Lenze i510 protec Owner's manual

Inverter

i510 protec frequency inverter

0.37 kW ... 5.5 kW

0.5 hp ... 7.5 hp

Project planning EN

Contents

About this document 7

Document descripon 7

Further documents 7

Notaons and convenons 8

Product informaon 9

Product descripon 9

Load characteriscs 9

Features 10

Connecons and interfaces 10

Topologies / network 10

Funcons 11

Overview 11

Motor control types 12

Motor funcons 12

Motor seng range 12

Idencaon of the products 14

Ways of commissioning 16

Informaon on project planning 17

Project planning process 17

Dimensioning 17

Operaon in motor and generator mode 19

Overcurrent operaon 20

Safety instrucons 21

Basic safety instrucons 21

Applicaon as directed 22

Foreseeable misuse 22

Handling 23

Residual hazards 25

Decentralized topologies 26

Cables 26

Informaon on mechanical installaon 27

Important notes 27

Preparaon 27

Contents

3

Informaon on electrical installaon 28

Important notes 28

Preparaon 30

EMC-compliant installaon 31

Connecon according to UL 33

Important notes 33

Fusing data 34

Branch Circuit Protecon (BCP) 34

Mains connecon 35

1-phase mains connecon 120 V 36

1-phase mains connecon 230/240 V 37

3-phase mains connecon 230/240 V 38

3-phase mains connecon 400 V 39

3-phase mains connecon 480 V 40

Motor connecon 40

Control connecons 41

Networks 42

CANopen 42

Modbus RTU 43

Contents

4

Technical data 44

Standards and operang condions 44

Conformies and approvals 44

Protecon of persons and device protecon 44

EMC data 44

Motor connecon 45

Environmental condions 45

Electrical supply condions 45

1-phase mains connecon 120 V 46

Rated data 47

Fusing data 49

Terminal data 49

1-phase mains connecon 230/240 V 50

Rated data 51

Fusing data 54

Terminal data 54

1-phase mains connecon 230/240 V "Light Duty" 55

Rated data 56

Fusing data 58

Terminal data 58

3-phase mains connecon 230/240 V 59

Rated data 60

Fusing data 63

Terminal data 64

3-phase mains connecon 230/240 V "Light Duty" 65

Rated data 66

Fusing data 68

Terminal data 68

3-phase mains connecon 400 V 69

Rated data 69

Fusing data 72

Terminal data 73

3-phase mains connecon 400 V "Light Duty" 74

Rated data 74

Fusing data 76

Terminal data 76

3-phase mains connecon 480 V 77

Rated data 77

Fusing data 80

Terminal data 81

3-phase mains connecon 480 V "Light Duty" 82

Rated data 82

Fusing data 84

Terminal data 84

Dimensions 84

Contents

5

Product extensions 89

Overview 89

I/O extensions 90

Standard I/O 90

Data of control connecons 91

Further control connecons 94

Relay output 94

Networks 95

CANopen 95

Modbus RTU 96

Accessories 97

Operaon and diagnoscs 97

Keypad 97

USB module 97

WLAN module 98

Memory modules 99

Memory module copier 99

Purchase order 100

Notes on ordering 100

Order code 101

Environmental notes and recycling 103

Appendix 104

Good to know 104

Approvals and direcves 104

Operang modes of the motor 105

Motor control types 106

Switching frequencies 108

Enclosures 109

Glossary 109

Contents

6

About this document

Document descripon

This document is intended for all persons who want to congure inverters with the products

described.

This document assists you with the conguraon and selecon of your product. It contains

informaon on mechanical and electrical installaon, on product expansions, and on

accessories.

Further documents

For certain tasks, informaon is available in further documents.

Document Contents/topics

Commissioning document Seng and parameterising the inverters

Mounng and switch-on instrucons Basic informaon on mounng and inial switch-on of the product

•Is supplied with each component.

More informaon

For certain tasks, informaon is available in other media.

Medium Contents/topics

Engineering Tools For commissioning

AKB arcles Addional technical informaon for users in the Applicaon Knowledge Base

CAD data Download in dierent formats from the EASY Product Finder

EPLAN macros Project planning, documentaon and management of projects for EPLAN P8.

Device descripons Standardized les for network conguraon

Informaon and tools with regard to the Lenze products can be found on the

Internet:

www.Lenze.com à Downloads

About this document

Document descripon

7

Notaons and convenons

Convenons are used in this document to disnguish between dierent types of informaon.

Numeric notaon

Decimal separator Point Generally shown as a decimal point.

Example: 1 234.56

Warnings

UL Warnings UL Are used in English and French.

UR warnings UR

Text

Engineering Tools " " Soware

Example: "Engineer", "EASY Starter"

Icons

Page reference ¶Reference to another page with addional informaon.

Example: ¶ 16 = see page 16

Documentaon reference ,Reference to other documentaon with addional informaon.

Example: , EDKxxx = see documentaon EDKxxx

Layout of the safety instrucons

DANGER!

Indicates an extremely hazardous situaon. Failure to comply with this instrucon will result

in severe irreparable injury and even death.

WARNING!

Indicates an extremely hazardous situaon. Failure to comply with this instrucon may result

in severe irreparable injury and even death.

CAUTION!

Indicates a hazardous situaon. Failure to comply with this instrucon may result in slight to

medium injury.

NOTICE

Indicates a material hazard. Failure to comply with this instrucon may result in material

damage.

About this document

Notaons and convenons

8

Product informaon

Product descripon

The frequency inverters from the i500 protec series use the same tried-and-tested technology

used in control cabinet inverters and only dier funconally in terms of a higher degree of

housing protecon with an adapted design. If your machine requires a lot of space, has a

modular design, or the space in the control cabinet is limited, we recommend a decentralized

installaon close to the motor. The latest connecon systems are available as accessories and

oer a great deal of exibility during installaon, while maintaining compliance with the

degree of protecon. The inverters comply with the future EN 50598-2 standard.

Highlights

•0.37 ... 5.5 kW with NEMA protecon 1 (IP20)

•Versions with keypad, USB module or WLAN module for easy commissioning

•Industry standard eldbus network opons: 4Topologies / network ^ 10

•The "Light Duty" load characterisc enables a higher output current

•High internal funconal range: 4Overview ^ 11

Applicaon ranges

•Pumps and fans

•Conveying and travelling drives

•Forming and tool drives

Load characteriscs

The inverters have two dierent load characteriscs: "Light Duty" and "Heavy Duty".

The "Light Duty" load characterisc allows for a higher output current with restricons

regarding overload capacity, ambient temperature and switching frequency. This allows the

motor required for the applicaon to be driven by a less powerful inverter. Select the load

characterisc according to the applicaon.

Heavy Duty Light Duty

Characterisc High dynamic requirements Low dynamic requirements

Typical applicaons Main tool drives, travelling drives, hoist drives,

winders, forming drives and conveyors

Pumps, fans, general horizontal materials handling

technology and line drives

Overload capacity 3 s/200 %, 60 s/150 %

See technical data

Restricted

See technical data

Product informaon

Product descripon

Load characteriscs

9

Features

Connecons and interfaces

The following gure gives an overview of the elements and connecons on the devices.

Posion, size and appearance of elements and connecons may vary depending on the

performance and size of the equipment.

Netw rk, o Option

X2xx

X9

X3

X100

X105

Control terminals

Network status LEDs

Inverter status LEDs

Memory module

Relay output

Diagnostic module

Shield connection control cable

Mains connection

Motor connection

CANopen or Modbus RTU

Standard I/O

Cable inlet

Cable gland shield connection for motor cable

Keypad, WLAN module or

USB module

PE connection

The i510 protec frequency inverters have these interfaces:

•Standard I/O:

•5x digital input

•1x digital output

•2x analog input

•1x analog output

•PNP/NPN logic

•Cycle me: 1 ms

•Frequency input: 0 ... 100 kHz

•1x NO/NC relay (DC 24 V max. 2 A; AC 240 V max. 3 A)

•External 24 V supply and internal 24 V power supply unit

•Spring terminals

•Diagnosc interface (USB module or WLAN module required)

Topologies / network

The inverters can be equipped with dierent eldbus networks.

The topologies and protocols typical for the prevailing networks are supported.

Currently available networks:

CANopen® is a communicaon protocol based on CAN.

CANopen® is a registered community trademark of the CAN user organisaon CiA® (CAN in Automaon e. V.).

Device descripons for the download: EDS les for Lenze devices

The Modbus protocol is an open communicaon protocol based on a client/server architecture and developed for

the communicaon with programmable logic controllers.

Further development is carried out by the internaonal user organisaon Modbus Organizaon, USA.

Product informaon

Features

Connecons and interfaces

10

Funcons

Overview

The funcons of the frequency inverters i510 protec are adapted to extensive applicaons.

Funcons

Motor control Monitoring

V/f characterisc control linear/square-law (VFC plus) Short circuit

V/f characterisc control (VFC closed loop) Earth fault

Energy-saving funcon (VFC-Eco) Device overload (ixt)

Sensorless vector control (SLVC) Motor overload (i²xt)

Sensorless control for synchronous motors (SL-PSM/SLSM-PSM) Mains phase failure

Servo control for asynchronous motors (SC-ASM) Stall protecon

Motor funcons Motor current limit

Flying restart circuit Maximum torque

Slip compensaon Ulmate motor current

DC braking Motor speed

Oscillaon damping Load loss detecon

Skip frequencies Motor temperature

Automac idencaon of the motor data Diagnoscs

Brake energy management Error history buer

Holding brake control Logbook

"Voltage add" funcon LED status displays

Raonal Energy Ride Through (RERT) Keypad language selecon German, English

Speed feedback (HTL encoder) Network

Brake resistor control (brake chopper integrated) CANopen

Frequency setpoint Modbus RTU

DC-bus connecon (400V devices) IO-Link

Applicaon funcons EtherCAT

Process controller EtherNet/IP

Access protecon Modbus TCP

Process controller - sleep mode and rinse funcon PROFINET

Freely assignable favorite menu Safety funcons

Parameter change-over Basic Safety - STO

S-shaped ramps for smooth acceleraon

Motor potenometer

Flexible I/O conguraon

Automac restart

OEM parameter set

Complete control with 8-key keypad

UPS operaon

Frequency output via digital output DO1

Cascade funcon for pumps and fans

"Light Duty" load characterisc can be adjusted for selected

inverters.

Product informaon

Funcons

Overview

11

Motor control types

The following table contains the possible control types with Lenze motors.

Motors V/f characterisc control Sensorless vector control ASM servo control

VFCplus SLVC SC ASM

Three-phase AC motors

MD ● ● ●

MF ● ● ●

mH ● ● ●

m500 ● ● ●

Lenze synchronous servo motors are not suitable for use with inverters, e.g. the types MCS,

MCM or m850.

Motor funcons

Motor seng range

Rated point 120 Hz

Only possible with Lenze MF motors.

The rated motor torque is available up to 120 Hz.

Compared to the 50-Hz operaon, the seng range increases by 2.5 mes.

Thus, a smaller motor can be selected at the same rated power.

V/f at 120 Hz

120 Hz f

M, U

MN

UAC

V Voltage VAC Mains voltage

M Torque MNRated torque

f Frequency

Product informaon

Funcons

Motor control types

12

Rated point 87 Hz

The rated motor torque is available up to 87 Hz.

Compared to the 50-Hz operaon, the seng range increases by 1.74 mes.

For this purpose, a motor with 230/400 V in a triangle is driven by a 400 V inverter.

The inverter must be dimensioned for a rated motor current of 230 V.

V/f at 87 Hz

f

M, U

MN

UAC

fN

V Voltage UAC Mains voltage

M Torque Mrated Rated torque

f Frequency frated Rated frequency

Rated point 50 Hz

The rated motor torque is available up to 50 Hz.

V/f at 50 Hz

f

M, U

MN

UAC

fN

V Voltage UAC Mains voltage

M Torque Mrated Rated torque

f Frequency frated Rated frequency

Product informaon

Funcons

Motor funcons

13

Idencaon of the products

Product name

The product name is used when lisng the technical data of the various product variants and

for the assignment of accessories. You can nd the assignment of product names to order

codes in chapter 4Purchase order ^ 100.

The product name contains:

•the designaon of the product range – e.g. i5xx

•the type – "P" for "protec" = inverter for decentralized mounng locaons

•its power rang – in kW for the load characterisc "Heavy Duty"

•the mains voltage class – e.g. 120 V, 230 V or 400 V

•the number of mains phases – the 1/3-phase inverters are labelled with "-2".

Device series Type Rated power Rated mains voltage No. of

phases Inverter Protecon

class

Light Duty Heavy Duty

kW kW V

i510 P - 0.37 120 1 i510-P0.37/120-1 IP20

NEMA 1

0.75 i510-P0.75/120-1

Device series Type Rated power Rated mains voltage No. of

phases Inverter Protecon

class

Light Duty Heavy Duty

kW kW V

i510 P

0.55 0.37

230 1/3

i510-P0.37/230-2

IP20

NEMA 1

1.1 0.75 i510-P0.75/230-2

1.5 1.1 i510-P1.1/230-2

2.2 1.5 i510-P1.5/230-2

3 2.2 i510-P2.2/230-2

Device series Type Rated power Rated mains voltage No. of

phases Inverter Protecon

class

Light Duty Heavy Duty

kW kW V

i510 P

0.55 0.37

240

1/3

i510-P0.37/230-2

IP20

NEMA 1

1.1 0.75 i510-P0.75/230-2

1.5 1.1 i510-P1.1/230-2

2.2 1.5 i510-P1.5/230-2

3 2.2 i510-P2.2/230-2

4 3 3i510-P3.0/230-3

5.5 4 i510-P4.0/230-3

Device series Type Rated power Rated mains voltage No. of

phases Inverter Protecon

class

Light Duty Heavy Duty

kW kW V

i510 P

1.1 0.75

400 3

i510-P0.75/400-3

IP20

NEMA 1

1.5 1.1 i510-P1.1/400-3

2.2 1.5 i510-P1.5/400-3

3 2.2 i510-P2.2/400-3

4 3 i510-P3/400-3

5.5 4 i510-P4/400-3

7.5 5.5 i510-P5.5/400-3

Product informaon

Idencaon of the products

14

Device series Type Rated power Rated mains voltage No. of

phases Inverter Protecon

class

Light Duty Heavy Duty

kW kW V

i510 P

1.1 0.75

480 3

i510-P0.75/400-3

IP20

NEMA 1

1.5 1.1 i510-P1.1/400-3

2.2 1.5 i510-P1.5/400-3

3 2.2 i510-P2.2/400-3

4 3 i510-P3/400-3

5.5 4 i510-P4/400-3

7.5 5.5 i510-P5.5/400-3

Product code

I 5 1 A P □□□ □ □ □ □ □ □ □ □□□

Product type Inverter I

Product family i500 5

Product i510 1

Product generaon Generaon 1 A

Mounng type Wall mounng P

Rated power

(Examples)

0.37 kW 0.5 hp 137

0.75 kW 1.0 hp 175

2.2 kW 3.0 hp 222

Mains voltage and connecon

type

1/N/PE AC 120 V A

3/PE AC 230/240 V C

1/N/PE AC 230/240 V

3/PE AC 230/240 V

D

3/PE AC 400 V

3/PE AC 480 V

F

Product variant Standard 0

Integrated funconal safety Without safety funcon 0

Degree of protecon NEMA 1 (IP20), uncoated 0

Interference suppression Without 0

Applicaon area Default parameter seng: Region EU (50-Hz networks) 0

Default parameter seng: Region US (60-Hz networks) 1

Product extension Standard I/O: ... 0

Keypad- module with Standard I/O ... K

WLAN module with Standard I/O ... W

... without network 00S

... with CANopen 02S

... with Modbus RTU 03S

Product informaon

Idencaon of the products

15

Ways of commissioning

There are three ways to commission the inverter quickly and easily.

Thanks to Lenze’s engineering philosophy, the high funconality is sll easy to grasp.

Parameterizaon and commissioning are a breeze thanks to clear structure and simple

dialogs, leading to the desired outcome quickly and reliably.

Keypad

If it’s only a maer of seng a few key parameters such as acceleraon and deceleraon

me, this can be done quickly on the keypad.

»EASY Starter«

If funcons such as the holding brake control or sequencer need to be set, it’s best to use

the »EASY Starter« engineering tool.

SMART Keypad App

The Lenze SMART Keypad App for Android or iOS allows you to diagnose and parameterize an

inverter. A WLAN module on the inverter is required for communicaon.

•Ideal for the parameterizaon of simple applicaons such as a conveyor belt.

•Ideal for the diagnoscs of the inverter.

The app can be found in the Google Play Store or in the Apple App Store.

Android

iOS

Product informaon

Ways of commissioning

16

Informaon on project planning

Project planning process

Dimensioning

3 methods for dimensioning

Fast: Selecon of the inverter based on the motor data of a 4-pole asynchronous motor.

Detailed: In order to opmize the selecon of the inverter and all drive components, it is

worthwhile to execute the detailed system dimensioning based on the physical requirements

of the applicaon. For this purpose, Lenze provides the Drive Soluon Designer (DSD) design

program.

Manual: The following chapter guides you step by step through the selecon of a drive

system.

Workow of a conguraon process

Dene required input variable

Calculate range of adjustment and determine rated point

Determine motor based on the rated data

Determine correcon factors for the inverter

Determine inverter based on the rated data

Check motor/inverter combinaon

Determine brake resistance

Final conguraon

Dene required input variables

Operang mode S1 or S6

Max. load torque ML,max Nm

Max. load speed nL,max rpm

Min. load speed nL,min rpm

Site altude H m

Ambient temperature (inverter) TU°C

Informaon on project planning

Project planning process

Dimensioning

17

Calculate range of adjustment and determine rated point

Calculaon

Seng range

=L,max

L,min

n

Vn

Seng range Rated point

Motor with integral fan

≤ 2.50 (20 - 50 Hz)

≤ 4.35 (20 - 87Hz)

≤ 6 (20 - 120Hz)

50 Hz

87 Hz

120 Hz

Motor with blower ≤ 10.0 (5 - 50 Hz)

≤ 17.4 (5 - 87Hz)

≤ 24 (5 - 120Hz)

50 Hz

87 Hz

120 Hz

Motor with integral fan

(reduced torque)

Determine motor based on the rated data

Check

Rated torque

Operang mode S1 Mrated Nm

³´

L,max

NH,Mot U,Mot

M

MT T

Operang mode S6 Mrated Nm

³´ ´

L,max

NH,Mot U,Mot

M

M2 T T

Rated speed nrated rpm nrated ≥ nL,max

£

nL,min

nn

V

Note

Rated torque Mrated Nm → Rated motor data

Rated speed nrated rpm

Rated point at Hz → seng range

Power factor cos ϕ

→ Rated motor data

Rated current IN,MOT A

Rated power Prated kW

Correcon factor - site altude TH,MOT → Technical motor data

Correcon factor - ambient temperature TU,MOT

Select motor

Correcon factors for the inverter

Site altude Amsl H

[m] ≤ 1000 ≤ 2000 ≤ 3000 ≤ 4000

kH,INV 1.00 0.95 0.90 0.85

Temperature in the control cabinet TU

[°C] ≤ 40 ≤ 45 ≤ 50 ≤ 55

Switching frequency

2 or 4 kHz kTU,INV

1.00 1.00 0.875 0.750

8 or 16 kHz 1.00 0.875 0.750 0.625

Switching frequency with the "Light Duty" load characterisc

2 or 4 kHz kTU,INV 1.00 0.875 0.750 -

8 or 16 kHz - - - -

Determine the inverter based on the rated data

Check

Output current

Connuous operaon Iout A Iout ≥ IN,Mot / (kH,INV x kTU,INV)

Overcurrent operaon cycle 15 s Iout A Iout ≥ IN,Mot x 2 / (kH,INV x kTU,INV)

Overcurrent operaon cycle 180 s Iout A Iout ≥ IN,Mot x 1.5 / (kH,INV x kTU,INV)

Informaon on project planning

Project planning process

Dimensioning

18

Determine the inverter based on the rated data for the "Light Duty" load characterisc

Check

Output current

Connuous operaon Iout A Iout ≥ IN,Mot / (kH,INV x kTU,INV)

Overcurrent operaon cycle 15 s Iout A Iout ≥ IN,Mot x 1.65 / (kH,INV x kTU,INV)

Overcurrent operaon cycle 180 s Iout A Iout ≥ IN,Mot x 1.25 / (kH,INV x kTU,INV)

Check motor/inverter combinaon

Calculaon

Motor torque M Nm

( )

æ ö

= - - j ´

ç ÷

ç ÷ j

è ø

2

out,INV 2N

N,MOT

lM

M 1 cos

I cos

Check

Inverter overload capacity

£

L,max

M1.5

M

Braking operaon without addional measures

To decelerate small masses, the "DC injecon brake DCB" funcon can be parameterised. DC-

injecon braking enables a quick deceleraon of the drive to standsll without the need for

an external brake resistor.

•A code can be used to select the braking current.

•The maximum braking torque to be realised by the DC braking current amounts to approx.

20 ... 30 % of the rated motor torque. It is lower compared to braking acon in generator

mode with external brake resistor.

•Automac DC-injecon braking (Auto-DCB) improves the starng performance of the

motor when the operaon mode without speed feedback is used.

Final conguraon

Product extensions and accessories can be found here:

4Product extensions ^ 89

4Accessories ^ 97

Operaon in motor and generator mode

The energy analysis diers between operaon in motor mode and generator mode.

During operaon in motor mode, the energy ows from the supplying mains via the inverter

to the motor which converts electrical energy into mechanical energy (e. g. for liing a load).

During operaon in generator mode, the energy ows back from the motor to the inverter.

The motor converts the mechanical energy into electrical energy - it acts as a generator (e. g.

when lowering a load).

The drive brakes the load in a controlled manner.

The energy recovery causes a rise in the DC-bus voltage. If this voltage exceeds an upper limit,

the output stage of the inverter will be blocked to prevent the device from being destroyed.

The drive coasts unl the DC-bus voltage reaches the permissible value range again.

Informaon on project planning

Project planning process

Operaon in motor and generator mode

19

Overcurrent operaon

The inverters can be driven at higher amperages beyond the rated current if the duraon of

this overcurrent operaon is me limited.

Two ulisaon cycles of 15 s and 180 s are dened. Within these ulisaon cycles, an

overcurrent is possible for a certain me if aerwards an accordingly long recovery phase

takes place.

Cycle 15 s

During this operaon, the inverter may be loaded for 3 s with up to 200 % of the rated current

if aerwards a recovery me of 12 s with max. 75 % of the rated current is observed. A cycle

corresponds to 15 s.

Cycle 180 s

During this operaon, the inverter may be loaded for 60 s with up to 150 % of the rated

current if aerwards a recovery me of 120 s with max. 75 % of the rated current is observed.

A cycle corresponds to 180 s.

The monitoring of the device ulizaon (Ixt) triggers an error if the ulizaon value exceeds a

threshold of 100 %.

The maximum output currents correspond to the switching frequencies and the

overload behaviour of the inverters are given in the rated data.

In case of rotang frequencies < 10 Hz, the me-related overload behaviour

may be reduced.

The graphics shows a cycle. The basic condions given in the table (graphics eld highlighted

in grey) have to be complied with in order that the inverter will not be overloaded. Both cycles

can be combined with each other.

t

I [%]

100

T1T2

0

A

B

Cycle Max. output current Max. overload me Max. output current during

the Recovery me

Min. recovery me

A T1B T2

s % s % s

15 200 3 75 12

180 150 60 75 120

Informaon on project planning

Project planning process

Overcurrent operaon

20

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Lenze i510 protec Owner's manual

Lenze i510 protec Owner's manual

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