Engineering Guide CDA300!12!99

EN
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
The easy route

to your drive solution
Overview of documentation
Engineering Guide
CDA3000 Catalogue
CDA3000
Before purchase
C
Selecting and ordering a Dimensioning a drive

drive system system
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
Quick and easy initial Operation via Adaptation of the drive

commissioning DRIVEMANAGER and KEYPAD system to the application
CANLust Communication CANopen Communica- PROFIBUS-DP Communi-

Module Manual tion Module Manual cation Module Manual
G1 G2 G3
Project planning, installa- Project planning, installa- Project planning, installa-

tion and commissioning of tion and commissioning of tion and commissioning of
the CDA3000 on the field the CDA3000 on the field the CDA3000 on the field
bus bus bus
Engineering Guide CDA3000

C
ID no.: 0840.25B.1-00 Sheets for Engineering Guide
Date: December 1999
We reserve the right to make technical changes.

About this manual This guide is intended for users looking for background information
relating to the engineering of inverter drives.
The term “engineering” (or “project planning”) in this context covers the
design and configuration of complex technical systems through to receipt
of the order to implement. General project planning tasks including:
➢ Analysis of the task

➢ Concept design of the system
➢ Design of the system components
➢ Selection of the best solution to be implemented.
How to use this

manual
Project planning process
System overview, Revision history
1 Analysis of task 1
2 Definition of drive 2
3 Selection of inverter module 3
4 Selection of user and communication

4
modules
5 Selection of supplementary components 5
6 Tips for system installation 6
Appendix: Formula bank, Copy templates

Bibliography and index A
Table of contents
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Engineering Guide CDA3000 FR
Project planning
flowchart
STEPS SECTION
➢ Basics - see section 1

Record movement task in
1. processing process ➢ Checklist for recording
the task - see section 2.1
Calculate drive variables,

2. such as power output, torque, ➢ See sections 2.2 to 2.4
speed, etc.
Select motor, transmission gear

3. and gearing
➢ See sections 2.5 to 2.6
Select inverter module and ➢ See section 3

4. software performance ➢ See section 6
Select user
5. and/or communication ➢ See section 4
modules
Select supplementary
6. components such as filters, ➢ See section 5
line choke, etc.

Drive system layout
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)
(13) (12) (11) (10)
System modules Section
(1) Inverter module See section 3

(2) DRIVEMANAGER PC user software See section 4.1.4
(3) KEYPAD control unit See section 4.1.3
(4) Line choke See section 6.1
(5) Software performance - Preset solutions See section 4.2
(6) I/O terminal expansion See section 4
(7) CANLust, CANopen,
Profibus-DP bus interface See section 5.3
(8) Braking resistor See section 6.3
(9) Motor chokes See section 6.2
(10) HF spindle See section 2.5.5
(11) Asynchronous servomotor See section 2.5.2
(12) IEC standard motor See section 2.5.1
(13) Geared motor See section 2.5
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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

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
3 Selection of inverter module

3.1 Technical data .........................................................3-3
3.1.1 Acceptance tests .................................................3-5
3.1.2 Ambient conditions ..............................................3-6
3.1.3 Installation and cooling methods ..........................3-7
3.2 Extreme operating conditions ..............................3-14
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
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
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
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
3.3 Special applications ..............................................3-60
3.3.1 Project planning for three-phase AC motors .......3-60
3.3.2 Efficiency of the motor control methods .............3-62
3.3.3 Standard inverter operation ................................3-67
3.3.4 70 Hz characteristic with 25% field weakening ..3-69
3.3.5 87 Hz characteristic / Expanded manipulating
range .................................................................3-73
3.3.6 Multi-motor operation on one inverter ................3-76
3.3.7 DC network operation ........................................3-79
3.3.8 Design of the braking resistor ............................3-83
3.3.9 Power failure bridging ........................................3-87
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4 Software functions
4.1 User interface and data structure .......................... 4-2
4.1.1 Data structure ..................................................... 4-2
4.1.2 Initial commissioning ........................................... 4-6
4.1.3 Operation via KEYPAD KP200 .............................. 4-11
4.1.4 Operation via DRIVEMANAGER .............................. 4-12
4.2 Device and terminal view .....................................4-15
4.2.1 Specification of control terminals ....................... 4-16
4.2.2 Isolation method and connection tips ................. 4-19
4.3 Preset solutions .................................................... 4-20
4.3.1 Traction and lifting drive .................................... 4-24
4.3.2 Rotational drive ................................................. 4-39
4.3.3 Field bus operation ............................................ 4-49
4.3.4 Master/Slave operation ...................................... 4-56
5 Communication and user modules

5.1 Principle of function ............................................... 5-2
5.2 User module ............................................................5-3
5.3 CAN-BUS ................................................................. 5-4
5.3.1 Interconnection of inverter modules on the
CAN bus .............................................................. 5-6
5.3.2 Communication via CANLUST ................................. 5-8
5.3.3 Communication via CANopen .............................. 5-12
5.4 PROFIBUS-DP ........................................................5-13
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
5.4.3 Communication via PROFIBUS-DP ..................... 5-18

6 Selection of supplementary components
6.1 Line choke ...............................................................6-2
6.1.1 Effect of the line choke ........................................6-2
6.1.2 Operation with reactive current compensation
system .................................................................6-4
6.1.3 Technical data of line chokes LR3x.xxx ................6-6
6.1.4 Assignment of line choke to inverter module ........6-7
6.2 Motor choke ............................................................6-8
6.2.1 Technical data of the motor chokes .....................6-8
6.2.2 Assignment to the inverter modules ...................6-10
6.3 Braking resistors ...................................................6-12
6.3.1 Technical data of series BRxxx, xx-xx ................6-12
6.3.2 Assignment to inverter modules CDA3000 .........6-13
6.4 Radio interference suppression filter ...................6-14
6.4.1 Technical data of RFI filters EMC34.xxx ..............6-14
6.4.2 Permissible motor cable length with internal
RFI filter .............................................................6-15
and external RFI filter .........................................6-16
6.4.4 Permissible motor cable length with external
RFI filter .............................................................6-16
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
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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
B Practical working aids for the project

engineer
C Bibliography and source reference
D Index

1
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:
• Inverter module • Motor choke

• Operator module • Braking resistor
• User module • Cable
• Communication module • Motors
• Software modules • Gearing
• Line choke • etc.
• Mains filter
The chain is only as strong as
Interface
its weakest link
to the
System
environment
Inverter
module
User Motor
module
Comm. Software
module Gearing
modules
Braking Line choke

resistor
Services
Figure 1.1 Inverter system
Engineering Guide CDA3000 1-2

1 Analysis of task
In summary: An inverter system is a combination of standalone

products and services which create new usable drive 1
system properties with added value.
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
Processing process Environmental 5

ML = f (n, s, ) and installation
conditions
Inverter
6
module
User Motor
module
Comm. Software
Gearing
7
module modules
Braking
resistor Line choke
Services
Standards,
A
Automation
process regulations
and safety
Figure 1.2 System environment
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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1 Analysis of task
1.2 Process analysis

F irst find out what processing process1 the drive solution is to be used
for. Apply the principles of process analysis, because process analy-
sis will provide you with a non-solution-specific view of the task at hand.
Do not perform a functional analysis at the beginning of an analysis,
because the functions used always describe the specific solution.
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
1.2.1 Example of a Standard screw-type extruder

process analysis ➢ An extruder is a machine which takes in solid to liquid (synthetic)
in comparison molding compounds and presses them out of an opening, for the
with functional most part continuously.
analysis It compresses, mixes, plasticizes and homogenizes the compound in
the process.
The screw-type extruder shown (see Figure 1.3) principally comprises a
drive unit and a plasticizer unit. The plasticizer unit consists of a screw
cylinder, a screw, a material funnel, and heating and cooling zones.
(1) (2) (3) (4) (5)
(6)
(1) Screw (4) Funnel

(2) Cylinder (5) Gearing
(3) Heater (6) Motor
Figure 1.3 Schematic of an extruder
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.

1 Analysis of task
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
Figure 1.4 Load characteristic of the plastics extruder 5

Task for a new drive unit
In order to provider a higher degree of machine availability, the drive is to 6
be switched from DC to three-phase AC. The DC drive used to date has a
speed manipulating range of 1:1000 and an overload capacity to 200%.
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
Figure 1.5 Old solution with DC drive
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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)
(1) Inverter with field-oriented regulation

(2) AC motor
(3) Encoder
(4) Gearing
(5) Screw return thrust bearing
Figure 1.6 Solution from functional analysis
The functional analysis produces a solution with speed feedback - See

Table 1.1.
DC drive Three-phase AC drive
1 DC controller 1 Inverter with field-oriented regulation
2 DC motor 2 AC motor
3 Tacho 3 Encoder
4 Gearing 4 Gearing
5 Screw return thrust bearing 5 Screw return thrust bearing
Old solution Functional analysis (NEW 1)
Table 1.1 Comparison between old solution and solution from functional
analysis

1 Analysis of task
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
Answer the questions in this example:

4
1. Continuous material flow.
2. Is of no significance in applications with continuous material flow.
3. Speed manipulating range of 1:10.
4. No overload necessary, because the screw of the extruder would
5
otherwise be damaged. When the screw has become clogged, it is
drawn forward out of the extruder for cleaning.
The answers supplied in the process analysis deliver a solution with a 6
standard inverter without speed feedback. This means a substantial cost
reduction.
7
~ M
~ 3~ A
Figure 1.7 Solution from process analysis
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1 Analysis of task
Comparison of solutions:“Functional analysis / Process analysis”
Solution from functional analysis Solution from process analysis
~ M ~ M
~ 3~ ~ 3~
M M
1~ 1~
$
$
NEW 1 NEW 2
Inverter with field-oriented regulation Inverter with VFC
Figure 1.8 Comparison of solutions
In summary: Always analyze the processing process! Because just

because something is known does not necessarily
mean it is recognized!

1 Analysis of task
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
Paper machinery Stirrers Packaging machinery

Textile machinery Mills Optical machinery
6
Continuous material flow Material flow not continuous or irregular
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1 Analysis of task
Traction and mechanical function

The movement solution in the processing process in most cases involves
a traction function and a mechanical function. The mechanical function
usually generates a non-linear movement. The processing process coun-
teracts this movement with a specific load torque.
Processing
material Processing
process Product
ML=f(n,s,j)
Mechanical
function
X(n2(t))
n2
Drive function with servocontroller

n2
n1
n1
M
Movement solution
Drive function with
frequency inverter
3~
Energy
~ =
Reference ~
Figure 1.9 Movement solution in the processing process

1 Analysis of task
Example of a movement solution
Movement solution 1
x y
t x y(x(t))
2
t x
Drive function x(t) Mechanical function y(x)

3
start stop
enter return
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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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 Analysis of task
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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1 Analysis of task
Speed manipulating range

The speed manipulating range is the range in which the motor can always
deliver nominal torque.
MN
fmin fN f (n)
nmin nN
Figure 1.12 Speed manipulating range
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

1 Analysis of task
Static speed accuracy

The static speed accuracy refers to the speed deviation in the steady
(static) state after completion of startup. 1
(2)
2
(3)
(1)
3
n
4
t
(1) Lower limit 5

(2) Upper limit
(3) Variation range
Figure 1.13 Static speed accuracy 6
In operation with speed control a high-frequency ripple is superimposed

on the actual speed. The frequency of the ripple depends on the sampling 7
rate of the speed controller. The amplitude of the said ripple is dependent
on the encoder system used and on the mass inertia system (application
and motor).
A
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1 Analysis of task
Dynamic speed accuracy

The dynamic speed accuracy refers to the speed deviation during the
startup or braking process of a speed change. The greatest deviation
very often occurs in the transient response in settling to the desired
speed.
(1)
(3)
(2) (1)
(2) (3)
n n
t t
(1) Dynamic variation (1) Dynamic variation

(2) Reference (2) Reference
(3) Actual (3) Actual
Figure 1.14 Dynamic speed accuracy

1 Analysis of task
Positioning accuracy without position control (Start/Stop mode)

The term positioning accuracy refers to the position deviation at standstill.
The degree of deviation is decisively influenced by the response times of 1
the control and the drive controller.
SF = Vmax . tRF 2
Vmax. SF = Positioning error
in mm
3
(4) Vmax = Velocity
in mm/s
t (3) tRF = Response error 4

(1) (2) (terminal
scan cycle) in 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)
Figure 1.15 Start/stop positioning 7
The positioning and repeat accuracy is of course also dependent on other A

factors such as:
➢ Implementation of the mechanical function

➢ Mechanical system of the pickup
➢ Gearing used
➢ Constant response time of the control
➢ Measurement resolution from position transducer
➢ etc.
A precise analysis is only possible in specific cases.
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1 Analysis of task
Positioning accuracy with position control

In the case of a positioning operation with position control in the controller,
the positioning accuracy is dependent on the encoder system and the qual-
ity of the position control (with or without pre-control, sampling time, etc.).
Control system Inverter modul CDA3000
Destination nreference mreference Ureference

position xreference Modulator
Speed Torque and
- - -
Reference generator Position controller controller controller PWR
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

1 Analysis of task
In summary: The positioning accuracy is dependent on the meas-

urement system and on the position control sampling. 1
It is also of course dependent on the sources of error
of the machine (temperature, rigidity, vibration, etc.).
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
Winders, coilers, lathes 5

ML ~ 1/n
P = constant
P
6
ML,
P
7
M
n
A
Figure 1.17 Load characteristic: Winders, coilers, lathes
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1 Analysis of task
Lifting gear, conveyor systems, piston compressors, rolling

mills
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
Figure 1.19 Load characteristic: Extruders

1 Analysis of task
Blowers, fans, centrifugal pumps

ML ~ n²
P ML
P ~ n³
1
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)
(1) Hammer mill

(2) Centrifugal mill
(3) Ball mill
Figure 1.21 Load characteristics: Mills
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1 Analysis of task
Conveyors such as inclined lifts

ML = f (s)
ML
Figure 1.22 Load characteristic: Conveyors
Piston machines, eccentric presses, metal cutters
ML = f (α)
ML
Mm
Figure 1.23 Load characteristic: Piston machines, eccentric presses, metal

cutters

1 Analysis of task
Machine tools
ML = f (t)
1
ML 2
t
4
Figure 1.24 Load characteristic: Machine tools
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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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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:
The goal must be realistic Goal:
Key limits must be known Special background conditions:
Comments:
Author: Date: Sheet ..... of .....
You will find the copy template in the appendix under "Practical working
aids for the project engineer".

2 Drive definition
Movement requirement Project name:

for processing
1
Continuous Discontinuous Discontinuous
Movement requirement material flow batch process unit process
2
3
v
[ ]
t[ ]
1
4
T=Period
5
Rotational movement [n=f(t)] Translational movement [v=f(t)]
Radius of drive shaft by which the movement is generated: mm 6
Comments:
7
A
For definitions of terms in this context See section 1.3.

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2 Drive definition

for processing
Moment : [kgm²] Mass: [kg]

or
Movement requirement of inertia Mode of movement:
Speed manipulating range: Torque rise time: [ms]
Static speed accuracy: [rpm] Positioning accuracy: [ms]
Dynamic speed accuracy: [rpm]
Comments:
Load torque of processing process

ML~ 1/n, P=constant
ML=constant, P~n ML, P 1,5
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
For definitions of terms in this context see section 1.3.


2 Drive definition
Project name:
Additional environmental data
1
Automation process:
2
System interface
➢ Automate
➢ Environment 3
➢ Standards
Environmental and installation conditions: 4
Standards, regulations and safety:

6

A
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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.
Using the normogram: Continuous load characteristic in

Engine speeds inverter operation with IEC standard motor
750 rpm 1000 rpm 1500 rpm 3000 rpm 0,5 0,6 0,7 0,8 0,9 1,0 M
1. Plot the speed vertices 8-pole 6-pole 4-pole 2-pole MM UR
for the relevant motor. 100

200
200
500
10 2.
200 400 1.
2. Draw two straight lines 300 400 600
1000
20
to the continuous load 400 800

1500 P>
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
the load torque by a 1000 2000 4000

1400 70
straight line. 1100 2200
4500
1200 1600 2400 80
4. Connect the load tor- 5000
1300 2600
que to the rated power 1400
1800
2800
5500
90 3.
by a straight line. 1500 2000 3000 6000 n [rpm] 100 f [Hz]

6 10
5. Select your product 2 4
5
based on the perfor- 2
2,5
3 6 20
mance rating data. 2

2,5 4
7
8
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 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
150 200 300 2000
250 400
200
300 3000
250 PN UR [kW]
4000
300
M
[Nm]
Rated power, inverter and motor Load torque
aids for the project engineer". Continuous load characteristic - See sec-
tion 2.5.1.

2 Drive definition
2.2.1 Example of Continuous load characteristic in

solution with Engine speeds inverter operation
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
150 200 300 2000
250 400
200
300 3000
250 PN UR [kW]
4000
300
M
[Nm]
Solution:
The rated power of the motor (four-pole) and the inverter is 50 kW.
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2 Drive definition
2.2.2 Example of Continuous load characteristic in

solution with Engine speeds
750 rpm 1000 rpm 1500 rpm 3000 rpm
inverter operation
0,5 0,6 0,7 0,8 0,9 1,0 M
8-pole 6-pole 4-pole 2-pole MM UR
six-pole motor 100 200
500
200 10 2.
400 1.
Requirement: 200
1000
300 400 600 20
1500 P>
n1 = 150 rpm 400
600
800
30
500 1000 2000
n2 = 1500 rpm 600 800 1200 40
2500
M1 = M2 = 150 Nm 700 1400
750 1000 1500 3000 50
800 1600 1.
External ventilation 900 1200 1800
3500
60
not permitted. 1000 2000 4000

1400 70
1100 2200
4500
1200 1600 2400 80 3. 2.
5000
1300 2600
1800 90
1400 5500
2800
1500 2000 3000 6000 n [rpm] 100 f [Hz]

6 10
2 4
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
150 200 300 2000
250 400
200
300 3000
250 PN UR [kW]
4000
300
M
[Nm]
Solution:
The rated power of the motor (six-pole) and the inverter is 30 kW.

2 Drive definition
2.3 Drive definition

via power rating T he method of power rating is principally used in three areas of appli-
cation:
1
1. Metalworking machinery (milling, drilling, grinding, etc.)
2. Process engineering (pumps/fans, extruder, etc.)
3. General engineering (packaging and special machinery, manipula-
tors and conveyor systems, etc.) 2
The equations relating to areas of application 1 and 2 and their applica-
tion are described in Appendix A.2.2.
3
The following deals with area of application 3 and thus with the design of
traction and lifting drives.
4
Packaging machinery Manipulators Conveyor systems General engineering
• Discharge drive • Traveling axis, • Trolley drive with • Metalworking

(cladding removal, X/Z-axis 1, 2 and 4 motors machinery 5
vacuum packing • Lifting axis, Y-axis • Crane lifting gear, • Cross-cutters
sheet feed) trolley and running
• Indexing table drive • All kinds of special
• Metering drive gear machinery
(volume metering,
• Gripper drive
• Conveyor belt • etc.
6
screw-type mete- • etc.
• Door drive
ring)
• Shelf conveyor
• Traction/lifting axis
(packers, palleti- • Parquet flooring 7
zers) conveyor belt
• Belt drive (bucket • Roller and chain
drive
conveyor, product
loading belt) • etc.
A
• Labeling machine
(X/Y drive)
• etc.
Table 2.1 Typical examples of power rating from area of application 3
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2 Drive definition
2.3.1 Example 1: Example: Z-axis of a manipulator

Traction drive
m = 51.5 kg η = 0.88
a = 3 m/s2 ta = 0.5
v = 1.5 m/s µ = 0.01
1. Determine power requirement to move the application

2
m ⋅ a ⋅ v 51, 5kg ⋅ 3m ⁄ s ⋅ 1, 5m ⁄ s
P a = ------------------ = --------------------------------------------------------------- = 264W
η 0, 88
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.
Selected motor: Type 71L/4, 370W, JM = 0.00073 kgm

The motor is to be run at max. 2000 rpm
(70 Hz characteristic).
2
J M ⋅ nM 2
, 00073kgm ⋅ 2000 min - = 65W
2 –1
- = 0-----------------------------------------------------------------
P aR = -------------------
91, 2 ⋅ ta 91, 2 ⋅ 0, 5
3. Calculate gross output

PGross = Pa + PF + PaR = 264W + 9W + 65W = 338W
For more details on “Selection of inverter modules” refer to sections 3.3 to

3.6.

2 Drive definition
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
For a list of standard three-phase AC motors See section A.2.11 Motor

list. 5
Asynchronous motors See section 2.5.2.
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2 Drive definition
2.3.2 Example 2: Example: Z-axis of a manipulator

Lifting drive
m = 2.5 kg η = 0.88
a = 10 m/s2 ta = 0.15
v = 1.5 m/s µ = 0.01
1. Determine power requirement to move the application

2
m ⋅ a ⋅ v 2, 5kg ⋅ 10m ⁄ s ⋅ 1, 5m ⁄ s
P a = ------------------ = --------------------------------------------------------------- = 43W
η 0, 88
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.
Selected motor: Type 71S/4, 250W, IM = 0.00056 kgm2

The motor is to be run at max. 2000 rpm
(70 Hz characteristic).
2
J M ⋅ nM 2
, 00056kgm ⋅ 2000 min - = 164W
2 –1
- = 0-----------------------------------------------------------------
P aR = -------------------
91, 2 ⋅ ta 91, 2 ⋅ 0, 15
3. Calculate gross output

PGross = Pa + PF + PH + PaR = 43W + 1W + 42W + 164W= 250W
For more details on “Selection of inverter modules” refer to sections 3.3 to

3.6.

2 Drive definition
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.
Note: The LUDRIVE drive program is based on the theoretical prin-

ciples of the book entitled “Das 1x1 der Antriebsauslegung”
(“The ABC of drive design”) - see "Bibliography and source
reference".
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2 Drive definition
Where can you get LUDRIVE?

You can download the LUDRIVE drive design program for MS-DOS™ ver-
sion 1.6 (viable under Windows® 95) free of charge from our website:
http://www.lust-tec.de/produkte.
The program is easily controlled from the keyboard. The DOS user
interface provides access to calculation formulae which have been tried
and proven over decades of practical application.
Please note that the software LUDRIVE is only available in german lan-
guage.
Network printing
When printing from DOS applications under Windows® 95 in network

mode, the printer must be assigned to the parallel port LTP1.
From the “Start menu choose Settings > Printers”, select the printer
you want to use and click with the right mouse button to open the “Pro-
perties” dialog box.
On the “Details” tab click on the “Capture Printer Port” button.
Make sure that data to be printed to LTP1 are diverted to the network
printer - See Figure 2.1.
Figure 2.1 The network printer must be assigned to the parallel port LTP1

2 Drive definition
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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2 Drive definition
Steps in drive design

Calculate acceleration and deceleration by means
of “v/t diagram” program section.
1.
Calculate longitudinal coefficient of friction between

rail and wheel by means of “Tractive resistance/Fric-
2. tion moment” program section.
Calculate drive capacity by means of “Drive calcula-

tion/Traction drive” program section.
3. a) for max. motor speed 1440 rpm
b) for max. motor speed 2000 rpm
1.
Figure 2.3 Drive design with LUDRIVE

2 Drive definition
2. 1
4
Figure 2.4 Tractive/frictional resistance
5
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2 Drive definition
3.
Max. motor speed
1440 rpm
Figure 2.5 Drive capacity
Figure 2.6 Motor selection

2 Drive definition
3. 1
Max. motor speed 2

2000 rpm
4
Figure 2.7 Drive capacity
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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)
(1) Truck engines

Figure 2.9 Belt turning station
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
Positioning accuracy need only be approx. ± 2 mm, because mechanical

indices are used.

2 Drive definition
Steps in drive design
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
Figure 2.10 v/t diagrams
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2 Drive definition
2.
25% motor overload
with VFC
Factor for starting tor-

que = 1.25
(1.25 . MN)
Figure 2.11 Calculation

2 Drive definition
3. 1
100% motor overload 2

with “SFC”
3
Factor for starting
torque = 2 (2 . MN)
4
Figure 2.13 Calculation
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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.
Overview of three-phase AC motors
3-phase AC motor
Synchronous motor Asynchronous motor
with energized rotor Reluctance motor Standard motor Servomotor
Energized via Permanently With damper Without damper HF motors

slip ring energized cage cage
(brushless) (SYNCELL)

2 Drive definition
Typical areas of application of three-phase AC motors
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
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.
Table 2.2 Areas of application for three-phase AC motors 7

Use of the following sections
A
The following sections 2.5.1 to 2.5.5 summarize the typical characteristic
values. They provide an overview of the performance capabilities of the
various motor types. Selection of the motors, dependent on application, is
presented in sections 3.3 to 3.6.
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2 Drive definition
2.5.1 Characteristic Startup characteristic in mains operation

values of stan-
dard three- 2.4
phase AC motors 2.0 1.0
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
Figure 2.15 Typical startup characteristic of a standard three-phase AC

motor in mains operation
Operating characteristic
1.0
0.8
0.6
0.4
0.2
Figure 2.16 Typical operating characteristic of a standard three-phase AC

motor

2 Drive definition
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
nmax Limit speed

H Axle height
1 Greased groove ball bearings in two-pole motors
2 Greased groove ball bearings in four-pole motors and higher
3 Strength of the short-circuiting rings of the rotor cage
4 Bend-critical speed
Figure 2.18 Typical limit speed of a standard three-phase AC motor
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2 Drive definition
For more information on rotating electric machines, rating and operating

behavior, refer to standard DIN VDE 0530 or
EN 60034-1.
Tolerances of standard three-phase AC motor to DIN 57 530/IEC 34
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)
±5% at rated load and 45ºC ambient tem-

Voltage deviation [ u ]
perature
Table 2.3 Tolerances to DIN 57530 and IEC 34

2 Drive definition
Notes:
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2 Drive definition
Dependencies of the motor variables in inverter operation
Characteristic of referenced variable
Referenced Constant flux Field weakening

Variable
variable
P2= 1
M=const. P 2 ∼ --
const. n
Limit frequency in inver- n- f/fN

ter operation Speed [n] ---- f/fN f/fN
nN 1
0
MK
f G ≈ f N ⋅  ------- ⋅ 0, 7 U
 M N Voltage [U] ----- 1 f/fN 1 1
UN
0
Φ-
Flux [Φ]
1
------ 1 fN/f
ΦN fN/f
Current [I] ---I- 1 1 1 fG/f

IN
0
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
Stator P cu1 1 1 (fG/f) ²

------------
- 1
copper loss [Pcu1] P cu1N
0
Rotor P cu2 1 1 (fG/f) ²

------------
- 1
copper loss [Pcu2] P cu2N
0
P Fe fN/f
Core loss [PFe] ---------
- 1 (f/fN)3/2 fN/f
P FeN
0
0 fN fG f
Table 2.4 Dependencies of the motor variables

2 Drive definition
Abbreviations used in Table 2.4 f Frequency

fN Rated frequency
fG Limit frequency in inverter operation 1
I Current, effective value
IN Rated current
M Torque
Mk Breakdown torque 2
MkN Nominal breakdown torque
MN Nominal torque
n
nN
Speed
Nominal speed
3
Pcu1 Stator copper loss
Pcu2 Rotor copper loss
Pcu1, N Nominal stator copper loss of fundamental 4
Pcu2, N Nominal rotor copper loss of fundamental
PFe Core loss
PN Rated power
P2 Mechanical output
5
s Slip
U Voltage, effective value
Φ Magnetic flux
6
Achtung: Safe inverter operation can only be guaranteed when the
max. output frequency is not higher than the limit frequency
(f6). 7
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2 Drive definition
Typical torque characteristic of a standard three-phase AC motor

in standard inverter operation
2.0
(4)
1.5
(3) (2)
1.0
M P>
MN (2)
(2) (1)
0.5
0.1
10 50 100 120
f [ Hz]
(1) Delivered power output of a 3-phase AC motor with inverter

(2) Permissible torque characteristic of an internally cooled 3-phase AC
motor
(3) Permissible torque characteristic of an adequately externally cooled
3-phase AC motor
(4) Maximum permissible torque for 120 s to DIN VDE 0530 Part 1
Figure 2.19 Torque characteristic of a standard three-phase AC motor in
inverter operation

2 Drive definition
Typical acceleration behavior of standard three-phase AC

motors
1
2 JM Moment of inertia of the motor (rotor) in [kgm²]
JM ⋅ n
P MBE = ---------------------- tBE Acceleration time in [s]
91, 2 ⋅ t BE PMBE Motor acceleration time in [W]
2
2000
(1) (2) (3)
W 3
Acceleration from 1500
0 rpm to nominal
PMBE
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.
In summary: As the diagram shows, standard three-phase AC

motors with two pole pairs (four-pole) are particularly
well suited to dynamic drive tasks.
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2 Drive definition
Typical max. acceleration times of four-pole standard three-

phase AC motors
Acceleration time with moment

Power Idle acceleration time in
Size of inertia adaptation in ms
P in W ms [Ired=0]
[Ired=IM]
63L/4 250 55 110
71L/4 375 49 98
80/S/4 550 57 114
80L/4 750 54 108
90S/4 1100 52 104
90L/4 1500 52 104
90L/4a 2200 35 70
100L/4 2200 50 100
100L/4a 3000 50 100
112M/4 4000 123 246
Table 2.5 Max. acceleration times of four-pole standard three-phase AC

motors
Example: Equations for reduction via a gearbox
For further calculations of mass moments of inertia See Appendix A.2.8.

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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2 Drive definition
Standards and regulations
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
Typically 2 to 5 times nominal torque, depending on controller

Maximum pulse torque assignment.
3 to 5 times nominal torque is permissible for max. 0.2 s.
The average service life under nominal conditions
Bearing service life
(Mmax. ≤ MN) is 20,000 h.
Table 2.6 General technical data

2 Drive definition
Type code for asynchronous servomotor ASX
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
m
ng
va
ls
rs
ng
tec
rvo
e,
oli
ina
3
ge
de
ldi
Siz
Se
co
n
m
l ta
co
tio
No
us
n,
En
Vo
ina
sig
no
rm
ro
De
ch
Te
yn
As
The order designation

=
4
AS
must always be quoted

in full in the
specified order.
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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2 Drive definition
Technical data of the asynchronous servomotors with self coo-

ling
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
Table 2.7 Technical data, self cooling
Abbreviations used
Term Explanation
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.
the motors.

2 Drive definition
Technical data of the asynchronous servomotors with forced

cooling
1
M0 MN PN I0 IN nN JL m nmax
Forced cooling
[Nm] [Nm] [kW] [A] [A] [rpm] [kgcm²] [kg] [rpm]
ASF (V)-11 -2xxx3 2 1.7 0.54 2.1 1.8 3000 2.8 7.5 12000
ASF (V)-12 -2xxx3 2.7 2.3 0.72 2.8 2.4 3000 3.7 8.6 12000
2
ASF (V)-13 -2xxx3 3.6 3 0.94 3.54 2.9 3000 4.7 9.7 12000
ASF (V)-14 -2xxx3 5.6 4.7 1.5 5.1 4.3 3000 6.5 12.5 12000
ASF (V)-15 -2xxx3 7.7 6.5 2 7.3 6.2 3000 8.9 14,2 12000
3
ASF (V)-21 -2xxx3 5.6 4.7 1.5 4.6 3.9 3000 10.9 13.8 12000
ASF (V)-22 -2xxx3 8.4 6.5 2 6.5 5 3000 14.4 16.2 12000
ASF (V)-23 -2xxx3 12 10 3.1 8.9 7.4 3000 21.5 19,2 10000
4
ASF (V)-24 -2xxx2 15.5 13 2.7 8 6.7 2000 29.8 23.3 10000
ASF (V)-25 -2xxx2 19.7 16.5 3.4 9.8 8.2 2000 38.4 27 8000
ASF (V)-31 -2xxx1 21.5 18 2.8 8.4 7 1500 70 33.8 8000
5
ASF (V)-32 -2xxx1 27.5 23 3.6 10.6 8.9 1500 90 37.5 8000
ASF (V)-33 -2xxx1 38 32 5 13.8 11.6 1500 130 46.5 8000
ASF (V)-34 -2xxx1 56 47 7.4 18.4 15.4 1500 209 62.1 8000
6
ASV-41-2xxx1 83 70 11 33 27.5 1500 450 95 8000
ASV-42-2xx1 140 118 18.5 50 42 1500 740 121 8000
ASV-43-2xxx1 170 143 22.5 61 51 1500 960 145 8000
7
Table 2.8 Technical data, forced cooling
Abbreviations used A
Term Explanation
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.
the motors.
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2 Drive definition
Typical max. acceleration times of asynchronous servomotors
Idle accele- Acceleration

Accelera-
ASx Size Installation Power ration time time
tion torque
Length window [mm] class [kW] [ms] [ms]
[Nm]
Ired=0 Ired=IM
11 to 15 110x110 3,25 to 11.75 0.4 to 1.5 14 to 12 28 to 24
21 to 25 140x140 8.75 to 32.5 1.1 to 2.7 20 to 19 40 to 38
31 to 34 190x190 32.5 to 87.5 2.1 to 5.5 34 to 38 68 to 76
41 to 43 260x260 100 to 175 6.3 to 11 71 to 87 142 to 174
Precondition: Acceleration from 0 to 1500 rpm

at 2.5 times nominal torque and idle (Ired=0)
Table 2.9 Idle acceleration time
Example: Equations for reduction via a gearbox
Calculation of mass moments of inertia - See section A.2.8.

2 Drive definition
2.5.3 Characteristic Typical torque characteristic

values of reluc-
tance motors 4 MK
1
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
(2) Pull-out of synchronism Mksy ≈ 1, 6bis1, 8 ⋅ MN 6
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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2 Drive definition
Torque as a function of load angle
Idling of the reluctance/ Loading of the reluctance/

synchronous motor synchronous motor
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
Table 2.10 Torque as a function of rotor displacement angle β

(load angle)
β referred to the motor shaft

Mksg
Pole pairs βMN typical βMksg
1 20° 45°
MN
2 10° 22.5°
90˚ 3 6.75° 15°
4 5° 11,25°
Table 2.11 Internal torque as a function of load angle
Internal torque (Mi) M i = k ⋅ Φ ⋅ i ⋅ sin β

2 Drive definition
Project planning notes

A 3-phase AC reluctance motor is a special motor which must be tested
anew prior to every production deployment. Depending on the 1
situation, smooth running, heat, noise or vibration problems may occur.
The following table presents a listing of key points which may need to be
considered.
2
Detailed information can only be provided by the manufacturer of the
reluctance motor, however.
Subject Project planning notes 3

See manufacturer’s data sheet
Tips:
• Winding always in star configuration (high inductance) 4
Motor design • Inquiries for motors for S3 to S6 operation must usually be
submitted separately
• Motor protection only possible via PTC or Klixon
• High tendency to vibrate, especially < 25Hz 5
In static operation
• I-Inverter ≈ 1,2 IN Motor
In dynamic operation 6
• I-Inverter ≈ 1.8 IN Motor
• Shut down the slip compensation, load compensation and V/F
characteristic adaptation software functions
Inverter design • V/F characteristic with at least 3-6 fully programmable inter- 7
polation points
• At frequencies > 150 Hz an additional filter must very often be
inserted in the motor cable
• The max. output frequency must not be higher than FN
A
(frequency nominal point).
• When motors are connected up a very high short-circuit cur-
rent flows (typically up to 30-40 times IN)
Table 2.12 Project planning notes for drive system with reluctance motors
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2 Drive definition
2.5.4 Characteristic Synchronous motor with salient-pole rotor

values of syn- 4
chronous motors
3
Mksy
M
2
M
N
0.2 0.4 0.6 0.8 1
n/nN
Figure 2.23 Typical torque characteristic of a synchronous motor with

salient-pole rotor
Synchronous motor with cage winding and permanent magnets
2.5
2 Mksy
M Msy
MN 1.5
1
(2)
(1)
0.2 0.4 0.6 0.8 1
n/nN
Typical startup characteristic of a permanent magnet excited synchronous motor with cage winding for asynchronous self-running
(1) Pull-in to synchronism Msy ≈ 0, 9 ⋅ M N
(2) Pull-out of synchronism Mksy ≈ 1, 35 ⋅ M N (corresponding to VDE 0530)
Figure 2.24 Typical synchronous motor of a synchronous motor with cage

winding and permanent magnets

2 Drive definition
Torque as a function of load angle
Idling of the reluctance/ Loading of the reluctance/ 1

synchronous motor synchronous motor
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
Figure 2.25 Torque as a function of load angle in the synchronous machine

with salient-pole rotor
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2 Drive definition
Project planning notes

A synchronous motor, too, is a special motor which must be tested anew
prior to every production deployment. Depending on the situation, smooth
running, heat, noise or vibration problems may occur. The following table
presents a listing of key points which may need to be considered.
Subject Project planning notes
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.
Table 2.14 Project planning notes for permanent magnet excited

synchronous motors with cage winding for asynchronous
self-starting.

2 Drive definition
Detailed information can only be provided by the manufacturer of the syn-

chronous motor, however.
1
2.5.5 Characteristic Not available at time of going to press. 2

values of high-
frequency
motors 3
At frequencies > 1000 Hz special project planning directives must be
followed.
4
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2 Drive definition
2.6 Selection of gea-

ring T his section presents the key gearing data in table form. For precise
data regarding design, magnetic flux direction, transmission, play etc.
refer to the various manufacturers’ catalogues.
What points need to be considered in designing the gearing?
• Fitting location conditions (room conditions, temperature, position)
• Max. drive speed
• Max. output torque
• Service factor (the standard gears are designed for uniform load)
• Transversal forces, axial forces
• Circumferential backlash
• Torsional rigidity
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)
(1) Transmission gear with chain wheels

Figure 2.26 Transmission gear
Practical tip
➢ In practice the transmission gear is usually implemented by way of
toothed belts
imax ≈ 4, itypical = 2 to 3
➢ itot = iv . iG iv Transmission gear reduction

iG Gear reduction

2 Drive definition
2.6.2 Characteristic Spur Flat spur Worm

Characteristics Bevel gear
values of gear gear gear
standard gears Magnetic flux straight straight rectangular rectangular
1
approx. approx. approx. approx.
Max. torque [Nm]
15,000 6,000 4000 40,000
2nd shaft end not possible possible possible possible 2
Hollow output shaft not possible possible possible possible
Reduction range
approx. approx. approx. approx.
(without compound
transmission)
3.5 to 230 6 to 270 6 to 290 6 to 165 3
Efficiency 0.93 to 0.98 0.93 to 0.98 0.3 to 0.85 0.9 to 0.96
Circumferential back- approx. approx. approx. approx.
lash in1) angle minutes 30 to 40 30 to 40 30 to 40 25 to 40 4
Reduction mathema-
tically2) precise? no no no no
(rating plate) 5
Cost DM/Nm low low medium relatively high
1) For explanation See section 2.6.3
2)
The cogs of the cogwheel pairing have common dividers so that different cogs always
engage with each other.
6
Example: i = Z2/Z1 = 96/16 = 5.9375 ⇒ Catalogue specification 5.94
Table 2.15 Characteristic values of standard gears

7
2.6.3 Characteristic Characteristics Standard gear Planetary gear Bevel gear
values of
Gear stages 1/2/3 1/2 1/2
planetary gears A
Efficiency
very good very good very good
(without worm gear)
Circumferential backlash
approx. 25 to 40 1 to 10 6 - 15
in angle minutes
Impulse torques poor very good poor
Torsional rigidity medium very good medium
Dynamics medium very good medium
Power density poor very good poor
Transmission math.
no yes yes
precise? (rating plate)
Cost DM/Nm low relatively high medium
Table 2.16 Characteristic values of planetary gears DE

EN
2 Drive definition
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.
➢ Figures are always absolute values and in angle minutes.

➢ Figure is obtained with drive shaft stopped.
➢ Figure relates to the output and is obtained by means of an alterna-
ting load of approx. 3 to 5% Mmax.
Torsional rigidity
Torsional rigidity is the torsion of a gear relative to the loading.
➢ Figure always in Nm per angle minute.

➢ Figure is obtained with drive shaft stopped.
➢ Figure relates to the output and is obtained by means of an alterna-
ting load of approx. 0 to 100% Mmax.

1
2
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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3.3 Special applications .............................................3-60

3.3.1 Project planning for three-phase AC motors ....... 3-60
3.3.2 Efficiency of the motor control methods ............ 3-62
3.3.3 Standard inverter operation ............................... 3-67
3.3.4 70 Hz - Characteristic with 25% field
weakening ......................................................... 3-69
3.3.5 87 Hz characteristic / Expanded manipulating
range ................................................................. 3-73
3.3.6 Multi-motor operation on one inverter ................ 3-76
3.3.7 DC network operation ........................................ 3-79
3.3.8 Design of the braking resistor ............................ 3-83
3.3.9 Power failure bridging ....................................... 3-87

3.1 Technical data Type codes of inverter modules
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
*) The design code is separated by a comma. A maximum of 5 designs 6

can be suffixed.
7
Single-phase inverter modules
Rec. 4-pole Rated

Peak current1)
Inverter module
standard motor current
Power loss Device output
A
CDA32.003,Cx.x 0.375 kW 2.4 A 4.3 A 25 W 0.95 kVA
CDA32.004,Cx.x 0.75 kW 4.0 A 7.2 A 45 W 1.5 kVA
CDA32.006,Cx.x 1.1 kW 5.5 A 9.9 A 75 W 2.1 kVA
CDA32.008,Cx.x 1.5 kW 7.1 A 12.8 A 95 W 2.7 kVA
1) 1.8 x IN for 30 s Mains voltage 1 x 230 V -20 % +15 %
Power stage switching frequency 4, 8, 16 kHz
Mains frequency 50/60 Hz ±10 %
Output frequency 0 ... 1600 Hz
Cooling air temperature
(1000 m above MSL) 45 °C at 4 kHz
Table 3.1 Overview of inverter modules for 230 V systems
DE
EN
Three-phase inverter modules
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

3.1.1 Acceptance Acceptance tests /

tests Standards / Characteristic data
Directives 1
CE The inverter modules conform to the requirements for installation in a
machine or system under the terms of the Low Voltage Directive.
Approvals cUL (in preparation) 2
Conformance to • Fitting-out of power installations with electronic equipment
standards E50178
• EMC1) interference immunity
IEC 1000-4-2 / EN 61000-4-2 3
IEC 1000-4-3 / EN 61000-4-3
IEC 1000-4-4 / EN 61000-4-4
IEC 1000-4-5 / EN 61000-4-5
• EMC, line-borne and radiated interference emission 4
EN 50081-1 and EN 50081-2
IEC 55011 integrated radio interference suppression level A2)/B2)
for inverter modules to 7.5 kW.
For inverter modules 11 to 90 kW a wide range of filters is availa- 5
ble to ensure conformance to IEC 55011.
• All devices conform to the product norm
EN618000-3 for speed-adjustable electric drives.
1) EMC = Electromagnetic compatibility 6
2) Motor cable length - See section 6.4
Table 3.3 Acceptance tests/Standards

7
Explanation of the “Acceptance tests and standards” table
Standard Test Comments
EN 61000-4-2 • By touch Test of immunity to electrostatic dis-

A
Discharge 6 kV charge (ESD)
• In air
Discharge 8 kV
EN 61000-4-3 • 26-1000 MHz (10 V/m) Test of the electromagnetic field
EN 61000-4-4 • at control terminals 2 kV Test of immunity to rapid transient
• on mains and motor cable electrical interference (burst)
Impulse voltage 4 kV
EN 61000-4-5 • Conductor / conductor Immunity to voltage surge
1 kV
• Conductor / ground
2 kV
Table 3.4 Explanation of the “Acceptance tests and standards” table
DE
EN
Standard Test Comments
EN 50081-1 • Residential and business Protection against emission of electri-

• Motor cable length - See cal, magnetic and electromagnetic
section 6.4 interference and against conducted
interference
EN 50081-2 • Industrial Protection against emission of electri-
• Motor cable length - See cal, magnetic and electromagnetic
section 6.4.2 interference and against line-borne
interference
EN 55011 • Industrial Protection against line-borne interfer-
Class A ence
• Residential and business
Class B
• Motor cable length - See
section 6.4
Table 3.4 Explanation of the “Acceptance tests and standards” table
3.1.2 Ambient Feature Characteristic data

conditions
Tempera- -10 ... 45 °C with derating to 55 °C (BG1 ... BG5)
in operation
ture range 0 ... 40 °C (BG6 ... BG8)
in storage -25 ... +55 °C
in transit -25 ... +70 °C
Relative air humidity 15 ... 85 %, condensation not permitted
Mechanical in stationary Vibration: 0.075 mm in frequency range 10 ... 58 Hz
strength to operation Shock: 9.8 m/s2 in frequency range >58 ... 500 Hz
IEC 68-2-6
in transit Vibration: 3.5 mm in frequency range 5 ... 9 Hz
Shock: 9.8 m/s2 in frequency range >9 ... 500 Hz
Protection Device menu IP20 (NEMA 1)
Cooling Cold plate IP20
method Push-through heat sink IP54 (3...15kW)
Push-through heat sink IP20 (22...37kW)
Touch protection VBG 4
Power reduction See section 3.2.x
Table 3.5 Ambient conditions

3.1.3 Installation The CDA3000 inverter module offers three different methods of installa-
and cooling tion and cooling:
methods ➢ Cold plate 1

➢ Wall mounting with heat sink
➢ Push-through heat sink
2
General project planning notes
Subject Project planning notes 3

• Inverter modules 0.37 to 15 kW can be mounted next to each
other with no gap.
Side clearance
• Above 22 kW a side clearance of 50 mm must additionally be
maintained. 4
Clearance above • There must be a clearance of 100 mm above and below.
and below
5
• Polluted cooling air (dust, fluff, oil, aggressive gases) may impair
the functioning of the inverter modules.
- Take adequate precautions; cold plate; separate
ventilation; installation of filters; regular cleaning etc. 6
• Do not exceed the permissible range of the operational cooling
temperature (see sections 3.1.2 and 3.2.14).
• Observe other ambient conditions (see section 3.1.2).
• Mounting orientation: Vertical on the rear of the switch cabinet or 7
other mounting surface.
• With “cold plate and push-through heat sink” cooling, comply
with the special conditions for discharge of power loss.
Table 3.6 Project planning notes

A
DE
EN
Overview of the permissible cooling methods referred to size

and power output
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
Table 3.7 Overview of inverter modules and possible cooling methods
At 8 kHz power stage clock frequency the power losses increase

by 40%.

“Cold plate” cooling method based on the example of size 3

(3 and 4 kW)
CDA3..., Cx.x
1
Installation Vertical on mounting plate W D
(heat-conducting) or cooling
profile, ) cold plate principle
start
enter
stop
return
2
Protection IP20
Cooling air 45 °C (at 4 kHz switching
temperature frequency of power stage)
3
H
Weight 2.8 Kg
CDA3..., Cx.x
H (height) 303 mm
W (width) 100 mm
4
D (depth) 182.5 mm
Table 3.8 Cold plate installation and cooling method

5
DE
EN
Project planning notes, “Cold plate”
• Evenness of contact surface of 0.05 mm

RZR 6.3 = maximum roughness of contact surface
Thermal connection to
• Coat area between inverter module (“cold plate” backing plate) and cooler with heat transfer
cooler
compound (coat thickness 30-70µ).
• The temperature in the middle of the inverter module backing plate must not exceed 85 °C.
Size Power output Heat sink Housing
Distribution of BG 1/2 0.37 to 2.2 kW approx. 65% approx. 35%

power loss BG 3 3 to 4 kW approx. 70% approx. 30%
BG 4 5.5 to 7.5 kW approx. 75% approx. 25%
BG 5 11 to 15 kW approx. 80% approx. 20%
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
BG 3 3 to 4 kW 100 303 120 260

a
BG 4 5.5 to 7.5 kW 150 303 65 215

BG 5 11 to 15 kW 200 303 80 300
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
Table 3.9 Project planning notes, “Cold plate”

Example: Heat transfer via a cooler

The inverter module has a • Inverter module CDA34.014
temperature evaluation facility • Power stage clock frequency 4 kHz
1
as standard.
The current temperature at

point 1 of the heat sink is
Point 1: 85˚C, see table 3.9 2
displayed by way of parameter Point 2: To be ascertained (max.
427-KTEMP in subject area temperature on cooling plate)
_VAL (actual values).
3
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
3. Maximum temperature at point 2 and on the cooler
ϑ Point 2 = ϑ Point 1 -DJ = 85 °C - 2.7 °C = 82.3 °C
4. Calculation of the cooler:

• At point 2 the max. temperature of 82.3 °C must not be exceeded.
• 135 W of power loss must be discharged by way of the cooler.
• The exact solution depends on the cooler used, e.g. heat sink to air
or water, heat exchanger etc.
DE
EN
“Wall mounting” cooling method based on the example of size 3

(3 and 4 kW)
CDA3..., Wx.x
Installation Vertical wall mounting with W D

heat sink
Protection IP20 start
enter
stop
return

Weight 3.7 Kg
H
H (height) 330 mm CDA3..., Wx.x
W (width) 70 mm355 mm
D (depth) 250.5 mm
Table 3.10 Wall mounting installation and cooling method
With this cooling method the inverter module can even be mounted on
non-heat-conducting surfaces.
“Push-through heat sink” cooling method based on the example

of size 3 (3 and 4 kW)
L
CDA3..., Dx.x
Installation Vertical mounting with W D

push-through heat sink
Protection IP20 units, start
enter
stop
return
IP54 heat sink side

H
Weight 3.9 Kg
CDA3..., Dx.x
H (height) 340 mm
W (width) 110 mm
D (depth) 170.5 mm
Table 3.11 Push-through heat sink installation and cooling method

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
Size of inverter modules dependent on 5

cooling method
Clearance
Push-through
Size
Power output Cold plate1) Wall mounting1)
heat sink1)
above/ 6
[kW] WxHxD WxHxD below2)
WxHxD
[mm]
BG 1 0.37 to 0.75 70x193x153 70x193x228 no 100 / 100

BG 2 1.1 to 2,2 70x218x178 70x218x253 no 100 / 100
7
BG 3 3 to 4 100x303x183 70x330x251 110x340x171 100 / 100
BG 4 5.5 to 7.5 150x303x183 120x330x251 160x340x171 100 / 100
BG 5 11 to 15 200x303x183 170x330x251 210x340x171 100 / 100
A
BG 6 22 to 37 no 250x375x325 250x411x248 100 / 100
BG 7 45 to 55 no 300x600x305 no 100 / 100
BG 8 75 to 90 no 412x540x370 no 100 / 100
1) Max. outer dimensions to be maintained
2) The bending radii of the cables must be taken into account for the mounting clearance below
Note: The modules can be mounted side-by-side. As from size 6 an additional side clearance of 50 mm is required.
Table 3.13 Size of inverter modules dependent on on cooling method
DE
EN
3.2 Extreme operat- Safety instructions

ing conditions While in operation, inverter surfaces can be conductive,
uninsulated, sometimes also moving or rotating, and hot, according to
their type of protection. This means that a frequency inverter drive can
endanger human life.
To prevent serious physical injury or considerable material damage, only

qualified persons familiar with electrical drive equipment may work on the
equipment. Only those persons who are familiar with mounting, installing,
commissioning and operating inverters and have appropriate professional
qualifications shall be regarded as qualified. Those persons must read
the Operation Manual carefully before installation and commissioning,
and follow the safety instructions.
In this context the standards IEC 364 and CENELEC HD 384 or DIN VDE
0100 and IEC-Report 664 or VDE 0110 and national accident prevention
regulations or VBG 4 must be observed.
Repairs to the device may only be carried out by the manufacturer or by a

repair workshop approved by the manufacturer. Unauthorized opening
and unprofessional intervention could lead to physical injury or material
damage.
Intended use
Inverters are components that are intended for installation in electrical

systems or machines.
The inverter may not be commissioned (i.e. it may not be put to its
intended use) until it has been established that the machine complies with
the provisions of EC Directive 89/392/EEC (Machinery Directive);
EN60204 is to be observed.
In addition to the Low Voltage Directive 73/23/EEC the harmonized stand-
ards of the prEN 50178/DIN VDE 0160 series in conjunction with EN
60439-1/DIN VDE 0660 Part 500 and EN 60146/DIN VDE 0558 are to be
applied with regard to the inverters.
The technical data and the instructions concerning connection conditions
are given on the name plate and in the documentation, and are to be
observed under all circumstances.
The inverters are to be protected against unauthorized stress. In particu-
lar, components may not be bent, nor may insulation distances be altered
during transport and use.
Inverters contain components that are vulnerable to electrostatic accumu-
lation and can therefore easily be damaged if incorrectly handled. Ensure
that electrical components are not mechanically damaged or destroyed.

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
DE
EN
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
Figure 3.1 IT, TN and TT systems
First letter - Link from the supply system to the ground:

T Direct connection of a point to the ground
I Either all active parts isolated from ground or one point connected
to ground via an impedance.

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
DE
EN
Figure 3.2 Voltage and current conditions in the IT system
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.

System conditions for the CDA3000 inverter drive system
For operation of the CDA3000 drive controllers on the various mains 1

power systems the following conditions must be met.
2
Operation with
Power system Comments
Inverter CDA3000
• Pay attention to con- 3

nection data
Permitted without restriction
• Best system form in
terms of EMC
• Split symmetrically
4
TN and TT across the three outer
conductors
Operation of several
CDA32.xxx (1x230V) in the • Pay attention to the
loading of the common
5
3AC/N/PE system
zero conductor,
increase the cross-sec-
tion as necessary.
• Radio interference sup-
6
pression filters (inter-
nal/external) may be
destroyed in the event
of “ ground fault”.
7
• In the event of a
“ground fault” the volt-
Operation of inverter mod-
IT with insulated center point ules in this system type is not
age load is increased
(to around twice as
A
permitted. much), as a result of
which the creepages
and clearances are not
maintained and so the
system no longer con-
forms to the Low Volt-
age Directive EN50178
(safety-low voltage).
Table 3.14 System conditions
DE
EN
Additional comments on the IT system
For devices, machines and plant which need to be run in an IT system, an

isolating transformer must be fitted. The secondary side of the power
transformer must be configured as a TN system (TN-S with isolated
grounding lead).
Radio interference suppression filters must not be inserted/opera-

ted in the IT system. The IEC1800-3 standard stipulates that the fil-
ters cannot be used in this type of system because correct opera-
tion of the insulation monitoring cannot then be guaranteed.
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 choke With line choke Change
Without line
4 kW inverter, line 4 kW inverter, line
choke to
impedance impedance
with line
0.6 mH 0.6 mH
choke
Voltage distortion (THD) 99 % 33 % -67 %

Mains current amplitude 18.9 A 9.7 A -48 %
Mains current effective 8.5 A 6,23 A -27 %
Commutation notches
referred to the mains volt- 28 V 8V -70 %
age
Life of the DC-link capaci- 2 to 3 times nomi-
Nominal life +200 to 300 %
tors nal life
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

For more information on “System load” and “Line chokes” refer to

section 6.1. 1
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
Multi-wire cable (e.g. non-metallic sheathed cables or

moveable cables) 5
Nominal cross-section
in mm Protective device rated
Rated current of cable (Cu)
current
in A
in A 6
0.75 12 6
1.0 15 10
1.5 18 101)
2.5 26 20
7
4 34 25
6 44 35
10 61 50 A
16 82 63
25 108 80
35 135 100
50 168 125
70 207 160
95 250 200
120 292 250
150 335 250
185 382 315
240 453 400
300 504 400
1) For cables with only two wires under load a 16 A protective device can continue to be
selected until the final specification is made.
Table 3.16 Current load capacity of multi-wire cables
DE
EN
Current load capacity of multi-wire cables dependent on ambient

temperature to VDE 0298 Part 4
Insulating material*) NR/SR PVC EPR

Permissible operating temperature 60 °C 70 °C 80 °C
Ambient temperature °C Conversion factors
10 1,29 1.22 1.18
15 1.22 1.17 1.14
20 1.15 1.12 1.10
25 1.08 1.06 1.05
30 1.00 1.00 1.00
35 0.91 0.94 0.95
40 0.82 0.87 0.89
45 0.71 0.79 0.84
50 0.58 0.71 0.77
55 0.41 0.61 0.71
60 - 0.50 0.63
65 - - 0.55
70 - - 0.45
*) At higher ambient temperatures based on manufacturer's specifications
Table 3.17 Current load capacity of multi-wire cables dependent on ambi-

ent temperature
For more information on “current load capacity and protection of

cables with PVC insulation” refer to VDE 0100 Part 430 supplement
sheet 1 (11/91).
Protection of the mains power cable

Normal time-lag fuses (see Table 3.16) can be used to protect the mains
power cable.1
The fuses must be designed in conformance with local safety standards,
the matching mains voltage and the corresponding rated input current of
the inverter.
If standard commercially available miniature circuit-breakers are

used for protection purposes, the tripping characteristic “C” must
be configured.
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
Minimum cross-section of the grounding lead to VDE 0100 2

Part 540
Cross-section PE mains connection
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
Only all-current sensitive fault current breakers suitable for inverter

operation may be used.
The fault current breaker must meet the following conditions:
• Suitable for protection of devices with DC component in the lea-
kage current (only with three-phase rectifier bridge)
• Suitable for short-term pulse-shaped leakage currents
• Suitable for high leakage currents
DE
EN
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.
The inverter module may be connected to the mains every

60 seconds.
Frequent connection will not result in destruction of the input circuit
on the inverter module. The inverter module protects itself by means
of high-resistance through isolation inverter from the mains power.
This is made possible by a special PTC precharge technique.
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.
If the insulation resistance is nonetheless to be tested, the proce-

dure set out below should be followed:
1. The high-voltage test must be performed prior to connection of
the CDA3000 inverter.
2. The inputs and outputs U, V, W, +, -, RB, L1, L2 and L3 must be
shorted.
3. The control inputs (X2, X3) and control outputs must be connec-
ted to PE.
4. The high-voltage test is performed by applying a maximum of
1.9 VDC for 1 second. The voltage is applied between the shor-
ting jumper at point 2. and the shorting jumper at point 3.

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
Control and monitoring unit

7
serial
Figure 3.3 Block diagram of a voltage transformer A
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Forming of the DC-link capacitors

To form the DC-link capacitors the inverter modules must be connected to
the mains power at 400/460 V (CDA34.xxx) approx. every 6 months for
1 hour. The time is dependent on the storage temperature: Inverter
modules stored at approx. 45 °C only need be connected to the mains
approx. every 8 months.
ANTRIEBSTECHNIK
D- 35633 Lahnau
Typ: CDA34.032.C1x
Netz: 400 V + 15/-20%

50/60 Hz 16,2 kVA
Ausg.: 3x0-400 V 32 A
15 kW 0-400 Hz
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.
LUST Service Center Tel. 06441 / 966-136

Gewerbestraße 7 Fax 06441 / 966-211
35633 Lahnau e-mail: service@lust-tec.de

3.2.8 Direction of The direction of rotation is referred to the drive side.

rotation and
terminal 1
designation Anti-
clockwise
(acw)
2
View: drive side Clockwise 4

(cw)
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”
Table 3.19 Clockwise/anti-clockwise
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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~
Figure 3.6 Circuitry example “Switching at the inverter output”
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.

Note on AC-3 contactors
Note: If contactors of usage category AC-3 are used (conforming to 1

IEC 947-4-1, EN 60947 or VDE 0660 Part 102), the number
of actuations must not exceed five per minute and 10 every
10 minutes. For higher actuating rates different switching
elements should be selected accordingly. 2
Activation of energized motors or direct switching of the number of

poles in variable-pole motors, and reversing the direction of the
3
motor - such as by means of a reversing contactor - is not permitted
during operation.
4
3.2.10 Short-circuit The inverters of series CDA3000 are fitted with one current sensor per
and ground motor phase. In the event of a short-circuit or ground fault in the motor
fault proofing
cable, the power stage is disabled and an appropriate error message is 5
delivered.
The CDA3000 inverter modules are short-circuit and ground fault

proof.
6
3.2.11 Motor cable The maximum motor cable length depends on a number of different 7
length factors (see following table).
Factor Section
Standard EN 55011 A/B Section 6.4

A
Clock frequency of power stage Section 3.2.14
Voltage drop on the motor cable See explanation below
Connection of a motor choke du/dt Section 6.3
Table 3.20 Motor cable length
Voltage drop on the motor cable

In designing a drive solution it should be noted that the mains voltage can
fall by 10% and the components used (line choke, inverter, motor cable,
etc.) cause a voltage drop.
The system undervoltage (-10%) and the voltage drops mean that, in cer-
tain operating states, the full motor torque is not attained and the field
weakening begins earlier.
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Typical voltage drops
Typical voltage drop referred to the

Component
respective mains voltage
Line choke with 4 % UK approx. 1%

Mains filter <0.1%
Inverter module ≈3%

Motor choke < 1%
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)
Table 3.21 Typical voltage drops

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
du/dt Problems with IEC 3

Technology Special motors2)
Typical standard motor1)
Inverter technology
with standard tran-
3-6 kV/µs Not known Isolated cases known
4
sistors (on the market
for over 15 years)
Inverter technology
with IGBTs
10-20 kV/µs Isolated cases known Isolated cases known 5
Inverter technology
with IGBTs and du/dt
3-6 kV/µs Not known Isolated cases known
limitation to around 6
kV/µs 6
Inverter technology
with IGBTs and du/dt < 1kV/µs Not known Not known
motor choke
7
1) With vacuum-saturated winding insulation (without air bubbles) and insulated winding heads
2) Without vacuum-saturated winding insulation (with air bubbles) and without insulated winding heads
Table 3.22 Practical experience with du/dt voltage load

A
The rate of rise of voltage of the CDA3000 inverter modules is typically
3-6 kV/µs. For applications with special motors we provide a wide range
of motor chokes (see 6.2).
Our experience shows that no problems arise in connection with IEC

standard motors with vacuum-saturated windings and insulated winding
heads. However, the decisive factor in each individual case is the specifi-
cations of the motor manufacturer!
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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Motor protection possibilities

A B C D C+D
Motor-PTC moni-
Motor circuit- Motor-PTC Software function:
Thermistor toring and motor
Overload type breaker monitoring of the motor protection
protective relay protection of the
(e.g. PKZM) CDA3000 of the CDA3000
CDA
Overload in continu-
ous operation 1)
3) 3)
Heavy starting 2)
Blocking 1)
3) 3)
Blocking 2)
Ambient tempera-
ture >50°C 1)
Impairment of
cooling 1)
Inverter operation 4)
<50 Hz
No protection Limited protection Full protection
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
Table 3.23 Motor protection possibilities
Fuses are not included in this comparison because they only pro-
tect the cable and not the motor.
In summary: From the point of view of “motor protection” the use of

additional motor circuit-breakers or thermistor protec-
tive relays is not required. All required safety functions
are provided by the inverter module as standard.

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
1.0 1% per 100 m 4

0.9
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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Permissible rated current of the single-phase inverter modules

0.37 kW to 2.2 kW
1 x 230 V mains voltage

45 °C ambient temperature
16 kHz clock frequency


10 m motor cable
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]
CDA32.003,Cx.x1 ) 2.40 2.40 2.40 2.25 2.15 2.00
CDA32.004,Cx.x2 ) 4.00 4.00 3.00 3.85 3.70 2.60

CDA32.006,Cx.x 5.60 5.40 4.00 5.45 5.25 3.85
3) 7.10 7.10 5.20 6.95 6.85 4.80
CDA32.008,Cx.x
1) Mounted side-by-side, with no additional cooling area
2) Mounted side-by-side, with backplane (940 mm x 70 mm = 0.065 m²) as additional cooling area
3) inverter module With Heat sink “HS32.200”
4) The rated current with a 25 m motor cable is less than that with a 10 m motor cable by the amount of the current loss occurring on the motor
cable (see table 3.2.7)
Table 3.24 Output current for inverter modules with 230 V power supply

Permissible rated current of three-phase inverter modules

0.75 kW to 90 kW

1


10 m motor cable
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
CDA34.005,Cx.x2 ) 4.1 4.2 2.3 3.9 3.6 1.4

CDA34.006,Wx.x 5.7 5.7 3.5 5.7 5.7 2.6 5
CDA34.008,Wx.x 7.8 7.8 * 7.8 * *
CDA34.010,Wx.x 10 10 * 10 * *
CDA34.014,Wx.x 14 14 * 14 * * 6
CDA34.017,Wx.x 17 17 * 17 * *
CDA34.024,Wx.x 24 24 * 24 * *
CDA34.032,Wx.x 32 32 * 32 * * 7
CDA34.045,Wx.x 45 45 * 45 * *
CDA34.060,Wx.x 60 60 * 60 * *
CDA34.072,Wx.x 72 72 * 72 * * A
CDA34.090,Wx.x 90 90 * 90 * *
CDA34.110,Wx.x 110 110 * 110 * *
CDA34.143,Wx.x 143 143 * 143 * *
CDA34.170,Wx.x 170 170 * 170 * *
* Not available at time of going to press
1) Mounted side-by-side, with no additional cooling area
2) Mounted side-by-side with heat sink “HS32.200” or with 0.3 m² backplane
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10 m motor cable
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

Current characteristic, CDA32.003,Cx.x (0.37 kW)

Cooling method: Cold plate without additional cooling area
Motor cable length: 10 m 1
Rated current: 2.4 A
Switching frequency
of power stage: 4, 8, 16 kHz
Mounting type: side-by-side 2
Mounting height: 1000 m
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
[˚C] Cooling air temperature J K

Figure 3.8 Max. current load of the CDA32.003,Cx.x / 0.37 kW / side-by-
side / without additional cooling area
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Motor cable length: 10 m
Rated current: 4A
Switching frequency
Mounting type: side-by-side
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
[˚C] Cooling air temperature JK


Cold plate with backplane (0.065 m2)

Cooling method:
as additional cooling area
1
Rated current: 4A
Switching frequency
2
3
5
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
side / with backplane (0.065 m) as additional cooling area
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Current characteristic, CDA32.008,Cxx (1.5 kW)

Switching frequency
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



Cooling method: Cold plate with heat sink HS32.200
Switching frequency
Mounting type: side-by-side 2
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
[˚C] Cooling air temperature JK A

side with 20 mm clearance between the units / with accessory
heat sink HS32.200
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Cooling method: Cold plate with backplane
(0.3 m) as additional cooling area
Switching frequency
Mounting type: not side-by-side
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

Figure 3.13 Max. current load of the CDA32.008,Cx.x / 1.5 kW / not side-by-
side / with backplane (0.3 m2) as additional cooling area


Switching frequency
Mains voltage: 3 x 400 V 2
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

side / without additional cooling area / mains voltage 3 x 400 V
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Switching frequency
Mains voltage: 3 x 460 V
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



Switching frequency
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

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Switching frequency
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



Cooling method: Cold plate with additional heat sink HS32.200
Switching frequency
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
Figure 3.18 Max. current load of the CDA34.035,Cx.x / 1.5 kW / side-

by-side / with additional heat sink HS32.200 / mains voltage
3 x 400 V
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Cooling method: Cold plate with additional heat sink HS32.200
Switching frequency
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
[˚C] Cooling air temperatureJ K
Figure 3.19 Max. current load of the CDA34.035,Cx.x / 1.5 kW / side-

by-side / with additional heat sink HS32.200 / mains voltage
3 x 460 V

Cold plate with backplane (0.3 m2)

Cooling method:
1
Switching frequency
2
3
5
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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Cooling method: Cold plate with backplane (0.3 m2)

Switching frequency
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

Current characteristic, CDA34.006,Wxx (2.2 kW)

Cooling method: Wall mounting
Switching frequency
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

Figure 3.22 Max. current load of the CDA 34.006,Wx.x / 2.2 kW / side-by-
side / wall mounting / mains voltage 3 x 400 V
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Current characteristic, CDA34.006,Wxx (2.2 kW)

Switching frequency
of power stage: 4, 8 kHz
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

Figure 3.23 Max. current load of the CDA 34.006,Wx.x / 2.2 kW / side-by-
side / wall mounting / mains voltage 3 x 460 V

Current characteristic, CDA34.008,Wxx (3 kW)

Switching frequency
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
Figure 3.24 Max. current load of the CDA 34.008,Wx.x / 3 kW / side-by-side

/ wall mounting / mains voltage 3 x 400 V
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Rated current: 10 A
Switching frequency
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



Rated current: 10 A
Switching frequency
of power stage: 4, 8 kHz
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

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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

Long motor cables

The specified rated currents relate to the current still available at the end
of a 10/25 m long motor cable; see Table 3.24 to Table 3.26. If the motor 1
cable is longer than 10/25 m, the current losses resulting from the additio-
nal motor cable length must be taken into account.
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
Table 3.27 applies to motor cable lengths up to 150 m.

6
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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
Figure 3.27 Effective inverter capacity utilization
2 2 2
I 1 ⋅ t1 + I 2 ⋅ t2 + I 2 ⋅ t3
I eff = ----------------------------------------------------------
T
The inverter module is defined by Ieff < IN-Inverter . The condition

[ILoad2 - IN Inverter2] x tOverload < 75A2s must additionally be met,
otherwise the inverter module will shut down due to overload.
For ease of effective value calculation we recommend the LUDRIVE drive

dimensioning program.

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
1 1.8 . IN 15 s 0 0 1.8 . IN 15 s 70 s Ieff < IN X 2

2 1.8 . IN 15 s 0.3 . IN 75 s 1.8 . IN 15 s 0s Ieff < IN X
3 1.5 . IN 30 s 0 0 1.5 . IN 30 s 80 s Ieff < IN X

3
4 1.5 . IN 1s 0.7 . IN 3s 1.5 . IN 1s 1s Ieff < IN X
5 1.8 . IN 0.2 s 0,2 . IN 0.5 s 1.8 . IN 0.2 s 0.45 s Ieff < IN X
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
8 1.7 . IN 0.1 s 0 0 1.7 . IN 0.1 s 0.4 s Ieff < IN X 5

Table 3.28 Calculation example for the effective inverter current
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Software function: “Device capacity utilization”

To enable the calculation to be checked, the inverter module provides a
peak current value storage facility for checking of the drive dimensioning
as a standard feature in the “Device capacity utilization” software function.
When the values have been read they can be reset.
(1) (2) (3)
F/Hz
t/s
IMAXBR
IMAXBE
IMAXST
t/s
(1) Acceleration (max. acceleration current in parameter IMAXBE)

(2) Stationary operation (max. current in stationary operation in parameter
IMAXST)
(3) Braking (max. braking current in parameter IMAXBR)
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:
module • Motor frequency • Motor voltage 1

• Motor speed • DC-link voltage
• Motor apparent current • Motor temperature
• Motor active current • Heat sink temperature 2
• Motor apparent power • Device interior temperature
• Motor active power • etc.
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).
If measurements are nevertheless to be taken on the CDA3000, the 4

following conditions must be met.
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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Figure 3.29 Measuring circuit for a voltage inverter (suggested configura-

tion) with oscillograms (block diagrams)

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
Synchronous motor Asynchronous motor

7
with energized rotor Reluctance motor Standard motor Servomotor
A
Energized via Permanently With damper Without damper HF motors
slip ring energized cage cage
(brushless) (SYNCELL)
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Areas of application for three-phase AC motors
Working
Motor type Application
principle
In all industrial sectors. Around 10-15% of all

Standard three-phase
asynchronous motors are speed-adjustable by way of invert-
AC motor
ers.
pumps, galette drives or roller drives etc.
Synchronous motor synchronous
Further areas of application are in the glass
and paper industry as winding drives, etc.
pumps, galette drives or roller drives etc.
asynchronous/
Reluctance motor Further areas of application are in drafting
synchronous
equipment and for synchronous running of two
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
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.
Displacement-type asynchronous In conveyor systems as a traction and lifting
armature motor with motor brake motor.
Table 3.29 Areas of application for three-phase AC motors

Project planning notes for three-phase AC motors
Motor type Project planning notes

1
Standard three-
See section 2.5.1 and 3.3
phase AC motor
Asynchronous
servomotor
See section 2.5.2 2
In a displacement-type armature motor the brake is ventilated by the
magnetic field of the motor. The motor must always be run with the VFC
Displacement-
type
control method. The “Current injection” software function must be
adapted.
3
armature motor
Note: A high current flows when the motor is idling. Operation at low
speeds is only permissible for short periods of time.
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)
Table 3.30 Project planning notes for synchronous and asynchronous

three-phase AC motors 6
3.3.2 Efficiency of the During commissioning of the inverter module three different motor control
motor control methods can be selected. The asynchronous motor is identified automati-
cally by the inverter module based on the “plug-and-play” principle. All
7
methods control loops are optimized in the process.
Voltage Frequency Control (VFC)

A
With VFC the voltage of the motor is modified proportional to the output
frequency of the inverter module. This method is particularly suitable for
reluctance motors, synchronous motors and special motors.
Sensorless Flux Control (SFC)

The new control method SFC, applicable to asynchronous motors, calcu-
lates the rotor speed and the current angle of the rotor from the electrical
variables. Based on the calculated information, the currents to form the
torque can be fed into the motor in a favorable way. In this way, outstand-
ing control characteristics are attained even without the use of a cost-
intensive encoder.
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Field-Oriented Regulation (FOR)

In FOR the rotor and speed positions are ascertained with an encoder.
Based on those measurement variables, the flux- and torque-forming cur-
rents can always be fed into the motor in optimum positions relative to
each other. This produces maximum dynamics and smoothness.
VFC SFC
FOR
General characteristics of the Voltage Sensorless
Field-Oriented
motor control methods Frequency Flux
Regulation
Control Control
Torque rise time approx. 10 ms <2 ms < 2ms

Dynamic disturbance correction NO YES YES
Standstill torque NO NO YES
Correction time for a load surge
<100 ms <100 ms <100 ms
of 1 x MN
Anti-stall protection limited YES YES
Speed manipulating range MConst. 1:20 1:50 >1:10000
Static speed accuracy n/ nN <2% <1% quartz-accurate
Frequency resolution 0.01 Hz 0.0625 Hz 2-16 Hz
asynchronous
Motor principle synchronous asynchronous asynchronous
reluctance
Multi-motor operation yes no no
Encoder evaluation no no yes
Table 3.31 Efficiency of the motor control methods with standard three-
phase AC motor

Break-away and acceleration torques dependent on motor con-

trol method
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)
Break-away torque1) with servomo-

tor (UN = 330 V)
2.5 x MN 2.6 x MN 2.8 x MN 3
Acceleration torque1) with standard 1,2 x MN 1.8 x MN 2 x MN
motor (UN = 400 V)
4
Acceleration torque1) with servomo- 1.6 x MN 1.8 x MN 2 x MN
tor (UN = 330 V)
1) IInverter = 2 x IMotor
5
Table 3.32 Break-away and acceleration torques
The table above indicates what typical torque is available on the motor
shaft of an asynchronous machine when the machine is driven by a 6
CDA3000 inverter module. The maximum motor rated current is limited by
the inverter module to 2 x IN-Motor.
7
For data relating to the servomotors refer to section 2.5.2.
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Positioning accuracy with Start/Stop operation as a function of

motor control method
ϕF = ω .. tRF
ϕF = Positioning error
in °
(4)
ω = Velocity
in mm/s
t (3) tRF = Response error

(1) (2) (terminal
scan cycle) in s
(1) Scan cycle of control terminals (CDA3000 = 1 ms) 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
control signals on inverter)
(4) Slip range (depending on control mode the braking ramp
is slip-dependent)
Figure 3.30 Start/stop positioning
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
4° 4° 3°
1500 rpm to 0 rpm
Servomotor (UN = 330 V)
12° 10° 8°
1500 rpm to 0 rpm
6° 5° 4°
1500 rpm to 0 rpm
Braking time 500 ms, external moment of inertia = motor moment of inertia
Table 3.33 Typical positioning errors referred to the motor shaft in °

VFC
SFC FOR
Voltage
Property
Frequency
Sensorless Flux Field-Oriented
Control Regulation
1
Control
9° 9° 9°
1500 rpm to 0 rpm
2
4° 4° 3°
1500 rpm to 0 rpm
1500 rpm to 0 rpm
12° 10° 8° 3
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 °
10° positioning error, referred to the motor shaft, is equivalent to a posi- 5

tioning error of a traction drive (i=20, drive pinion 60 mm) of +0.15 mm.
For more information on start/stop operation refer to section 1.3.3.
π ⋅ d ⋅ 10°
∆ s = ----------------------- = [ mm ] d = Diameter of drive pinion in mm
6
360° ⋅ i
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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]
Figure 3.31 Typical torque characteristic of a standard three-phase AC

motor
(1) Delivered power output of a standard three-phase AC motor in standard

inverter operation
(2) Permissible torque characteristic of an internally cooled standard three-
phase AC motor in standard inverter operation
(2.1) Typical characteristic at motor power output <4 kW
(2.2) Typical characteristic at motor power outputs >15 kW
Note: Precise data can only be given by the manufacturers of the

motors.
(3) Permissible torque characteristic of an adequately externally cooled

standard three-phase AC motor with standard inverter. It should, how-
ever, be noted that at motor power outputs >15 kW a rotor fan is very
often used, meaning that the characteristic (3) may need to be reduced.
Note: Note: Precise data can only be given by the manufacturers of

the motors.

(4) Maximum permissible torque of a standard three-phase AC motor to VDE

0530 Part 1 (120s).
Maximum torque with inverter modules which permit 150% overload and
have activated motor control method SFC or FOR.
1
(5) Maximum torque with inverter modules which permit 180% overload and
have activated motor control method SFC or FOR.
For break-away and acceleration torques dependent on motor control

2
method refer to section 3.3.2.
3
Special applications
Design (solution) Application

4
Area of application of solution:
Motor power lower
• In applications with acceleration times <500 ms, See section
than power output of
2.3.1 and 2.5.1.
inverter modules
• In applications requiring high overload torques 5
• In applications in which internally cooled motors are to be
Motor power higher
than power output of
used in continuous operation (S1) over a very broad manipu-
lating range.
6
inverter modules
Note: The motor current consumer in continuous operation must not
exceed the rated current of the inverter module.
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
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
motors on inverter
• See section 3.3.1
module
Table 3.34 Special applications
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Design (solution) Application
Operation of a motor Area of application of solution:

with 25% field weak- • In applications such as traction and lifting drives.
ening For more information see section 3.3.4
Operation of a motor
• In applications such as traction and lifting drives with
with 87 Hz character-
expanded manipulating range at constant torque delivery.
istic
For more information see section 3.3.5
Several motors on one
• In conveying, textile machinery engineering etc.
inverter module
For more information see section 3.3.6
Table 3.34 Special applications
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.

1. Drive design with 50 Hz
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
Figure 3.33 70 Hz drive design
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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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.
3. Comparison of gear output torques in drive designs with

50 Hz and 70 Hz characteristic.
Figure 3.34 Comparison of gear output torque in a drive design for 50 and
70 Hz
Curve Curve
Explanation
50 Hz 70 Hz
Typical permissible torque characteristic of an internally

1 2
cooled standard motor (1.5 kW)
Typical permissible torque characteristic of an externally
3 4
cooled standard motor (1.5 kW)
Maximum attainable torque for 60 s of a drive with 1.5 times
5 6
overload and automatic load compensation
Table 3.35 Comparison of gear output torque in a drive design for 50 and
70 Hz

Summary: 40% higher acceleration torque

In a drive design for 70 Hz the motor is run at a speed higher by the factor
1.4. As a result the maximum power output delivered by the motor is 1
achieved as low as a frequency of 50 Hz and remains constant beyond
that level up to 70 Hz. Above 50 Hz the torque falls proportional to the
inverter output frequency. The higher rotation speed of the motor shaft is
compensated by s transmission ratio increased by a factor 1.4. As a result 2
of the speed adjustment the available torque increases by 40% between 0
and 50 Hz and 0 and 68 rpm. This is equivalent to 40% more acceleration
torque with no increase in cost.
3
40% more overload reserve and break-away torque
Proportional to the acceleration torque, a 40% higher maximum torque is
of course also achieved (see characteristics 5 and 6 in Figure 3.34) and
4
thus also a 40% higher break-away torque.
60% larger speed manipulating range

5
The motor speed increased by a factor of 1.4 produces an approx. 60%
larger speed manipulating range on the gear output shaft. Referred to to
the application set out in Figure 3.32, Figure 3.33 and Figure 3.34, the 70 6
Hz design even means that no external cooler is needed, and so the
space take-up is reduced.
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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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.
Expanded Example: Motor 4 kW / 50 Hz in delta configuration

manipulating • Rated power 4 kW
range • Nominal speed 1420 rpm
• Rated voltage 230 / 400 V
• Delta / star configuration
1. Reconfigure motor to delta configuration (230 V / delta)
2. Select inverter output
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

3. Drive solution: 87 Hz characteristic
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
Figure 3.35 Constant torque range to 87 Hz 5

Design / Application
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.
During initial commissioning all the parameters for

this application are automatically set.
Table 3.36 Applications
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The choice of maximum frequency has a major influence on the accelera-

tion power.
2 JM Moment of inertia of the motor (rotor) in [kgm]

JM ⋅ n
P MBE = ---------------------- tBE Acceleration time in [s]
91, 2 ⋅ tBE PMBE Motor acceleration power in [W]
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
L1= Line choke, See section 6.1

L2= Motor choke, See section 6.2
A
Figure 3.36 Multi-motor operation on one inverter
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Project planning notes for multi-motor operation
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.
If all the motors are started together, the small motor

will start up later, because the slip frequency is higher.
Table 3.37 Project planning notes for multi-motor operation

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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3.3.7 DC network DC network operation of the CDA3000 inverter modules enables an

operation energy exchange between the inverter modules.
The inverter modules which are run in DC network mode regeneratively
(braking) feed energy into the DC network which is consumed by the
motorized inverter modules. The regenerative energy does not need to be
delivered from the mains.
DC network operation of several inverter modules minimizes the energy
consumption from the mains and in most cases eliminates the need for
use of braking chopper units.
K1
L1
L2
L3
PE
F1 F4 Fn
L1 F2/3 L2 F5/6 Ln Fn+1/n+2
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~
Figure 3.37 Circuitry example, DC network operation

Project planning notes for DC network operation

1
Mains connection • All inverter modules must be operated with a line choke. The line
of the inverter choke limits the mains current and provides current/power sym-
modules metry of the inverter input circuits.
• For more information on this subject refer to section 3.2. 2
Mains fuse (F1) • By the use of mains fuses with signal contact the “Mains power
with signal contact supply failure” fault can be responded to by shutting down the
entire DC network. As a result the remaining inverter modules in
the DC network are not overloaded. 3
Mains power con- • It must be ensured that all inverter modules are connected simul-
nection condition taneously (K1) to the mains power.
DC link connection • Make short cable connections to the common DC-link center 4
point.
• Use cable cross-section corresponding to mains power cable
cross section (see Operation Manual and section 3.2).
• Select DC-link fuses corresponding to the cable cross-section and 5
local regulations. The fuses protect the cable.
• The DC fuses can be omitted if the cable cross-section used to
wire the DC network is at least as large as the mains power cable
cross-section of the highest-powered inverter module in the net- 6
work.
Tip: Where the DC network comprises only two inverter
modules only one fuse pair (F3/4) is sufficient for pro-
tection purposes. 7
If the DC network is connected to the mains - while an
inverter module has an internal short-circuit on the DC
link - the defective inverter module is automatically A
isolated from the DC network by its PTC precharging
circuit. All other inverter modules can continue in oper-
ation;
see Figure 3.37.
Table 3.38 Project planning notes for DC network operation
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Design of the If the energy balance in DC network operation is regenerative in individ-

external braking ual operating situations, the inverter modules must be operated with
resistors external braking resistors to absorb the regenerative energy.
The following conditions must be met when designing the braking
resistors:
1. The ohmic value of the external braking resistor must not be less
than the minimum ohmic connected load permitted by the inverter
module.
2. Adding together the peak braking powers of all braking resistors

operated in the DC network produces the peak braking power
referred to the DC network.
PSDC = PSW1 + PSW2 + ....PSWn
PSDC = total peak braking power in the DC network

PSW1 = peak braking power of braking resistor 1
3. The continuous braking power of the individual braking resistor is

ascertained by calculation of the effective braking power.
2 2
P SW ⋅ t1 + P SW ⋅ t 2 + …P SW ⋅ t n
P eff = -----------------------------------------------------------------------------
T
PSW = peak braking power of the selected braking resistor
t1, 2xn = braking time 1, 2 m ... n
The permissible continuous braking power of the

selected braking resistor must be > Peff. The sampling
time (T) must be <150 s.
Figure 3.38 Project planning notes for DC network operation

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
Figure 3.39 DC network operation with PTC precharging circuit

7
DC network operation with VF1000S/M/L, MC6000 and MC7000 is not

permitted. A
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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
Figure 3.40 Block diagram of an inverter with braking chopper

Calculation of effective braking power
1
V
[m/s]
0
2
3
t1 t2 t3 t4 t5 t6
t
T 4
1580 PS1 PS2

998 5
P 0
[W]
t3 t6
6
t
Figure 3.41 Effective braking power

7
2 2
P s1 ⋅ t 3 + P s2 ⋅ t 6
P eff = -------------------------------------------
T
A
PS = Peak braking power
PD = Continuous braking power
T= Sampling time (work cycle)
t1 = 0.2 s
t2 = 3s
t3 = 0.2 s
t4 = 0.2 s
t5 = 3s
t6 = 0.2 s
T = 8.4 s
The continuous braking power of the braking resistor must be > Peff. The
sampling time T must be < 150 s.
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Example: Calculation example for Figure 3.41

• Inverter module CDA34.005
• Minimum ohmic resistance
of an external braking resistor 180 Ω
• Load cycle see Figure 3.41
1. Calculation with LUDRIVE
Figure 3.42 Calculation of effective braking power with LUDRIVE
2. Choice of braking resistor (See section 6.3)

Braking resistor BR-270.02,541 was chosen
Peak braking power: 2080 W
Continuous braking power: 300 W
Resistance: 270 Ω
The resistance must not be less than the minimum ohmic connected load
permitted by the inverter module.

Parallel/series configuration of braking resistors

By means of a parallel configuration of braking resistors the peak braking
power can be adapted to the specific application. 1
By means of a series configuration the continuous braking power can be
adapted to the specific application.
2
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
PS = Peak braking power in [W]

U = DC-link voltage in [V]
PS = U² (390 V or 750 V)
RBR
RBR = Resistance of braking
resistor in [Ω]
Figure 3.45 Calculation of peak braking power
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3.3.9 Power failure Not available at time of going to press.

bridging

1
4.1 User interface and data structure ..........................4-2

4.1.1 Data structure ......................................................4-2
2
4.1.2 Initial commissioning ...........................................4-6
4.1.3 Operation via KEYPAD KP200 ...............................4-11
4.1.4 Operation via DRIVEMANAGER ...............................4-12 3
4.2 Device and terminal view .....................................4-15
4.2.1 Specification of control terminals .......................4-16
4.2.2 Isolation method and connection tips .................4-19
4
4.3 Preset solutions ....................................................4-20
4.3.1 Traction and lifting drive ....................................4-24 5
4.3.2 Rotational drive ..................................................4-39
4.3.3 Field bus operation ............................................4-49
4.3.4 Master-/Slave operation .....................................4-56
6
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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).
Application data set

Application data sets are complete preset parameter sets for handling a
wide variety of movement tasks (See Figure 4.2).
Loading an application data set into the RAM automatically configures the
inverter module. All subject areas and the signal processing inputs and
outputs are automatically preset to the desired solution.
Use of the application data sets simplifies and speeds up commissioning
of the inverter module and thus the movement solution.
Available application data sets

➢ “Traction and lifting drive” for typical applications such as
conveyor belt, rack, trolley, spindle and lifting gear drives
➢ “Rotational drive” for typical applications such as spindle,
extruder and winding drives or centrifuges
➢ “Field bus operation” for integration of the inverter system into a
network via CANLust, CANopen or PROFIBUS-DP
➢ “Master-/Slave operation” for reference coupling of several inverter
modules

Initial commissioning
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
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
Subject areas for function-oriented operation of the inverter

module. The functions are described in the sections quoted.
See section 4.9 See sections 4.10 and 4.11
7
6
5
4
3
2
1
EN
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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.
Application data sets User data sets
Traction and Rotational Traction and Traction and

lifting drive drive lifting drive 1 1 lifting drive 2 2
001 MODE 001 MODE 001 MODE 001 MODE
999 xyz 999 xyz 999 xyz 999 xyz
Bus Master/Slave User data User data

operation operation set 3 set 3 4
001 MODE 001 MODE

Unassigned Unassigned
999 xyz 999 xyz
Active
data set
Traction and
lifting drive
Load Factory Load

setting
Save
RAM
Figure 4.2 Data structure of the CDA3000

User data sets

When the application data set has been adapted to the specific applica-
tion, this new data set can be stored as a custom setting in a user data 1
set.
In the inverter module four user data sets can be managed (See 4.1).
The user data sets can be selected and activated via KEYPAD, DRIVE-
2
MANAGER, bus access or terminals.
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
Table 4.1 Example of selection of user data sets via terminals
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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
Table 4.2 Sequence of initial commissioning
1. Sensorless Flux Control

2. Field Oriented Regulation
3. Voltage Frequency Control

Step Function Explanation

• Voltage Frequency Control 1
6 Select control mode • Sensorless Flux Control
• Field-Oriented Regulation
• Initial commissioning com-
7 Save all settings in a user data set
plete 2
*)
For more information on application data sets and assistance parameters refer to
section 4.2.
Table 4.2 Sequence of initial commissioning 3

Example: Initial commissioning
Motor: Asynchronous motor 1.5 kW

4
Application: Linear drive with limit switches,
moment of inertia of application 0.003 kgm².
Positioning is to be dynamic with a quick jog/slow 5
jog profile.
1. Selection of an application data set to handle the movement

6
task
1.1 Call up "Initial commissioning" subject area 7

1.2 Select parameter RUNMD and set to “1”
This activates the presetting for traction and lifting drives A

1_DRV = Traction and lifting drive
2_ROT = Rotational drive
3_BUS = Field bus operation
4_M-S = Master-/Slave operation
2. Adaptation of the control terminal function to the application
2.1 Call up parameter ASTER and select setting DRV_3
The control terminal is assigned the quick jog/slow jog driving pro-
file and limit switch evaluation functions.
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3. Input of motor data
3.1 Read motor data from rating plate of motor
(2) 400 V 6.0 A (5)

(1) 1.5 kW cos j = 0.8 (6)
(4) 1450 rpm 50 Hz (3)
Figure 4.3 Motor rating plate
3.2 Call up the individual motor parameters and enter the read values
Parameter Setting Function
MOTYP ASM Motor type = asynchronous machine

(1) MOPNM 1.5 kW Motor rated power
(2) MOVNM 400 V Motor rated voltage
(3) MOFN 50 Hz Motor rated frequency
(4) MOSNM 1450 rpm Motor nominal speed
(5) MOCNM 6A Motor rated current
(6) MOCOS 0.8 cos ϕ of motor
Table 4.3 Parameters for the motor data

4. Enter moment of inertia of application
4.1 Enter moment of inertia of load

The moment of inertia of the load is necessary in order to attain
1
an optimum dynamic response with the SFC and FOR control
modes.
If no moment of inertia is specified, the external moment of inertia

2
is set equal to that of the motor shaft (moment of inertia adapta-
tion JM=Jred).
Calculation of “reduced” moment of inertia on motor shaft

3
7
Figure 4.4 Example
➢ In the example the moment of inertia of the load is known: A

Select parameter SCJ1 and set to 0.003 kgm²
4.2 Enter motor moment of inertia
If the motor is a standard motor to DIN VDE 0530, it is not neces-

sary to give the moment of inertia of the motor shaft. In the case
of a special motor (e.g. an asynchronous motor) it is required to
optimize the control loop.
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5. Start automatic motor identification
5.1 Call up parameter ENSC and set to “START”.
The motor identification takes approx. 3-4 minutes. When the

identification is complete parameter ENSC is automatically reset
to “STOP”.
6. Selection of control mode
6.1 Call up parameter CFCON and set to “SFC”.
The “Sensorless Flux Control” mode for optimum dynamics with-

out speed feedback is activated.
7. Save all parameters to one of the four user data sets.
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)
On the CDA3000 inverter module

On the switch cabinet door
y,,,,,,
yyyyy
,,
yy 4
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
VAL PARA CTRL CARD

A
Actual values Subject area Drive SMARTCARD
• Select • Select • Control • Read
• Display Parameter • Write
• Select • Write
Capacity indicator • Change protection
Initial
commissioning
Figure 4.6 Overview of the KP200 menu structure
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KP200 controls
(1)
Call up menu, subject area or parameter Save
changes
CARD
S MART
start
enter
Start in "Control drive" mode
stop
Quit menu, cancel changes
return
Stop in "Control drive" mode
VAL
Hz Select menu, subject area or parameter

Increase setting
stop start
return enter
Select menu, subject area or parameter
Reduce setting
Figure 4.7 Keys on the KEYPAD KP200 control unit
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

Subject area and parameter editor
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
operation manual! mode dèmploi!

ATTENTION
RB+
A
RB
ladezeit >3 Min. time >3 minutes.
L-
WARNING
L1
X3
beachten!
ACHTUNG
L2
L3
Figure 4.9 CDA3000 with DRIVEMANAGER
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Digital scope
With the digital scope up to four channels can be recorded simultane-
ously, permitting comprehensive diagnosis.
Figure 4.10 Example: Speed step response

4.2 Device and

terminal view CANopen/CANLust PROFIBUS-DP
1
X13 X13
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
Figure 4.11 Layout, CDA3000
No. Designation Function

H1, H2, H3 LEDs Device status display
Mains, motor, braking resistor,
X1 Power terminal
DC feed
4 digital inputs
3 digital outputs (of which 1 relay)
X2 Control terminal
2 analog inputs
1 analog output
Table 4.4 Key to Figure 4.11
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No. Designation Function

PTC, Klixon evaluation or linear temperature
X3 PTC terminal
transmitter
X4 RS232 terminal X4 for DRIVEMANAGER or KEYPAD KP200
Voltage supply for communi-
X10 + 24 V, ground
cation module
X11 CAN-In / PROFIBUS-DP
X12 CAN-Out
X13 Address coding plug
Voltage supply,
X15 User module UM-8I4O 8 digital inputs,
4 digital outputs
(1) Reset button
(2) Boot button
Table 4.4 Key to Figure 4.11
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
Table 4.5 Specification of control terminals


OSA00 X2-5 •
•
PWM PWM 2nd order filter
PWM with carrier frequency 19.8 kHz
1
• ROUT=100 Ω
✔
• Uout=+10 V DC
•
•
Imax=5 mA
Short-circuit-proof
2
Digital inputs
ISD00 X2-9 • Limit frequency 5 kHz
• PLC-compatible (IEC1131) 3
• Switching level Low/High: <5 V / >12 V DC
• Imax at 24 V = 10 mA ✔
• RIN = 3 kΩ
• Delay ≈ 2µs 4
• PLC-compatible (IEC1131)
• 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
•
•
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)
• 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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ENPO X2-8 • Power stage enable = High level
• Imax at 24 V = 10 mA
✔
• RIN = 3 kΩ
• Delay ≈ 2µs
Digital outputs
OSD00 X2-15 • Short-circuit-proof
• Imax = 50 mA ✔
• Protection against inductive load
• High-side driver
OSD01 X2-16 • Short-circuit-proof with 24V supply from inverter
module
• Imax 50mA ✔
• No internal freewheeling diode; provide external (restricted)
protection
• High-side driver
• Data output with reference coupling
Relay output
OSD02 X2-18 • Relay 48 V / 1 A AC, changeover contact
X2-19 • Usage category AC1 ✔
X2-20 • Operating delay approx. 10 ms
Motor temperature
PTC1/2 X3-1 • Measured voltage max. 12 V DC
X3-2 • Measuring range 100 Ω - 15 kΩ
• suitable for PTC to DIN 44082 ✔
• suitable for temperature sensor KTY84, yellow
• Sampling time 5 ms
Voltage supply
+10.5V X2-1 • Auxiliary voltage UR =10.5 V DC
• Short-circuit-proof –
• Imax = 5 mA
+24V X2-6 • Auxiliary voltage UV = 24 V DC
X2-7 • Short-circuit-proof
✔
X2-13 • Imax = 200 mA (overall, also includes the driver
currents for outputs OSDox)
MV = measured value

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
(2) AGND DGND (1)

7
(1) DGND = Digital ground

A
(2) AGND = Analog ground
Figure 4.12 Isolation method for the control terminals
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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.

Application data set: “Traction and lifting drive”
Application data set Designation Application

1
m2
Conveyor belt
2
Rack drive
m2
3
4
m2
Traction and lifting drive
Spindle drive
Section 4.3.1
Trolley drive m2
6
Lifting drive
7
Table 4.6 Application-specific basic settings A
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yy
@@

ÀÀ
,,
Application data set: “Rotational drive”
Application data set Designation Application
Extruder
Spindle drive
@@

ÀÀ
,,
yy
Rotational drive
Section 4.3.2
Stirrer
Winding drive
Table 4.7 Application-specific basic settings
Application data set: “Field bus operation”
Application data set Application
+ + + +
SPS
(1)
+ + + +
3 3 3
CPU ~= CPU ~= CPU ~=

Field bus operation ~ (2)
~ (2)
~ (2)
Section 4.3.3 M
3~
M
3~
M
3~
(3) (3) (3)
n1 n1 n1
(4) (4) (4)
n2 n2 n2
Process (5)

Application data set: “Master-/Slave operation”
Application data set Application 1

X3 X3 X3
~= i1 ~= i1 ~=
CPU
~ CPU ~ CPU ~
Master-/Slave operation
M M M
2
Section 4.3.4 3~ 3~ 3~
n1 n2 = n1 . i1 n3 = n1 . i2
Process
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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) (4) (5) (5.1)

Mains
3 ~= (2) M n1 m2
~ 3~
PTC
n2
CPU (6) (5.2)
(7) m2
(9)
(8)
(5.3)
m2
(1) Braking resistor (9)

(2) Inverter module
(3) IEC standard motor
(4) Gearing (5.4)
(5) Application
(5.1) Conveyor belt m2
(5.2) Rack drive
(5.3) Spindle drive
(5.4) Trolley drive (5.5)
(5.5) Lifting drive
(6) Thermistor
(7) Motor holding brake (9)
(8) Encoder
(9) Safety limit switch
Figure 4.13 Drive solution: “traction and lifting drive”

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
Quick jog driving profile ✔✔✔✔✔ 4

t
5
v
Quick jog/slow jog
driving profile
✔✔✔ ✔
6
t
v 7
Table sets with fixed
frequencies and ramps
✔
t A
M Motor brake actuation ✔✔✔✔✔

3~
v v
Characteristic data
switchover for load ✔
adjustment
t t
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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
Limit switch evaluation ✔ ✔
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)

(ASTER = DRV_1) Traction and lifting drive (configuration 1)
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
16 “Reference reached” message

17 Digital ground
18 Relay contact (break)
19 Relay contact (make)
K0
20 for "ready" signal
X3 Function
1
Motor PTC evaluation
2
Figure 4.14 Control terminal assignment with ASTER=DRV_1 DE

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Input signals
FMAX
590-ACCR 592-DECR
f [Hz] 0
594-STOPR
FMAX
1
STR 0
1
STL 0
1
S1 0
t [ms]
ACCR Acceleration ramp

DECR Braking ramp
STOPRStop ramp
Figure 4.15 Example of a quick jog/slow jog driving profile for two directions
of rotation (ASTER=DRV_1)
Output signals
f [Hz]
v [m/s] 0
1
H1 0
1
K1 0
t [ms]
Figure 4.16 Output signals dependent on driving profile

(ASTER = DRV_1 to DRV_5)

(ASTER=DRV_2) Traction and lifting drive (configuration 2)
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
5 0 ... FMAX
N1
6
7
Auxiliary voltage 24 V max.
200 mA
6
ENPO
STR
9 Start/Stop quick jog clockwise
STL
Start/Stop quick jog anti-clock-
7
S3 10
wise
S4
11 Selection of slow jog A

Characteristic data set
12
switchover
13 Auxiliary voltage 24 V
14 DGND
Figure 4.17 Control terminal assignment with ASTER=DRV_2
The remaining configuration of control terminals X2:15 to 20 (outputs)

and X3 is as shown in Figure 4.14 and Figure 4.16.
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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]
(1) DC braking torque

Figure 4.18 Example of use of the control terminal presetting with ASTER =
DRV_2
The output signals are shown in Figure 4.16.
User data set switchover (switchable offline)
S1 S2 Active UDS Example
0 0 UDS 1 for application 1 x-axis, traction drive

1 0 UDS 2 for application 2 y-axis, traction drive
0 1 UDS 3 for application 3 z-axis, lifting drive
1 1 UDS 4 for application 4 Sorting belt
Table 4.10 User data set switchover
Characteristic data set switchover (switchable online)
S4 Active characteristic data set Example
0 Characteristic data set 1 Lifting drive with load

1 Characteristic data set 2 Lifting drive without load
Table 4.11 Characteristic data set switchover

• 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
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
12 Limit switch left

A
14 DGND

DE
EN
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]
Figure 4.20 Example of use of the control terminal default with ASTER=3
S1 Active UDS Example
0 UDS 1 for application 1 x-axis, traction drive

1 UDS 2 for application 2 z-axis, lifting drive

Limit switch evaluation

S4
S3
1
2
Figure 4.21 Example of a limit switch evaluation
3
303-FMAX1
f [Hz] 592-DECR1 590-ACCR1 4

0
- 303-FMAX1 5
1
STR 0
STL 1
0 6
1
S3 0
S4 1
0
7
t [ms]
Figure 4.22 Limit switch evaluation of S4 and S3

Example: Limit switch right resets Start Clockwise. Resetting of
Start Clockwise is not evaluated. The Start Anti-clockwise com-
A
mand can be used to move out of the limit switch zone.
The limit switch must not be overrun. The signal must be applied continu-
ously (no pulse evaluation).
DE
EN

Function Application

quick jog driving profile • Rack drive
• Switchover for application • Spindle drive
• Encoder evaluation • Trolley drive
• Lifting drive
• etc.
X2 Function
S1
2
S2 User data set switchover
3
4 Actual frequency
5 0 ... FMAX
N1

7 200 mA
ENPO
STR
STL
9 Start/Stop clockwise
10 Start/Stop anti-clockwise
A
N2
B 11 Encoder track A
(1)
12 Encoder track B
14 DGND
(1) The encoder is evaluated only in control mode FOR.


A HTL encoder (see Figure 4.24) can be connected to terminals X2:11

and 12. Permissible pulse counts are in the range from 32 pulses per rev
to 16384 pulses per rev (2n where n=5 to 14). 1
Figure 4.24 Block diagram, HTL output circuit 4

Input signals
303-FMAX1
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)

Table 4.13 User data set switchover DE

EN

quick jog driving profile • Rack drive
• Selection of fixed frequencies • Trolley drive
• Encoder evaluation • Spindle drive
• Limit switch evaluation • Lifting drive
• Switchover of applications
X2 Function
2 not assigned
3 not assigned
4 Actual frequency
N1
5 0 ... FMAX
6
Auxiliary voltage 24 V max. 200 mA
7
ENPO
STR 8 Power stage hardware enable
STL 9 Start/Stop clockwise

A
N2
B 11 Encoder track A
(1)
12 Encoder track B
(1) The encoder is evaluated only in control mode FOR. For notes on the
encoder see also Figure 4.24.
The configuration of control terminals X2:13 to 20 (outputs) and X3 is as

shown in Figure 4.14 and Figure 4.16.

Control terminals of user module UM-8I4O
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
Selection of table sets for fixed

S3
24 frequencies 3
S4
X1 X2 25
20
U
19
S5
18
V
X15 26 Limit switch right
17
16
W
15
4
14
S6
1
13

12
11
3
10
!
4
RB+
9
S7
5
8
ACHTUNG
6
Kondensatorent-
RB
28
7
ladezeit >3 Min.

7
6
Betriebsanleitung
8
L- beachten!
5
User data set switchover

9
WARNING
4
10
S8
3
time >3 minutes.

11
2

29
12
1
L1 operation manual!
ATTENTION X3
temps de decharge
16
5
L2 du condensteur
17
>3 min. observer le

18
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
Figure 4.27 Assignment of control terminal expansion with ASTER=DRV_5 A
DE
EN
Input signals v/t diagram

602-FFTB7
602-FFTB2 615-TACR7
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)
(1) Braking resistor

(5.3) 5
(2) Inverter module
(4)
(5)
Gearing
Application
6
(5.1) Extruder (5.4)
(5.2) Spindle
(5.3) Stirrer
(5.4) Winding drive 7
(6) Thermistor
(7) Encoder
(8) Control unit
A
Figure 4.29 Drive solution: “rotational drive”
DE
EN
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.
Setting of assistance parameter ASTER for rotational drives
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
✔ ✔
n Speed change via

button ✔
n
(MOP function)
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
DE
EN
(ASTER=ROT_1) Rotational drive (configuration 6)

• Analog speed input for two directions • Spindle

of rotation • Winding drive
• Adjustment of speed via button (MOP • Vacuum pumps
function) • Extruder
• Stirrer
• etc.
X2 Function
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
STL 10 Start/Stop anti-clockwise
S1
11 Increase speed
S2
12 Reduce speed
14 Digital ground
H1
Message: “References
15
H2 reached”
16 Standstill
17 Digital ground
K0 20 for "ready" signal
X3 Function
1 Motor PTC evaluation
2 Function inactive
Figure 4.30 Control terminal assignment with ASTER=ROT_1


(1) (1)
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]
Figure 4.31 Example of a driving profile for two directions of rotation 5

(ASTER=ROT_1)
Output signals 6
f [Hz] 7
v [m/s] 0
H1
1
0
A
1
H2 0
t [ms]
H1 Speed reached
H2 Standstill
(ASTER=ROT_1, ROT_2 and ROT_4)
DE
EN


• Adjustment of speed via correction • Extruder
value • etc.
• Encoder evaluation
X2 Function
R1 2 Reference -10 V ... 10 V
R2 3 Correction value 0 V ... + 10 V
4 Actual frequency
5 0 ... FMAX
N1
7 200 mA
ENPO
STR
STL
A
11 Encoder track A
(1) B
12 Encoder track B
Figure 4.33 Control terminal device with ASTER=ROT_2
The configuration of control terminals X2:13 to 20 and X3 is as shown in

Figure 4.30 and Figure 4.32.

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
DE
EN


• Adjustment of speed via correction • etc.
value
• Selection of fixed frequencies
• Switchover of applications
• Encoder evaluation
X2 Function
R1 2 Reference -10 V ... +10 V
R2 3 Correction value 0 V ... + 10 V
4 Actual frequency
N1
5 0 ... FMAX
7 200 mA
ENPO
STR
STL
A
N2
(1) B 11 Encoder track A
12 Encoder track B
Figure 4.35 Control terminal assignment with ASTER=ROT_3


X15 Function
1 24 V supply + 20 %, 0.6 A 1
2 Digital ground
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
ladezeit >3 Min.

7
6
Betriebsanleitung
8
L- beachten!
5
WARNING
4
10
3
time >3 minutes.

11
2

12
1
ATTENTION X3
temps de decharge
16
L2 du condensteur
17
>3 min. observer le

18
mode dèmploi!
L3
19
20
Figure 4.37 Position of terminal strip X5

DE
EN

602-FFTB7
602-FFTB2 615-TACR7
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 4.38 Example of use of table sets with ramps (ASTER=ROT_3)
0 0 UDS 1 for application 1 Spindle 1


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
CPU ~= CPU ~= CPU ~= 3

~ (2)
~ (2)
~ (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
DE
EN
Setting of parameter ASTER for field bus operation
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
✔ ✔
Limit switch evaluation ✔

1) BUS_1 (Page 51) 2) BUS_2 (Page 52) 3) BUS_3 (Page 54)
Table 4.17 Preset control terminal functionality

(ASTER=BUS_1)
Field bus operation (configuration 9) 1

• Control of the inverter module over • Traction and lifting drive

the field bus
• All digital inputs and outputs can be
• Rotational drive 2
set and read over the bus.
X2 Function (1...10) 3
X10
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

14
13
12
11
7 200 mA
10
RB+ !
9
8
ACHTUNG
RB Kondensatorent-
7
ladezeit >3 Min.

6
Betriebsanleitung
L- beachten!
ENPO 8 Power stage hardware enable
5
WARNING
4
3
time >3 minutes.

2
6
1
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
14 Digital ground
15 Digital output 1: A
16 Digital output 2:
17 Digital ground
19 Relay with
20 changeover contact
X3 Function
1 Motor PTC connection
2 Function inactive
Figure 4.40 Control terminal configuration with ASTER=BUS_2
DE
EN
(ASTER=BUS_2)
Field bus operation (configuration 10)

the field bus • Rotational drive
• Control of the device in emergency
also independently of field bus
• Manual/automatic switchover
• Setting and reading of digital inputs
and outputs over the bus
X10
1
X2 Function
H1 H2 H3 2
ANTRIEBSTECHNIK
D-35633 Lahnau X4
X11
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
0 ... 10 V corr. to 0 ... FMAX

14
5
13
12
N1
11
10
RB+ !
6
9
8
ACHTUNG
RB Kondensatorent-
7
ladezeit >3 Min.
Auxiliary voltage 24 V max. 200 mA

6
Betriebsanleitung
L- beachten!
5
WARNING
4
7
3
time >3 minutes.

2

1
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
14 Digital ground
17 Digital ground
K0
X3 Function
1 Motor PTC connection
2 Function inactive

Input signals
(1) (1)
1
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
DE
EN
(ASTER=BUS_3)
Field bus operation (configuration 11)

the field bus
• Control of the device in emergency
also independently of bus
• Manual/automatic switchover
• Evaluation of safety limit switches
X2 Function
X10
H1 H2 H3
1
2
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
0 ... 10 V corr. to 0 ... FMAX

18
V
5
17
16
W
15
N1
14
13
6
12

11
10
RB+ !
9
8
ACHTUNG
RB Kondensatorent-
7 200 mA
7
ladezeit >3 Min.

6
Betriebsanleitung
L- beachten!
5
WARNING
4
ENPO
3
time >3 minutes.

2

1
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
14 Digital ground
17 Digital ground
K0
X3 Function
1 Motor-PTC connection
2 Evaluation inactive

(1) (1)
1
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
DE
EN
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)
FU0 FU1 FU2

~= i1 ~= i2 ~=
CPU
~ CPU ~ CPU ~
(2.1) (2.2) (2.2)
M M M
3~ 3~ 3~
(3) (3) (3)
n0 n1 = n0 . i1 n2 = n0 . i2
(4)
Process
(1) Reference coupling

(2) Inverter module
(2.1)Master
(2.2)Slave
(4) Application
Figure 4.45 Drive solution: “Master-/Slave operation”
In Master-/Slave operation the reference values of the inverter modules

are permanently coupled together. This reference coupling can be
effected with up to six units, with one unit being the master. The reference
value of the master is also the guide value for the devices connected to
the master (slaves). The master transmits the reference value to the
slaves by way of a data telegram. In each slave the guide value received
from the master can be scaled, meaning that any desired transmission
ratios can be set. In this way it is possible to replace mechanical speed
couplings.
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 of the control methods in comparison
Characteristics
VFC
Voltage Frequency
SFC
Sensorless
FOR
Field-Oriented
1
Control Flux Control Regulation
Speed manipulating range

M=MNom
1 : 20 1 : 50 >1 : 10000
2
Static speed accuracy
typically 1 to 5 % typically 0.5 % quartz-accurate
referred to the nominal speed
Frequency resolution 0.01 Hz 0.065 Hz 2-16 Hz 3
Table 4.18 Comparison of motor control methods
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
Figure 4.46 Master-/Slave coupling via two control cables
Note: The motors run speed-synchronously, not angle-synchro-

nously. In primary frequency coupling a dead time of
max. 2 ms is created between two axles.
A maximum of five slave drives can be connected.
DE
EN
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]
Figure 4.47 Speed curve in Master-/Slave operation

Setting of parameter ASTER for Master-/Slave operation
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)
DE
EN
(ASTER = M-S1) Master-/Slave operation (configuration 12)

• Speed synchronism of several drives • Replacement of mechanical gears

with programmable transmission ratio and line shafts (not angle-syn-
• Inverter module is master chronous)
• Analog guide value input • Winding drive
• Adjustment of guide value via button • Drafting equipment
(MOP function) • Trolley drive
X2 Function
R1
2 Reference -10 V ... + 10 V
3 not assigned
4 Actual frequency
N1 5 0 ... FMAX
7 200 mA
ENPO
STR
STL
S1
S2 11 Increase speed
12 Reduce speed
H1 14 Digital ground
15 Message: Standstill
Slave 16 Slave interface
17 Digital ground
K0
X3 Function
2 Function inactive
Figure 4.48 Control terminal assignment with ASTER = M-S1


(1)
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
(ASTER=M-S1)
6
Output signals
7
f [Hz]
v [m/s] 0 A
1
H1 0
t [ms]
H1 Standstill
(ASTER=M-S1 and M-S2)
DE
EN


with programmable transmission and line shafts (not angle-synchro-
ratio nous)
• Inverter module is master • Winding drive
• Analog guide value input • Drafting equipment
• Encoder evaluation • Trolley drive
X2 Function
R1
2 Reference -10 V ... + 10 V
3 not assigned
4 Actual frequency
5 0 ... 10V corr. to 0 ... FMAX
N1
7 200 mA
ENPO
STR
STL
A
11 Encoder track A
B
12 Encoder track B
14 Digital ground
H1
16 Slave interface
Slave
17 Digital ground
K0
X3 Function
2 Function inactive

Input signals
(2) (2)
1
f [Hz]
v [m/s] 0
590-ACCR1 592-DECR1 2
(1)
1
STR 0
3
1
STL 0
(1)
4
t [ms]

(2) Analog reference value of ISA00 5
(ASTER=M-S2)
6
The basic characteristic of the output signals is shown in Figure 4.50.
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ratio nous)
• Inverter module is slave • Winding drive
• Adjustment of guide value via button • Drafting equipment
(MOP function) • Trolley drive
X2 Function
2 Reference -10 V ... + 10 V
3 not assigned
4 Actual frequency
N1 5 0 ... FMAX
7 200 mA
ENPO
S1 10 Master interface
Master S2 11 Increase speed
12 Reduce speed
H1 14 Digital ground
H2 15 “Reference reached” message

17 Digital ground
X3 Function
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
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
(ASTER = M-S3 and M-S4)
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ratio nous)
• Inverter module is slave • Winding drive
• Encoder selection • Drafting equipment
• Trolley drive
X2 Function
2 Reference -10 V ... + 10 V
3 not assigned
4 Actual frequency
N1 5 0 ... FMAX
7 200 mA
ENPO
A
10 Master interface
Master B 11 Encoder track A
12 Encoder track B
H1
14 Digital ground
H2 15 “Reference reached” message

17 Digital ground
X3 Function
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
Figure 4.57 Example of a driving profile with Master-/Slave coupling 5
(ASTER = M-S4)
The basic characteristic of the output signals is shown in Figure 4.55.

6
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Software functions/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.
This section gives an overview of the performance capability of the soft-

ware functions. For a detailed description of the software functions refer
to the CDA3000 Application Manual.
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
See section 4.9 See sections 4.10 and 4.11

Commissioning 1
Subject area Function Effect
Automatic adaptation of the inverter 2

module to the application and the motor. Quick commissioning of the inverter
Initial commissioning All control circuits are automatically module.
optimized.
3
Inputs/outputs

4
Adaptation of the internal analog input
Flexible function assignment and free
Analog inputs scaling of the analog inputs
signal processing of the inverter module
to the process variables. 5
Adaptation of the output variable to the
Selection and free scaling of the actual process. Rapid diagnosis and monitoring
Analog outputs values for delivery at the analog output. of actual values with the aid of a simple 6
voltmeter.
The inverter can be used to control the

Digital inputs
Flexible function assignment of all digital input signals and to influence the refer- 7
inputs. ence structure and the open-loop and
closed-loop control functions.
Flexible function assignment of all digital The output signals can be used to deliver
A
Digital outputs outputs. control signals and process messages.
Identification of the source from which the

The inverter module can be controlled
Control location control commands (e.g. Start) are
from various locations.
received.
For special requirements the internal con-

Influencing of the internal processing of
Reference structure reference values.
figuration of the reference values can be
changed.
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Protection and information
The application is protected against

Limitation of the maximum and definition
Frequency limitation of the minimum rotating field frequency
excessive speeds. A minimum speed can
be defined.
Monitoring of the motor temperature by

means of an integral motor circuit- The motor is protected against destruction
Motor protection breaker and a thermoswitch or thermistor due to overheating.
evaluation.
A short-time interruption of the mains

After a power failure the inverter module
voltage merely results in a reduction in
Power failure bridging is fed in SFC and FOR mode by the rota-
motor speed, which can be reset to the
tional energy of the motor.
original level when the power is restored.
Protection of the inverter module against

Password setting for the user levels and
unauthorized access. An actual value
KP200 definition of the permanently visible actual
relevant to the process can be read from
value and a bar graph display
the KEYPAD.
Storage of the max. current in the phases:

Good verifiability of the inverter dimen-
Device capacity Acceleration, stationary operation and
sioning and helpful diagnosis of drive
utilization deceleration. The mean device capacity
system faults.
utilization is additionally registered.
Unique identification of the inverter

Device data Delivery of all data of the inverter module.
module and the device software.
Display of all information of importance Rapid diagnosis and monitoring of the

Display for the drive system. drive system.
When a programmable limit value is An impending fault in the drive system is

Warning signals exceeded for various actual values a signaled in good time, enabling appropri-
warning is delivered. ate countermeasures to be initiated.

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
Subject area Function Effect 3
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.
Open-loop and closed-loop

control functions 7
Actuation of a motor holding brake when

Safe standstill even when inverter is
A
Motor holding brake a programmable lower frequency limit is
inactive.
infringed.
The motor speed can very easily be

Facility to increase or reduce the refer-
MOP function ence value with two digital inputs.
adapted to the process by means of two
buttons.
Fixed rotating field frequencies selectable Preprogrammed speeds can be selected

Fixed frequencies by way of digital inputs. by way of a switch.
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Setting of the acceleration and decelera-

Driving profile tion times and of the ramp shape (linear,
Tuning of the motor dynamics to the appli-
generator cation.
sinusoidal).
Facility for setting the parameters of eight

Digital selection of fixed frequencies with
Driving sets fixed frequencies with associated acceler-
variable dynamics.
ation and deceleration ramps.
Online switchover of the characteristic

Characteristic data Adaptation of the motor to various load
parameters, driving set parameters and
set switchover situations.
speed control parameters.
Mechanical transmissions can be

Master-/Slave Speed coupling of several inverter mod- replaced in the VFC and SFC control
operation ules with adjustable transmission ratio. modes by fixed-ratio running. Only in FOR
mode is there speed synchronism.
No braking resistor is required to stop

DC braking Feed of a direct current into the motor,
motors. The braking energy is converted
causing it to brake.
as heat in the motor.
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.
Acceleration and braking processes can

Current-controlled Reduction of the dynamics of acceleration be run with max. dynamics without risk of
startup and braking processes when a program- a current overload shut-off. In stationary
mable current limit is reached. operation the motor is protected against
stalling.

Voltage Frequency Control

1
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.
Sensorless Flux Control / Field Oriented Regulation
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.
Adaptation of the inverter module to the

Encoder evaluation Input of the encoder data.
encoder of the motor.
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Optimum current usage of the motor and

Current controller Setting of the current control loop
prevention of current overload shut-offs.
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.
This section gives an overview of the performance capability of the soft-

ware functions. For a detailed description of the software functions refer
to the CDA3000 Application Manual.

1
2
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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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
Control terminal expansion

11
ACHTUNG
Kondensatorent-
3
10
ladezeit >3 Min.

4
RB+
9
Betriebsanleitung
RB+
beachten!
8
RB
7
WARNING
e.g. eight additional inputs and four addi-
7
RB
time >3 minutes.

8
L-
5

tional outputs
L-
9
4
operation manual!
10
3
ATTENTION
11
temps de decharge
2
12
du condensteur
1
L1 >3 min. observer le X3

L3
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
Voltage supply 24 VDC ±20 %

Current consumption 0.6 A
7
Input voltage for signal “0” from 0 to 5 V
Input voltage for signal “1” >15 V
Eight inputs
3.5 mA to 7.0 mA
A
Input current with signal “1”
(6 mA at 24 VDC)
Permissible
range with min. 5 mA max. 0.5 A
signal “1”
Four outputs Output current Mean 125 mA
Total current 0.5 A
Short-circuit cur-
max. 1.2 A short-time
rent per output
Dimensions
28 x 90 x 90 [mm]
(W x H x D)
Table 5.1 Technical data
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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
Figure 5.3 Topology of CAN
A CAN network is a multimaster network - that is to say, any station can

autonomously send messages on the bus which can in turn be received
by any other station on the bus.
Typically, however, transmissions are exchanged between two stations on
the bus.
The basic rule is: Any one can evaluate the information from an identifier
for its own ends. But only one station can have transmission rights for
each identifier.
Each transmission is assigned a priority by the selection of the identifier
for that transmission. The priority is antiproportional to the identifier
number - that is, a rise in the significance of the identifier results in fall in
the priority of the transmission. The monitoring of priorities and assign-
ment of access rights on the bus is controlled by hardware means by the
CAN controller.

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
Table 5.2 CAN characteristics

4
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5.3.1 Interconnection
of inverter
modules on the
CAN bus
Figure 5.4 Communication module CM-CAN1 or CM-CAN2
CM-CAN 1
Ambient temperature -10°C to 60°C

Voltage supply 24 ± 20%
Current consumption < 100 mA
Protection Ip 20
Standards VBG 4
Coding via bus connector, coding plug,
Address input address switch or
parameter in the device
Table 5.3 Technical data, CM-CAN2

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
CDA3000 CDA3000 CDA3000

4
Figure 5.5 Interconnection of Lust drive units on the CAN bus
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
Table 5.4 Voltage supply A
Cable type for self-assembly

If the supplied cables are not of the required length, it is also possible to
make your own cables (1:1 connection). This relates to LS-BUS cable
type I.
Cable type Shielded with at least nine wires

Wires Twisted-pair, 0.25 mm2
Surge impedance 120 Ω
Length Any, total distance must not exceed 80 mm
Table 5.5 Cable type

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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

DRIVECOM state machine

(mode 1) 13
6
ERROR RESPONSE
ACTIVE
x0xx 1111
14
1
0
ERROR
5
NOT
x0xx 1000
2
0 READY
x0xx 0000 15 Reset error
1xxx xxxx
Transition automatic
1 approx. 4 sec. after switch-on
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
Figure 5.7 DRIVECOM state machine

7
DRIVECOM control word
The 16 bits of the control word result from the logical linking of control
commands which act on the state machine. The following bits of the A
DRIVECOM status word are supported:
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
Table 5.6 DRIVECOM control word

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Bit Function
8 Reserve
9 Reserve
10 Reserve
11 vacant
12 vacant
13 vacant
14 vacant
15 vacant
Table 5.6 DRIVECOM control word
DRIVECOM status word

In the status word the current state of the device and additional messages
are displayed. The following bits of the DRIVECOM status word are sup-
ported:
Bit Status
0 Ready for start
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
Table 5.7 DRIVECOM status word

Direct function selection CANLust control word

(mode 2)
An inverter function is selected directly by setting the relevant bit.
1
Bit Function
0 Enable control
1 Invert reference
2
2 Braking
3 Set device to error state
4 Selection of table reference
3
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
Table 5.8 CANLust control word

7
CANLust status word A

The following device states are signaled with the status word:
Bit Function
0 Device in error state

1 One or more warning thresholds has been exceeded
2 Reference reached
3 Reference limitation active
4 Power stage activated
5 Speed 0Hz
6 Clockwise
7 Anti-clockwise
Table 5.9 CANLust status word

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Bit Function
8 Status of input ENPO

9 Reserve
10 Reserve
11 Reserve
12 Actual status of ISD 00
Table 5.9 CANLust status word
5.3.3 Communication Not available at time of going to press.

via CANopen
Summary:
• Control of the CDA3000 via CANopen
• Reference and actual value transfer
• State machine to CiA DS-402

5.4 PROFIBUS-DP The PROFIBUS is a non-manufacturer-specific, standardized field bus

of which the openness is guaranteed by the international standard
EN 50170. 1
PROFIBUS comprises the three variants PROFIBUS-DP, PROFIBUS-
FMS and PROFIBUS-PA. The PROFIBUS-DP version is aligned to the
fast data transfer rates and short response times required in drive engi-
neering. 2
Bus topology
3
Slave 1 Slave 2 Master Slave 3
Master
4
Slave 4 Slave 5 Slave 6 term 2
5
Device type Function
DP-Master class 1 Centralized control

6
Programming, project planning or operator
DP-Master class 2
control device
Slave Peripheral device (I/O, drive, valves)
7
Table 5.10 Topology of PROFIBUS-DP
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
Table 5.11 PROFIBUS characteristics
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There are two ways of connecting LUST drive units to PROFIBUS-DP:

1) PROFIBUS-DP Gateway CP-DP 1
− Cost-optimized PROFIBUS interface for interconnection of
several (up to 10) drive units on PROFIBUS-DP
− Drive units from the CDA3000, MC7000 and CDA3000 product
families can be run together on a PROFIBUS-DP Gateway
− For connection to the PROFIBUS-DP Gateway the drive units
must be fitted with the CANLust interface.
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
Figure 5.8 PROFIBUS Gateway type DP-CPx

PROFIBUS-DP Gateway CP-DP1

1
Ambient temperature 0 ... 50°C
Voltage supply +24 V DC +20%
Current consumption max. 1.4 A
2
Protection IP20
Address input DIL switch
Table 5.12 Technical data, PROFIBUS-DP Gateway 3

DP-Master
4
+ + + +
SPS
+ + + +
PROFIBUS-DP
5
Gateway CP-DP1
Slave 1 Slave 2 Slave 3 6
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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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
Figure 5.10 Interconnection of several drive units on PROFIBUS-DP
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)
Cable type for self-assembly

If the supplied cables are not of the required length, it is also possible to
make your own cables (1:1 connection). This relates to LS-BUS cable
type I.
Cable type Shielded with at least 9 wires

Wires Twisted-pair, 0.25 mm2
Surge impedance 120 Ω
Length Any, total distance must not exceed 80 m
Table 5.13 Cable type

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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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
+ + + +
˙ Parameter channel Process data ˚ PROFIBUS-DP
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
PKW: Parameter identifier value STW1: Control word 1 5

PZD: Process data ZSW1: Status word 1
PKE: Parameter identifier HSW: Primary reference
IND: Index HIW Primary actual
PWE: Parameter value
6
Selection aid for PPOs

7
Is transfer of parameter data required?
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
Table 5.15 Selection of a PPO
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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”

1
2
6 Selection of supplementary
components
3
6.1 Line choke ...............................................................6-2 4

6.1.1 Effect of the line choke ........................................6-2
6.1.2 Operation with reactive current compensation
system .................................................................6-4 5
6.1.3 Technical data of line chokes LR3x.xxx ................6-6
6.1.4 Assignment of line choke to inverter module ........6-7
6.2 Motor choke ............................................................6-8 6
6.2.1 Technical data of the motor chokes .....................6-8
6.2.2 Assignment to the inverter modules ...................6-10
6.3 Braking resistors ...................................................6-12 7
6.3.1 Technical data of series BRxxx, xx-xx ............... 6-12
6.3.2 Assignment to inverter modules CDA3000 ........ 6-13
6.4 Radio interference suppression filter ...................6-14 A
6.4.1 Technical data of
RFI filters EMC34.xxx .........................................6-14
RFI filter .............................................................6-15
and external RFI filter .........................................6-16
6.4.4 Permissible motor cable length with external
RFI filter .............................................................6-16
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6.1 Line choke

Function Effect
Use of the line choke reduces the Reduction of voltage distortion
voltage distortion in the system. (THD)1
The limit values to be observed for
variable-speed electric drives are Reduction of commutation notches
laid down in the standards Reduction of the amplitude of the
EN61800-3 and IEC1800-3. line charging current
Of course, the line choke also offers Increase in service life of the DC-
protection against transient system link capacitors
voltage peaks.
Attenuation of transient voltage
peaks from contaminated systems
1) THD = Total Harmonic Distortion
6.1.1 Effect of the line Based on the example of a 4 kW inverter CDA34.010

choke
A line impedance of 0.6 mH was assumed for the calculation. This

value results from IEC1800-3 para. 6.1.2 (short-circuit current of
system = 250 times fundamental current of load).
A line impedance of 6 mH was assumed for the calculation. This value

results from IEC1800-3 para. 6.1.2 and from the use of a line choke with
4 % short-circuit voltage (UK).
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
Table 6.1 Percentage shares of currents due to harmonics based on the

example of a 4 kW inverter CDA34.010

System load
Without line choke With line choke Change

1
4 kW inverter, line Without line
4 kW inverter, line
impedance choke to with
impedance 0.6 mH
0.6 mH line choke
Voltage distortion (THD) 99 % 33 % -67 %

2
Mains current amplitude 18.9 A 9.7 A -48 %
Mains current effective 8.5 A 6,23 A -27 %
Commutation notches
3
referred to the mains 28 V 8V -70%
voltage
Life of the DC-link
capacitors
Nominal life
2 to 3 times
nominal life
+200 to 300 % 4
Table 6.2 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 5
The total voltage distortion THD is calculated from the individual harmon-
ics according to the following formula:
2 2 2
6
TDH = U 5 + U 7 …U 41 Un as % of Ufundamental
Mains voltage asymmetry 7

Without line choke With line choke
4 kW inverter, line 4 kW inverter, line

impedance 0.6 mH impedance 0.6 mH A
Mains voltage asymmetry 0% +3 % -3 % 0% +3 % -3 %
Mains current amplitude 18.9 A 25.4 A 25.1 A 9.7 A 10.7 A 11 A
Mains current effective 8.5 A 10.5 A 10,2 A 6,2 A 6.7 A 6.8 A
Table 6.3 Effect of the line choke with asymmetrical mains voltage
based on the example of a 4 kW inverter CDA34.010
According to IEC1000-2-4 the mains voltage asymmetry may be only 2%.
In summary: The example shows that the benefit of a line choke

with 4 % short-circuit voltage is wide-ranging, and so it
should not be omitted from any machine or system.
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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.
6.1.2 Operation with Estimation of the resonance point

reactive current Capacitors in systems with inverters cause oscillations which additionally
compensation distort the mains voltage. The frequency of those oscillations depends on
system a number of different system parameters. Reactive current compensation
systems may under certain circumstances impair the quality of the volt-
age waveform.
The compensation system forms an anti-resonant circuit together with the
transformer inductance, which in the worst case may enter into resonance
with a harmonic frequency generated by the inverter. As a result the
capacitor battery draws the corresponding harmonic from the system,
possibly leading to overloading of the capacitor battery.
.
Figure 6.1 Anti-resonant circuit

The influence of the lowest system resonance can be estimated with an

acceptable margin of error as follows:
Sk = short-circuit power 1
n res = Sk ⁄ QC QC = power of capacitor battery
nres = harmonic number at which resonance occurs
2
Example: Calculation of system resonance
STr = 1600 kVA
Uk = 6 %
3
QC = 120 kVA
Sk = STr / Uk = 1600 kVA / 6 % = 266 kVA

4
n res = Sk ⁄ QC = ( 266kVA ) ⁄ ( 120kVA ) = 1, 3
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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6.1.3 Technical data

of line chokes
LR3x.xxx
Ambient conditions LR 32. xxx LR 34. xxx

1)
Rated voltage 1 x 230 V, -20 % +15 %, 50/60 Hz 3 x 460 V, -25 % +10 %, 50/60 Hz1)
1.8 x IN for 40 s up to rated current 32 A
Overload factor 1.8 x IN for 40 s
1.5 x IN for 60 s above rated current 45 A
Ambient temperature typically -25° C to +45° C, with power reduction to 60° C
Mounting height 1000 m, with power reduction to 4000 m
Relative air humidity 15 ... 95 %, condensation not permitted
Storage temperature -25° C to +70° C
Protection IP00, terminals VBG4
Short-circuit voltage UK 4 % at 230 V = 9.2 V UK 4 % at 400 V = 9.24 V
Permissible contamination P2 to EN 61558-1 P2 to EN 61558-1
Thermal configuration Ieff < IN
Material Only UL-listed materials are used
Table 6.4 General technical data of line chokes LR3x.xxx
If several inverter modules are connected

to one line choke, it must be ensured that ΣI Inverter ≤ I NLinechoke
the sum of the inverter rated currents does
not exceed the rated current of the line
choke.

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
Line chokes for inverter modules with mains connection 4

3 x 460 V -25 %, +10 %
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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6.2 Motor choke Function Effect

• Insertion of the motor choke between • Reduction of leakage currents
the inverter module and the standard • Reduction of rate of rise of voltage du/
three-phase AC motor improves the dt at the motor terminals
operating conditions and reduces leak- • Suppression of faults caused by
age currents and faults. switching in the motor cable
• Increase in motor cable length
6.2.1 Technical data Motor choke Motor choke

of the motor Characteristic MR32.xxx MR34.xxx
[3x230 V] [3x400/460 V]
chokes
res s.
ble to p
t a vaila going
No e of
m
a t ti
Table 6.6 Technical data of the motor chokes

Inverter
Inverter
rated Dimensions
module Rated Power
power Type HxWxD
current loss
[mm]
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
Table 6.7 Technical data of line choke with 4% UK


Inverter
Inverter
module
rated
Rated Power
Dimensions 1
power Type HxWxD
current loss
[mm]
CDA34.014
CDA34.017
2
s.
CDA34.024
ble pres
a vaila oing to
CDA34.034 Not e of g
CDA34.045 a t ti
m 3
CDA34.060
CDA34.072
CDA34.090
4
CDA34.110
CDA34.143
CDA34.170
5
Table 6.7 Technical data of line choke with 4% UK
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6.2.2 Assignment to Motor choke for inverter module with

the inverter mains connection 1x230 V -20%, +15%
modules
Motor choke Motor cable Motor cable

Rec. 4-pole du/dt 1)
Inverter du/dt 1) with
module
standard Rated without motor length2 ) without length2 ) with
motor Type motor choke
current choke motor choke motor choke
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
1) Rate of rise of voltage in V/µs

2) Maximum motor cable (shielded) without current reduction
Table 6.8 Technical data of motor choke for inverter modules
Motor choke for inverter modules

with mains connection 3x460 V -25%, +10%
Motor choke Motor cable Motor cable

Rec. 4-pole du/dt 1)
Inverter du/dt 1) with
module
standard Rated without motor length2 ) without length2 ) with
motor Type motor choke
current choke motor choke motor choke
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
1) Rate of rise of voltage in V/µs

2) Maximum motor cable (shielded) without current reduction
Table 6.9 Technical data of motor choke for inverter modules

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.
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6.3 Braking Function Effect

resistors
• Use of braking resistors in the braking • When the motor is braked electrical
chopper electronics integrated as energy is fed to the inverter module. To
standard in the inverter module permits prevent the DC-link voltage of the
two and four-quadrant operation (brak- inverter from reaching impermissible
ing and driving). values in such cases, the braking
energy in the braking resistor is con-
verted into heat.

of series BRxxx,
xx-xx
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
Table 6.10 Technical data of braking resistors
The sampling time T must be <150 sec.
2
P S ⋅ t ST …
P eff = --------------------------
T

6.3.2 Assignment to Braking resistor for inverter module

inverter modules
CDA3000 1
Tech.data Resistance Peak braking power [W]
Cont. braking
Order ref.
[Ω ±10 %] power [W]
390 VDC1) 750 VDC2)
Protection
2
BR-270.02, 540 270 150 560 2080 IP54
BR-270.03, 541 270 300 560 2080 IP54
BR-160.02, 540 160 150 950 3500 IP54
3
BR-160.03, 541 160 300 950 3500 IP54
BR-090.03, 541 90 300 1690 6250 IP54
BR-090.10, 201 90 1000 1690 6250 IP20
4
BR-090.10, 541 90 1000 1690 6250 IP54
BR-042.20, 201 42 2000 - 13390 IP20
BR-042.20, 541 42 2000 - 13390 IP54 5
BR-015.60, 541 15 6000 - 37500 IP20
BR-010.80, 541 10 8000 - 37500 IP54
1) 1 x 230 V mains connection -20%, +15%
6
2) 3 x 460 V mains connection -25%, +10%

7
For more detailed information on the dimensioning of the braking resis-
tors See section 3.3.8.
A
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6.4 Radio inter- Function Effect

ference sup-
• The insertion of radio interference sup- • Protection against line-borne
pression filter pression filters (RFI filters) between the interference emission to EN 55011 (A)
inverter module and the system and EN 55022 (B).
reduces the line-borne interference
down to the permissible level.

Characteristic RFI filter EMC34.xxx
of RFI filters
EMC34.xxx
.
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
[A] [B] [C] [D] [E] [F] 2

4 kHz power stage clock 8 kHz 8 kHz power stage contact 16 kHz power stage contact
frequency frequency frequency
With [A] and With [C] and With [E] and line
Rec. 4-pole
With integral
line choke UK
With integral
line choke UK
With integral
choke UK 3
mains filter mains filter mains filter
Inverter standard =4% =4% =4%
module motor Class Class Class Class Class Class Class Class Class Class Class Class
[kW] A B A B A B A B A B A B 4
[m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1)
CDA32.003 0.375 kW 25 10 25 10 25 10 25 10 25 - 25 -
CDA32.004 0.75 kW 25 10 25 10 25 10 25 10 25 - 25 -
5
CDA32.006 1.1 kW 15 10 15 10 25 15 25 15 25 - 25 -
CDA32.008 1.5 kW 15 15 15 15 25 15 25 15 25 - 25 -
CDA34.003 0.75 kW 15 15 25 15 25 10 25 15 25 - 25 -
CDA34.004 1.1 kW 15 15 25 15 25 10 25 15 25 - 25 -
6
CDA34.005 1.5 kW 15 15 25 15 25 10 25 15 25 - 25 -
CDA34.006 2.2 kW 15 15 25 15 25 10 25 10 25 - 25 -
CDA34.008 3.0 kW 25 10 25 15 25 - 25 10 25 - 25 -
7
CDA34.010 4.0 kW 25 10 25 15 25 - 25 10 25 - 25 -
CDA34.014 5.5 kW 25 10 25 15 25 10 25 25 15 - 25 15
CDA34.017 7.5 kW 25 10 25 15 25 10 25 25 15 - 25 15
A
1) Maximum permissible motor cable length at which the standard is maintained
Table 6.14 Permissible motor cable length with integral mains filter
dependent on standard EN 55011 A/B
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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
[A] [B] [C] [D] [E] [F]

4 kHz power stage clock 8 kHz power stage contact 16 kHz power stage contact
frequency frequency frequency
With [A] and With [C] and With [C] and
With external With external With external
Rec. 4- line choke UK line choke UK line choke UK
mains filter mains filter mains filter
Inverter pole stand- External =4% =4% =4%
module ard motor mains filter Class Class Class Class Class Class Class Class Class Class Class Class
[kW] A B A B A B A B A B A B
[m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1) [m]1)
EMC34.0
CDA34.024
24
CDA34.034 EMC34. xxx
CDA34.170 EMC3x. xxx
1) Maximum permissible motor cable length at which the standard is maintained
Table 6.15 Permissible motor cable length with external mains filter
dependent on standards EN 55011 (A) and EN 55022 (B)

1
2
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
7.1 Heat discharge

from the switch
cabinet
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:
Basic terms Explanations
Power loss (heat output) of the electrical components installed in the

QV [Watt]
switch cabinet.
Heat output introduced or emitted via the effective switch cabinet sur-
face (to VDE 0660 Part 500).
If the interior temperature of the cabinet is higher than the ambient tem-
QS [Watt] perature (Ti > Tu), heat is emitted from the cabinet (QS>0). If the ambi-
ent temperature is higher than the interior temperature (Ti<Tu), heat is
radiated into the cabinet (Qs < 0).
Necessary cooling power of an air-conditioning component; this refers
QE [Watt] to the heat output which the device must discharge from the switch
cabinet.
QH [Watt] Necessary heat output of a switch cabinet heater.
Maximum permissible cabinet interior temperature specified by the
Ti [°C] manufacturers of the electrical components. As a rule it is between
+35°C and +45°C.
Maximum ambient temperature at which fault-free functioning of all
Tu [°C] electronic components in the switch cabinet or electronics housing
must still be guaranteed.
V [m³/h] Necessary volumetric flow of a filter fan.
Effective switch cabinet surface calculated according to DIN 57 660 Part
A {m²]
500 / VDE 0660 Part 500.
Heat transfer coefficient of the switch cabinet. It is defined by the fol-
lowing equation:
l
k [W/m²K] k = ---------------------------
-
l s l-
----- + --- + -----
αi λ αa

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
Heat transfer resistance of the switch cabinet.

2
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]
Figure 7.1 Calculation of the effective emitting switch cabinet surface
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Radiated power of a switch cabinet surface

If the effective switch cabinet surface A and the heat transfer coefficient k
are known, the radiated power QS at maximum cabinet interior tempera-
ture Ti and maximum outside temperature Tu can be calculated as
follows:
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
Figure 7.2 Radiated power of a switch cabinet surface
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

The factor f [m³K/Wh] is dependent on the altitude above sea level at

which the fan is operated (see Tabelle 7.1). This takes into account the
fact that the air pressure - and thus the air density - decreases as the alti-
tude increases and the fan consequently discharges less and less heat to
1
the outside while the volumetric flow remains constant.
Altitude above sea level [m] f m³K/Wh) 2

0 - 100 3.1
100 - 250 3.2
250 - 500 3.3 3
500 - 750 3.4
750 - 1000 3.5
Tabelle 7.1 Calculation factor “f” for filter fans dependent on altitude above
4
sea level
Example: The fan is to be installed in a switch cabinet at an altitude of

80 m above sea level, having a power loss of 600 Watts. The temperature 5
values are Ti = +40° and Tu = +20°C. Application of these values in for-
mula (2) produces:
600 m
3 6
V = 3, 1 ⋅ -------- -------
20 h
Therefore a filter fan with a delivery rate of at least 93 m/h is required.

7
The filter fans should generally be selected somewhat larger than calcu-
lated, since the operational side of the filter mat becomes increasingly
clogged with dirt and the heat discharge is thereby impaired. For this rea-
son the heat emission via the switch cabinet surface should also be
ignored when calculating the necessary volumetric flow of the fan.
A
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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The radiated power of the switch cabinet surface is calculated according

to formula (1) as:
QS = k ⋅ A ⋅ ( Ti – Tu )
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
Therefore the necessary cooling power of the heat exchanger according

to formula (3) is:
QE = QV - QS = 900 W - 242 W = 658 W
Then a number of other variables need to be considered, depending on

whether an air-to-air or air-to-water heat exchanger is to be used.
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
ϑ1, ϑ2: Surface temperatures °C or K 4
Figure 7.3 Stationary heat conductance through a wall
The thermal conductivity λ is a temperature-dependent material property.

In electronic devices it can be considered as constant for most applica-
tions. Tabelle 7.2 summarizes λ values for a number of key materials.
Depending on the task at hand - provision of good heat conductance or
high insulation - materials with the corresponding thermal conductivity are
selected.
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The thermal resistance in heat conductance, the temperature lag RthL, is

produced from:
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
Thus equation (1) can be reformulated:
∆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.
Good heat conductors

λ
Material
Aluminum, pure 230
Cast iron 58
V2A steel 15
Sheet-steel 59
Tabelle 7.2 Thermal conductivity of some materials at ϑ = 20°
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.

1
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
A.1 Mathematical Appendix

symbols Equality and inequality
~ proportional < less than

≈ about, approximately > greater than
= equal to ≥ greater than or equal to
= corresponding to ≤ less than or equal to
≡ identically equal « very small against
not identically equal » very large against
≠ not equal, unequal
Geometric symbols
|| parallel ≅ congruent
not parallel angle
↑↑ equivalent to parallel AB distance AB
↑↓ opposite to parallel AB arc AB
⊥ rectangular to, perpendicular to ~ similar

∆ triangle
Table 7.3 Geometric symbols
A.1.1 SI units Units Formula

Formula
Variable (A cross-
symbol Name Abbreviation sectional area)
Voltage U Volt V U=I•R
Current rating I Ampere A I = U/R
Resistance R Ohm Ω R = U/I
Conductivity, elec. G Siemens S, 1/Ω G = 1/R
Specif. el. resistance ρ Ohm/m Ωm; Vm/A ρ = 1/σ
El. conductivity σ, χ Siemens/m S/m; A/Vm σ = 1/ρ
Note: For vector values many formula symbols are designated by German letters.
Table 1.1 SI units

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
Magn. field strength H

Amp./m;
Oerstedt
A/m; N/Wb, (Ö) H = B/µ = I · w/l A
Magn. inductance Tesla; Weber/ m2
(flux density)
B T; Wb/m2 (G) B=µ·H
(Gauß)
Magn. field constant µo Henry/m H/m; Wb/Am µo = 4π/107
Permeability, absolute µ Henry/m H/m; Wb/Am µ = B/H
Permeability coeffi-
µt - - µt = µ/µo
cient
Magn. polarization J Tesla; Weber/ m T; Wb/m² J=B-µo
Table 1.1 SI units
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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
Magn. resistance R 108/Henry 108/H Rm = 1/A · µ

El. susceptibility χ - - = 4π χ'
Magn. susceptibility χ - - =M/H = µr-1
Table 1.1 SI units
A.1.2 Important units Important units

Force
kg ⋅ m
1N = 1 -------------
2
-
s
Force
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
Table 1.2 Important units

A.2 Drive engineer- Translation Rotation

ing equations Travel/angle
1
s = v⋅t ϕ = ω⋅t
A.2.1 Basic physical Velocity
equations π⋅n 2
v = s- v = ω ⋅ r = ---------- ⋅ d
t 60
Angular velocity
⋅π⋅n = ϕ
ω = ϕ = 2-----------------
·
--- 3
60 t
Acceleration
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
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A.2.2 Power Rotational power Rotational acceleration

2
M ⋅ n- J⋅n
P = ---------- P = ----------------------
9, 55 91, 2 ⋅ t BE
Translation/friction power Translation/friction power with rise
⋅ v- = m ⋅ g ⋅ µ ⋅ v- m⋅g⋅v
P = F-------- ------------------------- P = ------------------ ⋅ ( µ ⋅ cos α + sin α )
η η η
Translation with acceleration Lift
⋅ a ⋅ v- ⋅ g ⋅ v-
P = m
----------------- P = m
-----------------
η η
Table 7.5 General drive capacity
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
nP Face plate speed rpm

PS Cutting power kW
PP Drive capacity of a press kW
r Turn radius m
s Sheet thickness mm
sZ Advance per cutting edge mm
vS Cutting speed m/min
vSt Plunger speed m/min
zE Number of active cutting edges
κ Setting angle deg.

Specific cutting forces Tensile

kC11
kC in N/mm² at h in mm 1
h = f · sinκ
of various metals strength
Material in
in N/mm²
N/mm
and hardness 0.063 0.1 0.16 0.25 0.4
St 34, St 37, St 44 500 1780 2820 2600 2400 2240 2060

2
St 50, C 35 520 1990 4200 3610 3190 2830 2500
St 60 620 2110 3310 3080 2830 2620 2440
St 70 720 2260 5120 4500 3920 3410 2990
3
C 45, Ck 45 670 2220 3240 3040 2840 2660 2500
C60, Ck60 770 2130 3430 3150 2920 2700 2490
16 Mn Cr 5 770 2100 4350 3830 3400 3020 2660 4
18 Cr Ni 6 630 2260 5140 4510 3920 3410 3000
42 Cr Mo 4 730 2500 5000 4500 4000 3550 3150
34 Cr Mo 4 600 2240 4000 3610 3200 3000 2750 5
50 Cr V 4 600 2220 4620 4100 3610 3290 2820
15 Cr Mo 5 590 2290 3660 3390 3130 2890 2680
55 Ni Cr Mo 6-G 940 1740 3470 3070 2720 2390 2170 6
55 Ni Cr Mo 6-V 1220 1920 3470 3310 2950 2860 2380
100 Cr 6-G 620 1730 3680 3320 2900 2560 2240
Mn, Cr Ni steels 850...1000 2350 4200 3800 3450 3150 2850 7
Cr, Mo & other alloy steels 1000...1400 2600 4450 4050 3700 3350 3100
Stainless steels 600...700 2550 4200 3850 3530 3250 3000
Mn hard steels 3300 6100 5500 4980 4500 4080 A
X 12 Cr Ni 18 8 HB 160 1600 3810 3480 2880 2500 2140
X 6 Cr Ni Mo 18 10 HB 163 1500 3930 3520 2960 2510 2110
GG 25 HB 200...250 1160 2360 2110 1870 1660 1470

GS 45 300...500 1600 2560 2360 2180 2000 1860
GTW 40, GTS 35 HB 220 1180 2240 2000 1800 1600 1460
Brass HB 80...120 780 1300 1200 1100 1000 920

Cast bronze 1780 2870 2600 2400 2240 2060
Red cast 640 1250 1120 1000 900 800
Cast aluminum 300...420 640 1250 1120 1000 900 800
Table 7.7 Specific cutting forces of various metals

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kC11 Specific basic cutting force for face cross-section 1 mm x 1 mm
kCSpecific cutting force for various face thicknesses h
Drive capacities in Drive capacities in process engineering

process engineering Fan
QF ⋅ p
P = ------------
η
Pump
QF ⋅ p
P = ------------
η
Extruder
P = V⋅ϒ
Table 7.8 Drive capacities in process engineering

p Total pressure N/m²
P Drive capacity kW
QF Delivery m³/s
V Specified throughput kg/h
γ Specific drive power kWh/kg
η Fan efficiency/pump efficiency
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:
Specific drive power

Thermoplast
in kWh/kg
ABS 0,2 to 0.3

CAB 0.1 to 0,2
Table 7.9 Specific drive power for various thermoplasts

Specific drive power

Thermoplast
in kWh/kg
PA 6 and PA 66 0.2 to 0.4
1
PE - LD 0.2 to 0.25
PE - HD 0.25 to 0.3
PP 0.25 to 0.3
2
PVC 0.15 to 0.2
Table 7.9 Specific drive power for various thermoplasts

3
A.2.3 Torques Torques
Torque to produce translational movement 4
F ⋅ r- = 9, 55 ⋅ P--
M = ----------
1000 n
Acceleration torque 5
· n· ∆n
M BE = J ⋅ ω = J ⋅ ----------- = J ⋅ ----------------------
9, 55 9, 55 ⋅ t BE
Acceleration time
6
∆n ( ∆n ) 2
tBE = J ⋅ -------------------------------------- = J ⋅ -----------------------------------
9, 55 ⋅ ( M – M L ) 91, 2 ⋅ ( P – P L )
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
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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 
Table 7.11 Work

From these general equations, with ω2 = ω and ω1 = 0, with v2 = v and

v1 = 0, with h2 = h and h1 = 0 and with x2 = x and x1 = 0 the following
results are produced: 1
Kinetic energy of the translational movement
1 2
W = -- ⋅ m ⋅ v
2 2
Kinetic energy of the rotational movement
1 2
W = -- ⋅ J ⋅ ω
2
Potential energy of the position
3
W = m⋅g⋅h
Potential energy of the fields
1
W = -- ⋅ c ⋅ x
2 4
2
Table 7.12 Energy 5

c Spring rigidity Nm
FR Friction force N
g Acceleration due to gravity m/s²
h Lift height m
6
h1 Lift height at time t=t1 m
h2 Lift height at time t=t2 m
J Mass moment of inertia kg · m² 7
m Mass kg
M Torque Nm
MR Friction torque Nm
s Effective travel of friction force m A
v Velocity m/s
v1 Velocity at time t=t1 m/s
v2 Velocity at time t=t2 m/s
W Work Nm
x Spring travel m
x1 Spring travel at time t=t1 m
x2 Spring travel at time t=t2 m
α Angle of inclination of inclined plane deg
µ1 Coefficient of friction for longitudinal movement
µr Coefficient of friction for rotational movement
ϕ1 Angle of revolution at time t=t1 rad
ϕ2 Angle of revolution at time t=t2 rad
ω Angular velocity 1/s
ω1 Angular velocity at time t=t1 1/s
ω2 Angular velocity at time t=t2 1/s
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A.2.5 Friction Friction force of Coulomb friction (dry friction)
F R = F N ⋅ µ l = m ⋅ g ⋅ µ l ⋅ cos α
Tractive resistance to rolling friction
2 dW
F W = m ⋅ g ⋅ -- ⋅  ------ ⋅ µ r + f ) + c
d 2
Friction torque in thread
dm
MR = F ⋅ ------ ⋅ tan ρ
2
Table 7.13 Friction

c Rim friction
d Wheel diameter m
dm Mean thread diameter m
dw Axle/shaft diameter m
F Longitudinal force in screw/
threaded spindle N
FN Normal force N
FR Friction force with Coulomb friction N
FW Tractive resistance to rolling friction N
f Lever arm of rolling friction m
g Acceleration due to gravity m/s²
m Mass kg
MR Friction torque Nm
α Angle of inclination of inclined plane deg.
µl Coefficient of friction in longitudinal movement
µr Coefficient of friction in rotational movement
ρ Friction angle in threaded spindles deg.

A.2.6 Effective motor

torque/power 1-- n 2
1
M eff = ⋅Σ M ⋅t
T i=1 i i
output
2 2
M 1 ⋅ t 1 + M2 ⋅ t 2 ⋅ M 3 ⋅ t3
2 2
M eff = ---------------------------------------------------------------
T
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
Table 7.14 Effective motor torque/power output 5
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The following diagrams relating to a working example illustrate the mean-

ings of the formula symbols used.
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
The motor is defined at PN > Peff.

A.2.7 Choice of max. Slip of a conveyed item

acceleration
m 1
m.a
S
M m.g.µ
2
m.g
Figure 8.1 Conveyor belt with unsecured object during acceleration

3
Maximum acceleration: a = g⋅µ

4
a Belt acceleration in m/s²
g Acceleration due to gravity in m/s²
µ Coefficient of friction
5
Tip limit of a conveyed item
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
b Width of body in m
h Height of body in m
DE
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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.
x Coordinates in horizontal direction in m
z Coordinates in vertical direction in m

Pendulum of a suspended load
a 1
3
m m.a
4
m.g
Figure 8.4 Schematic view of a crane with suspended load 5

Maximum acceleration: a = g ⋅ tan α
a Belt acceleration in m/s² 6
α Angle of deflection of cable in degrees
7
In most applications the angle α should not exceed a value of 3°. With this
value the result for the acceleration is:
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A.2.8 Mass moments

of inertia Thin-walled hollow cylinder
dm d3m
J = m ⋅ ------ = -------- ⋅ π ⋅ b ⋅ ρ ⋅ δ
4 4 rm
b dm
Mass moments of
inertia of bodies
Cylinder with full circular
cross-section
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
Long, thin bar with pivot point at center of A

gravity m
m 2 A⋅ρ 3
J = ----- ⋅ l = ---------- ⋅ l
12 12 l
Table 7.15 Mass moments of inertia of bodies

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
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

Reduction via a gear
Reduction via two gears 4
A
Movement by conveyor roller
DE
EN
Movement by rack
Movement by cable reel
Movement by spindle

Conversion from translation into rotation
4
Conversion from translation into rotation with several motors
DE
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Indexing table with eccentric loads

A.2.9 V/t diagram

1
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
v/t diagram for minimum torque
Acceleration time
Acceleration travel
Braking time
Braking travel
Total travel
Total time

v/t diagram with sinusoidal characteristic
1
Period
Acceleration time
3
Acceleration travel 4
5
Braking time
6
Braking travel
Acceleration
A
DE
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A.2.10Efficiencies, Efficiencies of transmission elements

coefficients of Transmission
Characteristic Efficiency
friction and element
density Each complete wrap of the cable reel (friction
η = 0.91 - 0.95
Wire cable or roller bearing supported)
Each complete wrap of the V-belt pulley (nor-

η = 0.88 - 0.93
V-belt mal belt tension)
Each complete wrap; rollers on roller bearings

η = 0.81 - 0.85
Plastic belts (normal belt tension)
Each complete wrap; rollers on roller bearings

η = 0.81 - 0.85
Rubber belts (normal belt tension)
Each complete wrap; chains on roller bearings

η = 0.90 - 0.96
Chains (depending on chain size)
Trapezoidal threaded spindle η = 0.30 - 0.70

Spindles
Recirculating ball spindle η = 0.70 - 0.95
Table 7.16 Efficiencies of transmission elements

Coefficients of friction for bearing friction
Bearing type Coefficient of friction

1
Roller bearing µ = 0.001 to 0.005
Friction bearing µ = 0.08 -0.1
Table 7.17 Coefficients of friction for bearing friction 2

Coefficients of friction for roller bearing friction
Roller bearing Coefficient of friction 3

Axial groove ball bearing 0.0013
Radial self-aligning ball bearing 0.0010
Radial self-aligning roller bearing 0.0018 4
Radial groove ball bearing 0.0015
Radial taper roller bearing 0.0018
Radial cylinder roller bearing 0.0011 5
Radial needle bearing 0.0045
Table 7.18 Coefficients of friction for roller bearing friction

6
Coefficients of friction for spindles
Spindle type Coefficient of friction

7
µ = 0.05 - 0.08 (greased)
Trapezoidal threaded spindle
µ = 0.1 - 0.18 (dry)
µ = 0.005 -0.05
Recirculating ball spindle A
Table 7.19 Coefficients of friction for spindles
Coefficients for rim and side friction
Wheel type Coefficients for rim and side friction
Roller bearing supported wheels c=0.003

Friction bearing supported wheels c=0.005
Side guide rollers c=0.002
Table 7.20 Coefficients for rim and side friction
DE
EN
Coefficients of friction of various material pairings
Friction pairing Friction type Coefficient of friction
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
Static friction (dry) µ0=0.45-0.75

Wood on steel
Sliding friction (dry) µ =0.30-0.60
Wood on wood
Plastic belt on steel
Sliding friction (dry) µ =0,25
Steel on plastic
Table 7.21 Coefficients of friction of various material pairings
Lever arm of rolling friction for various material pairings
Material pairing Lever arm of rolling friction
Steel on steel f=0.5 mm

Wood on steel (roller conveyor) f=1,2 mm
Plastic on steel f=2.0 mm
Hard rubber on steel f=7.0 mm
Plastic on concrete f=5.0 mm
Hard rubber on concrete f=10 mm - 20 mm
Medium-hard rubber on concrete f=15 mm - 35 mm
Table 7.22 Lever arm ofrollingfriction forvariousmaterialpairings
Density ρ of various materials

Aluminum 2700 kg/m³
Gray-cast 7600 kg/m³
Copper 8960 kg/m³
Brass 8400-8900 kg/m³
Steel 7860 kg/m³
Zinc 7130 kg/m³
Table 7.23 Density of various materials

Tin 7290 kg/m³

Epoxy resin 1200 kg/m³
Rubber 920-990 kg/m³
1
Phenol resin, type 31 1400 kg/m³
Polyethylene 900-950 kg/m³
PVC 1300-1400 kg/m³
2
Table 7.23 Density of various materials
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
A.2.11Motor lists Three-phase AC motors with squirrel-cage rotor to DIN VDE 0530,
3000 rpm, 50 Hz, IP54 protection, internally cooled
Standard 3-phase AC Mass

Nominal Rated
motor Power Efficiency moment of
Size torque current at
3000 rpm, 50 Hz P in kW η in % Mn in Nm
inertia
230/400 V
J in kgm²
56S/2 0.09 50 0.31 0.000130 0.80/0.5

56L/2 0.12 49 0.41 0.000160 0.96/0.6
63S/2 0.18 57 0.63 0.000141 1,22/0.75
63L/2 0.25 59 0.86 0.000188 1.5/0.91
71S/2 0.37 69 1,25 0.00035 1.83/1.1
71L/2 0.55 75 1.87 0.000455 2.45/1.45
80S/2 0.75 72 2.58 0.000678 3.25/1.93
80L/2 1.1 78 3.73 0.000904 4.6/2.7
90S/2 1.5 78 5.1 0.00137 5.8/3.4
90L/2 2.2 82 7.4 0.00183 8.4/4.9
100S/2 3.0 73 10.0 0.00282 12.5/7.3
112M/2 4.0 80 13.3 0.00556 14.8/8.6
132S/2 5.5 85 18.3 0.00837 21.1/12.1
132S/2a 7.5 84 24.9 0.012 27.1/15.7
160M/2 11.0 87 36.0 0.033 37.3/21.6
160M/2a 15.0 88 49.0 0.045 48.1/28.1
160L/2 18.5 92 60.0 0.054 59.1/34.1
180M/2 22.0 91 71.0 0.073 74.1/43.1
200L/2 30.0 90 97.0 0.12 96.1/56.1
200L/2a 37.0 92 119.0 0.15 114.1/66.1
225M/2 45.0 93 145.0 0.22 148.1/81.1
250M/2 55.0 95 177.0 0.36 170.1/98.1
280S/2 75.0 93 241.0 0.61 -/135.1
280M/2 90.0 92 289.0 0.70 -/165.1
315S/2 110.0 93 353.0 1.46 -/202.1
315M/2 132.0 92 424.0 1.70 -/244.1
315M/2a 160.0 93 514.0 2.00 -/289.1
315M/2b 200.0 87 641.0 2.20 -/385.1
The data given represent mean values which may vary slightly depending on manufacturer.
Table 7.25 Standard 3-phase AC motor, 3000 rpm, 50 Hz

Standard 3-phase AC motor, 1500 rpm, 50 Hz

Three-phase AC motors with squirrel-cage rotor to DIN VDE 0530,
1500 rpm, 50 Hz, IP54 protection, internally cooled 1
Mass
Nominal Rated
Size
Power
P in kW
Efficiency
η in %
torque
moment of
inertia
current at 2
Mn in Nm 230/400 V
J in kgm²
56S/4 0.06 42 0.42 0.000130 0.62/0.4

56L/4 0.09 39 0.63 0.000160 0.97/0.6 3
63S/4 0.12 49 0.85 0.000210 0.97/0.6
63L/4 0.18 63 1.26 0.000280 1.1/0.7
71S/4 0.25 61 1.72 0.000560 1.5/0.9 4
71L/4 0.37 65 2.56 0.000730 2.0/1.2
80S/4 0.55 73 3.8 0.00128 2.7/1.6
80L/4 0.75 80 5.1 0.00165 3.4/2.0 5
90S/4 1.1 72 7.5 0.00235 5.1/3.0
90L/4 1.5 77 10.2 0.00313 6.5/3.8
90L/4a 2.2 76 15.0 0.00316 9.6/5.6 6
100L/4 2.2 76 14.9 0.00450 9.5/5.5
100L/4a 3.0 77 20.3 0.00600 12.9/7.5
112M/4 4.0 83 27.0 0.0199 15.7/9.1 7
132S/4 5.5 85 36.0 0.0233 20.0/11.6
132M/4 7.5 87 49.0 0.0317 28.1/16.3
132M/4a 9.2 87 60.0 0.0354 35.1/20.1 A
160M/4 11.0 89 72.0 0.062 39.4/23.1
160L/4 15.0 89 98.0 0.083 54.1/31.1
180M/4 18.5 91 121.0 0.127 66.1/38.1
180L/4 22.0 94 143.0 0.153 80.1/44.1
200L/4 30.0 89 195.0 0.249 99.1/57.1
225S/4 37.0 91 240.0 0.392 124.1/70.1
225M/4 45.0 95 290.0 0.474 152.1/85.1
250M/4 55.0 93 355.0 0.736 176.1/98.1
280S/4 75.0 94 484.0 1.22 -/140.1
DE
EN
Mass
Nominal Rated
Power Efficiency moment of
P in kW η in % Mn in Nm
inertia
230/400 V
J in kgm²
280M/4 90.0 95 581.0 1.46 -/168.1

315S/4 110.0 94 707.0 2.12 -/210.1
315M/4 132.0 96 849.0 2.54 -/240.1
315M/4a 160.0 96 1029.0 2.97 -/285.1
315M/4b 200.0 93 1286.0 3.25 -/370.1

Standard 3-phase AC motor, 1000 rpm, 50 Hz

Three-phase AC motors with squirrel-cage rotor to DIN VDE 0530,
1000 rpm, 50 Hz, IP54 protection, internally cooled 1
Mass
Nominal Rated
Size
Power
P in kW
Efficiency
η in %
torque
moment of
inertia
current at 2
Mn in Nm 230/400 V
J in kgm²
63S/6 0.09 47 0.97 0.00031 0.88/0.55

63L/6 0.12 41 1.29 0.00042 1.2/0.74 3
71S/6 0.18 58 1.89 0.00091 1.23/0.75
71M/6 0.25 64 2.58 0.0012 1.66/1.0
80S/6 0.37 57 3.84 0.0022 2.5/1.5 4
80L/6 0.55 69 5.71 0.0028 3.0/1.78
90S/6 0.75 69 7.83 0.0037 4.1/2.3
90L/6 1.1 68 11.5 0.0050 5.6/3.4 5
100L/6 1.5 73 15.1 0.010 7.2/4.2
112M/6 2.2 81 22.1 0.018 9.85/5.75
132S/6 3.0 82 29.8 0.031 13.5/7.9 6
132M/6 4.0 84 39.8 0.038 16.8/9.8
132M/6a 5.5 81 55.8 0.045 23.3/13.5
160M/6 7.5 85 74.0 0.093 28.6/16.6 7
160L/6 11.0 86 109.0 0.127 42.1/24.1
180M/6 13.0 85 130.0 0.168 49.1/28.1
180L/6 15.0 85 148.0 0.192 55.1/32.1 A
200LK/6 20.0 88 196.0 0.281 73.1/42.1
200L/6 22.0 91 215.0 0.324 78.1/45.1
225M/6 30.0 89 290.0 0.736 103.1/60.1
250M/6 37.0 93 360.0 1.01 123.1/71.1
280S/6 45.0 92 436.0 1.48 156.1/90.1
280M/6 55.0 92 533.0 1.78 190.1/110.1
315S/6 75.0 92 727.0 2.63 -/143.1
DE
EN
Mass
Nominal Rated
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
Asynchronous servomotors
Asynchronous servomotors with squirrel-cage rotors to DIN 42 950, self-
cooling, IP 65 protection
Mass
Nominal Nominal Rated
Size torque speed current
inertia
n in rpm in A
J in kgm²
ASM(H)31 2.1 83.0 13.0 0.0070 1500 5.2

ASM(H)32 2.7 85.0 17.0 0.0090 1500 6.8
ASM(H)33 3.6 85.0 23.0 0.0130 1500 8.7
ASM(H)34 5.5 87.0 35.0 0.0209 1500 12.6
ASM(H)24 2.1 84.0 10.0 0.00298 2000 5.3
ASM(H)25 2.7 85.0 13.0 0.00384 2000 6.6
ASM(H)11 0.41 76.0 1.3 0.00028 3000 1.4
ASM(H)12 0.54 77.0 1.7 0.00037 3000 1.8
ASM(H)13 0.72 79.0 2.3 0.00047 3000 2.3
ASM(H)14 1.1 80.0 3.5 0.00065 3000 3.3
ASM(H)15 1.5 82.0 4.7 0.00089 3000 4.5
ASM(H)21 1.1 82.0 3.5 0.00109 3000 3.0
ASM(H)22 1.5 83.0 4.7 0.00144 3000 3.9
ASM(H)23 2.2 84.0 7.0 0.00215 3000 5.6
Table 7.28 Asynchronous servomotors, self cooling

Asynchronous servomotors with squirrel-cage rotors to DIN 42 950,

forced cooling, IP 65 protection
1
Mass
Nominal Nominal Rated
Size torque speed current
inertia
n in rpm in A
J in kgm² 2
ASF(V)3 1 2.8 80.0 18.0 0.0070 1500 7.0
ASF(V)3 2 3.6 83.0 23.0 0.0090 1500 8.9
ASF(V)3 3 5.0 85.0 32.0 0.0130 1500 11.6 3
ASF(V)3 4 7.4 87.0 47.0 0.0209 1500 15.4
ASF(V)2 4 2.7 83.0 13.0 0.00298 2000 6.7
ASF(V)2 5 3.4 85.0 16.5 0.00384 2000 8.2 4
ASF(V)1 1 0.54 76.0 1.7 0.00028 3000 1.8
ASF(V)1 2 0.72 78.0 2.3 0.00037 3000 2.4
ASF(V)1 3 0.94 79.0 3.0 0.00047 3000 2.9 5
ASF(V)1 4 1.5 81.0 4.7 0.00065 3000 4.3
ASF(V)1 5 2.0 82.0 6.5 0.00089 3000 6.2
ASF(V)2 1 1.5 82.0 4.7 0.00109 3000 3.9 6
ASF(V)2 2 2.0 83.0 6.5 0.00144 3000 5.0
ASF(V)2 3 3.1 85.0 10.0 0.00215 3000 7.4
The data given represent mean values which may vary slightly depending on manufacturer. 7
Table 7.29 Asynchronous servomotors, forced cooling
DE
EN
A.3 Protection
A.3.1 Protection to Protection against touch and foreign body contact

IEC/EN
First Scope of protection
code
digit Designation Explanation
No special protection of personnel against random touch contact

with live or moving parts.
0 No protection
No protection of equipment against intrusion of solid foreign
bodies.
Protection against random large-area touch contact with live parts
Protection
and internal moving parts, e.g. with back of hand, but no protec-
against for-
1 tion against intentional accessing of said parts.
eign bodies
Protected against solid foreign bodies with a diameter of 50 mm
> 50 mm
and larger.
Protection Protection against touch contact by fingers with live parts or inter-
against for- nal moving parts.
2
eign bodies Protected against solid foreign bodies with a diameter of 12.5 mm
> 50 mm and larger.
Protection against touch contact with live parts or internal moving
Protection
parts by tools, wires or similar items of a thickness of 2.5 mm and
against for-
3 thicker.
eign bodies
Protected against solid foreign bodies with a diameter of 2.5 mm
> 2.5 mm
and larger.
Protection against touch contact with live parts or internal moving
Protection
parts by tools, wires or similar items of a thickness of 1 mm and
against for-
4 thicker.
eign bodies
Protected against solid foreign bodies with a diameter of 1 mm and
> 1 mm
larger.
Complete protection against touch contact with live parts or inter-
Protection nal moving parts.
5 against dust Protection against damaging dust deposits. The intrusion of dust is
deposits not entirely prevented, but the dust must not penetrate to the
extent that operation or safety is impaired.
Protection
Complete protection against touch contact with live parts or inter-
against dust
6 nal moving parts.
intrusion
Protection against intrusion of dust.
Dust-proof
Table 1.3 Protection against touch and foreign body contact

Examples of protection figures: IP 4 4

1
Code letters
First code digit
2
Second code digit
For water protection 3

code
4
0 No protection No special protection
Protection
against vertically
5
1 Water dripping vertically must not have any damaging effect.
falling dripping
water
Protection
against dripping Water dripping vertically must not have any damaging effect
6
2 water with hous- when the housing is at a tilt angle of 15° to either side of the
ing at a tilt of up vertical.
to 15°
Protection
7
Water splashing at any angle up to 60° on either side of the
3 against splash-
vertical must not have any damaging effect.
ing water
Protection
Water splashing onto the housing from any direction must not
A
4 against splash-
have any damaging effect.
ing water
Protection
A water jet from a nozzle directed from any direction onto the
5 against water jet
equipment must not have any damaging effect.
spray
Table 1.4 For water protection
DE
EN

code
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.
Table 1.4 For water protection

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.
Marking of the housing and the protection

2
type Marking of the
housing and the
to NEC NFPA 70 protection type to Comparable IP
(National CSA-C22.1 protection to IEC 3
Electrical Code) to NEMA ICS6-19831) (Canadian Electrical 529 / DIN 40050
to UL 508 to to EEMAC E 14-22) Code)
NEMA No. CSA-C22.2 No. 94
250-1985 4
Housing 1
Housing type 1
Housing type 1 Housing for general IP 20
General use
use
5
Housing type 2 Housing type 2 Housing 2
IP 22
Drip-tight Drip-proof Drip-proof housing
Housing type 3 Housing type 3
dust-tight, rain- Dust-tight, rain-tight, resist- IP 54 6
tight ant to sleet and ice Housing 3
Housing type 3 R Weather-proof housing
Housing type 3 R
Rain-proof, resistant to sleet
Rain-proof
and ice 7
Housing type 3 S Housing type 3 S
Dust-tight, rain- Dust-tight, rain-tight, resist-
tight ant to sleet and ice
Housing type 4
A
Housing type 4 Housing 4
Rain-tight, water- IP 65
Dust-tight, water-tight Water-tight housing
tight
Housing type 4 X
Housing type 4 X
Rain-tight, water-
Dust-tight, water-tight, cor-
tight, corrosion-
rosion-resistant
resistant
Housing type 6
Housing type 6 Dust-tight, water-tight, sub-
Rain-tight mersible, resistant to sleet
and ice
Table 7.30 Protection types of electrical equipment for USA and Canada
DE
EN
Marking of the housing and the protection

type Marking of the
housing and the
to NEC NFPA 70 protection type to Comparable IP
(National CSA-C22.1 protection to IEC
Electrical Code) to NEMA ICS6-19831) (Canadian Electrical 529 / DIN 40050
to UL 508 to to EEMAC E 14-22) Code)
NEMA No. CSA-C22.2 No. 94
250-1985
Housing type 6 P
Rain-tight,
corrosion-proof
Drip-tight, Drip-proof, corrosion-resist-
corrosion-proof ant, oil-immersed
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
1) NEMA= National Electrical Terms in German/English:

Manufacturers Association
2) EEMAC= Electrical and Electronic allgemeine
Manufacturers Association Verwendung: general purpose
of Canada tropfdicht: drip-tight
staubdicht: dust-tight
regendicht: rain-tight
regensicher: rain-proof
wettersicher: weather-proof
wasserdicht: water-tight
eintauchbar: submersible
eisbeständig: ice resistant
hagelbeständig: sleet resistant
korrosionsbeständig: corrosion resistant
öldicht: oil-tight

1
Appendix B Practical working aids for

the project engineer 2
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:
Special background conditions:
Comments:


for processing
1
Continuous Discontinuous Discontinuous
material flow batch process unit process
2
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

DE
EN

for processing
Moment of [kgm²] Mass: [kg]

or
inertia: Mode of movement:
Speed manipulating range: Torque rise time: [ms]
Static speed accuracy: [rpm] Positioning accuracy: [ms]
Dynamic speed accuracy: [rpm]
Comments:
Load torque of processing process

ML~ 1/n, P=constant
ML=constant, P~n ML, P 1.5
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
Environmental and installation conditions: 4
6
Standards, regulations and safety:
DE
EN
Continuous load characteristic in inverter

Engine speeds operation with IEC standard motor
750 rpm 1000 rpm 1500 rpm 3000 rpm 0.5 0.6 0.7 0.8 0.9 1.0 M
8-pole 6-pole 4-pole 2-pole
MM UR
100 200
500
200 10
200 400
1000
300 400 600 20
P>
1500
400 800
600 30
500 1000 2000
600 800 1200 40

2500
700 1400
750 1000 1500 3000 50
800 1600
3500
900 1200 1800 60
1000 2000 4000

1400 70
1100 2200
4500
1200 1600 2400 80
5000
1300 2600
1800 90
1400 5500
2800
1500 2000 3000 6000 n [rpm] 100 f [Hz]

6 10
2 4
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
150 200 300 2000
250 400
200
300 3000
250 PN UR [kW]
4000
300
M
[Nm]

1
Appendix C Bibliography and source

reference 2
Das 1x1 der Antriebstechnik

Friedrich Wilhelm Garbrecht - Joachim Schäfer 3
ISBN 3-8007-2005-1
VDE Publishing
Maschinenbau Lexikon
Prof. Dr.-Ing. habil. Heinz M. Hiersig
ISBN 3-18-401372-3
4
VDE Publishing
Feldschwächung bei Umrichterantrieben bietet viele Vorteile
Joachim Schäfer
Specialist article in “Antriebstechnik” 36 (1997) no. 4 5
Projektmanagement
J. Boy - C. Dudek - S. Kuschel
ISBN 3-930799-01-4
Gabal
Taschenbuch der Technik
6
T. Krist
ISBN 3-87807-124-8
Technik - Tabellen Publishing
Der Drehstrommotor A
Karl Falk
ISBN 3-8007-2078-7
VDE Publishing
Elektrische Antriebstechnik
Heinz Stüben
ISBN 3-7736-0839-x
W. Girardet Publishing
DE
EN
Appendix C Bibliography and source reference
Grundlagen der elektrischen Antriebstechnik mit Berechnungsbei-

spielen
Johannes Vogel
ISBN 3-7785-1547-0
VEB Technical Publishing
Moderne Stromrichterantriebe
Peter F. Bosch
ISBN 3-8023-0241-9
Vogel Publishing
Feldbussysteme im Vergleich
Robert Busse
ISBN 3-7905-0722-9
Pflaum Publishing
Dynamische Eigenschaften von Drehstrom-Motoren
Joachim Schäfer
Specialist article in AGT 1994, no. 2
Positionieren mit Frequenzumrichtern durch Echtzeitverarbeitung,
Teil 1
Joachim Schäfer
Specialist article in “Antriebstechnik” 1991, no. 3
Positionieren mit Frequenzumrichtern durch Echtzeitverarbeitung,
Teil 2
Joachim Schäfer
Specialist article in “Antriebstechnik” 1991, no. 5
Klöckner Moeller Schaltungsbuch
Klöckner Moeller, Bonn
Oberschwingungen
Albert Kloss
ISBN 0175-9965
VDE Publishing
Absicherung von Maschinen vor gefahrbringenden Bewegungen
Elan Corporation in D-35435 Wettenberg
Schutztechnik mit Isolationsüberwachung
Wolfgang Hofheinz
ISBN 3-8007-2215-1
VDE Publishing
ZVEI research report “Elektrische Belastung und Ausfallverhalten
der Wickelisolierung von Asynchronmaschinen mit Umrichterbe-
trieb”.
Berth, Eberhardt, Kaufhold, Speck, Auinger
Elektrie, H.8/9 (1995) p. 336

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
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
Appendix D Index
Device and terminal view ....................... 4-15 Friction ........................................... A-14

Digital scope ..................................... 4-14 Functional analysis .......................... 1-6, 1-8
Dimensioning
Air-to-air heat exchanger .................... 7-4
Air-to-water exchanger ....................... 7-5
G
Filter fan ....................................... 7-3 General points on the mains connection ....... 3-21
Direction of rotation and terminal designation . 3-27 General technical data .......................... 2-36
Drive capacities in process engineering ........ A-10
Drive capacity ............................ 2-18, 2-19 H
Drive capacity, general ............................ A-6 Harmonics load .................................... 6-2
Drive definition Heat discharge from the switch cabinet .......... 7-2
via LuDrive PC program .................... 2-13 High-voltage test/Insulation test ................ 3-24
via normogram ................................ 2-6
via power rating .............................. 2-9
Drive design with LuDrive ....................... 2-16 I
Drive design, in steps ........................... 2-16 Idle acceleration time ........................... 2-40
Drive engineering equations ...................... A-5 Important units .................................... A-4
Drive solution Initial commissioning .............................. 4-6
Master-/Slave operation .................... 4-56 Initial commissioning, example ................... 4-7
traction and lifting drive .................... 4-24 Initial commissioning, sequence .................. 4-6
DRIVECOM Installation and cooling methods ................. 3-7
Control word .................................. 5-9 Interconnection
State machine ................................ 5-9 Drive units by PROFIBUS-DP Gateway ..... 5-14
Status word ................................. 5-10 of inverter modules on the CAN bus ......... 5-6
DriveManager user software .................... 4-13 of Lust drive units on the CAN bus ........... 5-7
via the PROFIBUS-DP module .............. 5-17
Interconnection of several drive units on
E PROFIBUS-DP ............................... 5-16
Effect of the line choke ............................ 6-2 Internal torque as a function of load angle ..... 2-42
Efficiencies, coefficients of friction and density A-30 Inverter module rating plate .................... 3-26
Energy ........................................... A-13 Inverter module with modules .................... 5-2
Example of a driving profile for two directions Inverter modules, single-phase ................... 3-3
of rotation ............................ 4-61, 4-63 Inverter system .................................... 1-2
Example of a driving profile with Master-/Slave coupling Isolation .......................................... 4-19
4-65, 4-67 Isolation method for the control terminals ..... 4-19
Example of a limit switch evaluation ........... 4-33
Example of solution with four-pole motor ........ 2-7
Example of solution with six-pole motor ......... 2-8 K
Example of use of control terminal presetting . 4-30 KEYPAD control unit, keys ...................... 4-12
Example of use of emergency operation ....... 4-55 KP200 controls .................................. 4-12
Example of use of manual mode ............... 4-53
L
F Layout, CDA3000 ................................ 4-15
Field bus operation .............................. 4-49 Lifting drive ...................................... 2-12
Forming of the DC-link capacitors .............. 3-25 Limit speed, standard three-phase AC motor .. 2-27
Formula bank ...................................... A-1 Line choke ......................................... 6-2

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
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

Appendix D Index
W
Work .............................................. A-12
Work output for metalworking machinery ....... A-7
1
DE
EN
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
ID no.: 0840.25B.1-00 • Date: 12/99

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The easy route

Selecting and ordering a Dimensioning a drive

Quick and easy initial Operation via Adaptation of the drive

CANLust Communication CANopen Communica- PROFIBUS-DP Communi-

Project planning, installa- Project planning, installa- Project planning, installa-

Engineering Guide CDA3000

We reserve the right to make technical changes.

➢ Analysis of the task

How to use this

System overview, Revision history

3 Selection of inverter module 3

4 Selection of user and communication

5 Selection of supplementary components 5

6 Tips for system installation 6

Appendix: Formula bank, Copy templates

➢ Basics - see section 1

Calculate drive variables,

Select motor, transmission gear

Select inverter module and ➢ See section 3

Engineering Guide CDA3000

(13) (12) (11) (10)

System modules Section

(1) Inverter module See section 3

Engineering Guide CDA3000

3 Selection of inverter module

5 Communication and user modules

Engineering Guide CDA3000

B Practical working aids for the project

C Bibliography and source reference

Engineering Guide CDA3000

• Inverter module • Motor choke

Braking Line choke

Figure 1.1 Inverter system

Engineering Guide CDA3000 1-2

In summary: An inverter system is a combination of standalone

Processing process Environmental 5

Figure 1.2 System environment

1.2 Process analysis

1.2.1 Example of a Standard screw-type extruder

(1) (2) (3) (4) (5)

(1) Screw (4) Funnel

Figure 1.3 Schematic of an extruder

Engineering Guide CDA3000 1-4

Figure 1.4 Load characteristic of the plastics extruder 5

Figure 1.5 Old solution with DC drive

(1) Inverter with field-oriented regulation

Figure 1.6 Solution from functional analysis

The functional analysis produces a solution with speed feedback - See

Engineering Guide CDA3000 1-6

Answer the questions in this example:

Comparison of solutions:“Functional analysis / Process analysis”

Solution from functional analysis Solution from process analysis

Figure 1.8 Comparison of solutions

In summary: Always analyze the processing process! Because just

Engineering Guide CDA3000 1-8

Paper machinery Stirrers Packaging machinery

Traction and mechanical function

Drive function with servocontroller

Engineering Guide CDA3000 1-10

Example of a movement solution

Drive function x(t) Mechanical function y(x)

Engineering Guide CDA3000 1-12

Speed manipulating range