Lenze 8200 vector User Manual

Basic units in the power range 3 ... 11 kW
Wiring according to EMC (installation of a CE-typical drive system)
6
Basic unit wiring
6.5
6.5.1
L
6.5-3
EDS82EV903-1.0-11/2002
M
3~
L < 500 mmL<40mm
1
2
3
4
5
6
7
8
9
0
PES
PES
PE
PE
PE
PES
88200vec066
Fig. 6.5-1 Wiring in compliance with EMC standards
0
Mounting plate with electrically conductive surface
1
Control cable to function module, connect the shielding to the EMC shield sheet
(PES)withasurfaceaslargeaspossible
2
2-pole terminal for motor PE and motor shield
3
PE of the motor cable
4
Shield of the motor cable
5
Shielded motor cable, low-capacity
(core/core up to 1.5 mm
2
≤ 75 pF/m; from 2.5 mm
2
≤ 100 pF/m; core/shield ≤
150 pF/m)
6
Shielded PTC cable or thermal contact cable
7
Connect cable shields to the EMC shield sheet (PES) with a surface as large as
possible. Use enclosed clamps.
8
Star or delta connection as indicated on the motor nameplate
9
EMC-cable connector (not included in the delivery package)
Realisation
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Lenze 8200 vector Specifications

General

Category	DC Drives
Series	8200 vector
Enclosure Rating	IP20
Control Method	Vector control
Communication	CANopen, DeviceNet, Profibus
Protection Features	Overcurrent, overvoltage, undervoltage, overtemperature, short circuit
Humidity	< 95 % non-condensing
Operating Temperature	0 to +45 °C (derating above 40°C)

Summary

Preface

The 8200 vector frequency inverter

Provides a general overview of the 8200 vector frequency inverter's capabilities and applications.

How to use this System Manual

Guidance on navigating and utilizing the System Manual effectively for installation and operation.

Products to which the System Manual applies

Details the specific product variants covered by this System Manual, including type, power, and controller generation.

Guide

Glossary

Provides definitions for terminology and abbreviations used throughout the manual.

Meaning of the signal names

Explains the meaning of various signal names used in the manual, essential for understanding system logic.

Total index

An index of all topics covered in the manual, allowing quick access to specific information.

Safety information

Safety and application notes for Lenze controllers

Crucial safety guidelines and application notes for installing and operating Lenze controllers.

General safety and application notes for Lenze motors

Safety precautions and handling instructions for Lenze low-voltage motors and their components.

Residual hazards

Identifies potential hazards and risks associated with the operation and maintenance of the controllers.

Layout of safety notes

Explains the standardized layout of safety information, including pictographs, signal words, and meanings.

Technical data

General data/application conditions

Provides essential environmental, conformity, and packaging standards for the controllers.

Operation with rated power (normal operation)

Detailed technical data for rated power operation under various mains voltages and configurations.

Operation with increased rated power

Technical data for operating the controllers with increased rated power under specific conditions.

Basic device installation

Important notes

Key considerations for safe and effective installation, including ventilation and handling of sensitive components.

Basic units in the power range 0.25 ... 2.2 kW

Details mounting instructions for basic units in the 0.25-2.2 kW power range using various methods.

Basic units in the power range 3 ... 11 kW

Provides mounting guidelines for basic units in the 3-11 kW power range, including fixing rails and cold plate techniques.

Basic units in the power range 15 ... 30 kW

Instructions for installing basic units in the 15-30 kW range, covering mains chokes, footprint filters, and built-on filters.

Basic units in the power range 45 ... 55 kW

Guidelines for installing basic units in the 45-55 kW range, including mains chokes, footprint filters, and built-on filters.

Basic units in the power range 75 ... 90 kW

Instructions for installing basic units in the 75-90 kW range, covering mains choke and footprint filter mounting.

Basic unit wiring

Important notes

General safety notes, including protection of persons, motor protection, and mains conditions.

Basics for wiring according to EMC

Guidelines for proper wiring to ensure EMC compliance, covering cable requirements, shielding, and control cabinet installation.

Basic units in the power range 0.25 ... 2.2 kW

Details wiring practices for units in the 0.25-2.2 kW range, including EMC compliance and power connections.

Basic units in the power range 3 ... 11 kW

Wiring instructions for units in the 3-11 kW range, focusing on EMC compliance, power connections, and relay outputs.

Basic units in the power range 15 ... 30 kW

Wiring guidelines for units in the 15-30 kW range, covering EMC, power connections, and relay outputs.

Basic units in the power range 45 ... 55 kW

Wiring instructions for units in the 45-55 kW range, emphasizing EMC compliance and power connections.

Basic units in the power range 75 ... 90 kW

Wiring guidelines for units in the 75-90 kW range, focusing on EMC compliance and power connections.

Extensions for automation

Basic units in the power range 0.25 ... 2.2 kW

Details function modules and terminal assignments for basic units in the 0.25-2.2 kW range.

Basic units in the power range 3 ... 11 kW

Covers function modules and terminal assignments for basic units in the 3-11 kW range.

Basic units in the power range of 15 ... 90 kW

Information on function modules and terminal assignments for basic units in the 15-90 kW range.

Commissioning

Before switching on

Essential checks and safety measures to perform before applying mains voltage to the controller.

Selection of the control mode

Guidance on selecting the appropriate control mode (V/f, Vector, Sensorless Torque) for different applications.

Parameter setting with the E82ZBC keypad

Step-by-step instructions for parameter setting using the E82ZBC keypad for V/f and Vector control modes.

Parameter setting with the XT EMZ9371BC keypad

Instructions for parameter setting using the XT EMZ9371BC keypad for V/f and Vector control modes.

Important codes for quick commissioning

A summary of key codes and parameters for efficient controller commissioning.

Parameter setting

Important notes

General notes and considerations for setting controller parameters via keypad or PC.

Parameter setting with the E82ZBC keypad

Detailed instructions on installation, commissioning, display elements, and function keys for the E82ZBC keypad.

Parameter setting with the XT EMZ9371BC keypad

General data and application conditions for the XT EMZ9371BC keypad and its installation.

Function library

Important notes

Key information on adapting the controller to applications and understanding signal linkage and code tables.

Operating mode

Explains different control methods: V/f characteristic, Vector control, and Sensorless Torque control.

Optimising the operating behaviour

Details on optimizing drive performance through slip compensation, chopper frequency, oscillation damping, and skip frequencies.

Behaviour in the event of mains switching, mains failure or controller inhibit

Describes controller behavior during mains issues, including start conditions and flying restart.

Limit value setting

Covers setting speed ranges, current limits, and other limit values for controller operation.

Process controller

Explains process controller functions, including gain, readjustment time, and influence settings.

Digital setpoints via frequency input

Details how to configure digital inputs for frequency input, enabling digital frequency selection as setpoint or actual value.

Setpoints via function ”motor potentiometer”

Explains how to use the motor potentiometer function for setpoint selection via digital inputs.

Setpoints via keypad

Describes how to select setpoints directly using the keypad, which are added to the main setpoint.

Setpoints via a bus system

Information on preselecting setpoints or actual values for FIF using bus function modules or AIF.

Automatic detection of motor data

Details the function for detecting motor data and cable influences, essential for vector control.

Basic device installation

Mounting with fixing rails (standard)

Instructions for mounting basic units using fixing rails, including dimensions and side-by-side placement guidelines.

Thermally separated mounting (push-through technique)

Guidelines for installing controllers in a push-through technique, including dimensions and cutouts.

Mounting in ”cold plate” technique

Instructions for mounting controllers using the cold plate technique, emphasizing thermal contact and requirements.

DIN rail mounting

Details the procedure and notes for DIN rail mounting, including limitations for CE-typical drive systems.

Lateral mounting

Describes lateral mounting options, including fixed and swivelling methods, and required mounting kits.

Troubleshooting and fault elimination

Troubleshooting

Guidance on interpreting controller LED status and analyzing errors using the history buffer.

Drive performance in case of errors

Describes how the controller reacts to different error types (TRIP, Message, Warning) and their associated displays.

Error elimination

Provides a comprehensive list of common faults, their causes, and recommended remedies for drive maloperation.

Resetting error messages

Instructions for resetting TRIP error messages after eliminating the cause, including manual and automatic methods.

Network of several drives

General information

Provides an overview of DC-bus connections for frequency and servo inverters in networked systems.

Function

Explains the function of DC-bus connections for energy exchange and advantages of networked drive systems.

Conditions for a trouble-free network of several drives

Outlines essential conditions for reliable network operation, including mains voltage and controller combinations.

Mains connection

Guidelines for mains connection in networks, covering fuses, cable cross-sections, and EMC compliance.

DC-bus connection

Details on DC-bus connections, including cable cross-section selection and inductance reduction measures.

Fuses and cable cross-sections for a network of several drives

Provides fuse and cable cross-section recommendations for networks, categorized by controller type and mains voltage.

Protection in DC-bus operation

Describes protection concepts for network operation, analyzing risks and damage due to faults and short circuits.

Selection

Provides basic data and examples for selecting drive networks, including conditions and supply requirements.

Required mains filters or mains chokes

Lists prescribed mains chokes and filters required for network operation, specified by controller type and current.

Supplies - 230 V controller

Details supply power requirements for 230 V controllers in network configurations, including three-phase and single-phase connections.

Supplies - 400 V controllers

Outlines supply power requirements for 400 V controllers in network configurations, including DC-bus and three-phase connections.

Selection examples

Provides practical examples for selecting drive networks and supply units, demonstrating DC-power calculations.

Braking operation

Braking operation without additional measures

Describes methods for braking smaller loads using DC-injection brake or AC motor brake functions.

Braking operation with three-phase AC brake motor

Details braking operation with three-phase AC brake motors, including brake rectifier selection and control methods.

Braking operation with external brake resistor

Explains braking operation using external brake resistors for high inertia loads or generator mode.

Selection of the brake resistors

Provides criteria and conditions for selecting appropriate brake resistors based on load and application requirements.

Wiring of brake resistor

Instructions for correctly wiring brake resistors, including mounting, safety switch-off, and temperature contact connections.

Application examples

Pressure control

Example of using the internal process controller for pressure regulation in a pipe system.

Speed control

Details on implementing speed control using inductive sensors and configuring parameters for optimal performance.

Group drive (operation with several motors)

Explains how to connect multiple motors in parallel to a controller, ensuring total current does not exceed limits.

Sequential circuit

Describes a sequential circuit example controlling refrigeration compressors with a 8200 vector controller.

Setpoint summation (basic and additional load operation)

Explains how to combine setpoints from different sources for conveyors, pumps, and other applications requiring variable speed.

Power control (torque limitation)

Details the power control function for generating constant mass flow in applications with changing environmental conditions.

Signal-flow charts

Important notes

Provides guidance on interpreting signal flow diagrams and understanding symbols used in Lenze settings.

Overview of signal processing

Illustrates signal processing for controllers with standard I/O, communication modules, and fieldbus modules.

Controller with standard I/O

Shows the signal flow for controllers using standard I/O, detailing connections for various functions.

Controller with Standard I/O and communication module

Illustrates signal flow for controllers with standard I/O and communication modules, showing connections.

Controller with Application I/O

Diagrams the signal flow for controllers utilizing Application I/O for various control functions.

Controller with Application I/O and communication module

Shows signal flow for controllers with Application I/O and communication modules, detailing connections.

Controller with fieldbus function module and communication module

Illustrates signal flow for controllers with fieldbus and communication modules, detailing terminal assignments.

Controller with system bus function module

Provides signal flow overview for controllers using system bus function modules and communication modules.

Speed setpoint conditioning (NSET1)

Diagrams the signal flow for speed setpoint conditioning, showing input and output connections.

Speed setpoint conditioning (NSET1) with Application I/O

Illustrates the signal flow for speed setpoint conditioning when using Application I/O.

Process controller and setpoint processing (PCTRL1)

Shows the signal flow for process controller and setpoint processing, including various control functions.

Process controller and setpoint processing (PCTRL1) with Application I/O

Diagrams the signal flow for process controller and setpoint processing when using Application I/O.

Motor control (MCTRL1)

Illustrates the signal flow for motor control functions, including vector control and parameter settings.

Motor control (MCTRL1) with Application I/O

Shows the signal flow for motor control functions when using Application I/O, detailing parameter settings.

Device control (DCTRL1)

Diagrams the signal flow for device control functions, including various input and output signals.

Controller state (STAT1, STAT2)

Illustrates the signal flow for controller states STAT1 and STAT2, showing status bits and output signals.

Process data of system bus function module (CAN1, CAN2)

Shows the signal flow for process data input words from CAN bus function modules.

Process data of fieldbus function module (FIF-IN, FIF-OUT)

Illustrates the signal flow for process data input and output words for fieldbus function modules.