference speed of the
motor is maintained.
− The speed reference can be specified via +10 V to -10 V or via
CAN or PROFIBUS
2
1.3.4 Load torque All machinery counteracts the drive with a specific torque. This torque is
composed of a static torque which is defined by the technological process
and the acceleration or deceleration torque determined by the change of
speed and the inert mass. 3
The static torque is generally termed "load torque", and in most cases
acts opposing the direction of motion. In exceptional cases, such as on
lifting gear during lowering, the load torque also acts in the direction of
motion.
4
n
A
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Engineering Guide CDA3000 1-19
1 Analysis of task
P ML = constant
P ~n
ML
ML,
P
(1)
n
(1) Break-away torque
Figure 1.18 Load characteristic: Lifting gear, conveyor systems, piston com-
pressors, rolling mills
Extruders
P ML ML = f (n)
P = f (n)
ML,
P
2
ML,
P
3
n 4
Figure 1.20 Load characteristic: Blowers, fans, centrifugal pumps
5
Mills
ML = f (n)
(2) 6
(3)
7
ML,
P (1)
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Engineering Guide CDA3000 1-21
1 Analysis of task
ML
ML = f (α)
ML
Mm
Machine tools
ML = f (t)
1
ML 2
t
4
Figure 1.24 Load characteristic: Machine tools
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Engineering Guide CDA3000 1-23
1
2
2 Drive definition
3
2.1 Recording of movement task ................................. 2-1
2.2 Drive definition via normogram ..............................2-6 4
2.2.1 Example of solution with four-pole motor ............2-7
2.2.2 Example of solution with six-pole motor ..............2-8
2.3 Drive definition via power rating ............................2-9 5
2.3.1 Example 1: Traction drive ..................................2-10
2.3.2 Example 2: Lifting drive .....................................2-12
2.4 Drive definition via LUDRIVE PC PROGRAM .............. 2-13 6
2.4.1 Example 1: Trolley drive for gantry crane ...........2-15
2.4.2 Example 2: Belt turning station for
truck engine distribution ....................................2-20 7
2.5 Selection of motor .................................................2-24
2.5.1 Characteristic values of standard three-phase
AC motors ..........................................................2-26 A
2.5.2 Characteristic values of asynchronous
servomotors ASx ............................................... 2-35
2.5.3 Characteristic values of reluctance motors .........2-41
2.5.4 Characteristic values of synchronous motors .....2-44
2.5.5 Characteristic values of high-frequency motors ..2-47
2.6 Selection of gearing ..............................................2-48
2.6.1 Transmission gear .............................................2-48
2.6.2 Characteristic values of standard gears ..............2-49
2.6.3 Characteristic values of planetary gears .............2-49
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Engineering Guide CDA3000 2-1
2 Drive definition
2.1 Recording of his process involves the description of the movement task in the pro-
movement task T cessing process. For information on the basics of this subject
See section 1.
The procedure proposed in the following does not claim to be generally
applicable to all movement tasks. It is merely intended to illustrate a pos-
sible procedure which can be applied with little labor commitment.
Project name::
Recording of movement task
Company: Name/Function:
Industry/Application:
Comments:
You will find the copy template in the appendix under "Practical working
aids for the project engineer".
3
v
[ ]
t[ ]
1
4
T=Period
5
Rotational movement [n=f(t)] Translational movement [v=f(t)]
Comments:
7
A
Author: Date: Sheet ..... of .....
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Engineering Guide CDA3000 2-3
2 Drive definition
Comments:
ML=f(n), P=f(n) MN PN
1,0
ML~n², P~n³
ML=f(n) 0,5
ML=f(s)
ML=f( )
n
ML=f(t) nn
Project name:
Additional environmental data
1
Automation process:
2
System interface
➢ Automate
➢ Environment 3
➢ Standards
You will find the copy template in the appendix under "Practical working
aids for the project engineer".
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Engineering Guide CDA3000 2-5
2 Drive definition
2.2 Drive definition he normogram provides user-friendly graphical power ratings for
via normogram T applications with IEC standard motor. It is primarily used to define the
power outputs of rotational drives such as winders, mills, extruders, cen-
trifuges, mixers, etc. Any break-away torques or load surges occurring
must be calculated separately.
characteristic. 500
600
1000 2000
30
1200
3. Connect the lowest 600 800
2500
40
700 1400
point on the continuous 750
800
1000 1500
1600
3000 50
1. 2.
load characteristic to 900 1200 1800
3500
60
5
based on the perfor- 2
2,5
3 6 20
3 4 6 40
7
5 15 50
4 8
6 9 60
5 10 20
7 70
6 8 25 80
7 9 90
10 15 30 4. 100
8
9
10 20 40
15
25 50
15 20 30 60 200
70
25 5.
20 40 80
30 90 300
25 50 100
30 40 60 400
70
50 150 500
40 80
60 90 600
50 100 200
70 700
60 80 250 800
90 900
70 150 300
100 1000
80
90
100 200 400
150
250
250 400
200
300 3000
250 PN UR [kW]
4000
300
M
[Nm]
Rated power, inverter and motor Load torque
You will find the copy template in the appendix under "Practical working
aids for the project engineer". Continuous load characteristic - See sec-
tion 2.5.1.
four-pole motor
750 rpm
8-pole
1000 rpm
6-pole
1500 rpm
4-pole
200
3000 rpm
2-pole
0,5 0,6 0,7 0,8 0,9 1,0 M
MM UR
1
100 500
200 10 2.
200 400 1.
Requirement: 600
1000
300 400 20
1500 P>
n1 = 150 rpm
n2 = 1500 rpm
400
500
600
800
1000 2000
30
2
600 800 1200 40
2500
M1 = M2 = 150 Nm 700 1400
750 1000 1500 3000 50
800 1600 1. 2.
External ventilation
not permitted.
900
1000
1200 1800
2000
3500
4000
60
3
1400 70 3.
1100 2200
4500
1200 1600 2400 80
5000
1300 2600
1400
1800
2800
5500
90
4
1500 2000 3000 6000 n [rpm] 100 f [Hz]
6 10
2 4
2,5 5
2 3 6 20
2,5
2,5
3
4
5
7
8
9
10
30
5
3 4 6 40
7
5 15 50
4 8
6 9 60
5 10 20
7 70
6
7
8
9
8
9
10 15
25
30
80
90
100
6
10 20 40
15
25 50
15 20 30 60 200
70
25 80
40 4.
7
20
30 90 300
25 50 100
30 40 60 400
70
50 150 500
40 80
60 90 5. 600
50 100 200
70 700
60 80 250 800
90 900
70
A
100 150 300 1000
80
90
100 200 400
150
250
250 400
200
300 3000
250 PN UR [kW]
4000
300
M
[Nm]
Rated power, inverter and motor Load torque
Solution:
The rated power of the motor (four-pole) and the inverter is 50 kW.
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Engineering Guide CDA3000 2-7
2 Drive definition
2,5 5
2 3 6 20
7
2,5 4 8
2
3 9 30
2,5 5 10
3 4 6 40
7
5 15 50
4 8
6 9 60
5 10 20
7 70
6 8 25 80
7 9 90
10 15 30 100
8
9
10 20 40
15
25 50
15 20 30 60 200
70
20
25 40 80 4.
30 90 300
25 50 100
30 40 60 400
70
50 150 500
40 80
60
5. 90 600
50 100 200
70 700
60 80 250 800
90 900
70 150 300
100 1000
80
90
100 200 400
150
250
250 400
200
300 3000
250 PN UR [kW]
4000
300
M
[Nm]
Rated power, inverter and motor Load torque
Solution:
The rated power of the motor (six-pole) and the inverter is 30 kW.
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Engineering Guide CDA3000 2-9
2 Drive definition
s
m ⋅ g ⋅ µ ⋅ v 51, 5kg ⋅ 9, 8m ⁄ s ⋅ 0, 01 ⋅ 1, 5m ⁄ s
P F = -------------------------- = ------------------------------------------------------------------------------------ = 9W
η 0, 88
P Fahr = P a + P F = 273W
2. Select motor
The selected motor must have a power rating higher than PDrive. Select
the motor from the list.
2
J M ⋅ nM 2
, 00073kgm ⋅ 2000 min - = 65W
2 –1
- = 0-----------------------------------------------------------------
P aR = -------------------
91, 2 ⋅ ta 91, 2 ⋅ 0, 5
Abbreviations used
Pa Power to accelerate the load [W]
PaR Power to accelerate the rotor [W] 1
PF Power to overcome the
tractive resistance/friction [W]
PH Power to lift the load [W]
m Total mass [kg] 2
a Acceleration [m/s²]
v Velocity [ms]
µ Tractive resistance/Coefficient of friction
η Efficiency of the drive solution 3
g Acceleration due to gravity [9.8m/s²]
JM Moment of inertia of the selected motor [kgm²]
nM Max. speed of the selected motor [rpm]
ta Acceleration time [s]
4
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Engineering Guide CDA3000 2-11
2 Drive definition
s
m ⋅ g ⋅ µ ⋅ v 2, 5kg ⋅ 9, 8m ⁄ s ⋅ 0, 01 ⋅ 1, 5m ⁄ s
P F = -------------------------- = ---------------------------------------------------------------------------------- = 1W
η 0, 88
s
m ⋅ g ⋅ v 2, 5kg ⋅ 9, 8m ⁄ s ⋅ 1, 5m ⁄ s
P H = ------------------ = ----------------------------------------------------------------- = 42W
η 0, 88
P Lift = P a + P F + P H = 86W
2. Select motor
The selected motor must have a power rating higher than PLift. Select the
motor from the list.
2
J M ⋅ nM 2
, 00056kgm ⋅ 2000 min - = 164W
2 –1
- = 0-----------------------------------------------------------------
P aR = -------------------
91, 2 ⋅ ta 91, 2 ⋅ 0, 15
2.4 Drive definition he LUDRIVE drive calculation program meets the wishes of many
via LUDRIVE T users for quick and easy calculation of the various drive solutions.
The drive program is divided into two sections. 1
PC PROGRAM
The first section contains a formula bank with 38 formulae for calculation
of:
• Moments of inertia of various bodies 2
• Moments of inertia of applications
• v/t diagrams
• Tractive resistances and friction moments 3
• Effective torque loads
• Various drive capacities
• Drive torques
4
With the aid of the second section complete drive units can be configured.
The drive data are entered in a practice-oriented sequence. This second
section supports the design of:
• Horizontal traction drives
5
• Traction drives with rise for upward movement
• Traction drives with rise for downward movement
• Lifting drives without counterweight (lifting)
6
• Lifting drives without counterweight (lowering)
• Indexing tables with ball rim
• Indexing tables with shaft through the center point 7
• Spindle drives
• Rotational drives
After calculating the drive LUDRIVE displays a graph on the PC. The graph A
shows the characteristic of the mean torque, the speed and the moment
over time. Based on this graph, the behavior of the drive solutions in prac-
tical applications can be assessed. Of course, all influencing factors
such as the rotor moment of inertia of the motor, the field weakening
range, the nominal winding point of the motor etc. are analyzed and/or
calculated and translated onto the graph.
In addition to the functions described, the LUDRIVE program also sup-
ports ancillary functions such as Help, Print, Save and Load.
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Engineering Guide CDA3000 2-13
2 Drive definition
Please note that the software LUDRIVE is only available in german lan-
guage.
Network printing
Figure 2.1 The network printer must be assigned to the parallel port LTP1
2.4.1 Example 1: Because of the narrow track width the trolley has a central drive powering
Trolley drive for a running wheel on each side. The running wheels are coupled together
gantry crane
by a shaft. The drive system is a four-pole helical gearbox motor with
brake.
1
4
Figure 2.2 Standard trolley drive with geared motor
5
Known data:
Intrinsic weight of the trolley 5t
Lifting weight 10 t
Running speed 30 m/min. 6
Two wheels are driven
Wheel diameter 315 mm
Journal diameter 80 mm
Friction pairing (rail/wheel)Steel/steel 7
Transmission gear z1=18
z2=34
Efficiency of the drive 80%
Mass moment of inertia of the running wheels A
and the shaft 0.85 kgm²
Acceleration and braking time 1.5 s
Max. factor for starting torque 1.25
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Engineering Guide CDA3000 2-15
2 Drive definition
1.
2. 1
4
Figure 2.4 Tractive/frictional resistance
5
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Engineering Guide CDA3000 2-17
2 Drive definition
3.
Max. motor speed
1440 rpm
3. 1
4
Figure 2.7 Drive capacity
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Engineering Guide CDA3000 2-19
2 Drive definition
2.4.2 Example 2: Belt The indexing table for the belt turning station is designed to distribute the
turning station truck engines across two different conveyor belts. The indexing table is
incremented in steps of 90°.
for truck engine
distribution The rotating upper section is supported by a slewing ring. Slewing rings
permit a highly compact design combined with a low center of gravity
(only one bearing to absorb all forces and moments).
The size of the bearing support means that correspondingly very high
radial and axial forces and moments are absorbed.
(1)
Known data:
Mass of indexing table with slewing ring etc. 130 kg
Indexing table diameter 1600 mm
Mass of truck engine 500 kg
Distance of truck from pivot point 600 mm
Max. cycle time for 90° 1.4 s
Acceleration/deceleration time 0.2 s
Ball rim z1=29
z2=180
Efficiency 90%
Motor nominal speed 1440 rpm
1
Calculate rotational velocity, rotational acceleration
1. and rotational deceleration by means of “v/ t dia-
gram for indexing table” program section.
2
Calculate drive capacity by means of “Drive calcula-
tion / Indexing table with slewing ring” program sec-
2. tion. 3
a. Startup factor 1.25 typical values with
Voltage Frequency Control (VFC)
b. Startup factor 2 typical values with Sensor- 4
less Flux Control (SFC)
5
1.
6
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Engineering Guide CDA3000 2-21
2 Drive definition
2.
25% motor overload
with VFC
3. 1
3
Factor for starting
torque = 2 (2 . MN)
4
Figure 2.13 Calculation
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Engineering Guide CDA3000 2-23
2 Drive definition
2.5 Selection of
motor A wide variety of three-phase AC motors can be run on the CDA3000
inverter system. Three-phase AC motors are manufactured in syn-
chronous and asynchronous design versions. The stator winding is desi-
gned such that, when in service in a three-phase AC system, a rotating
field is created in the motor which drives the rotor. The rotation speed is
determined by the following variables:
ns = synchronous speed
⋅ 60
n s = f----------- P = number of pole pairs
P
f = stator frequency
The motor type is determined by the rotor introduced into the rotating
field.
3-phase AC motor
Motor type
Working
principle
Application 1
In all industrial sectors. Around 10-15% of all
Standard three-phase
asynchronous motors are speed-adjustable by way of inver-
AC motor
ters. 2
In the textile industry for: Spoolers, viscose
pumps, galette drives, roller drives etc.
Synchronous motor synchronous
Further areas of application are in the glass
and paper industry as winding drives, etc. 3
In the textile industry for: Spoolers, viscose
pumps, galette or roller motors, etc.
asynchronous/
Reluctance motor Further areas of application are in drafting
synchronous
equipment and for synchronous running of two 4
axles.
In the timber processing industry as the main
drive. Further areas of application are grinding
High-frequency motor asynchronous
and milling spindles, centrifuges, vacuum 5
pumps and winders.
In the packaging and food industries as a clock
Asynchronous
asynchronous and positioning drive. Further applications as
servomotor
the main drive for machine tools.
6
Displacement-type asynchronous In conveyor systems as a traction and lifting
armature motor with motor brake motor.
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Engineering Guide CDA3000 2-25
2 Drive definition
1.6 0.8
1.2 0.6
0.8 0.4
0.4 0.2
0 0
0 0.2 0.4 0.6 0.8 1.0
Operating characteristic
1.0
0.8
0.6
0.4
0.2
Power factor
1.00
1500 rpm
1
0.75
2
0.50
0.25
3
0
0 0.25 0.50 0.75 1,00 1.25 4
P/PN Loading on the shaft
Figure 2.17 Power factor cos ϕ of a four-pole standard three-phase AC
motor
5
Limit speed
6
rpm 7
nmax
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Engineering Guide CDA3000 2-27
2 Drive definition
Property Tolerance
PN ≤ 50 kW - 0.15 (1- η)
Efficiency [ η ]
PN > 50 kW - 0.1 (1- η)
– cos ϕ-
– 1--------------------
Power factor [ ϕ ] 6
min. 0.02; max. 0.07
Slip [ s ] ± 20%
Break-away starting current [ lA ] + 20%
Break-away torque [ MA ] -15% to +20%
Breakdown torque [ MK ] -10%
Noise [ LA ] +3 dB(A)
Notes:
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Engineering Guide CDA3000 2-29
2 Drive definition
Φ-
Flux [Φ]
1
------ 1 fN/f
ΦN fN/f
M-
------ 1 fN/f
Torque [M] 1 (fG/f) ²
MN
0
Breakdown torque Mk 1
--------
- 1 (fN/f) ²
[Mk] MkN (fN/f) ²
0
Mechanical P 1
----2- 1 f/fN fG/f
output [P2] PN
0
s-
----
Slip [s] 1 fG/f
sN 1 fN/f
0
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Engineering Guide CDA3000 2-31
2 Drive definition
(4)
1.5
(3) (2)
1.0
M P>
MN (2)
(2) (1)
0.5
0.1
10 50 100 120
f [ Hz]
speed in 100 ms
1000
4
500 5
0
250 W 370 W 550 W 750 W 1.1 kW 1.5 kW 2.2 kW
(1) 186 345 449 669 928 1350 1800
6
(2) 138 180 316 407 580 772 780
(3) 132 248 307 406 548 1100 1970
7
(1) 1 pole pair
(2) 2 pole pairs
(3) 3 pole pairs
A
Figure 2.20 Acceleration behavior as a function of of number of pole pairs of
standard three-phase AC motor
Motors with one pole pair are unsuitable for dynamic drive tasks.
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Engineering Guide CDA3000 2-33
2 Drive definition
2.5.2 Characteristic
values of asyn- Mmax (A)
chronous servo- M
5 1
motors ASx MN
(1)
4
2
1
3
M~
n
Without incremental
encoder 2
(2)
3
M0
MN
(3)
4
1 2 3 4 n
With incremental nN nN
encoder
5
(1) Pulse mode (2) Intermittent (3) Continuous
Figure 2.21 M-n characteristic for asynchronous motors
6
Abbreviations used
Term Explanation 7
M0 Standstill torque Thermal limit torque of the motor at standstill. The motor can
deliver this torque for an unlimited length of time.
I0 Standstill current Effective value of the motor phase current required to generate
the standstill torque.
A
MN Nominal torque Thermal limit torque of the motor at nominal speed nN.
IN Rated current Effective value of the motor phase current required to generate
the nominal torque.
PN Rated power Full-load power of the motor at the nominal working point (MN,
nN) at rated current IN and rated voltage UN.
Mmax, Imax Limit curve A maximum of five times the rated current may be applied to
the motors.
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Engineering Guide CDA3000 2-35
2 Drive definition
Asynchronous servomotors
Property
ASx
Machine type Asynchronous servomotor
Design (DIN 42948) IM B35, IM B5, BV1, V3
Protection (DIN 40050) IP65, shaft seal IP64 (option IP65)
Insulating material Insulating material class F to VDE0530 winding overtemperature
class ∆τ = 105, coolant temperature tu=+40°C
Self cooling (IC 0041) IP65
Cooling
forced cooling (IC 0641) IP44,54
Coating RAL 9005 (black)
Shaft end on the A (D) Cylindrical shaft end DIN 748, featherkey
side and featherkey way DIN 6885, tolerance band k6
Flange dimension DIN 42948 and IEC 72
Smooth running,
Tolerance N (normal)
coaxiality and concen-
R (reduced) on request
tricity to DIN 42955
Vibration severity to ISO
Stage N, optionally R
2373
Therm. motor
PTC thermistor in stator winding
monitoring
To prevent thermal overloading of the motors, the effective
load torque must not be greater than the nominal torque of the
servomotor.
Torque load
2
ΣM n × t n
Meff = ----------------------- M eff ≤ M N
A B C D E F G H 2
e
e
tem
e
ed
or
iqu
ak
t
typ
Ho rian
gt
ot
pe
r
len
ys
hn
b
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va
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rs
ng
tec
rvo
e,
oli
ina
3
ge
de
ldi
Siz
Se
co
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m
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co
tio
No
us
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En
Vo
ina
sig
no
rm
ro
De
ch
Te
yn
As
4
AS
5
ASM - 23 - 20003 - 0
No encoder connection 6
Nominal speed 3000 rpm
Without encoder
Without holding brake 7
Voltage variant 330V
Size 2, length 3
Flange, self cooling A
Asynchronous servomotor
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Engineering Guide CDA3000 2-37
2 Drive definition
M0 MN PN I0 IN nN JL m nmax
Self cooling
[Nm] [Nm] [kW] [A] [A] [rpm] [kgcm²] [kg] [rpm]
ASM (H)-11 -2xxx3 1.5 1.3 0.41 1.6 1.4 3000 2.8 6.5 12000
ASM (H)-12 -2xxx3 2 1.7 0.54 2.1 1.8 3000 3.7 7.5 12000
ASM (H)-13 -2xxx3 2.7 2.3 0.72 2.74 2.3 3000 4.7 8.5 12000
ASM (H)-14 -2xxx3 4.2 3.5 1.1 4 3.3 3000 6.5 10.2 12000
ASM (H)-15 -2xxx3 5.2 4.7 1.5 5.4 4.5 3000 8.9 12.8 12000
ASM (H)-21 -2xxx3 4.2 3.5 1.1 3.6 3 3000 10.9 10.8 12000
ASM (H)-22 -2xxx3 5.6 4.7 1.5 4.7 3.9 3000 14.4 13.2 12000
ASM (H)-23 -2xxx3 8.4 7 2.2 6.7 5.6 3000 21.5 16.2 10000
ASM (H)-24 -2xxx2 12 10 2.1 6.4 5.3 2000 29.8 20.3 10000
ASM (H)-25 -2xxx2 15 13 2.7 7.7 6.6 2000 38.4 24 8000
ASM (H)-31 -2xxx1 15.5 13 2.1 6.2 5.2 1500 70 29.8 8000
ASM (H)-32 -2xxx1 20 17 2.7 8.2 6.8 1500 90 33 8000
ASM (H)-33 -2xxx1 27.5 23 3.6 10.3 8.7 1500 130 41.5 8000
ASM (H)-34 -2xxx1 42 35 5.5 15.1 12.6 1500 209 56.6 8000
ASH-41-2xxx1 47 40 6.3 21 17.9 1500 450 87 8000
ASH-42-2xxx1 70 60 9.4 30 25.5 1500 740 113 8000
ASH-43-2xxx1 85 70 11 37 30.4 1500 960 135 8000
Abbreviations used
Term Explanation
M0 Standstill torque Thermal limit torque of the motor at standstill. The motor can
deliver this torque for an unlimited length of time.
I0 Standstill current Effective value of the motor phase current required to generate
the standstill torque.
MN Nominal torque Thermal limit torque of the motor at nominal speed nN.
IN Rated current Effective value of the motor phase current required to generate
the nominal torque.
PN Rated power Full-load power of the motor at the nominal working point
(MN, nN) at rated current IN and rated voltage UN.
Mmax, Imax Limit curve A maximum of five times the rated current may be applied to
the motors.
Abbreviations used A
Term Explanation
M0 Standstill torque Thermal limit torque of the motor at standstill. The motor can
deliver this torque for an unlimited length of time.
I0 Standstill current Effective value of the motor phase current required to generate
the standstill torque.
MN Nominal torque Thermal limit torque of the motor at nominal speed nN.
IN Rated current Effective value of the motor phase current required to generate
the nominal torque.
PN Rated power Full-load power of the motor at the nominal working point
(MN, nN) at rated current IN and rated voltage UN.
Mmax, Imax Limit curve A maximum of five times the rated current may be applied to
the motors.
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Engineering Guide CDA3000 2-39
2 Drive definition
M
3
2
Mksy
MN
2
(2)
1
(1)
0.2 0.4 0.6 0.8 1 4
n/nN
5
(1) Pull-in to synchronism Msy ≈ 1, 2 ⋅ M N
M K ≈ 3, 5 ⋅ M N
7
Figure 2.22 Typical torque characteristic of a reluctance motor in mains
operation
A
Note: The motor may only be run to accelerate in asynchronous
mode. If asynchronous mode is run for longer the motor will
be destroyed.
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Engineering Guide CDA3000 2-41
2 Drive definition
N N
X X
S
I1 I1
I2
I2
The stator field Φ1 with the field system of As the load on the shaft increases, the rotor
the rotor Φ2 represents a fixed magnetic displacement angle/load angle increases
adhesion. steadily. The speed remains synchronous.
X Direction of rotation
β Load angle
1 20° 45°
MN
2 10° 22.5°
4 5° 11,25°
Table 2.12 Project planning notes for drive system with reluctance motors
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Engineering Guide CDA3000 2-43
2 Drive definition
Mksy
M
2
M
N
n/nN
2.5
2 Mksy
M Msy
MN 1.5
1
(2)
(1)
n/nN
Typical startup characteristic of a permanent magnet excited synchronous motor with cage winding for asynchronous self-running
N
X
N
X 2
S
S
3
I1 I1
I2
I2 4
The stator field Φ1 with the field system of As the load on the shaft increases, the rotor 5
the rotor Φ2 represents a fixed magnetic displacement angle/load angle increases
adhesion. steadily. The speed remains synchronous.
X Direction of rotation
β Load angle 6
Table 2.13 Torque as a function of rotor displacement angle β
(load angle)
7
Mksy M
A
Motor
-22.5˚ -45˚
45˚ 22.5˚
Generator
Mksy
Motor design For precise data refer to the manufacturer’s data specification booklet
Tips:
• Synchronous motors with cage winding can be run on the mains
and on the inverter.
• The synchronous breakdown torque Mksy is approx. 1.35 x MN.
If a higher breakdown torque is required (e.g. 1.6 times), a hig-
her-powered motor must be chosen.
• The external moment of inertia specified by the manufacturer
must not be exceeded, otherwise the motor will not be able to
generate the acceleration torque required for synchronization.
• At low frequencies the no-load current may be higher than the
load current.
• Motor protection only possible via PTC
• High tendency to vibrate
Inverter design In static operation with manipulating range < 1:5 (20-100 Hz)
• I-Inverter ~ IN Motor
In static operation with manipulating range < 1:5 (5-100 Hz)
• I-Inverter ~ 1.2 x IN Motor
With group drive
• Refer to the “Multi-motor operation” project planning notes,
section 3.3. The startup currents for connection of the motor to
max. frequency may be 30 times the motor rated current.
• V/F characteristic with at least three programmable interpolation
points
• Shut down the slip compensation, load compensation and V/F
characteristic adaptation software functions
For rapid synchronization the motor should be run in the frequency
range to 50 Hz with current injection. In individual applications it will
be necessary to stop the acceleration process for 10 s at 5 Hz to allow
the motor time to switch to synchronous mode.
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Engineering Guide CDA3000 2-47
2 Drive definition
2.6.1 Transmission Insertion of a transmission gear stage between the geared motor and the
gear output shaft results in different gear output speeds and torques.
(1)
Practical tip
➢ In practice the transmission gear is usually implemented by way of
toothed belts
imax ≈ 4, itypical = 2 to 3
Transmission math.
no yes yes
precise? (rating plate)
Circumferential backlash
The circumferential backlash of a gear is the angular tolerance between
the output and the drive, referred to the output shaft with the drive blocked
and a torque of approx. 3 to 5% of the nominal torque of the gear.
Torsional rigidity
Torsional rigidity is the torsion of a gear relative to the loading.
2
3 Selection of inverter module
3
3.1 Technical data .........................................................3-3
3.1.1 Acceptance tests .................................................3-5
3.1.2 Ambient conditions ..............................................3-6
4
3.1.3 Installation and cooling methods ..........................3-7
3.2 Extreme operating conditions ..............................3-14
5
3.2.1 Mains side/system condition ..............................3-16
3.2.2 Loading on the supply system ............................3-20
3.2.3 General points on the mains connection .............3-21
3.2.4 Operation of fault current breakers .....................3-23 6
3.2.5 Switching at the inverter input ...........................3-24
3.2.6 High-voltage test/Insulation test .........................3-24
3.2.7 Forming of the DC-link capacitors ......................3-25 7
3.2.8 Direction of rotation and terminal designation ....3-27
3.2.9 Switching at the inverter output .........................3-28
3.2.10 Short-circuit and ground fault proofing ...............3-29 A
3.2.11 Motor cable length .............................................3-29
3.2.12 Voltage load on the motor winding .....................3-31
3.2.13 Motor protection possibilities .............................3-31
3.2.14 Power reduction .................................................3-33
3.2.15 Calculation of effective inverter
capacity utilization ............................................ 3-55
3.2.16 Measurement on the inverter module .................3-58
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Engineering Guide CDA3000 3-1
3 Selection of inverter module
1
C DA 3 x . x x x X x.x , x x
Design code*)
2
Hardware default configuration
Cooling method:
C = Cold plate 3
W= Wall mounting
D = Push-through heat sink
Continuous output current
4
Mains voltage:
2 = 1 x 230 V -20% +15%
4 = 3 x 460 V -25% +10%
Inverter module series
5
7
Single-phase inverter modules
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Engineering Guide CDA3000 3-3
3 Selection of inverter module
Inverter module Rec. 4-pole Rated current Peak current Power loss Device output
standard motor at 4 kHz
CDA34.003,Cx.x 0.75 kW 2,2 A 4.0 A1) 45 W 1.5 kVA
CDA34.005,Cx.x 1.5 kW 4.1 A 1) 80 W 2.8 kVA
7.4 A
CDA34.006,Cx.x 2.2 kW 5.7 A 10.3 A1) 100 W 3.9 kVA
CDA34.008,Wx.x 3.0 kW 7.8 A 1) 140 W 5.4 kVA
14 A
CDA34.010,Wx.x 4.0 kW 10 A 1) 180 W 6.9 kVA
18 A
CDA34.014,Wx.x 5.5 kW 14 A 1) 210 W 9.7 kVA
25 A
CDA34.017,Wx.x 7.5 kW 17 A 31 A1) 270 W 11.7 kVA
CDA34.024,Wx.x 11 kW 24 A 43 A1) 390 W 16.6 kVA
CDA34.032,Wx.x 15 kW 32 A 1) 480 W 22.1 kVA
58 A
CDA34.045,Wx.x 22 kW 45 A 81 A2) 600 W 31 kVA
CDA34.060,Wx.x 30 kW 60 A 90 A2) 720 W 42 kVA
CDA34.072,Wx.x 37 kW 72 A 108 A2) 840 W 52 kVA
CDA34.090,Wx.x 45 kW 90 A 135 A2) 1080 W 62 kVA
CDA34.110,Wx.x 55 kW 110 A 165 A2) 1300 W 80 kVA
CDA34.143,Wx.x 75 kW 143 A 214 A2) 1680 W 104 kVA
CDA34.170,Wx.x 90 kW 170 A 2) 2040 W 125 kVA
255 A
1) 1.8 x IN for 30 s Mains voltage 3 x 460 V -25 % +10 %
Power stage switching frequency 4, 8, 16 kHz
Mains frequency 50/60 Hz ±10 %
2) 1.5 x IN for 60s Output frequency 0 ... 1600 Hz to 15 kW
Cooling air temperature
0 ... 400 Hz 22 kW to 90 kW
(1000 m above MSL) 45 °C at 4 kHz
Table 3.2 Overview of inverter modules for 460 V systems
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Engineering Guide CDA3000 3-5
3 Selection of inverter module
3.1.3 Installation The CDA3000 inverter module offers three different methods of installa-
and cooling tion and cooling:
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Engineering Guide CDA3000 3-7
3 Selection of inverter module
Power Push-
Power Inverter Wall
Size 1) Cold plate through
output module loss mounting
heat sink
0.375 kW CDA32.00 3 25 W
BG1
0.75 kW CDA32.00 4 45 W
YES YES2) NO
1.1 kW CDA32.00 6 75 W
1.5 kW CDA32.00 8 95 W
BG2
0.75 kW CDA34.00 3 45 W
YES YES2) NO
1.5 kW CDA34.00 5 80 W
BG2 2.2 kW CDA34.00 6 100 W YES YES NO
3.0 kW CDA34.00 8 120 W
BG3
4.0 kW CDA34.01 0 150 W
YES YES YES3)
5.5 kW CDA34.01 4 180 W
BG4
7.5 kW CDA34.01 7 225 W
YES YES YES3)
11 kW CDA34.02 4 330 W
BG5
15 kW CDA34.03 2 400 W
YES YES YES3)
22 kW CDA34.04 5 500 W
BG6 30 kW CDA34.06 0 600 W NO YES YES4)
37 kW CDA34.07 2 700 W
45 kW CDA34.09 0 900 W
BG7 NO YES NO
55 kW CDA34.11 0 1100 W
75 kW CDA34.14 3 1400 W
BG8 NO YES NO
90 kW CDA34.17 0 1700 W
1) With a power stage clock frequency of 4 kHz
2) See current curves in section 3.2.14
3) The push-through heat sink has IP54 protection
4) The push-through heat sink has IP20 protection
H
Weight 2.8 Kg
CDA3..., Cx.x
H (height) 303 mm
W (width) 100 mm
4
D (depth) 182.5 mm
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Engineering Guide CDA3000 3-9
3 Selection of inverter module
Active cooling area Power output Device basic area Active cooling area
Size
[kW] [mm] [mm]
B
B H a b
BG 1 0.37 to 0.75 kW 70 193 50 165
BG 2 1.1 to 2.2 kW 70 218 90 200
H
Thermal resistance
Temperature lag between
Power output
Size active cooling area and cooler
[kW]
Rth [K/W]
Rth BG 1 0.37 to 0.75 kW 0.05
BG 2 1.1 to 2.2 kW 0.05
Cooler
BG 3 3 to 4 kW 0.03
BG 4 5.5 to 7.5 kW 0.02
BG 5 11 to 15 kW 0.015
Heat transfer
compound
Mounting plate
CDA3000
Cooler
4
Heat transfer
compound
Mounting plate
CDA34.014
5
1. Power loss discharged by way of the mounting plate of the inverter
module.
6
The CDA34.014 has a power loss of 180 W (table 3.2).
75% of the power loss is discharged via the mounting plate (active cool-
ing area) and 25% as radiated heat via the housing (table 3.9)
PMountingplate = 180 W x 0.75 = 135 W 7
2. Calculate temperature difference between mounting plate and cool-
ing plate. A
∆ϑ = PMounting plate x Rth1) = 135 W x 0.02 K/W = 2.7 K
1)
See table 3.9
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Engineering Guide CDA3000 3-11
3 Selection of inverter module
CDA3..., Wx.x
H
H (height) 330 mm CDA3..., Wx.x
W (width) 70 mm355 mm
D (depth) 250.5 mm
With this cooling method the inverter module can even be mounted on
non-heat-conducting surfaces.
CDA3..., Dx.x
Weight 3.9 Kg
CDA3..., Dx.x
H (height) 340 mm
W (width) 110 mm
D (depth) 170.5 mm
When the “push-through heat sink” cooling method is used, the heat sink
of the inverter module can be mounted outside the switch cabinet, or 1
mounting space, in order to reduce the heat generated. The power loss
split is dependent on size, and is shown in the following table.
2
Size Power output To the outside To the inside
BG 3 3 to 4 kW 70% 30%
BG 4 5.5 to 7.5 kW 75% 25% 3
BG 5 11 to 15 kW 80% 20%
BG 6 22 to 37 kW 85% 15%
Table 3.12 Distribution of power loss with the “push-through heat sink”
4
cooling method
Clearance
Push-through
Size
Power output Cold plate1) Wall mounting1)
heat sink1)
above/ 6
[kW] WxHxD WxHxD below2)
WxHxD
[mm]
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Engineering Guide CDA3000 3-13
3 Selection of inverter module
Intended use
When work is being carried out on live inverters, the applicable national
accident prevention regulations (e.g. VBG 4) are to be observed.
Electrical installation is to be carried out in accordance with the relevant
regulations (e.g. cable cross section, fuses, grounding lead connection).
1
Other details are contained in the documentation.
Electronic devices are fundamentally not fail-safe. Users are themselves
responsible for ensuring that the drive is rendered safe if the device fails. 2
If the inverter is used for special applications (e.g. subject to explo-
sion hazards), the required standards and regulations (e.g. EN50014
and EN50018) must be observed. 3
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Engineering Guide CDA3000 3-15
3 Selection of inverter module
3.2.1 Mains side/sys- DIN VDE 0100-300: 1996-01 distinguishes between three different mains
tem condition power systems. It is made especially clear how the IT system differs from
the TT and TN systems based on the means of ground connection.
Grounding lead
PEN conductor
Neutral conductor
Second letter - Link from the bodies of the electrical system to ground:
T Body grounded directly, regardless of any grounding of a point of
the supply system 1
N Body grounded directly with the grounded point of the supply
system (in AC systems the grounded point is generally the center
point or, if there is no center point, an outer conductor).
2
Voltage conditions in the IT system
In an IT system the voltages of the outer conductors are adjusted against
ground according to the voltage distribution by the discharge imped-
3
ances. These impedances comprise the capacitors of the conductors and
those of the equipment against ground, and the parallel switched insula-
tion resistors. If the said discharge impedances are equally large for every
conductor, all outer conductors likewise conduct the same voltage against
4
ground. High-resistance voltmeters connected between the outer conduc-
tor and ground display the same value. In three-phase AC systems this is
the star voltage; in AC systems half the conductor voltage is displayed.
Insulation monitors should therefore be connected symmetrically. If a
5
ground fault occurs on a conductor, its voltage to ground collapses. How-
ever, because the voltage between the conductors is maintained the
healthy conductors are raised to the conductor voltage against ground.
6
It should be considered that in the event of a ground fault on a conductor
in ungrounded systems the center point of the transformer takes on
phase voltage and the non-faulty outer conductors are raised to the outer
conductor voltage against ground. 7
This increased voltage load may result in puncture at a point with low
electrical insulation resistance, and this cause a double short circuit to
frame. A
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Engineering Guide CDA3000 3-17
3 Selection of inverter module
a) IT system with ground fault on conductor L3. The ground fault current ld
flows via the capacitors of the healthy conductors.
b) Conductor voltage against ground with symmetrical conductor capacity.
All conductors conduct the star voltage against ground.
c) Conductor voltage against ground in the system. System with a ground
fault on conductor L3. The healthy conductors conduct the conductor volt-
age against ground. It determines the amount of the ground fault current
by way of the conductor capacitors.
2
Operation with
Power system Comments
Inverter CDA3000
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Engineering Guide CDA3000 3-19
3 Selection of inverter module
3.2.2 Loading on the All inverter systems draw a non-sinusoidal current from the system. This
supply system is because of the 1/3-phase input rectifier in the inverter input. This non-
sinusoidal current consumption results in voltage distortions (THD=Total
Harmonic Distortion) in the system.
Depending on local conditions, line chokes may need to be inserted to
reduce the voltage distortions. A line choke reduces the voltage distortion
in the system by approx. 67%.
System load
Without line
4 kW inverter, line 4 kW inverter, line
choke to
impedance impedance
with line
0.6 mH 0.6 mH
choke
Table 3.15 Change in system load resulting from insertion of a line choke
with 4 % short-circuit voltage based on the example of a 4 kW
inverter CDA34.010
If you want to know more about “harmonics and input rectifiers” we can
recommend the book entitled “Oberwellen” ("Harmonics" - German) by
2
Albert Kloss - see the bibliography and source reference.
3
3.2.3 General points The minimum cross-section of the mains power cable is based on the
on the mains local provisions (to VDE 0100 Part 523, VDE 0298 Part 4), the ambient
temperature and the specified rated current of the inverter.
connection 4
Current load capacity of multi-wire cables and assignment of pro-
tective devices to VDE 0100 Part 523
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Engineering Guide CDA3000 3-21
3 Selection of inverter module
1. The fuse does not protect the input rectifier bridge of the inverter module, it merely protects the
cable.
Please note that the mains power cable and fuses used must conform to
the specified listings (such as cUL). 1
Mains power cable Grounding lead (PE) cross section of at least 10 mm or lay a 3
second electrical conductor parallel to the existing grounding
< 10 mm2 lead, because the operational leakage current is > 3.5 mA.
Mains power cable PE conductor with cross-section of mains power cable - see VDE
>10 mm2 0100 Part 540 4
Table 3.18 Minimum cross-section of the grounding lead
3.2.4 Operation of In operation of the inverter, because of the internal suppression capaci-
5
fault current tors, the high clock frequencies, the parasitic capacitors, the power stage
of the parasitic capacitors, the motor cable and the radio interference sup-
breakers pression filters the leakage current is > 3.5 mA. In individual cases it may
be several hundred mA.
6
The inverter module must therefore always be thoroughly grounded (VDE
0100 Part 540, EN 50178) in order to conform to the provisions regarding
increased leakage currents applicable above 3.5 mA. 7
Fault current breakers must be used in accordance with local regulations.
It should however be noted that, due to the three-phase input rectifier, the
leakage current contains a DC component and short-term pulse-shaped
leakage currents occur on power-up.
A
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Engineering Guide CDA3000 3-23
3 Selection of inverter module
3.2.5 Switching at the The CDA3000 inverter modules must be connected to the mains power
inverter input by way of an external mains isolator (e.g. power circuit-breaker, contactor
(AC3), etc.).
The mains isolator must conform to EN 60204-1 or local safety standards.
The mains isolator must not be used to control the inverter module (in jog
mode) - extensive control functions are provided for that purpose.
3.2.6 High-voltage Every shipped inverter module is tested by means of a high-voltage test
test/Insulation for insulation resistance between the main circuit and the housing or
chassis (1.9 k VDC for 1 s). It is therefore not necessary to monitor the
test insulation resistance of the modules.
3.2.7 Forming of the All Voltage inverters have an input current inverter (rectifier) by way of
DC-link capaci- which the 50/60 Hz AC or three-phase voltage is rectified. The rectified
tors
voltage is stored in the so-called DC-link capacitors. The motor-side
power inverter in the output circuit of the inverter reforms the DC link volt-
1
age into a new three-phase voltage system, with variable frequency (f)
and voltage (u).
2
Pulse-controlled inverter (PWR)
Rectifier DC link
3
Mains
3-phase
a.c. motor 4
5
6
PWM 6
parallel
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Engineering Guide CDA3000 3-25
3 Selection of inverter module
ANTRIEBSTECHNIK
D- 35633 Lahnau
Typ: CDA34.032.C1x
SN.: 991204342
Serial no.
Calendar week
Year
Figure 3.4 Inverter module rating plate with year and month identification
Attention: If the inverters have been left standing for more than
8 months after shipping (see rating plate) the DC-link
capacitors must be reformed. This can be avoided if the
inverters are connected to the mains for one hour
approx. every 6 months.
Of course you can also arrange for our Service department to carry out
the forming.
5
Figure 3.5 Direction of rotation
The terminals should be labeled such that the alphabetical order of the 6
terminal designation (inverter U, V, W - motor U1, V1, W1) corresponds to
the phase sequence over time of the mains voltage (L1, L2, L3) in clock-
wise running.
7
Clockwise1) Terminals
Inverter
U V W
CDA3000
A
Motor U1 V1 W1
Anti-clockwise2) Terminals
Inverter
V U W
CDA3000
Motor U1 V1 W1
1) Control signal “Clockwise
2) Control signal “Anti-clockwise”
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Engineering Guide CDA3000 3-27
3 Selection of inverter module
3.2.9 Switching at the The motor connected to the inverter may be isolated by means of a con-
inverter output tactor or motor circuit-breaker. It is not possible to damage the CDA3000
inverter module by shutting down the motor.
When motor loads are shut off very high switching overvoltages
occur, because the inductance of the motor does not permit stepped
current changes. These switching overvoltage may also lead to fault
shutdowns and/or error messages from the inverter, depending on
the drive configuration. In such cases a motor choke must be inser-
ted - see section 6.2.
L1
L2
L3
PE
F1
K1
L1
L1 L2 L3 PE
CDA3000
- + U V W PE
K2
M1 M
3~
Multi-motor operation
Several motors can be run in parallel on one CDA3000 inverter module. In
this application case motors not only need to be shut down, but also acti-
vated. For details of the operating conditions under which such cases
apply refer to section 3.3.6.
fault proofing
cable, the power stage is disabled and an appropriate error message is 5
delivered.
3.2.11 Motor cable The maximum motor cable length depends on a number of different 7
length factors (see following table).
Factor Section
U= m
56 .A
Motor cable
l = Length of motor cable in [m]
I = Current in [A]
A = Cable cross-section in [mm2]
1)
Typical factor for inverter operation (1.73x0.9)
3.2.12 Voltage load When a standard three-phase AC motor is operated on an inverter the
on the motor winding insulation is subjected to higher stress than in a sinusoidal sys-
winding
tem. The reason lies in the periodic switching operations by the inverter
which lead to high rates of rise of voltage (du/dt) and voltage peaks
1
(Upeak) on the motor winding. This increased voltage load on the motor
winding may shorten the service life of the motors - see the research
report from the ZVEI in the "Bibliography and source reference" section. 2
Market practice
3.2.13 Motor The following chart presents a summary of frequently occurring overload
protection types and the possibilities for protection offered by various devices (motor
circuit-breakers, thermistor protective relays, inverter functions).
possibilities
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Engineering Guide CDA3000 3-31
3 Selection of inverter module
Blocking 1)
3) 3)
Blocking 2)
Ambient tempera-
ture >50°C 1)
Impairment of
cooling 1)
Inverter operation 4)
<50 Hz
1) The inverter and motor have the same power rating (1:1)
2) The inverter is at least four times larger than the motor (4:1)
3) Effective when motor warm, too long response time when motor cold
4) No full protection, because only the permissible current is applied as the basis
Fuses are not included in this comparison because they only pro-
tect the cable and not the motor.
3.2.14 Power The maximum permissible inverter rated current and the peak current are
reduction specified referred to 400 V mains voltage, a 10/25 m motor cable, a power
stage clock frequency of 4 kHz and an ambient temperature of 45 °C. 1
If background conditions such as the mains voltage, motor cable length,
power stage clock frequency or ambient temperature change, the max.
permissible current load on the inverter modules also changes. For
details of which current load on the power stage modules is permissible 2
under which changed background conditions, refer to the following char-
acteristic diagrams and tables.
3
Maximum output current as a function of mounting height
KH 0.8 5
0.7
0.6 6
~
0 1000 2000 3000 4000
H [m]
7
Figure 3.7 Current correction factor (KH) as a function of mounting height
A
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Engineering Guide CDA3000 3-33
3 Selection of inverter module
40 °C ambient temperature
40 °C ambient temperature
45 °C ambient temperature
40 °C ambient temperature
40 °C ambient temperature
16 kHz clock frequency
10 m motor cable
10 m motor cable
25 m motor cable
25 m motor cable
25 m motor cable
Rated current Rated current Rated current Rated current4) Rated current4) Rated current4)
Inverter modules
[A] [A] [A] [A] [A] [A]
Table 3.24 Output current for inverter modules with 230 V power supply
40 °C ambient temperature
40 °C ambient temperature
45 °C ambient temperature
40 °C ambient temperature
40 °C ambient temperature
45 °C ambient temperature
10 m motor cable
10 m motor cable
25 m motor cable
25 m motor cable
25 m motor cable
2
3
Rated current Rated current Rated current Rated current Rated current Rated current
Inverter modules
[A] [A] [A] [A] [A] [A]
4
CDA34.003,Cx.x1 ) 2.2 2.2 1.4 2.0 1.7 0.5
Table 3.25 Output current for inverter modules with 400 V power supply
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Engineering Guide CDA3000 3-35
3 Selection of inverter module
40 °C ambient temperature
40 °C ambient temperature
45 °C ambient temperature
40 °C ambient temperature
40 °C ambient temperature
16 kHz clock frequency
10 m motor cable
10 m motor cable
25 m motor cable
25 m motor cable
25 m motor cable
Rated current Rated current Rated current Rated current Rated current Rated current
Inverter modules
[A] [A] [A] [A] [A] [A]
CDA34.003
CDA34.005
CDA34.006
CDA34.008
CDA34.010
CDA34.014 .
CDA34.017
ble o press
t
CDA34.024
t a vaila going
CDA34.032 No e of
m
CDA34.045 at ti
CDA34.060
CDA34.072
CDA34.090
CDA34.110
CDA34.143
CDA34.170
Table 3.26 Output current for inverter modules with 460 V power supply
2.4 A 3
2.5 2.4 A
4
2.25
4/8 kHz
5
2 2A
I 16 kHz
[A]
1.75
6
1.5 7
~
A
~
20 25 30 35 40 45 50 55
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Engineering Guide CDA3000 3-37
3 Selection of inverter module
4.5 4A
3.75 A
4
4 kHz
3.5
8 kHz
3.1 A
3
16 kHz
2.6 A
I 2.5
[A]
2 2A
1.5
0.5
~
20 25 30 35 40 45 50 55
4.5 4A
4
4
4 kHz
8 kHz
3.5
3.3 A
3
5
16 kHz 2.8 A
I 2.5
[A]
2
2.2 A
6
1.5
1 7
0.5
~
20 25 30 35 40 45 50 55 A
[˚C] Cooling air temperature JK
Figure 3.10 Max. current load of the CDA32.004,Cx.x / 0.75 kW / side-by-
side / with backplane (0.065 m) as additional cooling area
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Engineering Guide CDA3000 3-39
3 Selection of inverter module
9
7.1 A
8
7
5.4 A 4 kHz
6
I 5 8 kHz
4.9 A
[A] 16 kHz
4 4.1 A
3 3.1 A
1
~
20 25 30 35 40 45 50 55
3
9
7.1 A
8
4 kHz 4
7
8 kHz
6 6.1 A
16 kHz 5.4 A 5
I 5
[A] 4.2 A
4
3 6
2
1 7
~
20 25 30 35 40 45 50 55
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Engineering Guide CDA3000 3-41
3 Selection of inverter module
9
7.1 A
8
4 kHz
7
8 kHz
6 6.1 A
16 kHz 5.4 A
I 5
[A] 4.2 A
4
1
~
20 25 30 35 40 45 50 55
3
2.5
2,2 A 4 kHz
2.2 A
2
4
2A 8 kHz
1.5 5
16 kHz 1.3 A
I
[A]
1 1A
6
0.5
7
~
20 25 30 35 40 45 50 55
A
[˚C] Cooling air temperature J K
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Engineering Guide CDA3000 3-43
3 Selection of inverter module
2.5
2.2 A 4 kHz
2.2 A
1.8 A
8 kHz
1.5
16 kHz
I 1.25 A
[A]
1 1A
0.5
~
20 25 30 35 40 45 50 55
3
5
4.5
4.1 A
4 4
3.6 A
3.5 4 kHz
3 5
I 2.5 8 kHz
2A
[A] 2.2 A
2
16 kHz
6
1.5
1.3 A
1 1A
7
0.5
~
20 25 30 35 40 45 50 55
A
[˚C] Cooling air temperature J K
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Engineering Guide CDA3000 3-45
3 Selection of inverter module
4.5
3.5 ss
o pre
in gt
3
f go
eo
I 2.5 tim
at
[A] le
2 ilab
va
ta
1.5 No
0.5
~
20 25 30 35 40 45 50 55
3
5
4.5 4.1 A
4 kHz
4 4
3.6 A
3.5
8 kHz 3.2 A
3 5
2.6 A
I 2.5
[A]
2
16 kHz 6
1.5
1.4 A
1
7
0.5
~
20 25 30 35 40 45 50 55
A
[˚C] Cooling air temperature J K
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Engineering Guide CDA3000 3-47
3 Selection of inverter module
4.5
4
ress
3.5 top
o ing
ofg
3
time
at
I 2.5
ilable
[A] ava
t
2 No
1.5
0.5
~
20 25 30 35 40 45 50 55
4.5 4.1 A
4 kHz
4
4
3.6 A
3.5
8 kHz 3.2 A 5
3
2.6 A
I 2.5
[A] 6
2
16 kHz
1.5
1.4 A
1
7
0.5
A
~
20 25 30 35 40 45 50 55
Figure 3.20 Max. current load of the CDA 34.005,Cx.x / 1.5 kW / not
side-by-side / with backplane as additional cooling area / mains
voltage 3 x 400 V
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Engineering Guide CDA3000 3-49
3 Selection of inverter module
4.5
4
s
p res
3.5 to
ing
f go
3
m eo
at ti
2.5
I ble
[A] aila
2 t av
N o
1.5
0.5
~
20 25 30 35 40 45 50 55
Figure 3.21 Max. current load of the CDA 34.005,Cx.x / 1.5 kW / not
side-by-side / with backplane as additional cooling area / mains
voltage 3 x 460 V
3
5.7 A
6
4 kHz
5.5 8 kHz 4
5 5.1 A
4.7 A
4.5
5
4
I 3.5
[A]
3
2.6 A 6
16 kHz
2.5
2 7
1.5~
1A
A
~
20 25 30 35 40 45 50 55
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Engineering Guide CDA3000 3-51
3 Selection of inverter module
5.7 A
6
4 kHz
5.5
8 kHz
5 5.1 A
4.7 A
4.5
I 3.5
[A]
3
2.5
1.5~
~
20 25 30 35 40 45 50 55
9 8A
4 kHz 4
8
7 8 kHz
6
6,5 A
5
4,8 A 5,5 A
I 5 16 kHz
[A]
4 6
3,5 A
3
2 7
1
~
20 25 30 35 40 45 50 55 A
[˚C] Cooling air temperature JK
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Engineering Guide CDA3000 3-53
3 Selection of inverter module
10 A 4 kHz
10
9
8 kHz
8 8,2 A
7 6,2 A
7,0 A
I 6 16 kHz
[A]
5
4,4 A
4
2 ~
~
20 25 30 35 40 45 50 55
3
10 A
10 4 kHz
8,8 A 4
9
8 8 kHz
7
7,5 A 5
I 6 6,2 A
[A]
5 6
4
3 7
2~
~
20 25 30 35 40 45 50 55 A
[˚C] Cooling air temperature JK
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Engineering Guide CDA3000 3-55
3 Selection of inverter module
u les
m od
er ss
v ert pre
e r in ng to
h
ot f goi
h e
o f t me o
i
s t ics he t
i t
c ter le at
r a b
cha aila
nt a v
u rre not
e c were
Th
2
Mains voltage Mains voltage Mains voltage
1 x 230 V 1 x 400 V 1 x 460 V
Clock
Frequency
Motor choke Motor choke Motor choke 3
without with without with without with
[mA per m] [mA per m] [mA per m] [mA per m] [mA per m] [mA per m]
4 10 * 15 * 20 * 4
8 15 * 30 * 40 *
16 25 * 60 * 70 *
* Not available at time of going to press 5
Table 3.27 Current losses on motor cable dependent on clock frequency
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Engineering Guide CDA3000 3-57
3 Selection of inverter module
3.2.15 Calculation of The CDA3000 inverter modules have an overload capability of typically
effective 1.8 x IN for 30 s (1.5 x IN for 60 s).
inverter capac-
ity utilization Calculation of effective inverter capacity utilization
V
m/s
t1 t2 t3
T
t
I1 I3 I1
1.8
1.5
1.0
I
0.5
A I2
2 2 2
I 1 ⋅ t1 + I 2 ⋅ t2 + I 2 ⋅ t3
I eff = ----------------------------------------------------------
T
Calculation examples
Appli-
Acceleration
Current at
V = constant
Deceleration
Stopping
Effective
inverter
Permissible 1
cation time capacity
Current Time Current Time Current Time utilization Yes No
6 .
1.8 IN 0.2 s 0.3 . I N 0.3 s 1.8 . I N 0.2 s 0.2 s Ieff > IN X 4
7 1.8 . IN 0.1 s 0.3 . IN 0.3 s 1.8 . IN 0.1 s 0.2 s Ieff < IN X
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Engineering Guide CDA3000 3-59
3 Selection of inverter module
F/Hz
t/s
IMAXBR
IMAXBE
IMAXST
t/s
Figure 3.28 Peak current value storage for checking of drive dimensioning
The peak current value memory continuously stores the absolute peak
values in the acceleration, stationary operation and braking phases. The
mean device capacity utilization can also be ascertained.
3.2.16 Measurement Measurement on the inverter module is not necessary, because the
on the inverter inverter delivers all required actual values. Actual values such as:
are available. The actual values can be called up by way of the KP200 3
control unit or the DRIVEMANAGER user software (with the digital scope
function).
5
Measurement on the CDA3000 inverter module
Because of the non-sinusoidal variables at the input and output of the
inverter, only measurements with special measuring equipment are 6
permitted. Since such equipment is not usually available to practicians
on-site, conventional measuring equipment can be used as a fallback. A
measuring circuit with device data is shown in Figure 3.29 on the follo-
wing page. However, it should be made clear that the measuring device 7
displays - in particular at the inverter output - are only guide values.
When using an oscilloscope to represent the pulsed voltage, measure-
ments should be taken with differential inputs.
A
In all measurement operations you should remember that the DC-link
capacitor on the voltage transformer may still be live long after the device
has been shut off.
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Engineering Guide CDA3000 3-61
3 Selection of inverter module
3.3 Special
applications
1
3.3.1 Project
planning for A wide variety of three-phase AC motors can be run on the CDA3000
inverter system. Three-phase AC motors are manufactured in syn-
chronous and asynchronous design versions. The stator winding is
three-phase designed such that, when in service in a three-phase AC system, a rotat- 2
AC motors ing field is created in the motor which drives the rotor. The rotation speed
is determined by the following variables:
3
ns = synchronous speed
⋅ 60
n s = f----------- P = number of pole pairs
P
f = stator frequency
4
The motor type is determined by the rotor introduced into the rotating
field.
5
Overview of three-phase AC motors
3-phase AC motor
6
A
Energized via Permanently With damper Without damper HF motors
slip ring energized cage cage
(brushless) (SYNCELL)
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Engineering Guide CDA3000 3-63
3 Selection of inverter module
Working
Motor type Application
principle
Reluctance motor
The reluctance motor is a special motor which must be tested anew
prior to every production deployment (See section 2.5.3).
4
Synchronous The synchronous motor is likewise a special motor which must be tested
motor anew prior to every production deployment (See section 2.5.4).
High-frequency
HF motors are usually run with constant torque, at high frequencies up
5
motors
to 1600 Hz. For more information See section 2.5.5.
(HF motors)
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Engineering Guide CDA3000 3-65
3 Selection of inverter module
VFC SFC
FOR
General characteristics of the Voltage Sensorless
Field-Oriented
motor control methods Frequency Flux
Regulation
Control Control
Table 3.31 Efficiency of the motor control methods with standard three-
phase AC motor
VFC
1
SFC FOR
Voltage
Property Sensorless Flux Field-Oriented
Frequency
Control Regulation
Control
2
Break-away torque1) with standard 1.6 x MN 1.8 x MN 2 x MN
motor (UN = 400 V)
7
For data relating to the servomotors refer to section 2.5.2.
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Engineering Guide CDA3000 3-67
3 Selection of inverter module
ϕF = ω .. tRF
ϕF = Positioning error
in °
(4)
ω = Velocity
in mm/s
VFC
SFC FOR
Voltage
Property Sensorless Flux Field-Oriented
Frequency
Control Regulation
Control
Braking time 100 ms, external moment of inertia = motor moment of inertia
Standard motor (UN = 400 V)
10° 9° 9°
1500 rpm to 0 rpm
Standard motor (UN = 400 V)
4° 4° 3°
1500 rpm to 0 rpm
Servomotor (UN = 330 V)
12° 10° 8°
1500 rpm to 0 rpm
Servomotor (UN = 330 V)
6° 5° 4°
1500 rpm to 0 rpm
Braking time 500 ms, external moment of inertia = motor moment of inertia
VFC
SFC FOR
Voltage
Property
Frequency
Sensorless Flux Field-Oriented
Control Regulation
1
Control
Standard motor (UN = 400 V)
9° 9° 9°
1500 rpm to 0 rpm
2
Standard motor (UN = 400 V)
4° 4° 3°
1500 rpm to 0 rpm
Servomotor (UN = 330 V)
1500 rpm to 0 rpm
12° 10° 8° 3
Servomotor (UN = 330 V)
6° 5° 4°
1500 rpm to 0 rpm
Values referred to the motor shaft 4
Table 3.33 Typical positioning errors referred to the motor shaft in °
π ⋅ d ⋅ 10°
∆ s = ----------------------- = [ mm ] d = Diameter of drive pinion in mm
6
360° ⋅ i
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Engineering Guide CDA3000 3-69
3 Selection of inverter module
3.3.3 Standard Initial commissioning automatically optimizes the control circuits such
inverter that, with inverter output assigned equal to motor output, the typical
power output and torque characteristic shown in Figure 3.31 is produced.
operation
Typical torque characteristic of a standard three-phase AC motor
in standard inverter operation PInverter = PMotor
2.0
(5)
1.8
(4)
1.5
(3) (2)
1.0
M (2.1) P>
MN (2.2) (2)
(2) (1)
0.5
0.1
10 50 70 100 120
f [ Hz]
3
Special applications
Six-pole motor on
Area of application of solution: 7
• In applications such as mills, mixers and extruders etc.
inverter module
For more information See section 2.2
Area of application of solution:
Operation of a motor • In applications with falling load torque such as winders, coil-
A
with field weakening ers and lathes etc.
For more information See section 1.3.4
Operation of special
Area of application of solution:
motors on inverter
• See section 3.3.1
module
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Engineering Guide CDA3000 3-71
3 Selection of inverter module
3.3.4 70 Hz charac- Traction and lifting drives which operate with 25% field weakening (70 Hz
teristic with maximum frequency) offer a wide variety of advantages:
25% field − 40% more break-away and acceleration torque can be attained
weakening without increasing the cost of the inverter drive solution.
− Greater economy can be achieved based on saving on an exter-
nal cooler or reducing the motor power output by one type step.
Example: Drive design with 50 Hz (Fmax = 50 Hz) and 70 Hz character-
istic (Fmax = 70 Hz)
− Speed manipulating range from 20 to 95 rpm on the gear output
shaft
− Output torque on gear output shaft of 150 Nm
− Operation mode: S1 (continuous operation), ED = 100%
− There is no time requirement for the startup and braking
response.
3
Figure 3.32 50 Hz drive design
4
The drive design shown above occurs in similar form in almost all fields of
engineering. Initial commissioning automatically sets up all three motor 5
control methods.
6
2. Drive design with 70 Hz
In the 70 Hz drive design with 25% field weakening the maximum speed
of the 1.5 kW motor is increased by way of the inverter module from
1421 rpm (50Hz) to 2000 rpm (70Hz). The adaptation of the desired
output speed on the gearbox is compensated by a higher transmission.
However, since a two-stage gearing is required in both cases, the
increase in transmission has no influence on cost.
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Engineering Guide CDA3000 3-73
3 Selection of inverter module
In this case, too, all the motor control methods are set up automatically by
initial commissioning. In addition, the max. output frequency needs to be
set to 70 Hz in the “Output frequency limitation” software function.
Figure 3.34 Comparison of gear output torque in a drive design for 50 and
70 Hz
Curve Curve
Explanation
50 Hz 70 Hz
Table 3.35 Comparison of gear output torque in a drive design for 50 and
70 Hz
7
Or a reduction in motor power by one type step
A drive design with field weakening (70 Hz design) can, however, also be
designed to usually produce a reduction in motor power by one type step.
A reduced motor power saves space and money.
A
It should, however, be noted that the choice of maximum speed has a
major influence on the required acceleration torque and thus on the
acceleration time. In practice, at desired acceleration times below 400 ms
no reduction in the motor power or inverter output by one type step is usu-
ally attained.
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Engineering Guide CDA3000 3-75
3 Selection of inverter module
3.3.5 87 Hz charac- The operating range with constant torque of a 400 V / 50 Hz motor in star
teristic / configuration can be expanded to 87 Hz in delta configuration.
P Inverter ≥ P Motor ⋅ 3 =
.
= 4 kW 1.73 = 6.9 kW
Selected inverter module: CDA34.017
Rated power 7.5 kW
Rated voltage 0 ... 400 V
Max. output frequency 0 ... 100 Hz
U P M
kW MN
230 V / 50 Hz 1
V 400 V / 87 Hz
fN
600 12 1,2
1.2
500 10 1,0
1.0 2
0,8 M
400 8 0.8
U
6 0,6
300 0.6 P
3
200 4 0,4
0.4
100 2 0,2
0.2
4
0 20 40 50 60 80 87 100 f
Hz
Design/solution Applications
6
Motor with 4 kW / 50
Hz in star configura- Area of application of solution:
tion on inverter module • In applications with constant torque delivery to 50 Hz 7
CDA34.010 (4 kW)
Motor with 4 kW / 50 Area of application of solution:
Hz in delta configura- • In applications with constant torque delivery
tion on inverter module to 87 Hz, e.g. lifting drives A
CDA34.017 (7.5 kW)
Precise data relating to the full-load power (S1, ED
100° %) can only be given by the motor manufactur-
ers.
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Engineering Guide CDA3000 3-77
3 Selection of inverter module
The acceleration power rises with the square of the speed increase (e.g.
caused by the choice of max. 87 Hz instead of 50 Hz).
3.3.6 Multi-motor The CDA3000 inverter modules can be run with several motors config-
operation on ured in parallel. Depending on drive task, various project planning condi-
one inverter
tions must be met. 1
L1
L2
L3
PE 2
F1
K1
L1
3
L1 L2 L3 PE
CDA3000 4
- + U V W PE
L2 5
K2 K3
..........
Kn
6
M M M
3~ 3~ 3~
7
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Engineering Guide CDA3000 3-79
3 Selection of inverter module
Current configura- The sum of the motor currents must be less than the rated output cur-
tion of inverter rent of the inverter module
module Σ of motor currents, (IM1 + IM2 + IMn ) < Iinverter
Motor control Multi-motor operation is only permitted with the VFC motor control
method method.
Motor choke A motor output choke must always be used (See Figure 3.36). The
motor choke limits the du/dt and thus the leakage currents, and pro-
tects again switching voltage overload resulting from switching of the
motor inductance.
Motor cable length The total length of the overall motor cable is produced by adding the
individual lengths per motor.
Motor protection In multi-motor operation the parallel-connected motors cannot be pro-
tected by the inverter module. For that reason, depending on specific
depending on the motor should be protected by means of external
motor circuit-breakers or thermistor protective relays; see 3.2.13.
All motors have In this application the torque characteristics of all motors remain
the same power roughly equal.
output
The motors have If the motor outputs are very different, problems may occur on startup
different power and at low speeds. This is because of the high stator resistance of small
outputs motors and the resultant high voltage drop on the stator coil.
In practice: With a power ratio of around 1:4 between the motors,
the starting torque of the smallest motor is still approx.
70% of the nominal torque. If the torque of approx.
70% is not sufficient, a larger motor must be used.
Speed ratio run Differing motor output speeds can only be attained by using motors
with differing nominal speeds, e.g. 1440 rpm and 2880 rpm. The speed
1
ratio of approx. 1:2 is maintained during the speed change. The accu-
racy depends on the slip and thus on the load.
Shut-off and acti- Shut-off of motors, See section 3.2.9 2
vation of individ- When connecting motors, ensure that the connection current is not
ual motors higher than the inverter peak current. It is advantageous if the inverter
load is >40%.
This 40% base load backs up the output voltage of the inverter module
at the moment of connection of the motor.
3
During connection the motor must not be run in the
field weakening range, since the connected motor
would otherwise have to run at reduced runup torque.
4
Table 3.37 Project planning notes for multi-motor operation
5
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Engineering Guide CDA3000 3-81
3 Selection of inverter module
K1
L1
L2
L3
PE
F1 F4 Fn
L1 L2 L3 L1 L2 L3 L1 L2 L3
+ - + - + -
PE PE PE
U1 U2 Un
U V W PE U V W PE U V W PE
M1 M M2 M Mn M
3~ 3~ 3~
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Engineering Guide CDA3000 3-83
3 Selection of inverter module
1. The ohmic value of the external braking resistor must not be less
than the minimum ohmic connected load permitted by the inverter
module.
M1 1
3 F1 L1 3 M
Mains
3~
U1 2
F2/3
M2
Mains
3 F4 L2 3 M 3
3~
U2
F5/6 4
Mn
3 Fn Ln 3 M
Mains
3~ 5
Un
Fn+1/n+2
6
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Engineering Guide CDA3000 3-85
3 Selection of inverter module
3.3.8 Design of the In regenerative operation, e.g. braking the drive, the motor feeds energy
braking resistor back into the inverter. This increases the voltage in the DC link. If the volt-
age exceeds a permissible value, the internal braking transistor is acti-
vated and the regenerative energy is converted into heat by way of the
externally connected braking resistor.
Asynchronous
motor
External
braking resistor
1
V
[m/s]
0
2
3
t1 t2 t3 t4 t5 t6
t
T 4
[W]
t3 t6
6
t
The continuous braking power of the braking resistor must be > Peff. The
sampling time T must be < 150 s.
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Engineering Guide CDA3000 3-87
3 Selection of inverter module
The resistance must not be less than the minimum ohmic connected load
permitted by the inverter module.
replaceable 3
R1 . R2
R1 R2 R R=
R1 + R2
by 4
Table 3.39 5
Figure 3.43 Parallel configuration of two resistors
7
R1 replaceable
R R = R1 + R2
R2 by
A
Table 3.40
Figure 3.44 Series configuration of tworesistors
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Engineering Guide CDA3000 3-89
3 Selection of inverter module
4 Software functions
1
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Engineering Guide CDA3000 4-1
4 Software functions
4.1 User interface This section describes handling of the data sets and parameter setting of
and data the CDA3000 inverter module.
structure Users can adapt the “active data set” of an inverter module to the specific
application by way of the KEYPAD KP200 control unit or the user-friendly
DRIVEMANAGER PC user software.
4.1.1 Data structure Individual parameters, parameter groups (subject areas) or complete pre-
set parameter sets can be selected. The complete preset parameter set
is called an application data set.
Subject areas
For ease of handling the parameters of the CDA3000 inverter module are
assembled into groups. The parameter groups are called subject areas,
and permit function-oriented operation of the inverter module (See Figure
4.1).
Figure 4.1
Commissioning
See section 4.4 Current-controlled startup
Modulation
Error messages DC holding
Warning messages DC braking
Actual values Master/Slave operation
Control location
Reference structure Device data Characteristic switchover
Clock input/clock output Device capacity utilization Driving sets
Digital outputs KP 200 Fixed frequencies
Digital inputs Power failure bridging Driving profile generator
Analog output Motor protection Option modules MOP function
Analog inputs Frequency limitation LUSTBUS Motor holding brake
4-3
4 Software functions
See section 4.5 See section 4.6 See section 4.7 See section 4.8
Motor data
Speed controller FOR
Magnetizing
Current controller
Current injection
Encoder evaluation
Slip compensation
Speed controller SFC
I x R load compensation
VFC
EN
DE
A
4 Software functions
When the inverter module is started for the first time after delivery, appli-
cation data set 1: “traction and lifting drive” is active.
After every subsequent start the user data set selected by way of the con-
trol terminals or by parameter setting is automatically loaded.
The application data sets are adapted further by way of the assistance
parameter “ASTER”. By way of the application data sets and the assist-
ance parameter 15 preset solutions can be selected; See section 4.3.
Active
data set
Traction and
lifting drive
Save
RAM
Terminal Terminal
1 2
User data set/Custom data set 3
User data
set 1
0 0 001 MODE
4
999 xyz
User data
set 2 5
1 0 001 MODE
999 xyz
6
User data
set 3
0 1 001 MODE
999 xyz 7
User data
set 4
1 1 001 MODE
A
999 xyz
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Engineering Guide CDA3000 4-5
4 Software functions
4.1.2 Initial Selecting the “Initial commissioning” subject area calls up the parameter
commissioning group for initial commissioning of the inverter module. The parameters of
the subject area must be adapted successively to the specific application.
The automatic motor identification function ascertains the key parameters
of the motor and sets the appropriate control circuits.
This identification function is necessary for the SFC1 and FOR2 control
modes. Where the VFC3 open-loop control mode is used it is only
required if the particularly high demands are placed on the current control
loop (e.g. very heavy load surges in operation).
Sequence of initial commissioning
Activate application Step Function Explanation
data set
• Traction and lifting drive
• Rotational drive
Select control 1 Activate application data set*)
terminal presetting • Field bus operation
• Bus operation
• DRV_1 to 5
Motor data input
• ROT_1 to 3
2 Set assistance parameter*)
• BUS_1 to 3
• M-S_1 to 4
Enter application data
• Motor type
• Rated current
• Rated voltage
Motor identification
and controller setting 3 Enter motor data • Nominal speed
• Rated power
• Rated frequency
Select control mode • cos ϕ
• Moment of inertia of special
4 Specify moments of inertia motors
Save setting in user data set • Application
• Electrical parameters of the
5 Automatic motor identification motor are ascertained
• Control circuits are set
The control terminal is assigned the quick jog/slow jog driving pro-
file and limit switch evaluation functions.
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Engineering Guide CDA3000 4-7
4 Software functions
3.2 Call up the individual motor parameters and enter the read values
7
Figure 4.4 Example
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Engineering Guide CDA3000 4-9
4 Software functions
7.1 Call up parameter UMWR and enter the value “1” for user data
set 1.
Note: Only by saving the data sets to one of the user data sets are
the data from the volatile device RAM permanently stored.
Otherwise changes to the active data set are lost on power-
off or in the event of an error reset.
4.1.3 Operation via By way of the KEYPAD KP200 control unit the complete inverter module
KEYPAD KP200 can be monitored and adjusted.
The KEYPAD can be mounted directly on the inverter module or be fixed to 1
,yy,,,,,,
yyyyy
,,
yy
a switch cabinet door.
yyyyy
,,, ,,
KP200 KP200
X4
y, ,,
yy
stop
return
start
enter
3m
b)
max
. 3
a)
b)
a)
5
Figure 4.5 Mounting the KEYPAD (max. cable length 3 meters)
6
The KEYPAD KP200 has a user-friendly menu structure which is identical
to the menu structure of the KP100 for the SMARTDRIVE VF1000 inverters
and for the MASTERCONTROL servocontrollers. 7
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Engineering Guide CDA3000 4-11
4 Software functions
KP200 controls
(1)
Call up menu, subject area or parameter Save
changes
CARD
S MART
start
enter
stop
Quit menu, cancel changes
return
Stop in "Control drive" mode
VAL
A user data set of the inverter module can be saved to the SMARTCARD
and transferred to other drives.
4.1.4 Operation via The “DriveManager” PC user software for Windows® 95 and NT rounds
DRIVEMANAGER off the skillfully designed and user-friendly operator control concept.
The “DRIVEMANAGER” software tool provides the following functions:
➢ User-friendly subject area and parameter editor with plain text dis-
play (See Figure 4.8)
➢ Status display to monitor the operation-specific actual and reference
values
➢ Direct control of the inverter by PC
➢ User-friendly four-channel digital scope for real-time recording of
actual values such as current curve or v/t diagram (See Figure 4.10)
➢ Comparison function for problem-solving and data administration
and print functions
Figure 4.8 User-friendly subject area and parameter editor with plain text 5
display
yy
,,
H1 H2 H3
ANTRIEBSTECHNIK
D-35633 Lahnau X4
Typ: 3m m
Netz:
ax.
7
Ausg.:
SN.:
000.000.00000000
X1
U
X2
D RIV E
V
W
M AN AG ER
!
Betriebsanleitung Pay attention to the >3 min. observer le
Kondensatorent- capacitor disscharge temps de decharge
du condensteur
RB+
A
RB
ladezeit >3 Min. time >3 minutes.
L-
WARNING
L1
X3
beachten!
ACHTUNG
L2
L3
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Engineering Guide CDA3000 4-13
4 Software functions
Digital scope
With the digital scope up to four channels can be recorded simultane-
ously, permitting comprehensive diagnosis.
X10 X10 2
1
2
(1)
X11
X4
3
X12 X11
(2)
4
X2
X1 X1
X15 5
X3
7
UM - 8I4O A
CDA32.xxx CDA34.xxx
4.2.1 Specification
Des. Terminal Specification floating
of control
terminals Analog inputs
ISA00 X2-2 • UIN = +10 V DC, ±10 V DC
IIN = (0) 4-20 mA DC, software-switchable to:
• 24 V digital input, PLC-compatible (IEC1131)
U: ±1% of MV
• Switching level Low/High: <4.8 V / >8 V DC
I: ±1% of MV
• Resolution 10-bit
• Rin=110kΩ
• Floating against digital ground
ISA01 X2-3 • UIN = +10 V DC, software-switchable to:
• 24 V digital input, PLC-compatible (IEC1131)
• Switching level Low/High: <4.8 V / >8 V DC
U: ±1% of MV
• Resolution 10-bit
• Rin=110 kΩ
• Floating against digital ground
Analog output
MV = measured value
• RIN = 3 kΩ
• Delay ≈ 2µs 4
ISD01 X2-10 • Limit frequency 500 kHz
• PLC-compatible (IEC1131)
• Switching level Low/High: <5 V / >12 V DC
• Imax at 24 V = 10 mA ✔
5
• RIN = 3 kW
• Delay ≈ 2µs
ISD02 X2-11
• Data input in reference coupling
• Limit frequency 500 kHz
6
• PLC-compatible (IEC1131)
• Switching level Low/High: <5 V / >12 V DC
•
•
Imax at 24 V = 10 mA
RIN = 3 kΩ
7
✔
• Delay ≈ 2µs
• A-input with square encoder evaluation for 24V
HTL encoder against GND_EXT
• Permissible pulse counts 32...16384 pulses per
A
n with n =
rev. (2 5..14)
ISD03 X2-12 • Limit frequency 500 kHz
• PLC-compatible (IEC1131)
• Switching level Low/High: <5 V / >12 V DC
• Imax at 24 V = 10 mA
• RIN = 3 kΩ
✔
• Delay ≈ 2µs
• B-input with square encoder evaluation for 24V
HTL encoder against GND_EXT
• Permissible pulse counts 32...16384 pulses per
rev. (2n with n = 5..14)
MV = measured value
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Engineering Guide CDA3000 4-17
4 Software functions
4.2.2 Isolation The isolation in the inverter module safely isolates all control terminals
method and from the live circuit components. The reference potentials of the control
connection tips
terminals are in turn split such that all analog and digital signals are each
connected to one reference potential (DGND and AGND). As a result of
1
this split an n analog signal, e.g. for the speed reference, is immune to
interference entering the inverter module over the digital signal lines.
The two analog inputs may be used either both with analog or both with 2
digital function.
If the analog inputs are to be assigned digital functions, when using the
internal 24 V auxiliary voltage it is necessary to interconnect the two
grounds (DGND and AGND).
3
RB 4
Motor
Mains
Live components
M
3~ 5
6
Analog control Digital control
terminals terminals
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Engineering Guide CDA3000 4-19
4 Software functions
4.3 Preset solutions The inverter module contains preset solutions for the most common appli-
cations. The object of these presets is to find the optimum device setup
for the application with minimal parameter setting.
Based on the application-specific basic settings for the “traction and lifting
drive” and “rotational drive” areas, all software functions relevant here are
already optimized to these applications. With two additional basic settings
the inverter module can be very easily preset for operation on the field
bus and for network operation with several inverter modules (Master-/
Slave operation).
When one of these four basic settings has been selected the inverter
module also offers the user the opportunity to select various control termi-
nal settings. In this way the inputs and outputs of the inverter module are
adapted to the signals required in the process.
With the total of 15 available presets the inverter module can be adapted
with a small number of parameters to virtually any application, thereby
greatly reducing commissioning times.
Rack drive
m2
3
4
m2
Traction and lifting drive
Spindle drive
Section 4.3.1
Trolley drive m2
6
Lifting drive
7
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Engineering Guide CDA3000 4-21
4 Software functions
yy
@@
ÀÀ
,,
Application data set: “Rotational drive”
Extruder
Spindle drive
@@
ÀÀ
,,
yy
Rotational drive
Section 4.3.2
Stirrer
Winding drive
+ + + +
SPS
(1)
+ + + +
3 3 3
n1 n1 n1
(4) (4) (4)
n2 n2 n2
Process (5)
n1 n2 = n1 . i1 n3 = n1 . i2
Process
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Engineering Guide CDA3000 4-23
4 Software functions
4.3.1 Traction and Loading of application data set 1 into the RAM causes the inverter mod-
lifting drive ule automatically to adopt the configuration of the software functions as
well as all inputs and outputs for the “traction and lifting drive” application
(see Figure 4.13).
(1)
~ 3~
PTC
n2
CPU (6) (5.2)
(7) m2
(9)
(8)
(5.3)
m2
Overview of traction and lifting The assistance parameter “ASTER” provides a further automatic configu-
drive ration of the inputs and outputs.
With the aid of the assistance parameter you are able to activate five dif- 1
ferent traction and lifting drive solution at the press of a button, without
having to read through the Operation Manual in detail to do so.
2
Setting of parameter ASTER for traction and lifting drives
DRV_11)
DRV_22)
DRV_33)
DRV_44)
DRV_55)
Function ASTER =
3
v
5
v
Quick jog/slow jog
driving profile
✔✔✔ ✔
6
t
v 7
Table sets with fixed
frequencies and ramps
✔
t A
v v
Characteristic data
switchover for load ✔
adjustment
t t
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Engineering Guide CDA3000 4-25
4 Software functions
DRV_11)
DRV_22)
DRV_33)
DRV_44)
DRV_55)
Function ASTER =
1 2
User data set
001 MODE 001 MODE
switchover
✔✔✔✔
999 xyz 999 xyz
Encoder evaluation
M (necessary for control ✔✔
3~ mode FOR)
Messages:
• Ready to start ✔✔✔✔✔
• Speed reached
Warnings:
• Inverter module
overloaded
• 80% of IN
reached ✔
• Motor overloaded
• Inverter ambient
temperature too
high
1) DRV_1 (Page 27) 2) DRV_2 (Page 29) 3) DRV_3 (Page 31)
4) DRV_4 (Page 34) 5) DRV_5 (Page 36)
Function Application 1
• Clock drive with time-optimized • Conveyor belt
quick jog driving profile or • Trolley drive
• Quick jog/slow jog driving profile • Rack drive
• Spindle drive
2
• etc.
X2 Function 3
1 Reference voltage 10V, 10mA
2 not assigned
3 not assigned
4
4 Actual frequency
0 ... 10 V corresponding to
5 0 ... FMAX
N1 6 Auxiliary voltage 24 V max. 5
7 200 mA
ENPO
8 Power stage hardware enable
STR 9 Start/Stop quick jog clockwise 6
STL
Start/Stop quick jog anti-clock-
10
wise
S1
7
11 Selection of slow jog
~
- 12 not assigned
K1 13 Auxiliary voltage 24 V A
14 Output signal for
M H1
3~ 15 Motor holding brake
X3 Function
1
Motor PTC evaluation
2
Input signals
FMAX
590-ACCR 592-DECR
f [Hz] 0
594-STOPR
FMAX
1
STR 0
1
STL 0
1
S1 0
t [ms]
Output signals
f [Hz]
v [m/s] 0
1
H1 0
1
K1 0
t [ms]
Function Application 1
• Clock drive with time-optimized • Conveyor belt
quick jog driving profile or • Trolley drive
• Quick jog/slow jog driving profile
• Application switchover
• Rack drive 2
• Spindle drive
• Switchover of setting when load • Lifting drive
changed • etc.
3
X2 Function (1...10)
1 Reference voltage 10 V, 10 mA 4
S1 2
User data set selection
S2 3
4 Actual frequency 5
0 ... 10 V corresponding to
5 0 ... FMAX
N1
6
7
Auxiliary voltage 24 V max.
200 mA
6
ENPO
8 Power stage hardware enable
STR
9 Start/Stop quick jog clockwise
STL
Start/Stop quick jog anti-clock-
7
S3 10
wise
S4
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Engineering Guide CDA3000 4-29
4 Software functions
Input signals
DECR
STOPR
f [Hz] ACCR
v [m/s] 0
1
STR 0
1
STL 0
1
S3 0
1
(1) 0
t [ms]
Function Application 1
• Clock drive with time-optimized • Rack drive
quick jog driving profile or • Spindle drive
• Quick jog/slow jog driving profile • Trolley drive 2
• Application switchover • Lifting drive
• Evaluation of safety limit switches • etc.
3
X2 Function
1 Reference voltage 10 V, 10 mA
S1
2 User data set switchover
S2
3 Selection of slow jog
4
4 Actual frequency
0 ... 10 V corresponding to
N1
5 0 ... FMAX 5
6 Auxiliary voltage 24 V max.
7 200 mA
ENPO
STR
8 Power stage hardware enable 6
9 Start/Stop quick jog clockwise
STL
Start/Stop quick jog
S3 10
anti-clockwise
S4 7
11 Limit switch right
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Engineering Guide CDA3000 4-31
4 Software functions
Input signals
303-FMAX1
270-FFIX1
590-ACCR1 592-DECR1
f [Hz]
v [m/s] 0
594-STPR1 - 303-FMAX1
1
STR 0
1
STL 0
1
S1 0
(1) 1
0
t [ms]
(1) DC braking torque
Figure 4.20 Example of use of the control terminal default with ASTER=3
2
Figure 4.21 Example of a limit switch evaluation
3
303-FMAX1
- 303-FMAX1 5
1
STR 0
STL 1
0 6
1
S3 0
S4 1
0
7
t [ms]
The limit switch must not be overrun. The signal must be applied continu-
ously (no pulse evaluation).
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Engineering Guide CDA3000 4-33
4 Software functions
X2 Function
1 Reference voltage 10 V, 10 mA
S1
2
S2 User data set switchover
3
4 Actual frequency
0 ... 10 V corresponding to
5 0 ... FMAX
N1
STR
8 Power stage hardware enable
STL
9 Start/Stop clockwise
10 Start/Stop anti-clockwise
A
N2
B 11 Encoder track A
(1)
12 Encoder track B
13 Auxiliary voltage 24 V
14 DGND
594-STPR1 590-ACCR1
5
f [Hz]
v [m/s] 0
- 303-FMAX1 6
STR
1
0 7
1
STL 0
t [ms]
A
Figure 4.25 Example of a quick jog driving profile for two directions of rota-
tion (ASTER=DRV_4)
Function Application
X2 Function
1 Reference voltage 10 V, 10 mA
2 not assigned
3 not assigned
4 Actual frequency
0 ... 10 V corresponding to
N1
5 0 ... FMAX
6
Auxiliary voltage 24 V max. 200 mA
7
ENPO
(1) The encoder is evaluated only in control mode FOR. For notes on the
encoder see also Figure 4.24.
X15 Function 1
1 24 V supply +20%, 0.6 A
2 Digital ground
21 Auxiliary voltage 24 V 2
S1
H1 H2 H3
22
ANTRIEBSTECHNIK
X4 S2
23
D-35633 Lahnau
U
19
S5
18
V
X15 26 Limit switch right
17
16
W
15
4
14
S6
1
13
3
10
!
4
RB+
9
S7
5
8
ACHTUNG
6
Kondensatorent-
RB
28
7
Betriebsanleitung
8
L- beachten!
5
WARNING
4
10
capacitor disscharge
S8
3
L1 operation manual!
ATTENTION X3
temps de decharge
16
5
L2 du condensteur
17
mode dèmploi!
L3
30 Digital ground
19
20
H2
31 Warning “Inverter module overloaded”
H3
32 Warning “Motor overloaded”
H4
33 Warning “80% of IN exceeded”
6
H5
34 Warning “Ambient temperature too high”
35 Digital ground
7
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Engineering Guide CDA3000 4-37
4 Software functions
270-FFIX1
610-TACR2 604-FFTB4
601-FFTB1
594-STPR1
590-ACCR1
608-TACR0 619-TDCR3
609-TACR1
612-TACR4
f [Hz]
v [m/s] 0 611-TACR3
TDCR4
600-FFTB0
603-FFTB3
1
STR 0
1
S1 0
1
S2 0
1
S3 0
1
S4 0
t [ms]
Figure 4.28 Example of use of table sets with fixed frequencies and ramps
(ASTER=DRV_5)
4.3.2 Rotational drive Loading of application data set 2 into the RAM causes the inverter
module automatically to adopt the configuration of the software functions
as well as all inputs and outputs for the “rotational drive” application (see
Figure 4.29).
1
yy
@@
ÀÀ
,,
(1) 2
@@
ÀÀ
,,
yy
(3) (4) (5) (5.1)
Netz/Main
3 ~= (2) M n1
3
~ 3~
PTC
n2
(6) (5.2)
(7) 4
(8)
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Engineering Guide CDA3000 4-39
4 Software functions
Overview of rotational drives The assistance parameter “ASTER” provides a further automatic configu-
ration of the inputs and outputs.
With the aid of the assistance parameter you are able to activate five dif-
ferent traction and lifting drive solution at the press of a button, without
having to read through the Operation Manual in detail to do so.
ROT_11)
ROT_22)
ROT_33)
Function Aster =
Speed input
-10 V ... +10 V
switchable to
✔ ✔ ✔
0 ... 10 V, 0(4) ... 20 mA
Speed correction
0 to 10 V
✔ ✔
v
Table sets with fixed
frequencies and ramps
✔
t
1 2
User data set
001 MODE 001 MODE
switchover
✔
999 xyz 999 xyz
Encoder evaluation
M (necessary for control ✔ ✔
3~ mode FOR)
ROT_11)
ROT_22)
ROT_33)
Function Aster =
1
Messages:
• Reference
reached ✔ ✔ ✔
• Standstill 2
• Ready to start
Warnings:
• Inverter module
overloaded
3
• 80% of IN
reached ✔
• Motor overloaded 4
• Inverter ambient
temperature too
high
1) ROT_1 (Page 42) 2) ROT_2 (Page 44) 3) ROT_3 (Page 46) 5
Table 4.15 Application-specific basic settings
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Engineering Guide CDA3000 4-41
4 Software functions
X2 Function
1 Reference voltage 10 V, 10 mA
R1 2 Reference -10 V ... + 10 V
3 not assigned
4 Actual frequency
5 0 ... 10V corr. to 0 ... FMAX
N1
6 Auxiliary voltage 24V max.
7 200 mA
ENPO 8 Power stage hardware enable
STR
9 Start/Stop clockwise
STL 10 Start/Stop anti-clockwise
S1
11 Increase speed
S2
12 Reduce speed
13 Auxiliary voltage 24 V
14 Digital ground
H1
Message: “References
15
H2 reached”
16 Standstill
17 Digital ground
18 Relay contact (break)
19 Relay contact (make)
K0 20 for "ready" signal
X3 Function
1 Motor PTC evaluation
2 Function inactive
590-ACCR1 592-DECR1
1
590-ACCR1
f [Hz] 592-DECR1
v [m/s] 0
590-ACCR1 592-DECR1
2
1
STR 0
STL
1 3
0
1
S1 0
S2
1
0
4
t [ms]
Output signals 6
f [Hz] 7
v [m/s] 0
H1
1
0
A
1
H2 0
t [ms]
H1 Speed reached
H2 Standstill
Figure 4.32 Output signals dependent on driving profile
(ASTER=ROT_1, ROT_2 and ROT_4)
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Engineering Guide CDA3000 4-43
4 Software functions
X2 Function
1 Reference voltage 10 V, 10 mA
R1 2 Reference -10 V ... 10 V
R2 3 Correction value 0 V ... + 10 V
4 Actual frequency
0 ... 10 V corresponding to
5 0 ... FMAX
N1
6 Auxiliary voltage 24 V max.
7 200 mA
ENPO
8 Power stage hardware enable
STR
9 Start/Stop clockwise
STL
10 Start/Stop anti-clockwise
A
11 Encoder track A
(1) B
12 Encoder track B
(1) The encoder is evaluated only in control mode FOR. For notes on the
encoder see also Figure 4.24.
Input signals
(1) (1)
1
590-ACCR1 594-STPR1 590-ACCR1
f [Hz]
v [m/s] 0
590-ACCR1 592-DECR1 2
(1)
1
STR 0
3
1
STL 0
t [ms]
(1) Reference value of ISA00 4
Figure 4.34 Example of a driving profile for two directions of rotation
(ASTER=ROT_2)
5
The output signals are shown in Figure 4.32.
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Engineering Guide CDA3000 4-45
4 Software functions
X2 Function
1 Reference voltage 10 V, 10 mA
R1 2 Reference -10 V ... +10 V
R2 3 Correction value 0 V ... + 10 V
4 Actual frequency
0 ... 10 V corresponding to
N1
5 0 ... FMAX
6 Auxiliary voltage 24 V max.
7 200 mA
ENPO
8 Power stage hardware enable
STR
9 Start/Stop clockwise
STL
10 Start/Stop anti-clockwise
A
N2
(1) B 11 Encoder track A
12 Encoder track B
(1) The encoder is evaluated only in control mode FOR. For notes on the
encoder see also Figure 4.24.
X15 Function
1 24 V supply + 20 %, 0.6 A 1
2 Digital ground
21 Auxiliary voltage 24 V
S1
22 2
S2
23 Selection of table sets for fixed
S3
24 frequencies
S4
25 3
S5
26
S6 User data set selection
27
28 4
not assigned
29
30 Digital ground
H3 5
31 Warning “Inverter module overloaded”
H4
32 Warning “Motor overloaded”
H5
H6
33 Warning “80% of IN exceeded”
6
34 Warning “Ambient temperature too high”
35 Digital ground
7
Figure 4.36 Assignment of control terminal expansion with ASTER=ROT_3
A
H1 H2 H3
ANTRIEBSTECHNIK
D-35633 Lahnau X4
X1 X2
20
U
19
18
V
X15
17
16
W
15
14
1
13
2
12
11
3
10
!
4
RB+
9
5
8
ACHTUNG
6
RB Kondensatorent-
7
Betriebsanleitung
8
L- beachten!
5
WARNING
4
10
capacitor disscharge
3
L1 operation manual!
ATTENTION X3
temps de decharge
16
L2 du condensteur
17
mode dèmploi!
L3
19
20
270-FFIX1
610-TACR2 604-FFTB4
601-FFTB1
594-STPR1
590-ACCR1
608-TACR0 619-TDCR3
609-TACR1
612-TACR4
f [Hz]
v [m/s] 0 611-TACR3
TDCR4
600-FFTB0
603-FFTB3
1
STR 0
1
S1 0
1
S2 0
1
S3 0
1
S4 0
t [ms]
4.3.3 Field bus Loading application data set 3 presets the inverter functions for field bus
operation operation. This requires that an appropriate communication module is
fitted to the CDA3000. 1
+ + + +
SPS
+ + + +
(1)
2
M
3~
M
3~
M
3~
4
(3) (3) (3)
n1
(4)
n1
(4)
n1
(4)
5
n2 n2 n2
Process (5) 6
(1) Field bus
(2)
(3)
Inverter module
IEC standard motor
7
(4) Gearing
(5) Application
Figure 4.39 Drive solution: “Field bus operation” A
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Engineering Guide CDA3000 4-49
4 Software functions
BUS_11)
BUS_22)
BUS_33)
Function ASTER
SPS/PLC
Reference and control
via PLC
✔ ✔ ✔
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
20
20
IN1
IN2 Digital inputs and
IN3
IN4 outputs readable and ✔
OUT1 writable over the bus
OUT2
OUT3
Manual mode
independent of bus
✔ ✔
(ASTER=BUS_1)
X2 Function (1...10) 3
X10
1 Reference voltage 10V, 10mA
1
H1 H2 H3 2
2 Analog input 1
ANTRIEBSTECHNIK
D-35633 Lahnau X4
X11
3 Analog input 2 4
X12 4 Analog ground
X1 X2
5 Analog output
20
U
19
18
V
17
5
16
W
6
15
7 200 mA
10
RB+ !
9
8
ACHTUNG
RB Kondensatorent-
7
Betriebsanleitung
L- beachten!
ENPO 8 Power stage hardware enable
5
WARNING
4
capacitor disscharge
3
6
1
L1 operation manual!
ATTENTION X3
L2
temps de decharge
du condensteur
>3 min. observer le
mode dèmploi!
9 Digital input 1
L3
10 Digital input 2
11 Digital input 3
12 Digital input 4 7
13 Auxiliary voltage 24 V
14 Digital ground
15 Digital output 1: A
16 Digital output 2:
17 Digital ground
18 Digital output 3:
19 Relay with
20 changeover contact
X3 Function
1 Motor PTC connection
2 Function inactive
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Engineering Guide CDA3000 4-51
4 Software functions
(ASTER=BUS_2)
Field bus operation (configuration 10)
Function Application
X10
1
X2 Function
H1 H2 H3 2
ANTRIEBSTECHNIK
D-35633 Lahnau X4
X11
1 Reference voltage 10 V, 10 mA
R1
2 Reference for manual mode 0 V ... +10 V
X12
3 not assigned
X1 X2
20
U
4
19
Actual frequency
18
V
17
16
W
15
5
13
12
N1
11
10
RB+ !
6
9
8
ACHTUNG
RB Kondensatorent-
7
Betriebsanleitung
L- beachten!
5
WARNING
4
capacitor disscharge
7
3
L1 operation manual!
ATTENTION X3
L2
temps de decharge
ENPO
L3
du condensteur
>3 min. observer le
mode dèmploi! 8 Power stage hardware enable
STR
9 Start/Stop clockwise for manual mode
STL
10 Start/Stop anti-clockwise for manual
S1
11 Selection of manual mode
12 Digital input
13 Auxiliary voltage 24 V
14 Digital ground
15 Digital output 1:
16 Digital output 2:
17 Digital ground
18 Relay contact (break)
19 Relay contact (make)
20 for "ready" signal
K0
X3 Function
1 Motor PTC connection
2 Function inactive
Input signals
(1) (1)
1
590-ACCR1 594-STPR1 590-ACCR1
f [Hz]
v [m/s] 0
590-ACCR1
(1)
592-DECR1
2
1
S1 0
STR
1
0
3
1
STL 0
t [ms] 4
(1) Analog reference value of ISA00
Figure 4.42 Example of use of manual mode independent of bus mode
ASTER=BUS_2
5
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Engineering Guide CDA3000 4-53
4 Software functions
(ASTER=BUS_3)
Field bus operation (configuration 11)
Function Application
X2 Function
X10
H1 H2 H3
1
2
1 Reference voltage 10 V, 10 mA
ANTRIEBSTECHNIK
X4 R1
D-35633 Lahnau
X11
2 Reference for manual mode 0 V ... +10
S1
3 Selection of manual mode
X12
X1 X2 4 Actual frequency
20
U
19
V
5
17
16
W
15
N1
14
13
6
12
RB+ !
9
8
ACHTUNG
RB Kondensatorent-
7 200 mA
7
Betriebsanleitung
L- beachten!
5
WARNING
4
capacitor disscharge
ENPO
3
L1 operation manual!
ATTENTION X3
temps de decharge
L2 du condensteur
>3 min. observer le
mode dèmploi! STR
L3
9 Start/Stop clockwise for emerg.op.
STL
10 Start/Stop anti-clockwise for
S2
11 Limit switch right
S3
12 Limit switch left
13 Auxiliary voltage 24 V
14 Digital ground
15 Digital output 1:
16 Digital output 2:
17 Digital ground
18 Relay contact (break)
19 Relay contact (make)
20 for "ready" signal
K0
X3 Function
1 Motor-PTC connection
2 Evaluation inactive
(1) (1)
1
590-ACCR1 594-STPR1 590-ACCR1
f [Hz]
v [m/s] 0
590-ACCR1
(1)
592-DECR1
2
1
S1 0
STR
1
0
3
1
STL 0
t [ms] 4
Figure 4.44 Example of use of emergency operation independent of bus
mode ASTER=BUS_3
5
The mode of functioning of the limit switch evaluation is shown in Figure
4.21 and Figure 4.22. 6
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Engineering Guide CDA3000 4-55
4 Software functions
4.3.4 Master-/Slave Application data set 4 includes a setup for Master-/Slave operation
operation between inverter modules. In this way the speeds of a maximum of six
drives are permanently coupled together.
(1)
M M M
3~ 3~ 3~
(3) (3) (3)
n0 n1 = n0 . i1 n2 = n0 . i2
(4)
Process
The coupling of the electrical axles in VFC and SFC control modes
causes the motors to run at a fixed ratio to each other. Only in the FOR
control mode do the motors run speed-synchronous.
Characteristics
VFC
Voltage Frequency
SFC
Sensorless
FOR
Field-Oriented
1
Control Flux Control Regulation
Master
4
Reference M1 n = 3000 rpm
3000 U/min X2
3~
17
16
5
Slave 1
X2
10
i=2
M2
3~
n = 1500 rpm 6
14
Slave 2
i=3
7
M3 n = 1000 rpm
X2
3~
10
14
A
Slave 5
i=5
M6 n = 600 rpm
X2
3~
10
14
n = 3000 rpm
Master
n [rpm]
Slave 1
i=2
n = 1500 rpm
Slave 2
i=3
n = 1000 rpm
Slave 5
i=5
n = 600 rpm
t [ms]
M-S11)
M-S22)
M-S33)
M-S44)
Function ASTER 1
MASTER
Inverter module is
master
✔ ✔ 2
SLAVE SLAVE
MASTER
3
Inverter module is slave ✔ ✔
SLAVE SLAVE
4
n
Speed change via but-
✔ ✔
n
ton (MOP function) 5
M Encoder evaluation ✔ ✔
6
3~
Messages:
7
• Standstill ✔ ✔✔ ✔
• Ready to start
A
Message:
• Reference ✔ ✔
reached
1) M-S1 (Page 60) 2) M-S2 (Page 62) 3) M-S3 (Page 64) 4) M-S4 (Page 66)
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Engineering Guide CDA3000 4-59
4 Software functions
X2 Function
1 Reference voltage 10 V, 10 mA
R1
2 Reference -10 V ... + 10 V
3 not assigned
4 Actual frequency
0 ... 10 V corresponding to
N1 5 0 ... FMAX
6 Auxiliary voltage 24 V max.
7 200 mA
ENPO
STR
8 Power stage hardware enable
9 Start/Stop clockwise
STL
S1
10 Start/Stop anti-clockwise
S2 11 Increase speed
12 Reduce speed
13 Auxiliary voltage 24 V
H1 14 Digital ground
15 Message: Standstill
Slave 16 Slave interface
17 Digital ground
18 Relay contact (break)
19 Relay contact (make)
20 for "ready" signal
K0
X3 Function
1 Motor PTC evaluation
2 Function inactive
590-ACCR1
592-DECR1
1
590-ACCR1
f [Hz] 592-DECR1
v [m/s] 0 590-ACCR1
594-STPR1 2
(1)
1
STR 0
STL
1 3
0
1
S1 0
S2
1
0
4
(2)
t [ms] 5
(1) Analog reference value of ISA00
(2) DC braking torque
Figure 4.49 Example of a driving profile for two directions of rotation
(ASTER=M-S1)
6
Output signals
7
f [Hz]
v [m/s] 0 A
1
H1 0
t [ms]
H1 Standstill
Figure 4.50 Output signals dependent on driving profile
(ASTER=M-S1 and M-S2)
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Engineering Guide CDA3000 4-61
4 Software functions
X2 Function
1 Reference voltage 10V, 10mA
R1
2 Reference -10 V ... + 10 V
3 not assigned
4 Actual frequency
5 0 ... 10V corr. to 0 ... FMAX
N1
6 Auxiliary voltage 24 V max.
7 200 mA
ENPO
8 Power stage hardware enable
STR
9 Start/Stop clockwise
STL
10 Start/Stop anti-clockwise
A
11 Encoder track A
B
12 Encoder track B
13 Auxiliary voltage 24 V
14 Digital ground
H1
15 Message: Standstill
16 Slave interface
Slave
17 Digital ground
18 Relay contact (break)
19 Relay contact (make)
20 for "ready" signal
K0
X3 Function
1 Motor PTC evaluation
2 Function inactive
Input signals
(2) (2)
1
590-ACCR1 594-STPR1 590-ACCR1
f [Hz]
v [m/s] 0
590-ACCR1 592-DECR1 2
(1)
1
STR 0
3
1
STL 0
(1)
4
t [ms]
6
The basic characteristic of the output signals is shown in Figure 4.50.
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Engineering Guide CDA3000 4-63
4 Software functions
X2 Function
1 Reference voltage 10 V, 10 mA
2 Reference -10 V ... + 10 V
3 not assigned
4 Actual frequency
0 ... 10 V corresponding to
N1 5 0 ... FMAX
6 Auxiliary voltage 24 V max.
7 200 mA
ENPO
S1 10 Master interface
Master S2 11 Increase speed
12 Reduce speed
13 Auxiliary voltage 24 V
H1 14 Digital ground
X3 Function
1 Motor PTC evaluation
2 Function inactive
Figure 4.53 Control terminal assignment with ASTER = M-S3; with S1 and
S2 an offset can be added to or subtracted from the guide value
Input signals
590-ACCR1 1
590-ACCR1 592-DECR1
f [Hz]
v [m/s] 0 594-STPR1
(1) 2
0
1
STR 0
3
S1 1
0
S2 1
0
4
(2)
t [ms]
5
(1) Guide value from master
(2) DC braking torque
Figure 4.54 Example of a driving profile with Master-/Slave coupling
(ASTER = M-S3) 6
Output signals
7
f [Hz]
v [m/s] 0 A
1
H1 0
H2 1
0
t [ms]
H1 Reference reached
H2 Standstill
Figure 4.55 Output signals dependent on driving profile
(ASTER = M-S3 and M-S4)
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Engineering Guide CDA3000 4-65
4 Software functions
X2 Function
1 Reference voltage 10V, 10mA
2 Reference -10 V ... + 10 V
3 not assigned
4 Actual frequency
0 ... 10 V corresponding to
N1 5 0 ... FMAX
6 Auxiliary voltage 24 V max.
7 200 mA
ENPO
A
10 Master interface
Master B 11 Encoder track A
12 Encoder track B
13 Auxiliary voltage 24 V
H1
14 Digital ground
X3 Function
1 Motor PTC evaluation
2 Function inactive
Input signals
1
f [Hz]
v [m/s] 0 594-STPR1
2
(1) 0
1
STR 0
3
(2)
t [ms]
4
(1) Guide value from master
(2) DC braking torque
Figure 4.57 Example of a driving profile with Master-/Slave coupling 5
(ASTER = M-S4)
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Engineering Guide CDA3000 4-67
4 Software functions
Initial commissioning
Magnetizing
See section 4.4 Current-controlled startup
Modulation
Error messages DC holding
Warning messages DC braking
Actual values Master/Slave operation
Control location
Reference structure Device data Characteristic switchover
Clock input/clock output Device capacity utilization Driving sets
Digital outputs KP 200 Fixed frequencies
Digital inputs Power failure bridging Driving profile generator
Analog output Motor protection Option modules MOP function
Analog inputs Frequency limitation LUSTBUS Motor holding brake
See section 4.5 See section 4.6 See section 4.7 See section 4.8
Motor data
Speed controller FOR
Current controller
Current injection
Encoder evaluation
Slip compensation
Speed controller SFC
I x R load compensation
VFC
Commissioning 1
Subject area Function Effect
Flexible function assignment of all digital The output signals can be used to deliver
A
Digital outputs outputs. control signals and process messages.
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Engineering Guide CDA3000 4-69
4 Software functions
Display of faults in the drive system with Quick localization of the cause of the
Error messages detailed information as to the cause. error. 1
2
SIO and options
LUSTBUS Parameter setting of the diagnostic inter- Adaptation of the inverter module inter-
face. face to a PC. 4
Parameter setting of the option modules,
The option modules are adapted to the
Option modules e.g. CAN bus address.
field bus and the user module to the 5
Parameter setting of the field bus modules
process.
and I/O status of the user module.
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Engineering Guide CDA3000 4-71
4 Software functions
DC holding Shutdown of the motor after braking with Rotation due to the load on the motor is
direct current. counteracted.
Modulation Setting of the switching frequency of the Optimization of the drive system in terms
inverter power stage. of power loss, smooth running and noise.
2
Adaptation of the inverter module to the
The motor generates the optimum torque
V/F characteristic motor and to the load characteristic of the
for the application.
application.
3
Automatic adaptation of the V/F charac-
I x R load teristic to the load situation. Compensa- In case of load surges a higher torque is
compensation tion for the voltage drop on the stator available, and the motor heats up less.
resistor of the motor. 4
The slip of the motor is compensated and
Increase in output frequency proportional
Slip compensation the speed thereby kept constant inde-
to the load on the motor.
pendent of the load. 5
Current injection
An adjustable current is injected into the
motor up to a limit frequency.
Increase in starting torque 6
Prior to acceleration of the motor a When the motor is started the full torque 7
Remagnetization magnetic field is injected into the motor. is available immediately.
Setting of the speed control loop for Very smooth running and good dynamics
Speed controller SFC Sensorless Flux Control of the drive without encoder evaluation.
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Engineering Guide CDA3000 4-73
4 Software functions
Setting of the speed control loop for Field- Very smooth running and good dynamics
Speed controller FOR Oriented Regulation. of the drive with encoder evaluation.
2
5 Communication and user modules
3
5.1 Principle of function................................................ 5-2
5.2 User module ............................................................5-3 4
5.3 CAN-BUS ..................................................................5-4
5.3.1 Interconnection of inverter modules on the
CAN bus .............................................................. 5-6 5
5.3.2 Communication via CANLUST .................................5-8
5.3.3 Communication via CANopen ...............................5-12
5.4 PROFIBUS-DP ........................................................5-13 6
5.4.1 Interconnection of LUST drive units with the
PROFIBUS-DP Gateway ......................................5-14
5.4.2 Interconnection via the PROFIBUS-DP module ....5-17 7
5.4.3 Communication via PROFIBUS-DP ......................5-18
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Engineering Guide CDA3000 5-1
5 Communication and user modules
5.1 Principle of Communication and user modules expand the functionality of the
function CDA3000 drive system. On the base module there are two slots, into
each of which one expansion module can be plugged.
Characteristics:
• Usability of the modules on all inverter
sizes
• Simple retrofitting of expansion module by the user
• On inverter modules up to 15kW side mounting, on modules above
22kW on the front of the device
• With side mounting the base unit is 25 mm wider
H1 H2 H3 Communication module
ANTRIEBSTECHNIK
D-35633 Lahnau X4
e.g. CANLust
CANopen
PROFIBUS-DP
X1 X2
1
20
U
2
19
18
U
V
17
16
X5
V
W
15
14
W
1
13
!
2
12
ACHTUNG
Kondensatorent-
3
10
RB+
9
Betriebsanleitung
RB+
beachten!
8
RB
7
WARNING
e.g. eight additional inputs and four addi-
7
capacitor disscharge
RB
L-
5
9
4
operation manual!
10
3
ATTENTION
11
temps de decharge
2
12
du condensteur
1
mode dèmploi!
16
L2
L2
17
18
L3
L1
19
20
Figure 5.1 Inverter module with one control terminal expansion module
and one communication module
5.2 User module With the user module UM-8I40 the digital inputs and outputs of the
inverter module are expanded by eight inputs and four outputs. The
functionality of the expanded inputs and outputs corresponds to that of 1
the I/Os of the inverter module.
5
Figure 5.2 UM 8I4O
6
Technical data UM-8I4O
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Engineering Guide CDA3000 5-3
5 Communication and user modules
5.3 CAN-BUS The CAN bus is a field bus which is in widespread use in automation. Its
data transfer was standardized in ISO 11898. However, most CAN net-
works work with custom conventions for the communication and interpre-
tation of user data.
Openness is attained through the use of the CANopen device profiles.
These profiles define the mode of communication (CiA/DS30x) and the
interpretation of the user data (CiA/ DS40x).
Master 1 Master 2
Priority 1 Priority 2
Master 3 Master 4
Priority 3 Priority 4
CAN bus
Topology Line 1
Data transfer ISO 11898
Transmission speed 25 kBit/s to 500 kBit/s
Transmission range 1000 m to 40 m 2
Data security Hd 6
Number of stations 30
Number of data bytes 0 to 8 3
Bus access Master/Master
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Engineering Guide CDA3000 5-5
5 Communication and user modules
5.3.1 Interconnection
of inverter
modules on the
CAN bus
CM-CAN 1
PLC
+ + + +
1
1
+ + + +
---
- +
24VDC
4 4 4
3 3
2
1
1
2
2
3
3
4
4
5
5
6
24 VDC
6
7
7
8
8
9
9
10
10
10
11
11
11
12
3
12
12
VF1000M VF1000M
13
13
13
14
14
14
15
15
15
16
16
16
17
17
17
18
18
18
19
19
19
20
20
20
VF1000S, G19
1 Control
5
2 Connection of 24 V supply voltage
3 Bus termination plug with resistor 120 Ω
4 Lust system bus cable type I or self-defined cable
6
Voltage supply, CAN bus
Voltage 24 V +20% 7
Voltage ripple 3 Vss
Current 100 mA per station
Shielding
Lust devices are connected by 9-pin connectors.
In the case of connections with D-SUB connectors, ensure that the shield
is connected via the connector housing (2). For that reason the screw
fittings (1) of the connectors must always be tightened.
2
,,,,,,,,,
1 1
,,
,,,,,
Figure 5.6 Open connectors with strain relief and cable shield
5.3.2 Communication Two modes are available for control of the inverter modules via CAN:
via CANLUST 1. Control of the drive unit by way of the state machine defined in
DRIVECOM profile no. 22 of January 1994 for Interbus.
2. Direct selection of the following functions of the drive unit by way of
the control word:
− Transfer of reference and actual values
− Starting and stopping the drive
− Selection of fixed frequencies and ramps
− Error resets
− User data set switchover
− Characteristic switchover
− Setting of digital outputs of the device
− Transfer of various states of the device
− Transfer of states of the digital inputs of the device
9 SWITCH-ON
3
Disable voltage
1 INHIBIT 12 Disable voltage
xxxx xx0x
xxxx xx0x x1xx 0000
Shutdown
2 xxxx x110
10 Disable voltage
xxxx xx0x
Emergency stop
8 READY
7 Disable voltage
xxxx xx0x
xxxx xx0x
4
Shutdown
2
x01x 0001
xxxx x110
Switch on
3 xxxx x111
5
Shutdown
6 xxxx x110
ON
3
x01x 0011
Enable operation
4 xxxx 1111
Disable operation
5
OPERATION
xxxx 0111
EMERGENCY
6
4 ENABLED
Emergency stop
7 STOP ACTIVE
x01x 0111 11 xxxx xx0x x00x 0111
Bit Function
0 Activate
1 Disable power
2 Emergency stop
3 Enable operation
4 Mode-dependent,
more detailed definition:
5
DRIVECOM profile no. 22
6 of January 1994
7 Reset fault
Bit Function
8 Reserve
9 Reserve
10 Reserve
11 vacant
12 vacant
13 vacant
14 vacant
15 vacant
Bit Status
1 On
2 Operation enabled
3 Fault
4 Power disabled
5 Emergency stop
6 Switch-on inhibit
7 Warning
8 No function
9 Remote
10 Reference reached
11 Limit value
12 Mode-dependent
More detailed definition:
13
DRIVECOM profile no. 22
of January 1994
14 vacant
15 vacant
0 Enable control
1 Invert reference
2
2 Braking
3 Set device to error state
4 Selection of table reference
3
5 Selection of table reference
6 Selection of table reference
7 Reset error
4
8 Data set selection
9 Selection of user mode
10 Selection of user mode
5
11 OSD 00 reference state
12 OSD 01 reference state
13 OSD 02 reference state 6
14 Reserve
15 Reserve
Bit Function
Bit Function
Bus topology
3
Slave 1 Slave 2 Master Slave 3
Master
4
Slave 4 Slave 5 Slave 6 term 2
5
Device type Function
A
PROFIBUS-DP
Topology Line
Data transfer RS 485
Bus access Master-/Slave access
Transmission speed 9.6 kBit/s to 12 MBit/s
Transmission range 1200 m to 100 m
Data security Hd 4
Number of stations max. 127 (32 per segment)
Number of data bytes 1 to 246 Bytes
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Engineering Guide CDA3000 5-13
5 Communication and user modules
2) PROFIBUS-DP module
− PROFIBUS-DP expansion module for CDA3000
− Optimized for connection of a CDA3000 inverter module to the
PROFIBUS-DP
− Supports the expanded PROFIBUS-DP functions in accordance
with Directive 2.084
5.4.1 Interconnection The PROFIBUS-DP Gateway connects up to 10 LUST drive units to the
of LUST drive PROFIBUS-DP. The drives are thereby turned into full-scale PROFIBUS-
DP stations.
units with the
PROFIBUS-DP 119 mm
22.5 mm
Gateway
99 mm
114.5 mm
4
+ + + +
SPS
+ + + +
PROFIBUS-DP
5
Gateway CP-DP1
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
7
14
15
15
16
16
17
17
18
18
19
19
20
20
CDA3000
1 2 --- 10
CDA3000 A
Figure 5.9 PROFIBUS-DP layout with Lust drive units
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Engineering Guide CDA3000 5-15
5 Communication and user modules
1
2 24 VDC
4 4 4
3
,,,
,,,
,,,,
,
,
,
,
,
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
MC7000
14
14
15
15
16
16
17
17
18
18
19
19
20
20
@,ÀÀ@,
VF1000S, G19
1 Gateway cable
2 24 V supply voltage
3 Bus termination plug (supplied with Gateway)
4 Lust system bus cable type I or self-assembled cable
5 Connection to PROFIBUS-DP
6 Floppy disk with GSD files (supplied with Gateway)
Shielding
Lust devices are connected by 9-pin connectors.
1
In the case of connections with D-SUB connectors, ensure that the shield
is connected via the connector housing (2). For that reason the screw
fittings (1) of the connectors must always be tightened.
2
2
,,,,,,,,,
1 1
3
,,
,,,,,
4
Figure 5.11 Open connectors with strain relief and cable shield
5
5.4.2 Interconnection Not available at time of going to press.
via the PROFI-
BUS-DP module Summary: 6
• Layout and technical data of the PROFIBUS-DP module
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Engineering Guide CDA3000 5-17
5 Communication and user modules
5.4.3 Communication By way of the PROFIBUS-DP the drive units can be controlled and their
via PROFIBUS- parameters set in accordance with the profile for variable-speed drives
(PROFIDRIVE).
DP
The unambiguous transfer of parameters and process data is achieved by
the configuration of “parameter process data objects” (PPOs). The
PROFIBUS-DP Gateway supports PPOs 1 to 4.
DP-Master
+ + + +
PLC
+ + + +
CP-DP1
Value
2 64
16 3
48
12
ON 7
6
5
4
3
2
1
ON
34
5
67 s: 3
12
Addres
Click
Click
Figure 5.12 Parameter process data object for user data traffic
The PPO illustrated in Figure 5.12 includes a control word and a refe-
rence value for process data transfer from the master to the slave as well
as a status word and an actual value for the reverse direction. The param-
eter area in the PPO is optional, which means it must be planned as
required during slave configuration and is then transferred together with
the process data area on a permanent basis in a cyclic telegram.
PKW PZD
PKE IND PWE PZD1
STW1
PZD2
HSW
PZD3 PZD4 PZD5 PZD6
1
ZSW1 HIW
1st 2nd 3rd 4th 1st 2nd 3rd 4th 5th 6th
word word word word word word word word word word 2
PPO1
PPO2 3
Table 5.14 PPO 1 to PPO 4
PPO3
4
PPO4
yes no
Are reference and actual values to be Are reference and actual values to be
A
transferred as 16-bit values? transferred as 16-bit or 32-bit values?
16 bits 32 bits 16 bits 32 bits
PPO 1 PPO 2 PPO 3 PPO 4
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Engineering Guide CDA3000 5-19
5 Communication and user modules
Transparent mode
In addition to the standardized control concept in accordance with the
PROFIDRÌVE profile, LUST-PROFIBUS modules offer another operation
mode in which no interpretation of the data is performed by the Gateway.
With this “transparent mode” the internal CAN can be accessed directly.
Transparent mode provides the following functions:
• Control of the drive unit according to the DRIVECOM state machine
• Direct selection of the following functions of the drive unit by way of
the control word:
− Transfer of reference and actual values
− Starting and stopping the drive
− Selection of fixed frequencies and ramps
− Error resets
− User data set switchover
− Characteristic switchover
− Setting of digital outputs of the device
− Transfer of various states of the device
− Transfer of states of the digital inputs
For more information see “Communication via CANLust”
2
6 Selection of supplementary
components
3
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Engineering Guide CDA3000 6-1
6 Selection of supplementary components
Harmonics load
Percentage Amplitude
Percentage Amplitude with
Harmonic without line without line
with line choke line choke
choke choke
1
100% 100% 8.58 A 8.31 A
(fundamental)
5 76% 30% 6.4 A 2.55 A
7 57% 8.9% 4.9 A 0.74 A
11 21% 6% 1.85 A 0.5 A
13 to 41 36% 10.9% 3.15 A 0.91 A
System load
Table 6.3 Effect of the line choke with asymmetrical mains voltage
based on the example of a 4 kW inverter CDA34.010
Procedure in practise
In order to establish whether your application conforms to the
EN61800-3/ IEC1800-3 standard or another standard, you must ascertain
the equivalent inverter referred to your line transformer. Based on the
equivalent inverter and the line impedance, you then calculate the voltage
distortion THD. You need to weight the result relative to the overall system
ratios.
Theoretical calculation of the system ratios can only serve as a guide. If
the theoretical calculation reveals that you are at the limits specified in the
standards, you should always carry out a system analysis by means of
systems analysts (measurement duration typically seven days). Only in
this way is a practise-oriented assessment of your power supply system
possible.
f = nres x 50 Hz = 1.3 x 50 Hz = 65 Hz 5
Result:
6
The lowest resonance point is at the harmonic number 1.3 - correspond-
ing to 65 Hz.
This calculation is used to estimate the lowest resonance point under
ideal system conditions.
7
If the calculated resonance point is not in the vicinity of the harmonic
numbers generated by the inverter of 5, 7, 9, 11, 13 etc., it can be
assumed that no resonance problems will occur. A
It should be mentioned that additional motor loads shift the resonance
points toward higher values and the ohmic resistance component in the
system brings about an attenuation of the resonant circuit. In complex
system layouts in particular, pre-calculation of any possible resonance
points is very difficult, so in such cases too it is advisable to perform
measurements only after installation of a harmonics generator. Appro-
priate remedial measured should be initiated accordingly.
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Engineering Guide CDA3000 6-5
6 Selection of supplementary components
6.1.4 Assignment of Line chokes for inverter modules with mains connection
line choke to 1 x 230 V -20 %, +15 %
inverter module 1
Tech. data Connec-
Suitable for Rated Power loss Induct- Weight
tion
inverter module current [A] tot. [W] ance [mH] [kg]
Order ref. [mm]
CDA32.003
2
LR32.8 8 10 3.66 0.8 4
CDA32.004
CDA32.006
LR32.14 14 16 2.1 1.5 4
CDA32.008 3
Figure 6.2 Assignment of line choke to inverter module
Inverter
Line choke with 4% UK
5
Inverter
rated Power Dimensions
module Rated
power Type loss HxWxD
current
[W] [mm]
6
CDA34.003 0.75 kW LR34.4 4,2 A 20 120x100x70
CDA34.005 1.5 kW LR34.6 6A 26.1 140x125x65
CDA34.006 2.2 kW LR34.6 6A 26.1 140x125x65
7
CDA34.008 3.0 kW LR34.8 8A 29 140x125x65
CDA34.010 4.0 kW LR34.10 10 A 33 140x125x75
CDA34.014 5.5 kW LR34.14 14 A 45 160x155x80
CDA34.017 7.5 kW LR34.17 17 A 45 160x155x80
A
CDA34.024 11 kW LR34.24 24 A 50 160x155x95
CDA34.032 15 kW LR34.32 32 A 67 195x190x85
CDA34.045 22 kW LR34.45 45 A 73 195x190x95
CDA34.060 30 kW LR34.60 60 A 85 195x190x105
CDA34.072 37 kW LR34.72 72 A 111 275x230x125
CDA34.090 45 kW LR34.90 90 A 135 280x230x150
CDA34.110 55 kW LR34.110 110 A 126 280x230x150
CDA34.143 75 kW LR34.143 143 A 168 330x265x145
CDA34.170 90 kW LR34.170 170 A 218 360x300x155
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Engineering Guide CDA3000 6-7
6 Selection of supplementary components
res s.
ble to p
t a vaila going
No e of
m
a t ti
CDA34.003
CDA34.004
.
CDA34.005 es s
i l able g to pr
ava oin
CDA34.006 Not e of g
t t im
CDA34.008 a
CDA34.010
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Engineering Guide CDA3000 6-9
6 Selection of supplementary components
CDA32.003
CDA32.004
.
es s
CDA32.006 i l able g to pr
ava oin
Not e of g
CDA32.008 t t im
a
CDA32.008
CDA32.003
CDA32.004
.
es s
CDA32.006 i l able g to pr
ava oin
Not e of g
CDA32.008 t t im
a
CDA32.008
In multi-motor operation ensure that the total motor cable length is the
sum of all individual motor cables. The permissible total length of the 1
motor cable must not be exceeded.
DE
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Engineering Guide CDA3000 6-11
6 Selection of supplementary components
BR-270.03, XX1
BR-270.02, XX0 BR-090.10, XX1 to
Technical data BR-160.03, XX1
BR-160.02, XX0 BR-010.80,XX1
BR-090.03, XX1
Surface temperature > 200° C < 80° C < 80° C
Touch protection no yes (< 80° C) yes (< 80° C)
Voltage max. 800 V max. 800 V max. 800 V
High-voltage strength 4000 V 4000 V 1800 V
Temperature monitoring yes yes yes
Acceptance tests CE
Connection 1 m long PTFE-insulated litz wire Ceramic terminals Ceramic terminals
2
P S ⋅ t ST …
P eff = --------------------------
T
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Engineering Guide CDA3000 6-13
6 Selection of supplementary components
.
es s
i l able g to pr
ava oin
Not e of g
t t im
a
Dimensions
RFI filter Rated current Power loss HxWxD
[mm]
res s.
able to p
t a vail going
No e of
m
a t ti
6.4.2 Permissible
motor cable
length with 1
internal RFI filter
Table 6.14 Permissible motor cable length with integral mains filter
dependent on standard EN 55011 A/B
DE
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Engineering Guide CDA3000 6-15
6 Selection of supplementary components
6.4.3 Permissible
motor cable
length with .
es s
i l able g to pr
internal and ava oin
Not e of g
external RFI t t im
a
filter
6.4.4 Permissible
motor cable
length with
external RFI
filter
Table 6.15 Permissible motor cable length with external mains filter
dependent on standards EN 55011 (A) and EN 55022 (B)
2
7 System installation
3
7.1 Heat discharge from the switch cabinet ................7-2
7.1.1 Basic terms for calculation ...................................7-2
7.1.2 Effective switch cabinet surface ...........................7-3
4
7.1.3 Calculation of filter fans .......................................7-4
7.1.4 Calculation of heat exchangers ............................7-5
7.2 Heat transfer by conduction ...................................7-7
5
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Engineering Guide CDA3000 7-1 FR
7 System installation
7.1.1 Basic terms for A number of calculations must be carried out in order to be able to dimen-
calculation sion the air-conditioning components correctly. The following variables
are key to the calculations:
αι and αα designate the heat transfer coefficients for the inner and outer
wall respectively; λ designates the heat transfer coefficient of the wall
material and s the wall thickness. 1
2
l m K
R = --- ----------
k W
7.1.2 Effective switch Of the variables cited above, the effective switch cabinet surface A
cabinet surface requires a special note of explanation: The heat output emitted from the 3
switch cabinet is not only dependent on its actual surface area; the mode
of installation of the cabinet is also decisive. A housing standing free and
open on all sides can emit more heat than one mounted on a wall or in a
niche. For that reason there are precise regulations as to how the effec- 4
tive switch cabinet surface is to be calculated dependent on the mode of
installation. The formulae to calculate A are laid down in DIN 57660 Part
500 / VDE 0660 DIN 500 (See Figure 7.1).
5
Enclosure installation type to VDE 0660 Part 500
Installation type
to VDE 0660/500 Formula for calculation of A [m2]
6
A = 1.8 x H x (W+D) + 1.4 x W x D
A = 1.4 x B x (H+D) + 1.8 x D x H
A = 1.4 x T x (H+W) + 1.8 x W x H
A = 1.4 x H x (W+D) + 1.4 x W x D 7
A = 1.8 x W x H + 1.4 x W x D + D x H
A = 1.4 x W x (H+D) + D x H
A = 1.4 x W x H + 0.7 x W x D + D x H
A
Single enclosure, all-round, freestanding
Single enclosure for wall mounting Middle enclosure, freestanding
Start or end enclosure, freestanding Middle enclosure for wall mounting,
Start or end enclosure for wall mounting Middle enclosure for wall mounting,
covered roof areas
W = Cabinet width [m] H = Cabinet height [m] D = Cabinet depth [m]
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Engineering Guide CDA3000 7-3
7 System installation
QS = k ⋅ A ⋅ ( Ti – Tu ) (1)
There are also diagrams from which the radiated power can be read
directly, without calculation (See Figure 7.2).
2000
30
1500
20
]
[K
1000
15
T
900
D
Radiated power Qs [W]
800
e
nc
700
10
re
600
ffe
di
5
500
7,
e
ur
t
400
ra
pe
m
300 5
Te
200
150
100
1 1,5 2 3 4 5 6 7 8 9 10
Switch cabinet surface A [m²]
to VDE 0660 Part 500
7.1.3 Calculation of The necessary volumetric flow of a filter fan depends on the power loss of
filter fans the components installed in the switch cabinet and on the difference
between the maximum permissible interior and exterior temperatures:
Necessary volumetric flow
Qv
V = f ⋅ --------------- (2)
Ti – Tu
Tabelle 7.1 Calculation factor “f” for filter fans dependent on altitude above
4
sea level
600 m
3 6
V = 3, 1 ⋅ -------- -------
20 h
7.1.4 Calculation of In contrast to the filter fans, the heat discharge via the switch cabinet sur-
heat exchangers face certainly does need to be taken into account in design of the heat
exchangers. The necessary cooling power QE which a heat exchanger
must deliver is calculated from the difference between the power loss and
the radiated power of the switch cabinet.
QE = QV - QS (3)
Example: A fully exposed sheet-steel switch cabinet is 60 cm wide, 2 m
high and 50 cm deep. The power loss in the cabinet is 900 Watts.
The maximum ambient temperature is +25°C, the temperature in the cab-
inet should not rise above +35°C.
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Engineering Guide CDA3000 7-5
7 System installation
k designates the heat transfer coefficient and A the effective switch cabi-
net surface.
The heat transfer coefficient for sheet-steel is 5.5 W/m²K.
The effective switch cabinet surface is calculated to DIN 57 660 Part 500 /
VDE 0660 Part 500 (see Tabelle 7.1):
A = 1.8 . H (W + D) + 1.4 . B . T
H, W and D indicate the height, width and depth of the cabinet in meters.
Thus in our example:
A = (1.8 . 2 . (0.6+0.5) + 1.4 .0.6 . 0.5) m² = 4.38 m²
Applying the approximation 4.4 m for A, formula (1) produces
: Q S = k ⋅ A ⋅ ( T i – T u ) = 5.5 . 4.4 . 10 W = 242 W
If you want to know more about this subject, we can recommend the book
entitled “Schaltschrank-Klimatisierung” ("Switch cabinet air conditioning" -
German) published by the “moderne industrie” publishing company; see
bibliography.
7.2 Heat transfer When a constant flow of heat P flows through a flat wall, the temperatures
by heat ϑ1 and ϑ2 are produced on the two surfaces (Figure 7.3). The relati-
conductance onship is described in the equation 1
A
P = λ --- ( ϑ 1 – ϑ 2 ) (1)
d
P: Heat flow W
2
λ: Thermal conductivity
W
-----------
m⋅K
A: Area of wall m² 3
d: Thickness of wall m
DE
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Engineering Guide CDA3000 7-7
7 System installation
d
R thL = ---------- (2)
λ⋅A
K-
RthL: Temperature lag ---
W
d: Wall thickness m
W
λ: Thermal conductivity -----------
m⋅K
A. Wall area m²
∆ϑ = ϑ 1 – ϑ 2 = P ⋅ RthL
If a wall comprises more than one layer, the resultant temperature lag is
equal to the sum of the temperature lags of the individual layers.
Cast iron 58
V2A steel 15
Sheet-steel 59
2
Cm ⋅ K
The specific thermal contact resistance ( ϒin ----------------- ) of metal on metal is
W
halved when heat transfer compound is used between two metal sur-
faces.
2
Appendix A Formula bank
3
A.1 Mathematical symbols ........................................... A-2
A.1.1 SI units ................................................................A-2
A.1.2 Important units ....................................................A-4
4
A.2 Drive engineering equations .................................. A-5
A.2.1 Basic physical equations ......................................A-5 5
A.2.2 Power output .......................................................A-6
A.2.3 Torques .............................................................A-11
A.2.4 Work ..................................................................A-12
A.2.5 Friction ..............................................................A-14 6
A.2.6 Effective motor torque/power output ..................A-15
A.2.7 Choice of max. acceleration ...............................A-17
A.2.8 Mass moments of inertia ...................................A-20 7
A.2.9 v/t diagram ........................................................A-27
A.2.10 Efficiencies, coefficients of friction and density ..A-30
A.2.11 Motor lists ..........................................................A-34 A
A.3 Protection ............................................................. A-40
A.3.1 Protection to IEC/EN ...........................................A-40
A.3.2 Protection to EEMAC and Nema .........................A-43
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Engineering Guide CDA3000 A-1
Appendix A Formula bank
Geometric symbols
|| parallel ≅ congruent
Units Formula
Formula
Variable (A cross-
symbol Name Abbreviation sectional area) 1
Frequency (c speed of
f Hertz Hz, (kHz) f = c/λ
light)
Wavelength λ Meter m, (cm) λ = c/f 2
Electrical charge Q Coulomb C, As Q=l·t
Capacitance C Farad F C = Q/U
Inductance L Henry H; Vs/A 3
Power output P Watt, Joule/s W; VA, J/s P=U·I
Work W, A Joule J; Ws W=P·t
Force, (weight) F, (G) Joule/m J/m; Ws/m F = W/1 4
El. field strength E Volt/m V/m; N/C E = U/1
Dielectric const. ε Farad/m F/m; C/Vm ε = c · 1/A
El. field constant, var. εο Farad/m F/m; C/Vm ε = εo · εr 5
Dielectric constant ερ - - εr = ε/εo
El. displacement flux ψ Coulomb C, As
El. displacement den-
D Coulomb/m2 C/m2 D = Q/A 6
sity
El. current density S, (i) Ampere/m2 A/m2 S = I/A
El. loading θ Ampere A; J/Wb θ=H·I 7
Magnetic flux Φ Weber, Maxwell Wb; Vs; M Φ=B·A
Magn. voltage V Ampere A; J/Wb V=H·s
DE
EN
Engineering Guide CDA3000 A-3
Appendix A Formula bank
Units Formula
Formula
Variable (A cross-
symbol Name Abbreviation sectional area)
Magnetization
M Webermeter Wbm; Vsm M = J/µo · H
intensity
Magn. conductivity Λ Henry H Λ = 1/Rm
1 kp = 9.80665 N
Power output
2
kp ⋅ m kg ⋅ m - Nm
1PS = 75 -------------- = 0, 7355kW = 735, 5 ----------------
3
= 735, 5 --------
s s s
Work, energy
2
kg ⋅ m
1Ws = 1Nm = 1J = 1 ----------------
2
-
s
Moment of inertia
2 3 2
1kg ⋅ m = 1W ⋅ s = 1Nm ⋅ s
Acceleration due to gravity
m
g = 9, 80665 ----2
s
a = v- ω = ϕ = ω 4
· ··
----
t t
Force
F = m⋅a F = m⋅r⋅ω
2
5
Torque
M = F⋅r ·
M = J⋅ω
Power output 6
P = F⋅v P = M⋅ω
Energy
W = F⋅s W = M⋅ϕ 7
Energy
1 2 1 2
W = -- ⋅ m ⋅ v W = -- ⋅ J ⋅ ω
2 2 A
Table 7.4 Basic physical equations
DE
EN
Engineering Guide CDA3000 A-5
Appendix A Formula bank
a Acceleration m/s²
F Force N
m Mass kg
M Torque Nm
n Speed rpm
P Power W
v Velocity m/s
η Efficiency
α Angle of inclination deg.
µ Coefficient of friction
Basic equation
Work output for metal-
working machinery FH ⋅ vs
1
P s = -------------
-
60000
Turning
FH ⋅ nP ⋅ 2 ⋅ π ⋅ r 2
P s = -----------------------------------
-
60000
Milling
zE ⋅ Fm z E ⋅ Fm d ⋅ π ⋅ nF
P s = --------------- ⋅ v s = --------------- ⋅ --------------------
3
60000 60000 1000
Shearing and cutting
Ks ⋅ l s ⋅ s ⋅ vs 4
P s = ----------------------------
-
60000
Drilling
zE ⋅ ( d1 – d2 ) ⋅ sZ ⋅ Ks
P s = ------------------------------------------------- ⋅ v s
60000
5
Cutting speed during drilling
d1 + d2 nB ⋅ π
v s = ---------------- ⋅ ------------- 6
2 1000
Pressing
F St ⋅ v St
P P = -----------------
60000 7
Table 7.6 Work output for metalworking machinery
b Face width mm A
d Cutter diameter mm
d1 Drill diameter mm
d2 Predrill diameter mm
f Advance per revolution mm
FH Main cutting force N
Fm Mean cutting force in milling N
FSt Plunger force in pressing N
KS Special cutting force (general) N/mm²
kC Specific cutting force for various
cutting thicknesses N/mm²
kC11 Specific cutting force for face
cross-section 1 mm x 1 mm N/mm²
lS Length of cut line mm
nB Drill speed rpm
nF Cutter speed rpm DE
EN
Engineering Guide CDA3000 A-7
Appendix A Formula bank
For fans:
η ≈ 0.3 at 1 kW
η ≈ 0.5 at 10 kW
η ≈ 0.65 at 100 kW
The following table shows the specific drive power for various thermo-
plasts:
7
Table 7.10 Torques
F Circumferential force N
J Overall mass moment of inertia kg · m² A
M Motor torque Nm
ML Load torque Nm
n Speed rpm
P Motor power W
PL Power output of load W
r Radius of drive roller mm
tBE Acceleration time s
∆ν Differential speed rpm
ω Angular velocity 1/s
DE
EN
Engineering Guide CDA3000 A-11
Appendix A Formula bank
A.2.4 Work
Work of friction force
W = F R ⋅ s = m ⋅ g ⋅ µ 1 ⋅ cos α ⋅ s
Work of acceleration force
2 2
v2 v1
W = m ⋅ ------- – -------
2 2
Work of gravity
W = m ⋅ g ⋅ ( h 2 – h1 )
Work of spring force
2 2
x2 x1
W = c ⋅ ------
- – -------
2 2
Work of friction torque
W = M ⋅ µr ⋅ ϕ
Work of acceleration torque
2 ·2 2 2
ϕ· 2 ϕ1 ω2 ω1
W = J ⋅ -------- – -------- = J ⋅ --------- – ---------
2 2 2 2
F R = F N ⋅ µ l = m ⋅ g ⋅ µ l ⋅ cos α
2 dW
F W = m ⋅ g ⋅ -- ⋅ ------ ⋅ µ r + f ) + c
d 2
dm
MR = F ⋅ ------ ⋅ tan ρ
2
1-- n 2 3
P eff = ⋅Σ P ⋅t
T i=1 i i
2 2
P 1 ⋅ t 1 + P2 ⋅ t 2 + P 3 ⋅ t3
2 4
P eff = -------------------------------------------------------------
T
DE
EN
Engineering Guide CDA3000 A-15
Appendix A Formula bank
v
m/s
t1 t2 t3
T
t
M3
M M1
Nm M2
t
The motor is defined at MN > Meff.
P3
P P1
P2
kW
b 6
m
m.a 7
S
M
A
m.g
Figure 8.2 Conveyor belt with a high body and small standing area
b
Maximum acceleration: a ≤ -- ⋅ g
h
a Belt acceleration in m/s²
b Width of body in m
g Acceleration due to gravity in m/s²
h Height of body in m
DE
EN
Engineering Guide CDA3000 A-17
Appendix A Formula bank
Overswill of a liquid
z P0
a
M
Figure 8.3 Conveyor belt in acceleration phase with a vessel filled with
liquid
a
Height difference during acceleration: z = -- ⋅ x
g
The value z indicates the height difference of the liquid level in a vessel of
length x accelerated at speed a. At the point of the lowest liquid level z is
always 0.
a Belt acceleration in m/s²
g Acceleration due to gravity in m/s²
x Coordinates in horizontal direction in m
z Coordinates in vertical direction in m
a 1
3
m m.a
4
m.g
7
In most applications the angle α should not exceed a value of 3°. With this
value the result for the acceleration is:
DE
EN
Engineering Guide CDA3000 A-19
Appendix A Formula bank
m d 2 π⋅b⋅ρ d 4
J = ---- ⋅ -- = ------------------ ⋅ --
2 2 2 2
r
d b
ra
Thick-walled hollow cylinder
ri
da
di
m da 2 di 2
J = ---- ----- + ---
2 2 2
b
A
Long, thin bar with pivot point at end of bar
m 2 A⋅ρ 3
m 1
J = ---- ⋅ l = ---------- ⋅ l
3 3
l
2
Rectangular plate with pivot point at center l
of gravity
m 2 2
3
h
J = ----- ⋅ ( h + b )
12 b
m
4
Solid ball with rotary axis through center of
gravity
5
d
5
2⋅m d 2
J = ----------- ⋅ -- = π ⋅ρ⋅d
--------------------
5 2 60
m
7
Thin-walled ball shell with rotary axis
through center of gravity
2 ⋅ m d 2 π ⋅ ρ ⋅ δ ⋅ d4
J = ----------- ⋅ -- = --------------------------- A
d
-
3 2 6
DE
EN
Engineering Guide CDA3000 A-21
Appendix A Formula bank
xis h ty
ya ug vi
tar ro ra
ro s th of g
i
ax ntre
Steiner’s set ce
2
JA = JS + m ⋅ s
A m
S
s
A
Movement by conveyor roller
DE
EN
Engineering Guide CDA3000 A-23
Appendix A Formula bank
Movement by rack
Movement by spindle
4
Conversion from translation into rotation with several motors
DE
EN
Engineering Guide CDA3000 A-25
Appendix A Formula bank
Acceleration time 2
Acceleration travel 3
Braking time
4
Braking travel
5
Travel with v=const.
6
Time for v=const.
7
Total travel
A
Total time
DE
EN
Engineering Guide CDA3000 A-27
Appendix A Formula bank
Acceleration time
Acceleration travel
Braking time
Braking travel
Total travel
Total time
1
Period
Acceleration time
3
Acceleration travel 4
5
Braking time
6
Braking travel
Acceleration
A
DE
EN
Engineering Guide CDA3000 A-29
Appendix A Formula bank
DE
EN
Engineering Guide CDA3000 A-31
Appendix A Formula bank
µ0=0.12-0.60
Static friction (dry)
µ =0.08-0.50
Sliding friction (dry)
Steel on steel µ0=0.12-0.35
Static friction (greased)
Sliding friction (greased) µ =0.04-0.25
3
Transversal forces
The expected transversal forces must be calculated in order to determine
the correct size of motor and gearing.
4
Transmission elements Comments Supplement fz
≥ 17 cogs 1
Cogwheels
< 17 cogs 1.15 5
≥ 20 cogs 1
Chain wheels < 20 cogs 1.25
< 13 cogs 1.4
6
Narrow V-belt pulley dependent on pre-tension 1.5-2
Flat belt with tension roller dependent on pre-tension 2-2.5
Flat belt without tension
roller
dependent on pre-tension 2.3-3 7
Table 7.24 Transversal forces
FQ=(M/r) . fz A
M Torque
r Radius
fz Supplement for radial force calculation
DE
EN
Engineering Guide CDA3000 A-33
Appendix A Formula bank
A.2.11Motor lists Three-phase AC motors with squirrel-cage rotor to DIN VDE 0530,
3000 rpm, 50 Hz, IP54 protection, internally cooled
DE
EN
Engineering Guide CDA3000 A-35
Appendix A Formula bank
Mass
Nominal Rated
Power Efficiency moment of
Size torque current at
P in kW η in % Mn in Nm
inertia
230/400 V
J in kgm²
DE
EN
Engineering Guide CDA3000 A-37
Appendix A Formula bank
Mass
Nominal Rated
Power Efficiency moment of
Size torque current at
P in kW η in % Mn in Nm
inertia
230/400 V
J in kgm²
315M/6 90.0 93 878.0 3.08 -/170.1
315M/6a 110.0 95 1061.0 3.63 -/205.1
315M/6b 132.0 93 1273.0 4.17 -/250.1
355S/6 160.0 95 1543.0 10.7 -/290.1
355S/6a 200.0 95 19,29.0 12.7 -/365.1
The data given represent mean values which may vary slightly depending on manufacturer.
Asynchronous servomotors
Asynchronous servomotors with squirrel-cage rotors to DIN 42 950, self-
cooling, IP 65 protection
Mass
Nominal Nominal Rated
Power Efficiency moment of
Size torque speed current
P in kW η in % Mn in Nm
inertia
n in rpm in A
J in kgm²
DE
EN
Engineering Guide CDA3000 A-39
Appendix A Formula bank
A.3 Protection
DE
EN
Engineering Guide CDA3000 A-41
Appendix A Formula bank
Protection
A powerful water jet directed from any direction onto the
6 against powerful
housing must not have any damaging effect.
water jet spray
Protection in case Water must not intrude in damaging quantities when the
7 of temporary equipment is immersed in water under standardized pressure
immersion and time conditions.
Water must not intrude in damaging quantities when the
Protection in case equipment is permanently immersed in water under conditions
8 of permanent which must be agreed between the manufacturer and the user.
immersion The conditions must be more severe than those for code
digit 7.
Protection in case Water directed from any direction under very high pressure
of high-pressure/ onto the housing must not have any damaging effect.
9K*
steam jet Water pressure 100 bar
cleaning Water temperature 80°C
* This code digit originates from the standard DIN 40050 Part 9.
A.3.2 Protection to Types of protection of electrical equipment for USA and Canada
EEMAC and conforming to IEC 529/EN 60529, VDE 0470 Part 1
Nema The IP protection types quoted represent a rough comparison. A detailed 1
comparison is not possible, because protection tests and assessment cri-
teria differ.
Table 7.30 Protection types of electrical equipment for USA and Canada
DE
EN
Engineering Guide CDA3000 A-43
Appendix A Formula bank
Housing type 6 P
Rain-tight,
corrosion-proof
Housing type 11 Housing type 11
Drip-tight, Drip-proof, corrosion-resist-
corrosion-proof ant, oil-immersed
Housing type 12 Housing type 12
Housing 5
Dust-tight, Use in industry, drip-tight, IP 54
Dust-tight housing
drip-tight dust-tight
Housing
Type 12 K
(as for type 12)
Housing type 13
Housing type 13
Dust-tight,
Dust-tight, oil-tight
drip-tight
Table 7.30 Protection types of electrical equipment for USA and Canada
DE
EN
Engineering Guide CDA3000 A-45 FR
Appendix B Practical working aids for the project engineer
Project name:
Recording of movement task
Company: Name/Function:
Industry/Application:
Goal:
Comments:
3
[ ] t[ ]
5
Rotational movement [n=f(t)] Translational movement [v=f(t)]
6
Radius of drive shaft by which the movement is generated: mm
Comments:
A
Comments:
ML=f(n), P=f(n) M N PN
1.0
ML~n², P~n³
ML=f(n) 0.5
ML=f(s)
ML=f(a)
ML=f(t)
Project name:
Additional environmental data
1
Automation process: 2
6
Standards, regulations and safety:
DE
EN
Engineering Guide CDA3000 A-49 FR
Appendix B Practical working aids for the project engineer
100 200
500
200 10
200 400
1000
300 400 600 20
P>
1500
400 800
600 30
500 1000 2000
700 1400
750 1000 1500 3000 50
800 1600
3500
900 1200 1800 60
2,5 5
2 3 6 20
7
2,5 4 8
2
3 9 30
2,5 5 10
3 4 6 40
7
5 15 50
4 8
6 9 60
5 10 20
7 70
6 8 25 80
7 9 90
10 15 30 100
8
9
10 20 40
15
25 50
15 20 30 60 200
70
25 40 80
20
30 90 300
25 50 100
30 40 60 400
70
50 150 500
40 80
60 90 600
50 100 200
70 700
60 80 250 800
90 900
70 150 300
100 1000
80
90
100 200 400
150
250
250 400
200
300 3000
250 PN UR [kW]
4000
300
M
[Nm]
Rated power, inverter and motor Load torque
DE
EN
Engineering Guide CDA3000 A-51 FR
Appendix C Bibliography and source reference
Frequenzumformer
Dr. Ing. P. F. Brosch
ISBN 3-478-93036-7
Moderne Industrie Publishing
Schaltschrank Klimatisierung
1
Heinrich Styppa
ISBN 3-478-93080-4
Moderne Industrie Publishing
Elektronische Gerätetechnik
Prof. Dipl.-Ing. Hans Brümmer
2
ISBN 3-8023-0610-4
Vogel Publishing
DE
EN
Engineering Guide CDA3000 A-53 FR
Appendix D Index
1
A CANLust
Acceleration behavior as a function of Control word ................................. 5-11
Status word .................................. 5-11
number of pole pairs ........................ 2-33
CANLust control word ........................... 5-11
2
Acceleration, choice of max. .................... A-17
Acceptance tests .................................. 3-5 Characteristic data set switchover .............. 4-30
Acceptance tests/Standards ...................... 3-5 Characteristic values
Ambient conditions ............................... 3-6 of asynchronous servomotors ASx ......... 2-35
Anti-resonant circuit .............................. 6-4 of HF motors ................................. 2-47
Application data sets ............................. 4-22 of machinery ................................. 1-9 3
Application-specific basic settings ...... 4-25, 4-59 of planetary gears ........................... 2-49
Areas of application for three-phase of reluctance motors ........................ 2-41
AC motors ........................... 2-25, 3-61 of standard gears ........................... 2-49
of standard three-phase AC motors ........ 2-26
Assignment
Line choke/inverter module .................. 6-7 of synchronous motors ...................... 2-44 4
to inverter modules CDA3000 ...... 6-13, 6-15 Circuitry example ................................ 3-28
to the inverter modules ..................... 6-10 Circumferential backlash ........................ 2-50
Communication
via CANLust .................................. 5-8
B via CANopen ................................. 5-12 5
Basic physical equations ......................... A-5 via PROFIBUS-DP ............................ 5-18
Basic settings, application-specific ..... 4-21, 4-22 Communication and user module ................ 5-1
Basic terms for calculation ....................... 7-2 Communication module CM-CAN1 or CM-CAN2 5-6
Belt turning station ............................... 2-20 Comparison of motor control methods .......... 4-57
Bibliography and source reference .............. C-51 Comparison of solutions .......................... 1-8 6
Block diagram of a voltage transformer ........ 3-25 Connector with strain relief and cable shield ... 5-17
Block diagram of an inverter with braking Connectors, open ................................. 5-8
chopper ...................................... 3-83 Control terminal assignments ................... 4-27
Braking resistors ................................. 6-12 Control terminals of user module UM-8I4O ..... 4-37
Break-away and acceleration torques .......... 3-64 Cooling methods .................................. 3-8 A
Cooling methods, for inverter modules .......... 3-8
Current characteristics .......................... 3-37
C
Cutting forces of various metals ................. A-9
Cable type for self-assembly .............. 5-7, 5-16
Calculation ....................................... 2-23
Calculation by way of LuDrive ................... 2-22 D
Calculation of effective inverter capacity Data structure ..................................... 4-2
utilization .................................... 3-55 DC network operation ............................ 3-79
Calculation with LuDrive ......................... 3-85 DC network operation with PTC precharging
CAN bus ........................................... 5-4 circuit ........................................ 3-82
CAN characteristics ............................... 5-5 Dependency of motor variables / Frequency ... 2-30 DE
EN
Engineering Guide CDA3000 A-55 FR
Appendix D Index
Load characteristic O
Blower, fan, centrifugal pump .............. 1-21 Operating characteristic, standard three-phase
Conveyors ................................... 1-22 AC motor ..................................... 2-26
Extruders .................................... 1-20 Operating conditions, extreme .................. 3-14
Lifting gear, conveyor systems ............. 1-20 Operation of fault current breakers ............. 3-23
1
Machine tools ............................... 1-23 Operation via DriveManager ..................... 4-12
Metal cutters ................................ 1-22 Operation via KeyPad KP200 .................... 4-11
Mills .......................................... 1-21 Operation with reactive current compensation
Piston compressors, rolling mills ........... 1-20 system ........................................ 6-4
Piston machine, eccentric presses ......... 1-22 Output current as a function of mounting 2
Winder, coiler, lathe ......................... 1-19 height ........................................ 3-33
Load characteristic, plastics extruder ............ 1-5 Overview
Load torque ...................................... 1-19 of inverter modules for 230 V systems ...... 3-3
Loading on the supply system ................... 3-20 of inverter modules for 460 V systems ...... 3-4
LuDrive - Where can you get it? ................ 2-14 Overview of the KP200 menu structure ......... 4-11 3
M
Mains side/system condition .................... 3-16 P
Mains voltage asymmetry ........................ 6-3 Parallel/series configuration of braking
Manipulating range and accuracy ............... 1-13 resistors ..................................... 3-86 4
Mass moments of inertia ........................ A-20 Parameters for the motor data ................... 4-8
Master-/Slave coupling via two control cables . 4-57 Position of terminal strip X5 ..................... 4-47
Master-/Slave operation ......................... 4-56 Positioning accuracy ............................. 1-17
Mathematical symbols ............................ A-2 Positioning with reference generator and
Measurement on the inverter module ........... 3-58 position control .............................. 1-18 5
Minimum cross-section of the grounding lead . 3-23 Power .............................................. A-6
M-n characteristic for asynchronous motors ... 2-35 Power factor, standard three-phase AC motor . 2-27
Moment of inertia ................................ 1-12 Power failure bridging ........................... 3-87
Motor cable length ............................... 3-29 Power rating application example ................ 2-9
Motor cables, length ............................. 3-54 Practical working aids for the project engineer B-45
Preset control terminal functionality ............ 4-50
6
Motor choke ....................................... 6-8
Motor lists ........................................ A-34 Preset solutions .................................. 4-20
Motor protection possibilities .................... 3-31 Principle of function .............................. 5-2
Motor rating plate ................................. 4-8 Procedure in practise ............................. 6-4
Process analysis ............................ 1-4, 1-7
Motor selection ........................... 2-19, 2-22
PROFIBUS characteristics ....................... 5-13
A
Motor torque/power output, effective ........... A-15
Motor, selection .................................. 2-24 PROFIBUS Gateway type DP-CPx ................ 5-14
Mounting the KeyPad ............................ 4-11 PROFIBUS-DP .................................... 5-13
Movement requirement ........................... 1-9 PROFIBUS-DP layout with Lust drive units ...... 5-15
Movement solution in the processing process . 1-10 Project planning notes ..................... 2-43, 3-7
Movement solution split into traction and Protection ........................................ A-40
mechanical function ........................ 1-11 to EEMAC and Nema ........................ A-43
Multi-motor operation ........................... 3-28 to IEC/EN ..................................... A-40
Protection of the mains power cable ............ 3-22
N
Network printing ................................. 2-14 DE
EN
Engineering Guide CDA3000 A-57 FR
Appendix D Index
R T
Radio interference suppression filter ........... 6-14 Technical data ..................................... 3-3
Recording of movement task ..................... 2-2 of line chokes LR3x.xxx ...................... 6-6
Resonance point ................................... 6-4 of series BRx.xxx, xxxx ..................... 6-12
Rotational drive .................................. 4-39 of series EMC3x.xxx ........................ 6-14
of series MR3x.xxx ........................... 6-8
Self cooling .......................... 2-38, 2-39
S Technical data, PROFIBUS-DP Gateway ........ 5-15
Schematic of an extruder ......................... 1-4 Three-phase inverter modules .................... 3-4
Screenshot, Motor selection .................... 2-23 Topology of CAN ................................... 5-4
Selection Topology of PROFIBUS-DP ...................... 5-13
of gearing ................................... 2-48 Torque as a function of load angle ............. 2-42
of supplementary components ............... 6-1 Torque as a function of rotor displacement
Selection aid for PPOs ........................... 5-19 angle ........................................ 2-42
Setting of parameter ASTER .................... 4-25 Torque characteristic of a reluctance motor ... 2-41
Setting of parameter ASTER for field bus Torque characteristic of a standard
operation .................................... 4-50 three-phase AC motor ...................... 2-32
Shielding ................................... 5-8, 5-17 Torque rise time ................................. 1-13
Short-circuit and ground fault proofing ......... 3-29 Torques .......................................... A-11
SI units ............................................. A-2 Torsional rigidity ................................. 2-50
Size referred to cooling method ................ 3-13 Traction and lifting drive ........................ 4-24
Software functions/Subject areas .............. 4-68 Traction and mechanical function .............. 1-10
Solution from process analysis ................... 1-7 Traction drive .................................... 2-10
Solution, functional analysis ...................... 1-6 Tractive/frictional resistance .................... 2-17
Solution, old in comparison with new ............ 1-6 Transmission gear ............................... 2-48
Solution, old with DC drive ........................ 1-5 Trolley drive for gantry crane ................... 2-15
Specification of control terminals ............... 4-16 Trolley drive, standard with geared motor ..... 2-15
Speed accuracy Type code ........................................ 2-37
dynamic ..................................... 1-16 Type codes of inverter modules .................. 3-3
static ........................................ 1-15 Typical positioning errors ....................... 3-65
Speed curve in Master-/Slave operation ....... 4-58
Speed manipulating range ...................... 1-14
Start/stop positioning ........................... 1-17 U
Startup characteristic, standard three-phase UM 8I4O ........................................... 5-3
AC motor .................................... 2-26 User data set switchover ........................ 4-30
Steps in drive design ............................ 2-21 User data sets ..................................... 4-5
Subject area and parameter editor ............. 4-13 User data sets, example .......................... 4-5
Subject area, function, effect ................... 4-69 User interface and data structure ................. 4-2
Switching at the inverter input .................. 3-24 User modules ...................................... 5-3
System conditions ............................... 3-19
System environment .............................. 1-3
System installation ................................ 7-1
V
System load ....................................... 6-3 v/t diagram ....................... 1-11, 2-21, A-27
System resonance ................................. 6-5 Voltage drops .................................... 3-30
Systematic thinking ............................... 1-2 Voltage load on the motor winding ............. 3-31
W
Work .............................................. A-12
Work output for metalworking machinery ....... A-7
1
DE
EN
Engineering Guide CDA3000 A-59 FR
Lust Antriebstechnik GmbH
Gewerbestrasse 5-9 • D-35631 Lahnau
Tel. 0 64 41 / 9 66-0 • Fax 0 64 41 / 9 66-137
ANTRIEBSTECHNIK Internet: http://www.lust-tec.de • e-mail: lust@lust-tec.de