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i510 protec

Lenze i510 protec Owner's manual

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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.
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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