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(Sami GS) User`s Manual

1. P usa w 600 3 011 3 500 016 5 ___ 009 3 400 011 5 300 006 3 009 5 200 005 3 100 006 5 004 3 3456789101112 ee f kHz Piece 2750 s Soe W 2500 050 3 _ 060 5 2000 041 3 050 5 1500 AR 030 3 041 5 1000 a e NEE 030 5 500 GEET eee 025 5 16 70HAV DRW ES 3456789101112 020 5 Figure 4 2 Output current derating curves as IS a function of ambient temperature and switching frequency l ACS 501 A 006 3 luso 009 5 Iys 15 SS 005 3 luso 42 kHz 006 5 luso CH 006 3 ee N 10 009 5 Iy 3 kHz 004 3 Lu 005 5 005 3 1 5 006 5 1 y 004 3 e 005 5 10 20 30 40 5 amo C 12 SAMI GS ACS 501 011 3 NSQ 016 5 NSQ 009 3 l Nsa 011 5 usa 011 3 1 016 5 009 3 011 5 ACS 501 020 3 l NSQ 025 5 I NSQ 016 3 l NSQ 020 5 l NSQ 020 3 025 5 016 3 020 5 10 20 30 40 5 Tim N C ACS 501 060 3 ot A l m 120 NSQ She 070 5 3 khz S 12 kHz 050 3 400 NG NSQ 060 3 I 060 5 8 _3 kHz GDS 12 kHz A 050 3 041 3 NSQ 060 5 050 5 a NSQ Ba 030 3 Z 25 7OLOA DRW t
2. Fault indication on display and the drive has stopped according to the setting of param eter 26 3 STOP FUNCTION CONST FREQ The SAMI GS drives the motor with the con stant frequency selected by parameter 24 7 66 SAMI GS 3 Mot Temp Fit Func Motor load This parameter defines the operation of the motor thermal protection function NO SS No activity required Temp t WARNING rise Warning indication is displayed when the motor temperature reaches the warning level 100 95 of the nominal value 63 T gt FAULT Warning indication at warning level and fault indication stop when the motor temperature MOTOR THERM TIME reaches 100 level 4 Motor Therm Time MOTOR THERM TIME is the time period Il A E TE Field weak area a which the motor temperature reaches i percent of the final temperature rise As a 150 rule of thumb MOTOR THERMAL TIME 150 120 t f in seconds is given by the motor 100 manufacturer SAMI GS automatically A o selects a typical motor thermal time as a AMES default value according to the selected a motor power and pole number Table 9 1 page 68 Figure 9 22 Motorthermal time wm 5 Motor Load Curve Figure 9 23 Motor load curve 6 External Fan EXTERNAL FAN NO The motor connected to the SAMI GS can be protected from overheating by the motor A i thermal protection The SAMI GS will calcu
3. Switching 004 011 3 005 016 5 016 3 020 3 020 025 5 025 3 060 3 030 5 070 5 frequency Screened Unscreened Screened Unscreened Screened Unscreened kHz cable m cable m cable m cable m cable m cable m 1 73 100 100 150 200 250 12 50 75 75 100 150 200 16 SAMI GS cable lengths given in Table 5 2 are exceed ed for types ACS 501 004 011 3 or ACS 501 005 016 5 the output choke should be used Note To avoid interference problems in control cables all the cabling should be screened and should not run parallel to the motor cables see page 20 for minimum dis tances ele elele ES a IP 21 types A ACS501 016 060 3 ACS 501 020 070 5 and all types as IP 54 construction except ACS 501 009 3 011 3 011 5and016 5 amialvialalala TD D OOOO OIDO D gaa az D S AS NT TT B IP 54 types ACS 501 009 3 011 3 011 5 and 016 5 sle e Figure 5 1 Installation ofthe cable entry insulator mum available torque If noise problems ex ist contact ABB for more detailed La information 5 3 Insulation Checks Note Insulation checks must be performed before connecting the SAMI to the mains Before proceeding wit
4. Check mains fuses and supply If mains supply is adequate an internal failure has occured Contact the nearest SAMI GS service representative Input reference has failed or control wire is broken Check the reference circuit SPEED CONTROL application macro can not be used without optional board SNAT 7610 BAC Select any other macro If SNAT 7610 BAC is used see its Opera tion Guide Fault message SAMI GS Possible reason Remedy 16 Pow Rang LILA 17 RS 485 D 19 In comms OD 20 Con intX DO 21 Mot contX OJO 22 Par rest D Power range programming does not match after replacing the Control Interface or Motor Control Card No serial communication on RS 485 at connector X51 EMC dis turbances on serial link Failure in serial communication within the Control Interface and or Motor Control Cards This fault is related to components on the Control Interface Card This fault is related to components on the Motor Control Card Parameter restoring error Param eter checksum does not match 76 Check the power range program ming on Motor Control Card Check that the Start up Data is given accordingly for the new Control Interface Card Remove power wait one minute then restore power If the fault persists contact the nearest SAMI service representative If no ser communication ought to be present set para 17 4 to NO Check connectors
5. 50 A 1200 V V4 V6 60021007 IGBT mod 2 75 A 1200 V V4 V6 60021023 IGBT mod 2 150 A 1200 V V4 V6 60021015 IGBT mod 2 100 A 1200 V V4 V6 60021031 IGBT mod 2 200 A 1200 V V4 V6 Charging switches 31163528 Thyristor V2 31163536 Thyristor V2 DC capacitors 60018782 1500 uF 350 V complete 60031363 2200 uF 350 V complete 60031371 3300 uF 350 V complete 60031380 4700 uF 350 V complete 60031398 2330 uF 280 V complete 60031401 3410 uF 280 V complete 60031410 5120 uF 280 V complete 60031428 7290 uF 280 V complete pcs set C2 C3 C2 C3 C2 C3 C2 C3 C1 C3 C1 C3 C1 C3 C1 C3 Other electrical parts 60015074 Recovery module A3 60024031 Recovery module A3 60024065 60024057 Clamping capacitor A3C Clamping diode A3V 60012415 Cable Ctrl Interface Motor Control 86 SAMI GS ACS 501 004 3 ACS 501 005 3 ACS 501 009 3 ACS 501 011 3 ACS 501 020 3 ACS 501 025 3 ACS 501 041 3 ACS 501 050 3 ACS 501 060 3 ACS 501 006 5 ACS 501 011 5 ACS 501 016 5 ACS 501 025 5 ACS 501 030 5 ACS 501 050 5 ACS 501 060 5 ACS 501 070 5 Fans 60012377 Heat sink fan IP21 M1 M2 60012849 Heat sink fan IP54 M1 M2 60013365 Heat sink fan M1 60013977 Heat sink fan M1 60022721 Internal fan IP21 M3 60022721 Internal fan IP54 M3 Connectors 61117580 Ctrl interf card X50 X51 loose part Mechanical par
6. If you enter Display mode by pressing after selecting CONTROL PLACE KEYPAD R1 the value of parameter KEYPAD REF1 will be the set MINIMUM FREQUENCY Keypad Reference 2 Keypad Reference 2 goes through an application block where it can be manip ulated Keypad Reference 2 can be used as a controller reference and it can be given its own acceleration deceleration ramps Refer to parameters 21 6 and 21 7 on page 49 7 8 External Control The external control place Ref1 Ref2 is selected with digital input 1 6 or Operating SAMI GS Data parameter 12 EXT REF 1 OR 2 de pending on the setting of parameter 11 2 EXT CONT PLACE SEL Keypad DI1 DI6 External Reference 1 External frequency reference from control place R1 The signal source selection is made with parameter 11 5 EXTERNAL REF 1 SEL Refer to page 37 for available options External Reference 2 External Reference 2 goes through an application block where it can be manip ulated as Keypad Reference 2 The signal source selection is made with parameter 11 6 EXTERNAL REF2 SEL Refer to page 37 for available options 7 9 Parameter Lock Parameter Lock prevents unauthorised per sons altering the parameters If parameter lock is active Operating Data parameter 23 or digital input 1 6 parameter 11 11 itis not possible to change to Setting mode control place can still be selected with para 9 The SAMI GS Parameter Lock can be controlled with the Keypad
7. Parameter 32 10 UNDERLOAD FUNC is set to WARNING Parameter 32 2 Al lt 2V 4mA FUNC is set to WARNING Parameter storage to EEPROM has failed Speed Control Macro selected but no Pulse Tachometer Card connected 73 Refer to flowchart on page 78 Refer to fault 3 Mot stall Refer to fault 4 Mot temp Refer to fault 7 Under ld Refer to fault 11 Al lt 2V 4mA Check DC link voltage If voltage is OK try to store again Ifwarning occurs again try to restore factory settings Ifthe warning persists contact the nearest SAMI service representative Check the connections Check that the card is present Fault message SAMI GS Possible reason Remedy 1 Start Stop 2 SAMI temp D 3 Mot stall 4 Mot temp D 7 Under Id D The start stop reference from the Control Interface Card is different from the start stop state of the Motor Control Card Heatsink temperature gt 70 C gt 75 C for ACS 501 050 3 060 3 060 5 070 5 or less than 5 C Restricted air flow caused by dust or improper installation overloading or compon ent failure fan fuse power semicon ductors Ifthe display shows 10 C temperature when the ambi ent heatsink obviously is warmer R10 circuit has opened If 100 C is shown R10 is in a short circuit The SAMI GS has determined that the motor is operating in the stall region Refer to STALL TIME FREQ parameter
8. Alternatively capacitor values may be measured directly with the multimeter e g FLUKE 79 B With an insulation tester A multimeter may not indicate faulty capa citors which can withstand voltages up to 300 V but not normal mains voltage levels Therefore it is recommended that capacitors be also tested with a DC insulation tester Megger or suitable DC voltage source 300V DC range Y D 405 G4 G5 G6 D if D en g TIR rd A 2 G1 2 S y _X X7 T1 H BRAKE ry d o Be MAINS ce t R5 c7 s10 R6 B cs R11 X9 oo T1 R7 Figure 10 2 Motor Control Card ACS 501 004 3 005 3 and 006 3 ACS 501 005 5 006 5and 009 5 80 Checking DC link capacitors SAMI GS WW ACS 501 009 3 060 3 x8 ACS 501 011 5 070 5 1 Disconnect SAMI from the mains X7 2 Ensure see page 29 that the SAMI is safe D405 G before proceeding with these measure x5 ments x2 3 Disconnect all wiring from the DC link capacitors to allow them to be measured separately XA q Figure 10 3 Motor Control Card ACS 5
9. B Application Factory C Applic Restore No D Supply Voltage 400 500 V E Pole Number 4 F Motor Nom Current G Motor Nom Power P of SAMI P of SAMI H Cos phi of Motor 0 83 10 Cont Connections 11 Dig Analog Input Sel 1 Run Enable Yes 2 Ext Cont Place Sel Keypad 3 Ext 1 I O Cont Sel DI1 2 4 Ext 2 I O Cont Sel Not Sel 5 External Refi Sel Al 6 External Ref2 Sel Keypad 7 Const Speed Sel DI3 4 8 Direction Request 9 Fault Reset Sel Not Sel 10 Acc Dec 1 or 11 Parat Lock Sel Keypad 12 Analogue Inputs 1 Filter Al1 0 1s 2 Minimum Al1 OV OMA 3 Invert Al1 No 4 Filter Al2 0 1s 5 Minimum Al2 OV OmA 6 Invert Al2 No 13 Ref Value Scaling 1 Ext Ref1 Min Scale 0 Hz 2 Ext Ref1 Max Scale 50 Hz 3 Ext Ref2 Min Scale 0 Hz 4 Ext Ref2 Max Scale 50 Hz 14 Output Signals 1 Analogue Out 1 Out Freq 2 Analogue Out 2 Out Cur 3 Relay RO1 Out Ready 4 Relay RO2 Out Run 5 Relay RO3 Out Fault 15 Analogue Outputs 1 Filter AO1 2 Minimum AO1 2s OmA 3 Invert AO1 No 4 Filter AO2 2s 5 Minimum AO2 OmA 6 Invert AO2 No 16 Out Sig scaling 1 Scale AO1 100 2 Scale AO2 100 17 Ext Communi cation 1 SAMI ID num
10. max continuous current 2A Serial link bus RS 485 ACS 500 protocol maximum 31 ACS 500 series units Auxiliary voltage supply for remote control panel SAGS 700 PAN Protections Overcurrent trip limit 3 57 instantaneous 2 65 RMS Slow current regulation limit max 1 5 RMS Rapid current regulation limit max 2 0 RMS Current switch off limit 3 0 instantaneous 2 1 RMS Overvoltage trip limit 1 35 U nax Undervoltage trip limit 0 65 U Overtemperature limit ACS 501 004 3 to 041 3 70 C heatsink ACS 501 005 5 to 050 5 70 C heatsink ACS 501 050 3 060 3 75 C heatsink ACS 501 060 5 070 5 75 C heatsink Undertemperature limit 5 C heatsink Auxiliary voltage short circuit protected Earth fault protection protects only the inverter itself in case of earth fault at motor output Microprocessor fault protected Motor stall protection Motor overtemperature protection Enclosure Enclosure classes IP 21 and IP 54 Dimensions and weight see page 15 89 SAMI GS 12 Options Remote control box SACE 11BOX SACE 12BOX SACE 20 BOX SACE 21 BOX A remote control box is an external control device connected to the terminal block of the Control Interface Card or an Optional Control Card Remote control panel SACE 11 PAN SACE 12 PAN A remote control panel is an external control device connected to the terminal block of the Control Interface Card or an O
11. 118 i D 2P 3 DI1P 2P 3P d sin enai veAnalogue O configuration ach ee P REF 1 amp 2 LIMITS INVERT AND Fl 12 1 12 6 13 1 13 4 LTER SEE SEP DIAGR 13EXTERNALREF1 KEYPAD EXTERNAL REF 1 SEL 11 5 MINIMUM Al1 122 OV OmA 2V 4mA 13 EXTERNAL REF1 DIGITAL INPUT INVERT AI1 EXT REF 1 MIN 1 SCALE 13 1 0 120 500 Hz FILTERAI1 121 0 01 10s EXT REF 1 MAX SCALE 13 2 0 120 500 Hz EXT REP FILTERAI2 124 0 01 10s MINIMUM Al2 125 0V OmA 2V 4mA NO YES 14 EXTERNAL REF 2 KEYPAD 23 NO YES EXT REF 2 MIN SCALE 13 3 INVERTAI2 12 6 0 120 500 Hz EXT REF 2 MAX SCALE 13 4 0 120 500 Hz EXT REF Figure 7 4 Standard control signal selections The software switches in the diagram are set either by parameter or digital inputs as indicated in the box at the end of the dashed line 27 SAMI GS tions Select Operating Data parameter 9 CONTROL PLACE KEYPAD R1 KEYPAD R2 for keypad control Control place is Ref 1 or Ref 2 accordingly or EXTERNAL for external control The valid control place is indicated on the display around the direction and run indicators means keypad control and without means Keypad control R1orR2 Externalcontrol Externalcontrol manual forexampleaPLC eo automatic P external c
12. Checking rectifier ACS 501 009 3 060 3 ACS 501 011 5 070 5 1 Disconnect SAMI from the mains 2 Ensure see page 29 that the SAMI is safe before proceeding with these measure ments 3 Disconnect all the control wiring X50 can be disconnected in one piece from the Control Interface Card and remove the Card Disconnect all the control wiring from the Motor Control Card and remove the Card to allow access to the rectifier 4 Disconnect all wires from the rectifier terminals 5 Select Diode Test function on the multimeter If your multimeter does not have a Diode Test function proceed to alternative measurement on page 85 6 Connect the negative measuring wire to the positive rectifier terminal 0 5V 100 Q 10 KQ 7 Measure all the rectifier phase poles The reading should be about 0 5 V 84 SAMI GS 8 Change polarity of the multimeter wires and repeat the measurement The reading 05V hould be infinity REECH 100 2 10k9 9 Meassure between and of the rectifier The reading should be about 0 8 V and infinity If the readings are different from the values given the rectifier module must be changed Alternative measurement 10 Select 1kQ range on the multimeter not Diode Test function 11 Carry out the measurements 6 9 as above The reading should be 100 2 10 kQ and infinity accordingly No
13. Constantflux Field Wee SS late the temperature rise of the motor using 150 the following assumptions a 100 the ambient temperature is 40 C o 100 the motor is at ambient when power is D eg applied to the SAMI GS 50 50 when stopped the motor cooling time is 4 times the cooling time when running Motor heating is calculated assuming a load Y Pp f curve The load curve is defined by the Figure 9 24 Motor load curve MOTOR LOAD CURVE and EXTERNAL EXTERNAL FAN YES FAN parameters 67 SAMI GS Table 9 1 Default values of motor thermal If MOTORLOAD CURVE is set to 100 the times when motor power and pole number Motor Thermal Protection allows the motor to are selected from START UP Data group be loaded with nominal current The load These values are typical for each motor curve level should be adjusted if for ex size Default value of pole number is 4 ample the ambient temperature differs from the nominal value Number of poles The motor temperature will rise above nom 2 4 6 inal when the motor operates in the region t t t above the curve and will fall when operated s s s below the curve The rate of heating and cooling is set by MOTOR THERM TIME 660 1020 1440 720 1060 1560 780 1140 1740 900 1260 1760 970 1380 1860 1140 1560 2040 1200 1740 2340 1260 1860 2340 1380 2040 1680 2220 2940 When using external cooling set EXTER 1860 2460 NAL FAN to YES The load curve wil
14. Excessive overcurrent may cause SAMI to stop the drive due to overtemperature Note If a value greater than 1 5 is entered the SAMI will automatically decrease the limit to 1 5 when the output frequency is higher than 0 74 FIELD WEAK POINT 4 Max freq Range This Parameter extends the setting range of parameter 22 1 22 2 13 1 to 13 4 23 2 to 23 11 24 1 to 24 7 28 7 28 9 to 28 14 31 2 31 4 and 31 8 49 SAMI GS 9 2 3 Group 23 Crit Frequencies These values can be altered with the SAMI running Parameter Range Unit Off On 120 500 Hz 120 500 Hz 120 500 Hz 120 500 Hz 1 Crit Freq Select 2 Crit Freq 1 Low 3 Crit Freq 1 High 4 Crit Freq 2 Low 5 Crit Freq 2 High 6 Crit Freq 3 Low 7 Crit Freq 3 High 8 Crit Freq 4 Low 9 Crit Freq 4 High 10 Crit Freq 5 Low 11 Crit Freq 5 High 120 500 Hz 120 500 Hz 120 500 Hz 120 500 Hz 120 500 Hz 120 500 Hz CO O o o o o o o oO Description Critical frequency jump over logic Critical frequency 1 start Critical frequency 1 end Critical frequency 2 start Critical frequency 2 end Critical frequency 3 start Critical frequency 3 end Critical frequency 4 start Critical frequency 4 end Critical frequency 5 start Critical frequency 5 end Max value is set automatically according to the setting of parameter 22 4 In some systems it may be necessary to avoid some frequencie
15. ID number para 17 1 All functions ofthe SAMI GS standard control panel can be utilised via the serial bus Start up Parameter setting Monitoring and supervision Drive commands Maximum control bus length depends on electromagnetic disturbances cable size and cable screening Recommended max cable length is 1200 m with 0 5 mm 50 pF m cable and 500 m with 0 2 mm 50 pF m cable Maximum common mode voltage difference between terminals GND2 or GND3 of any units may not exceed 7 V The cable is connected to the screw terminal X51 on the Control Interface Card see Figures below Note The last unit connected to the serial bus without any control device must be terminated by setting plugs S3 and S4 on the Control Interface Card to the position TERM For further information on RS 485 serial communication please refer to SAMI GS Bus protocol manual order code EN 5805782 7 Connection of Remote Control Panel SAGS 700 PAN Black Green Black Blue II t gt Orange yak gt j To the next drive Example PC connection SAGS 700 PAN RSs232c RS 485 bus Vas If the PC has an between the SA Za i Be eg el Terminal _ Signal Function 1 Power to the panel GND2 Power0V SGNA RS signal A 6 SGNB RS signal B 7 SCRN2 Screen2 Function Power to the panel 1 24 6 sons Signalterminal RS 232C seri
16. Operating Data parameter 23 or a digital input The control place is selected with parameter 11 11 PARAM LOCK SEL Keypad DI1 DI6 To activate the Parameter Lock set Operating Data parameter 23 PARAMETER LOCK to LOCKED xxx control place Keypad or activate the selected digital input control place DI The Parameter Lock control place is indic ated in Operating Data parameter 23 PA RAMETERLOCK Characters xxx after the parameter value OPEN xxx LOCKED xxx indicate that the current control place is Keypad To open the Parameter Lock you must enter the correct combination ice tia for all SAMI GS units is 358 Wh iewing PARAMETER LOCK indent to setting mode and set the 358 code Press to open the Parameter Lock 29 8 Commissioning 8 1 Safety Precautions Before commissioning observe the follow ing warnings The Motor Control Card is at mains potential when the SAMI GS is connected to the mains This voltage is extremely dangerous and can cause severe injury and even death if you come in contact with it When the supply voltage is disconnected it will take about 5 minutes before the capaci tors in the intermediate DC circuit are dis charged to a safe voltage Do not take any further actions within the frequency converter for at least these five minutes To ensure that the voltage level is safe al ways measure the voltage between X2 and on brake terminals see Fig 5 2 on page 18 Note If
17. Parameter 1 Ext Ref1 Min Scale Range Unit 0 120 500 Hz 2 Ext Ref1 Max Scale 0 120 500 Hz 3 Ext Ref2 Min Scale 0 120 500 Hz 4 Ext Ref2 Max Scale 0 120 500 Hz Max 120 Hz E para 13 2 is para 13 1 Min 7 7 OHz Ext ref1 f out Figure 9 3 External Reference scaling 9 1 4 Group 14 Output Signals Description External reference 1 minimum value Cannot be set gt Ext Ref1 Max Scale External reference 1 maximum value Cannot be set lt Ext Ref1 Min Scale External reference 2 minimum value Cannot be set gt Ext Ref2 Max Scale External reference 2 maximum value Cannot be set lt Ext Ref2 Min Scale Max value is set automatically according to the setting of parameter 22 4 Note If max min frequency setting is changed para 22 1 22 2 the setting of parameters 13 1 and 13 2 changes accord ingly Parameter 13 3 and 13 4 are not available with Macros PI or PFC Control These values can only be altered when SAMI GS is stopped Parameter Range Unit 1 Analogue Out 1 2 Analogue Out 2 3 Relay RO1 Out 4 Relay RO2 Out 5 Relay RO3 Out Refer to the text below for the available selections 1 Analogue Out 1 This parameter allows you to select which output signal is connected to Analogue Output 1 current signal NOT USED OUT FREQ Output frequency MOT SPEED Motor speed Description Analogue Output 1 content Analogue Output 2 conte
18. Squared torque SAMI GS rated hisa Overload capacity Constant torque 1 5 for 1 min every 10 min Squared torque 1 1 for 1 min every 10 min Starting duty 2 0 I approx TA 2severy 15s NSQ for NSQ Field weakening point 30 500 Hz Acceleration time 0 1 to 1800 s 120 Hz Deceleration time 0 1 to 1800 s 120 Hz Environmental limits Ambient operating temperature h f 3 kHz 0 to 45 C except for ACS 501 006 3 and ACS 501 009 5 0 to 40 C Leet f 3 kHz Oto 40 C except for ACS 501 006 3and ACS 501 009 5 0 to 35 C Also refer to pages 12 and 13 for output current derating curves Storage temperature 40 to 70 C Cooling method Internal fan Corrosiveness of cooling air up to G1 as specified in ISA S71 04 Relative humidity max 95 no condensation allowed Altitude max 1000 m above sea level 100 load 1 derating every 100 m above 1000 m External control connections Two programmable Analogue Inputs Voltage reference 0 2 10 V 200 KQ single ended Currentreference 0 4 20 mA 2509 single ended Potentiometer reference 10 V 0 1 10 mA Auxiliary voltage 24 V DC max 200 mA 88 SAMI GS Six programmable Digital Inputs Two programmable Analogue Outputs 0 4 20 mA 5009 Three programmable Relay Outputs max switching voltage 300 V DC 250 V AC max switching current 8A 24VDC 0 4A 250VDC max switching power 2000 VA 250 V AC
19. The motor is not turning because of increased load torque Motor may be too small for the application The SAMI GS has determined that there is a high probability that the motor is overheated Because the temperature rise is calculated from the motor current and not measured directly the motor may be within temperature specification The motor load has dropped below the supervision limit set by param eters 32 11 and 32 12 74 Check the connection between Control Interface and Motor Control Cards Ifthe fault persists contact the nearest SAMI service repre sentative Refer to flow chart page 78 Check R10 circuit see fig 10 4 page 81 Remove mechanical problem causing increased load torque Ifthe motor shaft is rotating and the motor is not overheating increase stall limit parameters Check dimensioning use larger SAMI GS and motor if neces sary Check the motor temperature If it is within temperature speci fication increase MOTOR LOAD CURVE and or MOTOR THERM TIME and restart Ifthe motor temperature is above rated temperature improve motor cooling or resize the motor Remove mechanical problem causing underload Check motor load cycle and increase UNDERLOAD TIME or change UNDERLOAD CURVE Fault message SAMI GS Possible reason Remedy 8 Overcurri 4 9 Overvolt OD 10 Underv1 11 Al lt 2V 4mA O 14 Op Card 1 O Th
20. refer to Section 10 page 71 Note Wait at least 5 minutes af 8 7 Keypad Control Test With Motor 1 Connect the motor to the SAMI after first making sure that the SAMI is discon nected from the mains 2 Connect the SAMI to the mains and switch power on 3 Select Operating Data 9 CONTROL PLACE KEYPAD R1 see Section 7 Control and Parameter Logic 4 Select KEYPAD REF 1 Choose 0 5Hz A critical do not increase speed reference more than necessary after start to make sure the motor is running in the right direction Ifthe rotation direction is not correct swap 2 of the motor cable connections 5 Give a start command by pushing D 3 6 Check the Operating Data parameter values for normal operation Warning If rotation direction is 7 Change to Setting Mode and increase the reference Verify that the frequency is increasing Increase the frequency to 50 Hz Return to Display Mode 8 If external controls analogue outputs relay outputs Pl controller or other control equipment are used in the application check that they operate correctly 9 Test the functioning of the emergency stop if installed SAMI GS 8 8 Drive Parameters and Their Factory Settings Factory Macro Operating Data not a Main Operating Data Start Up Data PARAMETER 9 Control Place DEFAULT Keypad R1 Cc USTOMER SET 12 Ext Ref 1 or 2 Ref1 23 Parameter Lock A Language Open xxx English
21. system to mains Restart system Internal fault Contact SAMI GS service represent Check for faults 79 SAMI GS 10 5 Service Note Pay attention to the Safety Instructions on page 2 before pro ceeding with any measurements Checking DC link capacitors ACS 501 004 3 005 3 and 006 3 ACS 501 005 5 006 5 and 009 5 refer to page 81 for other units 1 Disconnect SAMI from the mains 2 Ensure see page 29 that the SAMI is safe before proceeding with these measure ments 3 Disconnect all the control wiring X50 can be disconnected in one piece from the Control Interface Card and remove the Card to allow access to the Motor Control Card A With a multimeter Switch the multimeter to 1 KQ scale Measure the resistors R3 R6 R11 The multimeter should indicate a value which rises con stantly stabilising after a while see Table 10 1 Table 10 1 Values for discharging resistors and DC capacitors ACS 501 R3 R6 R11 C6 C8 C7 C6 C8 C7 Factory Spares 004 3 100 kQ 330uF 680uF 005 3 100 kQ 680 UF 680 UF 006 3 100 kQ 680 UF 680 UF 005 5 100 kQ 510uF 1050 uF 006 5 100 kQ 1050uF 1050uF 009 5 100 kQ 1050uF 1050uF Components marked with are only avail able in 500 V units If the reading is different from the values given the resistors or the capacitors on the other side of the card are faulty Contact the nearest SAMI service representative
22. 3 Switch on the tester 4 The tester should now read a small resistance which then rises towards infinity 5 Continue the measurement until the tester reading has stabilised or the voltage falls suddenly 6 If the reading suddenly falls the capacitor must be replaced Contact the nearest SAMI service representative IGBT module measurements ACS 501 004 3 060 3 ACS 501 005 5 070 5 Note The IGBT transistor is sensitive to static discharges Ensure that the meter and its operator are properly grounded during measurement 1 Disconnect the SAMI from the mains 2 Ensure see page 29 that the SAMI is safe before proceeding with these measure ments 3 Disconnect motor cable 4 Disconnect all the control wiring X50 can be disconnected in one piece from the Control Interface Card and remove the Card to allow access to the Motor Control Card 5 Only in 009 3 060 3 011 5 070 5 Disconnect terminals X6 X7 and X8 on the Motor Control Card 6 Only for009 3 060 3 011 5 070 5 Disconnect all the control wiring from the Motor Control Card and remove the Card to allow access to the IGBTs 7 Use the multimeter and select the Diode Testfunction 8 Make measurements according to the following tables 9 If the readings are different from the Table values contact the nearest SAMI service representative 82 SAMI GS Table 10 1 IGBT module measurements Collector Emitter ACS 501 0
23. 8 Group 28 PFC Control These values can be altered with the SAMI GS running except those marked with O The Parameters of this group will be available only when parameter B APPLICATIONS of the START UP DATA group has been set to PFC CTRL see Section 8 4 1 Pl Cont Gain 3 800 0 2 PI Cont Time 0 1 320s 3 Reference Step 1 0 100 0 4 Reference Step 2 0 100 0 5 Reference Step 3 0 100 0 6 Sleep Delay 0 3600s 7 Sleep Level 120 500 Hz 8 Wake Up Level 0 100 0 9 Start Freq 1 120 500 Hz 10 Start Freq 2 120 500 Hz 11Start Freq 3 120 500 Hz 12 Low Freq 1 120 500 Hz 13 Low Freq 2 120 500 Hz 14 Low Freq 3 120 500 Hz 15 Aux Mot Start DLY 0 3600s 16 Aux Mot Stop DLY 0 3600s 17 NBR of Aux Motors 0 3 18 Autochange Interv Omin 168h PI Controller Gain selection Pl Controller Lime selection Reference step when the first aux motor is started in of actual value Reference step when the second aux motor is started in of actual value Reference step when the third aux motor is started in of actual value Delay time for switch off with sleep function Frequency value to stop SAMI GS with sleep function Actual value for restarting when sleep function is active in of scaled actual value Output frequency at which the first aux motor will start The start frequency has a fixed 1 Hz hyster esis Output frequency at which the second aux mot
24. Bypass selection of the Pl Controller If bypassed the actual value acts as a direct speed reference for the regulated motor Automatic start and stop of constant speed motors also refers to the actual value signal instead of the output of the Pl Controller See Frequency f ACT 1 max Level of a tank Hna RUN Regulated pump RUN STOP 1 Aux pump Figure 9 20 Example of flow control of pre cipitation tanks using Pl Controller bypass function 64 SAMI GS Figure below 30 Display Unit Unitof ACT 1 and ACT 2 shown on the display Units bar m s C C kPa 9 3 Main 30 Protection 9 3 1Group 31 Supervision These values can be altered with the SAMI GS running Range Unit Parameter 1 Output Freq1 Func 2 Output Freq1 Lim 3 Output Freq2 Func 4 Output Freq2 Lim 5 Current Func No Lowlimit Highlimit 0 120 500 Hz No Lowlimit Highlimit 0 120 500 Hz No Lowlimit Highlimit 0 2 A No Lowlimit Highlimit 0 120 500 Hz No Lowlimit Highlimit 0 100 On Off 6 Current Lim 7 Ref1 Func 8 Ref1 Lim 9 Ref2 Func 10 Ref2 Lim 11Supervis Messages l min m3 min 31 Displ Unit Scale Scaling factor for display unit 32 NBR of Decimals Number of decimal digits of the displayed actual values Description Output Frequency 1 supervision Output Frequency 1 supervision limit Output Frequency 2 supervision Output Frequency 2 supervision limit Motor Current
25. History but remain on display until reset by pressing I O or by external fault reset The source of external fault reset can be selected by parameter 11 9 Note Factory testing of the SAMI GS in cludes tripping function However the Fault History is always erased before shipment which means that any faults within the history have occurred after shipment 72 SAMI GS 10 4 Fault Tracing with a Fault Display The Table below shows the displayed fault text the probable reason for the fault and advice on correcting the fault The proper fault reset action is indicated below the fault message ad Reset with one signal D D Switch off input power If after following the advice given the fault persists contact the nearest SAMI service repres entative In most cases disturbances are not related to a hardware failure in the SAMI GS but are caused by unexpected environmental or load conditions The principle of all fault tracing is to identify and isolate the cause and then remove it If the fault is caused by hardware failure within the SAMI GS the fault tracing procedure should allow quick on site repair Warning message Possible reason Remedy 1 SAMI temp d 8 EEPROM wr 10 Op card 1 d SAMI GS heatsink temperature gt 65 70 C Restricted air flow caused by dust or improper installation Parameter 32 7 STALL FUNC is set to WARNING Parameter 32 3 MOT TEMP FLT FUNC is set to WARNING
26. SAMI GS 9 Drive Parameters 9 1 Main 10 Control Connections 9 1 1 Group 11 Dig Analog Input Sel These values can only be altered when the SAMI GS is stopped Parameter 1 Run Enable 2 Ext Cont Place Sel 3 Ext 11 0 Cont Sel 4 Ext 2 I O Cont Sel 5 External Ref1 Sel 6 External Ref2 Sel 7 Const Speed Sel 8 Direction 9 Fault Reset Sel 10 Acc Dec 1or2 Sel 11 Param Lock Sel Range Unit Yes DI1 DI6 Std Commu Keypad DI1 DI6 Std Commu Not Sel Digital Input s Keypad Std Commu Refer to page 38 same values as para 11 3 Keypad Analogue and Digital Inputs Std Commu Refer to page 39 Keypad Analogue and Digital Inputs Std Commu Refer to page 39 Not Sel Digital Input s Refer to page 40 Reverse Forward Request Fast Rev Not Sel DI1 DI6 On Stop Std Commu Not Sel DI1 DI6 Keypad DI1 DI6 37 Description Run enable input External control place selection input External control reference R1 start stop and direction input External control reference R2 start stop and direction input External reference 1 input External reference 2 input Constant frequency input Rotation direction lock Fault Warning Supervision reset input Acceleration Deceleration ramp selection Parameter lock input SAMI GS 1 Run Enable This parameter selects the source of the Run Enable signal MES Run Enable signal active DI1 DI6 To activate the R
27. and stops the motor in Keypad control Resets faults warnings and supervision indications Note To accelerate the rate of change of parameter value keep the ih jor y button depressed continuously 22 SAMI GS 7 3 Parameter Logic Note When the power is switched on the last parameter displayed before the unit was switched off is displayed except for Start up Data parameters SAMI OUTPUT FREQ will be displayed 1 Start up Data fe A Language B Application NN R E Pole Number PA F Motor nom Current ii a C Applic Restore D Supply Voltage d d 5 G Motor nom Power ES 16 H Cos phi of Motor k gt A 14 7 2 Operating Data TL 13 12 FH gt gt gt 1 SAMI Output Freq gt o E Parameter 2 Motor Speed Le lt gt 3 Motor Current 20 lt ES Group 30 Main 23 Parameter Lock Figure 7 2 The parameters are divided into 3 Main and 19 Groups according to their function In addition there are Operating Data parameters and Start Up Data parameters Start up Data are application and motor specific which must be entered during commission ing The Operating Data display monitors values from the drive Control place and parameter lock selection is made in this mode A com
28. cece eeeeeeeeeeteeeeeteeeeeeneees 37 9 1 1 Group 11 Dig Analog Input Gel 37 9 1 2 Group 12 Analogue Inputs eeeeeeeeeeeee ereere rreren 41 9 1 3 Group 13 Ref Value Scaling 0 ceeeceeeeeeteereeeeeeetteeeeeeees 42 9 1 4 Group 14 Output Signals oooonoooccccnnnnnoocccccccoconcnccccconannnccnnnnnns 42 9 1 5 Group 15 Analogue Outputs cece eeeeeeeeeteeeeetteeeeees 44 9 1 6 Group 16 Out Sig Scaling oooonoooccccnnnnococccccccooonncccccccnnnncncnnnns 45 9 1 7 Group 17 Ext Communication 46 9 2 Main 20 Drives is 48 9 2 1 Group 21 Acceler Deceler ooooooooocinococnoccccoocccccconcnconnncccnnnncnnnnos 48 9 2 2 Group 22 Freq Cur mme 49 9 2 3 Group 23 Crit Frequencies oooonoocccccccocoonccccccononnnccncnonnoncncnnnns 50 9 2 4 Group 24 Const Frequencies oooooccccccocoooccccccoonnncncccnonnnnncncnnnns 51 9 2 5 Group 25 PI Controller ooooocooonnnnoocccnnonocccccnncononrn cc nccnnnnn nn 51 SAMI GS 9 2 6 Group 26 Gtartfztopn a g edt iin 55 9 2 7 Group 27 Motor Control 57 9 2 8 Group 28 PFC Control niei aiaa 60 9 3 Main 30 Protection a aruia i neea eaae aa a rrii 65 9 3 1Group 31 SUPeIViSION a Aei ak a deee aas a aeie aah 65 9 3 2 Group 32 Fault Function ooooocnoocccccccoconocccccccoonncncnononanoncncnnnos 66 9 3 3 Group 33 AutomatcHReset nn nn 70 9 3 4 Group 34 Information oooooocccnnnnnoncccccccooonncncnononnnnncccnonannnncnnnnns 70 SERVICE amp M
29. for actual 2 signal Bypass selection of the Pl Controller Selection of unit for ACT1 and ACT2 Scaling factor for display unit Number of decimal digits of the displayed actual values Max value is automatically set according to the setting of parameter 22 4 1 Pl Cont Gain 2 Pl Cont I Time See description Pl Control Section 9 2 5 3 Reference Step 1 4 Reference Step 2 5 Reference Step 3 Reference value increase after start of the first second third aux motor e g in pump applications with two or more pumps the reference value of the regulated pump can be increased with this parameter to corre spond to the increased system pressure 6 Sleep Delay If the output frequency remains below the sleep level frequency parameter 28 7 longer than the sleep delay set with this parameter the SAMI GS is stopped auto matically If the sleep delay is set to 0 s the sleep function is disabled 7 Sleep Level If the output frequency remains below the frequency set with this parameter longer than the sleep delay parameter 28 6 the SAMI GS stops automatically The PFC Function supervises actual value changes and re starts the SAMI GS when the wake up level para 28 8 is exceeded 61 SAMI GS 8 Wake Up Level Level is a percentage of the set reference range This parameter determines the level of the actual value at which the SAMI GS will restart If the reference value is set below the set wake u
30. in These parameters are displayed only if PFC Contrplitmeerqitigaaniester 28 30 26 SAMI GS 7 6 Control The SAMI GS can be controlled from two external control places or from the Control Panel Keypad Fig 7 5 on page 28 The Figure below presents the standard control signal selec CONTROL PLACE 9 How to set reference REVISE KEYPADR2 EXTERNAL 2 3 tH l KEYPAD REF 1 R HH KEYPADREF 2 23 11 3 EXTERNAL REF 1 R1 SEL 11 5 7 KEYPAD AI1 Al2 Ss P3U 4D R DI3U 4D ACC DEC REF 2 T f R2 pisu p We 216 217 P l USC af 018005 0 18008 APPLICATIONS ACC DEC TIME 1 ACC DEC RAMP EXTERNAL REF 2 Fe O Sech 212 213 SHAPE 21 1 5 Contr Gr Speed Ctrl Gr 29 0 1 1800s 0 1 1800s LINEAR KEYPAD ATA l ACC DEC TIME 2 S1 SHAPE 214 21 5 S2 SHAPE 0 1 180050 1 1800s S3 SHAPE ACCIDEC 1 OR 2 SEL H 140 O Erma ae Ge N i Sa big 0 120 500 Hz SSES MAXIMUMEREOUIENCKE a Se OTU cont 0 120 500 Hz era seas MAX FREQ RANGE Rai 224 i Jow to Set operation controls Ko 3 E H l EXT1 UO H GI X O CONTROL SEL 11 4 NOT SELDI1 DI6 DI1 2 R2 OPT COMMU selection added when an optional communication card is connected max value selected with parameter 22 4 see also group 13 page 42 Note Additional selections provided by I O Extension Card are de scribed in the Option card manual DIRECTION
31. internal braking option is used ter minal numbering X2 R and R measuring the voltage cannot be done safely The Control Interface and Optional Cards are isolated from the main circuit BUT CAN HAVE DANGEROUS VOLTAGES present at the relay contacts X50 terminals 21 29 if they are switching mains voltage Always check for high voltage at X50 terminals 21 29 and at relay contacts of Option Cards before working on the Control Interface and Optional Cards A N When the SAMI is connected to the mains the motor terminals U2 V2 and W2 and the brake terminals X2 are live even when the motor is not running DO NOT WORK ON THE FRE QUENCY CONVERTER WHEN POWER IS APPLIED SAMI GS 8 2 Sequence of Operations PREPARATION SAFETY PRECAUTIONS familiarisation with safety instructions INSTALLATION INSPECTION earthing supply and motor cables control cables availability and quality of cooling air etc START UP DATA PARAMETERS checking and completing the Start Up Data parameter values KEYPAD CONTROL TEST WITHOUT MOTOR checking the operation of SAMI without motor KEYPAD CONTROL TEST WITH MOTOR checking the operation of SAMI with motor checking external controls checking emergency stop if installed Figure 8 1 The sequence of operations during commissioning More detailed information describing the necessary functions in each block is given on pages 29 32 30 SAMI GS 8 3
32. of the RC circuit must be less than the holding current of the controlled contactor or relay SAMI GS 6 2 Connections of the Control Interface Card SNAT 7600 7640 factory settings bd Terminalx60 Eer Sech hee EF Reference voltage 10 V DC ee max 10 mA 1k2 lt R lt 10k0 Ke Reference signal O0V 10Vor0 mA 20 mA Not specified in this application 2V 10Vor4 mA 20 mA Aux voltage output 24 V DC SS max 200 mA total of term 7 amp 10 Not connected a 24 V max 200 mA tot of 7 amp 10 8 eege START STOP 8 A geil Direction Es Constant speed selection BR d Constant speed selection Not specified in this application A AA Acceleration Deceleration 1 or 2 Note Do not use external voltage supply to control the digital inputs A EE 0 20mA lt gt 0 50 Hz Cc a ae ee Motor current O 0 20mA lt gt 0 Relay output 1 B ch Output frequency Ready READY indication Relay output 2 Run i RUN indication A gt AA Fault EJ Relay output 3 230V FAULT indication AC A Function Power to remote panel see page 47 4 RS 485 serial link connections k 7 1 Select voltage or current reference with jumpers S1 and S2 on the Control Interface Card located besides the terminal X51 2 Refer to parameter 11 7 CONST SPEED SEL on pag
33. operation when the DC bus voltage returns to normal level If para 33 1 NUMBER OF TRIALS is set to 0 and this parameter is set to YES the undervoltage fault will be continu ously reset and the fault will not be updated in the Fault History In this case the fault is virtually undetectable 5 Overcurrent If you select YES the fault is reset and the SAMI GS resumes normal operation 6 Al Signal lt 2V 4mA If you select YES the SAMI GS resumes normal operation when the Analogue Input signal recovers the normal level gt 2V 4mA The parameter values can not be altered by the user 1 Cri Prog Version CRIxxy CNTxxy DD MM YY 2 MC Prog Version 3 Test Date 1 Cri Prog Version 2 MC Prog Version xx are running integers which correspond to the version y is a letter corresponding to the revision Control Interface Card program version Motor Control Card program version Test date day month year 3 Test Date Replacing the Control Interface Card will result in a new date To be sure of the date of manufacture check the name plates on the units or cards 70 SAMI GS 10 Fault Tracing amp Service 10 1 Fault Indications The SAMI GS continuously monitors itself during operation If a fault condition should arise the SAMI GS will display a description of the fault trip and wait for the operator to acknowledge the fault before resuming operation The SAMI GS will also display warnings which ind
34. reserved for this function only The number of reserved relays depends on the number of aux motors para 28 17 At least one relay will be reserved Programming of reserved relays is not possible and the parameter value for these relays is PFC CTRL These values can be altered with the SAMI GS running Parameter 1 Filter AO1 2 Minimum AC 3InvertAO1 4 Filter AO2 5 Minimum AO2 6 InvertAO2 Range Unit 0 01 10s 0 mA 4 mA No Yes 0 01 10s 0 mA 4 mA No Yes 1 Filter AO1 Filter time constant for Analogue Output 1 63 percent of the change of the Analogue Output value takes place within the time period given by this parameter If you select the minimum value 0 01 s the signal is not filtered referto Figure 9 2 2 Minimum AO1 The minimum value of the Analogue Output signal can be set to either O mA or 4 mA Description Filter time constant for AO1 Analogue Output signal 1 minimum Analogue Output signal 1 inversion Filter time constant for AO2 Analogue Output signal 2 minimum Analogue Output signal 2 inversion 3 Invert AO1 Ifyou select YES the Analogue Output 1 signal is inverted 4 Filter AO2 5 Minimum AO2 6 Invert AO2 Referto parameters 15 1 15 3 44 SAMI GS 9 1 6 Group 16 Out Sig Scaling These values can be altered with the SAMI GS running Range Unit Description 10 1000 10 1000 1 Scale AO1 2 Scale AO2 1 Scale AO1 2 Scale A
35. the SAMI is safe before proceeding with these measure ments Disconnect all the control wiring X50 can be disconnected in one piece from the Control Interface Card and remove the Card to allow access to the Motor Control Card Disconnect the choke wires from terminals X6 X7 X8 and X9 Select Diode Test function from the multimeter Ifyour multimeter does not have a Diode Test function proceed to Alternative measurement on page 84 83 SAMI GS 6 Connect the negative measuring wire to X6 7 Measure all the phase poles of terminal X1 The reading should be about 0 5 V 8 Change polarity of the multimeter wires and repeat the measurement The reading should be infinity 9 Make a measurement between X6 and X8 The reading should be about 0 8 V and infinity If the readings are different from the values given the rectifier module must be changed Alternative measurement 10 Select 1kQ range on the multimeter not Diode Test function 11 Carry out the measurements 6 9 as above The reading should be 100 Q 10 kQ and infinity accordingly Note In digital instruments the pole of the instru ment is positive when measuring resist ance In analogue instruments the pole is usually negative 12 Connect the positive measuring wire to X8 Repeat all the measurements against the negative pole 13 If the readings are different from the values given the rectifier module must be changed
36. with I O Extension card SNAT 7520 IOE 21 Error Value Inv The parameter determines whether or not the Pl Controller error signal is inverted 22 Actual 1 Input The parameter determines which of the analogue inputs is actual value 1 ACT1 Al3 and Al4 can be set if the I O extension card is in use STD COMMU control via RS 485 serial link The Parameter value can be changed only in stop status 23 Actual 2 Input The parameter determines which of the analogue inputs is actual value 2 ACT2 Al3 and Al4 can be set if the I O extension card is in use The Parameter value can be changed only in the stop status 24 Actual Value Sel The following mathematical operations can be performed with the actual signals ACT1 ACT1 without any operations ACT1 ACT2 Difference of ACT1 and ACT2 ACT1 ACT2 Sum of ACT1 and ACT2 ACT2 ACT2 Product of ACT1 and ACT2 MIN A1 A2 Min value of ACT 1 and ACT2 MAX A1 A2 Max value of ACT1 and ACT2 sqrt ACT1 Square root of ACT1 sqA1 sgA2 Sum of sq roots of ACT1 and ACT2 All operations are performed to the scaled values Square root signals can be used for example for flow control where the measured actual value is pressure 25 ACT1 Min Scale 27 ACT2 Min Scale Scaling factor to match ACT1 ACT2 to a minimum value of the reference signal 26 ACT1 Max Scale 28 ACT2 Max Scale Scaling factor to match ACT1 ACT2 to a maximum value of the reference signal 29 Regul Bypass Ctrl
37. 01 009 3 070 5 Figure 10 4 Main circuit diagram a ACS 501 009 3 070 5 X3 y NES X51 X50 X53 SS Di X3 X CRI 03X X905 X61 X56 E X54 X37 10 M M1 M2 M3 X4 X10 X11 X13 D404 X3 X9 MCR 02X X1 X2 IR IR _X6 X8 X5 x16 S i 3 4 Loa RO PE SR A E KA LA vi c2_ L PEU ya X1 1 C3 2 7 O T1 X3 1 2 A A3 V6 K ar 2 3 T1 3 AA 0 X2 R MM Ge X2 R 81 SAMI GS Measurements A With multimeter 1 Switch the multimeter to 1 KQ scale 2 Connect the positive measuring wire to the pole of the capacitor and negative wire to the pole Note In digital instruments the pole of the instrument is positive when measuring resistance In analog instruments the pole is usually negative 3 The multimeter should now read a small resistance which then rises towards infinity If the reading remains below 100 kQ the capacitor must be replaced Contact the nearest SAMI service representative Alternatively capacitor values may be measured directly with the multimeter e g FLUKE 79 B With an insulation tester A multimeter may not indicate faulty capa citors which can withstand voltages up to 300 V but not normal mains voltage levels Therefore it is recommended that capacitors be also tested with a DC insulation tester Megger or suitable DC voltage source 1 Connect the wire to the pole of the capacitor and the wire to the pole 2 Select 300 V DC range
38. 011 3 ACS501 016 020 3 ACS501 025 041 3 ACS501 050 060 3 005 009 5 mm 011 016 5 mm 020 025 5 mm 030 050 5 mm 060 070 5 mm iS ir 200 150 362 350 312 188 7 14 7 250 175 425 400 380 208 9 18 9 18 300 225 507 480 460 249 9 18 9 350 275 603 575 551 262 9 18 9 Figure 4 4 Dimensions of the SAMI GS unit Drawing presents 004 006 3 350 275 603 575 551 SAMI GS 5 Power Connections 5 1 Mains Cable SAMI GS is rated for a 380 V 400 V 415 V or 440 V 460 V 480 V 500 V 3 phase system A 4 conductor screened cable three phase with Protective Earth is recommended for the mains cabling The cables and fuses are to be dimensioned in accordance with the out put current See Table 5 1 for minimum di mensions When dimensioning cables al ways pay attention to local authority regula tions Note Remove all the compen sation capacitors from the line side so that they are not powered up at the same time as the SAMIGS occurring in variable frequency motor drive systems To avoid disturbances Install the motor cable away from other cable routes Avoid long parallel runs with other ca bles see page 20 Disturbances caused by radiation from the motor cable can be reduced by mounting chokes in the motor cable These chokes may reduce the motor voltage and the maxi The rapid voltage changes cause capaci tive
39. 04 3 006 3 005 5 009 5 Multi X3 Multi X2 Reading meter meter U2 0 4V U2 co V2 0 4V V2 oo W2 0 4V W2 oo SH U2 co U2 0 4V V2 co V2 0 4V W2 co W2 0 4V Example Connect the wire to the U2 pole of terminal X3 and the wire to the pole of terminal X2 The reading should be approx 0 4 V Refer to Figure 10 2 for measuring points Note If terminal X2 is marked R and R measure and from the DC link capacitors see Figure 10 2 Table 10 2 IGBT module measurements Gate Base Emitter and Gate Base Collector ACS 501 004 3 006 3 005 5 009 5 Multi MC Multi X2 X3 Read meter Card meter V D G1 U20 E15 G1 215 G2 WE Sl G2 1 5 a G3 W2 1 5 G3 1 5 a G4 UWA S112 G4 1 2 q G5 W2 ez G5 1 2 t G6 WE 21172 G6 1 2 Table 10 3 IGBT module measurements ACS 501 009 3 060 3 011 5 070 5 Example Connect wire to C1 and wire to E1 The reading should be Multi Tran Multi Tran Reading meter sistor meter sistor C_ E co CG E 0 35V B_ CG co B_ E oo i 201 Sil El El ee C2 Ik A ON B2 E2 Checking rectifier ACS 501 004 3 006 3 ACS 501 005 5 009 5 1 Disconnect SAMI from the mains Ensure see page 29 that
40. 36 0 15 0 28 0 31 0 34 18 5 ACS501 025 5 28 0 31 0 46 5 18 5 35 0 39 0 4 22 0 ACS501 030 5 35 0 39 0 58 0 22 0 41 0 47 0 52 30 0 ACS501 041 5 41 0 47 0 70 5 30 0 55 0 58 0 64 37 0 ACS501 050 5 55 0 58 0 87 0 37 0 63 0 65 0 72 45 0 ACS501 060 5 63 0 65 0 97 5 45 0 81 0 84 0 93 55 0 ACS501 070 5 81 0 84 0 126 55 0 101 112 123 75 0 1 Allowed for one minute every ten minutes 9 SAMI GS Mains connection Brake connection Motor connection Un Ss U out J f Measurements Gate drivers Inverter control Power supply Control Communication interface with Motor control X56 E300 X51 it Y Comm with lt Application control e PC PLCetc 2 6 2 progr progr X53 Digital Analog E Inputs Outputs X50 E E E E E E E E E E E EC CC Figure 3 1 SAMI GS block scheme 10 SAMI GS 4 Mechanical Installation SAMI GS is mounted on a wall in a vertical position using four fixing notches at the top and bottom of the unit When choosing the mounting location pay attention to the cool ing needs of the SAMI GS 4 1 Cooling SAMI GS frequency converters are provided with a cooling fan s on the bottom of the unit The ambient operating temperature for constant torque drives when the load current is and switchin
41. 7 NBR of aux motos 18 Autochang interv 19 Autochange level 20 Interlocks 21 Error value inv 22 Actual 1 input 23 Actual 2 input 24 Actual value sel 25 ACT1 min scale 26 ACT1 max scale 27 ACT2 min scale 28 ACT2 max scale 29 Regul Bypass CTRL 30 Display Unit 31 Display Unit Scale 32 NBR of Decimals 35 30 Protection 31 Supervision SAMI GS PARAMETER 1 Output Freq1 Func DEFAULT CUSTOMER SETTING 2 Output Freq1 Lim 3 Output Freq2 Func 4 Output Freq2 Lim 5 Current Func 6 Current Lim Oh A 7 Ref Func No 8 Ref1 Lim 0 Hz 9 Ref2 Func No 10 Ref2 Lim 0 11 Supervis messages Off 32 Fault Function 1 Serial Fault Func Stop 2 Al lt 2V 4mA Func No 3 Mot Temp Fit Func Warning 4 Motor Therm Time see Table 9 1 5 Motor Load Curve 150 6 External Fan No 7 Stall Func Warning 8 Stall Current 1 271 A 9 Stall Time Freq 20 s 25 Hz 10 Underload Func No 11 Underload Time 600 s 12 Underload Curve 1 33 Automatic Reset 34 Information 1 Number of Trials 2 2 Trial Time 3 Overvoltage No 4 Undervoltage 5 Overcurrent No 6 Al Signal lt 2V 4mA 1 Cri Prog Version No 2 MC Prog Version 3 Test Date 36
42. 8 9 1 Hz Stop limit 1 para 28 12 1 Hz f min 5 Start delay 28 15 Frequency increase during the start delay the stop delay Haley decrease during Aux motor 1 STOP START STOP Stop delay 28 16 Flow Increasing flow START Decreasing flow Figure 9 19 Example of pump control 18 Autochange Interv Elapsed time for automatic exchange of the connected motors The Parameter deter mines the time after which the starting order of the connected motors will be automatically altered Alternation is possible only when the actual signal goes below the limit set with parameter 28 19 In basic order relay output RO1 controls the regulated motor and relays RO2 to RO4 control the constant speed motors Setting the value 00 h 00 min disables the automatic exchange function and basic order will be used The interval time counter is only active when the SAMI GS is running 19 Autochange Level Actual value below which automatic ex change of the connected auxiliary motors will occur after the time set with parameter 28 18 has elapsed Setting the value 0 ensures automatic exchange takes place when the SAMI GS is stopped normal or sleep After this start takes place only when giving a new start command The autochange level is related to the set max frequency and to the capacity of the system If the value of the parameter is set to 45 and the system has only two motors the a
43. AGE Select the preferred language Press be to confirm the selection and move to the next parameter B APPLICATIONS Refer to the Application Macro Manual for complete information concerning the Ap plication Macros Select the Application Macro which best corresponds to your appli cation The parameter settings in each Macro can be set separately to adapt to your application Press gt to move to the next parameter C APPLIC RESTORE This parameter allows you to retrieve the factory settings of the selected Application Macro Press gt to move to the next parameter j D SUPPLY VOLTAGE U E POLE NUMBER F MOTOR NOM CURRENT h G MOTOR NOM POWER P H COS PHI OF MOTOR Set the correct values corresponding to the supply network and the driven motor Press gt to move to the next parameter When you have scrolled through all the parameters A H and pressed EA after setting the parameter H COS PHI OF MO TOR the display shows again Operating Data parameter 1 SAMI OUTPUT FREQ Note If the nominal current of the motor is different from the nominal current of the SAMI GS set parameter 27 3 MOTOR POWER accordingly refer to page 57 SAMI GS 8 5 Checking Selected Application Macro Parameters Selected macro parameters have default settings which suit most purposes The pa rameters which are not included in the Appli cation Macro retain the factory settings Ifitis necessary to adjust the para
44. AINTENANCE 10 Fault Tracing amp Service ccccccccesseeeeeseeeeeeeeeeeeeeeeeeeenseeeneeeseeseeeeeeeeeensesseenneees 71 10 1 Faubhtlndicatons conan nn nrnconnnnn nn r rr rrnnnnn nn 71 10 2 Fault Resetting iii AA 71 le ECH ell EE 71 10 4 Fault Tracing with a Fault Display ooooooo ccocnnnnnnnccccnnnnconcccccccnncnnnnncnnnn 73 TOLD SERVICE Murciana rte 80 106 Spare Pants eenig nent adeno di andi ened Eech 86 11 Technical Data carain ieee pido ei iii 88 IZ Options ii 90 13 Glossally is 91 MA NOX A A 92 SAMI GS 1 How To Use This Manual The information given in this manual is valid only for SAMI GS frequency converters This manual gives instructions for the proper and safe installation start up operation fault tracing and service of SAMI GS frequency converters We recommend you read this User s Manual carefully before starting any installation and connections or operating your SAMI GS SAMI GS user documentation also includes an Application Macros Manual Quick Reference Guide and Control Panel Opera tion Instruction sticker which are included in the delivery The sticker is to be placed on the front cover below the keypad For quick and easy use of this manual please refer to the table of contents on pages 3 5 or index on pages 92 93 ABB Industry Oy VSD Products P O Box 184 FIN 00381 Helsinki FINLAND Telephone 358 0 5641 Telefax 358 0 564 2681 Telex 57 12440502 strfi Short explanati
45. I Automatic start current boost which may be will start necessary in drives with high starting torque RAMP Allows using start current higher than the limit set with para 22 3 Automatic torque boost is Ramp acceleration as set in Group 21 active only from 0 Hz to 20 Hz or until the ref erence speed is reached Torque boost is FLYING not activated if the output frequency falls be Use this setting to start the motor if it is low 20 Hz while running already rotating such as in a fan drive The See also IR COMPENSATION in Group 27 drive will start smoothly at the present fre quency instead of starting at O Hz Selecting FLYING ensures the drive will ride through short interruptions of the mains supply Note Flying start searches for the running FLYING TQB speed by applying a small torque to the load at the MAXIMUM FREQUENCY and Both Flying Start and Torque Boost decreasing the output frequency until the functions are active load speed is found If the motor is not 2 Torque Boost Cur coupled to a load or the load has low inertia the shaft speed will follow this search The current level used in Torque boost is set program Flying start doesn t work properly if by this parameter Keep the boost current as several motors are connected to the low as possible for the application SAMIGS 55 SAMI GS 3 Stop Function This parameter determines how the SAMI will stop the drive COAST The fr
46. Installation Inspection Inspect the mechanical and electrical instal lation ofthe SAMI for compliance with the prevailing electrical installation regulations and the installation instructions contained in Sections 4 6 Note Ensure the motor cable is discon nected before proceeding with the Keypad control test without motor see page 32 Ensure the following is inspected protective earthing of the SAMI and the motor supply and motor cables cable cross section fuse protection connections cable screen earthing see Table 5 1 5 2 and Figure 5 2 5 3 on pages 16 and 18 control cables connections cable screen earthing location as far as possible from the power cables for analogue input signal selection see Figure 6 1 quantity and quality of cooling air for the SAMI see section 4 1 check that the on off switches of all external controls if existing are set to off Make sure that starting of the motor is allowed connect the SAMI to the mains Check by measurement that the voltage between U1 V1 U1 W1 and V1 W1 is U 10 8 4 Start Up Data Parameters Power up the SAMI The display shows Operating Data parameter 1 SAMI OUTPUT FREQ at the first power up Before proceed ing with the commissioning check and complete the Start Up Data parameter values While viewing para 1 SAMI OUTPUT FREQ firstpress and hold then press The display shows parameter 31 A LANGUAGE in Setting mode A LANGU
47. No braking chopper 1 Braking chopper Figure 2 1 Type designation code Note Do not destroy the packing The template printed on the protective cardboard can be used for marking the fixing points of the SAMI GS on the wall If the device is stored before commissioning check that the environmental conditions in the storage room are acceptable temperat ure 40 C to 70 C relative humidity lt 95 no condensation allowed The guarantee covers defects in manufacture The manufacturer carries no responsibility for damage occurred during transport or unpacking Under no circumstances shall the manufacturer be liable for damages and failures due to misuse abuse improper installation or abnormal conditions of temperature dust or corrosives or failures due to operation above rated capacities Nor shall the manufacturer be liable for consequential and incidental damages The period of manufacturer s guarantee is 12 months from commissioning and not more than 24 months from the date of delivery Local ABB companies or distributors may have a different guarantee period which is specified in their sales terms and conditions and guarantee terms If any queries arise concerning the SAMI GS please contact your Distributor or ABB local office SAMI GS 3 General Information About SAMI GS The DC Intermediate Circuit filters the pulsating DC voltage supplied by the Rectifier Stage Thanks to the diode bridge the po
48. O2 This parameter is the scaling factor for the Analogue Output 1 2 signal If you select 100 the nominal value of the output signal corresponds to 20 mA The nominal values for output signal Y are as follows Frequency 50Hz Speed motor speed at 50 Hz accord ing to motor pole number Current nominal current of motor Power nominal power of motor P Torque nom power of motor P speed motor data given in Start Up Data DC Voltage DC voltage is 1 35 nominal supply voltage U Start up Data par D Mot Volt Ux Start up Data para D Note If the output voltage is set higher than U para 27 2 gt 1 the scaling factor should be lt 100 to reach max voltage with 20 mA With PFC macro the nominal values are Reference value actual value 1 actual value 2 Pl Controller output 100 of scaled values Error value 100 20 mA 100 OmA 4 mA This means that 0 correspond to 10mA 12 mA If the desired value should be 20 mA the scaling factor is calculated as follows X 100 Y Z EEE Output signal 1 scaling factor Analogue Output signal 2 scaling factor 45 If the desired value should be lt 20 mA the scaling factor is calculated as follows a Minimum output is 0 mA X 100 1 Y 20 mA Z b Minimum output is 4 mA X 100 Us 4 mA Y 16 mA Z X scaling value 1 desired output current 0 4 20 mA AO Y the nominal value
49. ROM Electrically Erasable Programmable Read Only Memory Memory that can be changed with an electrical signal but retains the data when power is removed The parameters and the control programs are stored in the EEPROM Field weakening point Refer to page 58 IR compensation Refer to page 58 Joystick control Refer to page 39 Living zero Setting the minimum value of the Analogue Input to 4 mA 2 V provides the operator with a living zero function The existence of a control signal can then be supervised by setting the parameter 32 2 Al lt 2V 4mA FUNC to WARNING or FAULT which causes a warning fault indication ifinputis less than 4 mA 2 V Memory Place where data and instructions are stored for use by the program Parameter A memory address that is used to store data for use by the program The complete table of parameters is presented on pages 33 36 Slip compensation Refer to page 59 91 AA EDER ei CU ABBIndustry Oy VSDProducts P O Box 184 FIN 00381 Helsinki FINLAND Telephone 358 0 5641 Telefax 358 0 564 2681 Telex 57 12440502 strfi 1995 08 07 EN60019134C
50. Range Unit Description 1 Const Frequency 1 120 500 Hz 2 Const Frequency 2 120 500 Hz 3 Const Frequency 3 120 500 Hz Override frequency 1 4 Const Frequency 4 120 500 Hz Override frequency 4 Override frequency 2 Override frequency 3 5 Const Frequency 5 120 500 Hz 6 Const Frequency 6 120 500 Hz 7 Const Frequency 7 120 500 Hz Override frequency 5 Override frequency 6 Override frequency 7 Jog Par 32 1 Max value is set automatically according to the setting of parameter 22 4 Constant Frequencies override any other Note CONST FREQUENCY 7 is a jog reference when in External Control mode frequency which may be activated in case of Constant Frequencies are activated with serial communication fault Refer to Digital Input s according to parameter 11 7 parameter 32 1 CONST SPEED SEL 9 2 5 Group 25 Pl Controller These values can be altered with the SAMI GS running except those marked with O The parameters of this group will be available only when parameter B APPLICATIONS of the START UP DATA group has been set to PI CONTROL see chapter 8 4 Parameter Range Unit Description 1 Pl Cont Gain 3 800 PI Controller Gain selection 2 Pl Contl Time 0 02 320 00s Pl Controller time selection 3 PI Cont Min Lim 0 120 500 Hz Pl Controller output freq minimum limit 4 Pl Cont Max Lim 0 120 500 Hz Pl Controller output freq maximum limit 5 Error Valu
51. SAMI GS Frequency converters ACS 501 2 2to 75kW User s Manual EN 60019134 Frequency ConvertersACS 501 2 210 75kW User s Manual Code EN60019134C GSVBC UML1A1 EN 1995 08 07 EP v markdocu acs500 usermanu 501 en SAMI GS Safety Instructions ONLY A COMPETENT ELECTRICIAN SHOULD ZN CARRY OUT THE ELECTRICAL A N INSTALLATION SAMI GS must always be earthed through an earthing conductor connected to the earthing terminal If SAMI GS is connected to a system without system earth the earth fault protection must be capable of starting at earth fault currents containing high frequency and DC compon ents SAMI GS earth fault protection guards the frequency converter only against earth faults occuring in the motor or the motor cable Fault current circuit breakers do not neces sarily operate properly with frequency convert ers Circuit breaker function should be checked for possible earth fault currents arising in a fault situation Warning symbols For your own safety please pay special attention to instructions containing these symbols Dangerous voltage NA Generalwarning WARNINGS SAMI GS contains dangerous voltages when connected to the mains Note that the Motor Control Card of the SAMI GS is at mains supply voltage potential The Motor Control Card s capacitors contain dangerous DC voltage levels After discon necting the supply wait at least 5 minutes after the display readout on the contr
52. a 12 2 Al1 MINIMUM to 2V 4mA and para 32 2 Al lt 2V 4mA FUNC to FAULT and the drive stops in case of lost control signal Ext Ref1 M Seale E EN Maximum Freq Minimum Freq Ext Ref1 Min Scale Ext Ref1 mil Scale F Minimum Freq O Y Maximum Freq Ext Ref1 Max Scale 2 V 4mA Output freq Ref1 Figure 9 1 Joystick control DI3U 4D R DI3U 4D DISU 6D Motor potentiometer controlled with two Dig ital Inputs U Speed up 24 V DC D Speed down 24 V DC If DI3U 4D R is se lected the frequency reference is reset to the set minimum frequency when SAMI GS is in STOP status or the SAMI s power is switched off Acceleration and deceleration ramps are determined by parameters 21 4 and 21 5 STD COMMU External reference 1 via RS 485 serial link 6 External Ref2 Sel This parameter selects the signal source of External Reference 2 KEYPAD Reference is given from the Keypad Operat ing Data parameter 14 Al1 AI2 0 V DC corresponds to the set MINIMUM FREQUENCY and 10 V DC to the set MAX IMUM FREQUENCY DI3U 4D R DI3U 4D DISU 6D Motor potentiometer controlled with two Digital Inputs U Speed up 24 V DC D Speed down 24 V DC If DI3U 4D R is selected the frequency reference is reset to the set minimum frequency when SAMI is in STOP st
53. able control places for SAMI GS are a Keypad see Section 7 page 22 b The X50 screw terminal on the Control Interface Card SNAT 7600 7640 in the Control Unit c The RS 485 serial communication bus terminals X51 on Control Interface Card External control devices for example a PLC or a remote control panel SACE 11 PAN are connected to the screw terminal X50 according to the connection diagram of each Application Macro The connection 19 diagrams for Application Macros are pre sented in the Application Macro Manual The X50 connection diagram based on factory settings is presented in Section 6 2 on page 21 The terminal functions can be altered by means of parameter settings refer to Section 9 Some basic functions are selected by setting the jumpers on the Control Interface Card Refer to Figure 6 1 The Control Interface Card is accessible after removing the front cover of the SAMI GS SAMI GS 6 1 Control Cables Control cables for the SAMI GS should be 0 5 1 0 mm screened multi core cables The cable screens should be earthed at the PE of the frequency converter chassis When planning the cabling between the SAMI GS and an automation device such as a PLC attention should be given to interfer ence suppression signal levels galvanic isolation etc These cables should be separated from the mains and motor cables and not running in parallel with them mini mum separation 300 mm if parallel
54. al communication port a signal converter RS 232C RS 485 is needed MI GS and the PC 47 SAMI GS 9 2 Main 20 Drive 9 2 1 Group 21 Acceler Deceler These values can be altered with the SAMI GS running Parameter Range Unit 1 Acc Dec Ramp Shape 2 Acceler Time 1 0 1 1800s 3 Deceler Time 1 0 1 1800s 4 Acceler Time 2 0 1 1800s 5 Deceler Time 2 0 1 1800s 6 Acceler Ref2 Time 0 1 1800s 7 Deceler Ref2 Time 0 1 1800s Ee Hz 50 T T a 1 1 25 2t s Figure 9 5 Acceleration deceleration ramp shapes Linear S1 S2 and S3 1 Acc Dec Ramp Shape This parameter allows you to select the shape of the acceleration deceleration ramp The available options are refer to Figure 9 5 LINEAR Suitable for drives requiring steady accel eration deceleration and or slow ramps Linear S1 S3 Shape Description Accel Decel ramp shape selection Time for fa f acceleration ramp 1 Time for fa fun deceleration ramp 1 Time for fn LL acceleration ramp 2 Time for fax fin deceleration ramp 2 Ref2 acceleration ramp time for 0 100 Ref2 deceleration ramp time for 100 0 S1 SHAPE Suitable for ramp times less than one sec ond S2 SHAPE Suitable for ramp times less than 1 5 seconds S3 SHAPE Suitable for ramp times up to 15 seconds 2 Acceler Time 1 3 Deceler Time 1 4 Acceler Time 2 5 Deceler Time 2 These t
55. atus or the SAMI s power is switched off Acceleration and deceleration ramps are determined by parameters 21 4 and 21 5 STD COMMU Jo Min Mid Max 10V 20mA External reference via RS 485 serial link SAMI GS 7 Const Speed Sel 8 Direction This parameter defines which Digital Inputs This parameter allows rotation direction to are used to select Constant Speeds be fixed NOT SEL FORWARD No Digital Input selected Direction is fixed to Forward DI DI2 DI3 DI4 DIS DI6 REVERSE Constant speed number 1 DI1 Constant Direction is fixed to Reverse speed 1 etc connected to Digital Input 1 24 V DC Constant Speed activated SSES Di 3 The rotation direction is selected by Digital Inputs as defined in parameters 11 3 and Three Constant Speeds 1 3 are selected 11 4 or by keypad pushbutton ith two Digital Inputs with two Digital Inputs FAST REV DI DI2 o o No Gonetant bead This function works like REQUEST How 1 0 e Ga ES A ever when parameter 26 3 STOP FUNC 04 GE Des 2 TION is set to COAST the modulator starts A redioni i 1 4 Constant Speed 3 to operate in a reverse direction immedi ately after Reverse is requested This DI3 4 procedure results in fast reversing Note Fast reverse function does not oper DI5 6 ate if the selected start function parame
56. ber 0 2 Bit rate select 9600 bit s 3 Time out select 100 0 s 4 Comms fault funct None 5 Bad message counter number 6 Good mess counter 1 400 V in 400V units 500 V in 500 V units 33 number 21 Acceler Deceler SAMI GS PARAMETER 1 Acc Dec Ramp Shape DEFAULT Linear CUSTOMER SETTING 2 Acceler Time 1 3s 3 Deceler Time 1 3s 4 Acceler Time 2 60 s 5 Deceler Time 2 60s 6 Acceler Ref2 Time 60s 7 Deceler Ref2 Time 60s 22 Freq Cur Limits 1 Minimum Frequency 0 Hz 2 Maximum Frequency 50 Hz 3 Output Current 1 5 A 4 Maximum Freq range 120 Hz 23 CritFrequencies 1 Crit Freq Select Off 2 Crit Freq1 Low 0 Hz 3 Crit Freq1 High 0 Hz 4 Crit Freq2 Low 0 Hz 5 Crit Freq2 High 0 Hz 6 Crit Freq3 Low 0 Hz 7 Crit Freq3 High 0 Hz 8 Crit Freq4 Low 0 Hz 9 Crit Freq4 High 0 Hz 10 Crit Freq5 Low 0 Hz 11 Crit Freq5 High 0 Hz 24 Const Frequencies 1 Const Frequency 1 5 Hz 2 Const Frequency 2 10 Hz 3 Const Frequency 3 15 Hz 4 Const Frequency 4 20 Hz 5 Const Frequency 5 25 Hz 6 Const Frequency 6 7 Const Frequency 7 40 Hz 50 Hz 25 Pl Controller Parameters available only if PI Control macro has been selected 1 PI Cont Gain 100 2 P
57. bit rate Check parameter 17 3 Remove reasons for disturb ances Check the cabling between Control Interface and Motor Control Card Ifthe fault persists contact the nearest SAMI service repres entative Remove power wait one minute then restore power If the problem persists call the nearest SAMI GS service representative Record the specific fault code you may be asked for it Remove power wait one minute then restore power If the problem persists call the nearest SAMI GS service representative Record the specific fault code you may be asked for it Reset fault display the display is reset allowing parameters to be scrolled but the fault is not reset Check all parameter settings or reset the factory settings Remove power wait 1 minute then restore power to check that the fault has disappeared Fault message SAMI GS Possible reason Remedy 23 Underv2 24 Earth fl D DC voltage does not rise over 85 of its nominal value 1 35 U within 5 sec of connecting the mains In RUN status DC voltage remains below 65 and Fault 10 Undervoltage 1 occurs If auto matic reset is enabled with para 33 4 Fault 23 Undervoltage 2 is indicated if recharging to 85 of DC voltage is not possible in 3 min Earth fault in the motor motor cable or motor output terminal of the SAMI GS Due to capacitive leakage current the fault might also appear in multimotor ap
58. current through the motor cable stray ca 5 2 Motor Cable A 4 conductor screened cable is recom mended due to the rapid voltage changes pacitances This current rises as the switch ing frequency and cable length increase This phenomenon can cause substantially higher current measured by the SAMI GS than the actual motor current and can cause overcurrent tripping This means that when Table 5 1 Mains amp motor cables and fuse recommendations according to output current l Iyso Type E Fuse Cu cable aer Fuse Cu cable Max Cable Cu or Al ACS 501 A A mm A A mm mm 004 3 005 5 6 2 10 3 1 54 1 5 7 5 10 3 1 5 1 5 3 2 5 2 5 005 3 006 5 7 5 10 3 1 5 1 5 10 0 10 3 1 5 1 5 3 2 5 2 5 006 3 009 5 10 0 10 3 1 5 1 5 13 2 16 3 2 5 2 5 3 2 5 2 5 009 3 011 5 13 2 16 3 2 5 2 5 18 0 25 3 6 0 6 0 3 6 0 6 0 011 3 016 5 18 0 25 3 6 0 6 0 24 0 26 0 25 3 6 0 6 0 3 6 0 6 0 016 3 020 5 24 0 25 3 6 0 6 0 31 0 35 3 10 10 3 10 10 020 3 025 5 31 0 35 3 10 10 39 0 50 3 16 16 3 16 16 025 3 030 5 39 0 50 3 16 16 47 0 50 3 16 16 3 35 16 030 3 041 5 47 0 50 3 16 16 62 0 58 0 63 3 25 16 3 35 16 041 3 050 5 62 0 58 0 63 3 25 16 76 0 65 0 80 3 35 16 3 35 16 050 3 060 5 76 0 65 0 80 3 35 16 89 0 84 0 100 3 50 25 3 70 35 060 3 070 5 89 0 84 0 100 3 50 25 112 125 3 70 35 3 70 35 Table 5 2 Maximum recomm length ofthe motor cable in accord with switching frequency
59. d 24 V DC Reverse DI1P 2P 3P Start and Reverse commands are given simultaneously with two separate pulses Stop command is given separately Start Forward is connected to DI1 and is activated with 24 V DC pulse if Stop DI3 is con nected to 24 V DC Start Reverse is con nected to DI2 and is activated as Start Forward Stop is connected to DI3 During normal operation DI3 is connected to 24 V DC IF DI3 is disconnected with a pulse SAMI GS stops DI6 DI6 0 V DC Stop and DI6 24 V DC Start Rotation direction is fixed to Forward DI6 5 Start Stop is connected to DI6 as previ ously and Reverse to the DI5 DIS 0 V DC Forward 38 SAMI GS KEYPAD Start Stop is given from the Keypad STD COMMU Start Stop from RS 485 serial link 5 External Ref1 Sel This parameter selects the signal source of External Reference 1 KEYPAD Reference is given from the Keypad Operat ing Data parameter 13 Al1 Al2 0 V DC corresponds to the set EXT REF1 MIN SCALE and 10 V DC to the set EXT REF1MAXSCALE Al1 JOYST Joystick control 0 VDC EXT REF1 MAX SCALE para 13 2 Reverse 5 VDC EXT REF 1 MIN SCALE para 13 1 10 VDC EXT REF1 MAX SCALE para 13 2 Forward Warning Use only 2 10 V 4 20 A mA signal for joystick If a 0 10 V signal is used the drive will run at fia to Reverse if the control signal is lost Set par
60. e 40 21 SAMI GS 7 Control and Parameter Logic 7 1 Control Panel Main name Rotation direction The control panel situated on top of the gt forward Control Interface Card incorporates a 2 by lt reverse 20 character alphanumeric LCD and a keypad DRIVE The operational information parameters as well as fault indications are displayed in nine languages English Finnish Swedish Ger man Dutch French Danish Spanish and Italian The language selection is made in i Start Up Data Group parameter A LAN Main number Control place Run status GUAGE refer to page 31 Keypad l Run External O Stop 20 MAIN Factory setting is English 7 2 Control Panel Operation Panel keys Selects the Setting mode and saves s the selected parameter value Parameter number Active reference p and name R1 Ref 1 R2 Ref 2 Selects Operating Data as well as Main Group and Parameter levels In Setting mode returns to the Display 2 ACCELER TI mode without changing the Param 30 s R1 gt eter value In Display mode selects the next previous Main Group or Parameter In Setting mode increases de creases parameter value maj E Parameter value Mode indication Setting mode Display mode g He Changes the rotation direction in Keypad control refer to parameter Figure 7 1 Control panel displays Note that 11 8 on page 40 all the indications may not be visible at the same time Starts
61. e Inv No Yes Pl Controller error value inversion 6 Actual Value Sel O Act1 Act1 Act2 PI Controller Actual signal selection Act1 Act2 Act1 Act2 7 Actual 1 Input O No AI1 Al2 Std Commu Actual 1 signal input selection 8 Actual 2 Input O No AI1 Al2 Actual 2 signal input selection 9 Actual 1 Min Scale 1600 0 1600 0 Minimum scaling factor for act 1 signal 10 Actual 1 Max Scale 1600 0 1600 0 Maximum scaling factor for act 1 signal 11 Actual 2 Min Scale 1600 0 1600 0 Minimum scaling factor for act 2 signal 12 Actual 2 Max Scale 1600 0 1600 0 Maximum scaling factor for act 2 signal Max value is set automatically according to the setting of parameter 22 4 51 SAMI GS 1 Pl Cont Gain This parameter defines the gain of the PI Controller included in the Application Macros ofthe SAMI GS Setting range is 3 800 If you select 100 a 10 change in error value causes the controller output to change by 1 5 Hz Ifthe parameter value is setto 3 0 the Pl Controller operates as an I Controller 2 Pl Cont I Time If the parameter value is set to 320 00 s the Pl Controller operates as a P Controller How to start up the Pl Controller To start the Pl controller it is useful to measure the motor frequency and reference it to the Pl controller Ref 2 This can be done by setting the parameter 14 1 and 14 2 accordingly First the PI CONT I TIME is set to 320 s to op erate with a P Controlle
62. e of the heatsink 25 SAMI GS Operating Data continued Parameter Range Unit Description 10 Keypad Ref 1 Hz Control place selection R1 Reference 1 11Keypad Ref2 12 Ext Ref 1 or 2 Ref1 Ref2 R2 Reference 2 1 3ExtemalRef1 Hz Frequency reference from control panel 44ExtemalRef2 Controller reference from control panel 15 Appl Block Output Hz 16 Actual Value 1 17 Actual Value 2 18 Op Hour Counter h 19 kWh Counter 20 Last Recd Fault 21 Second Recd Fault 22 First Recd Fault 23 Parameter Lock Open xxx Locked xxx External control place selection External controller reference Controtter output signal Feedback signal for the Pl controller Feedback signal for the Pl controller Operation hour counter kWh counter The latest fault indication refer to p 71 The previou The oldest fault indication 24 Aux Motrs running number 25 Controller Output Parameter software lock xxx code 358 Number of running constant speed 26 Controller deviation mains connected motors Output value of PI regulator Values in of regulation range 27 Act value 1 PFC Deviation of PI regulator in of regula tion range including sign if ACT gt REF 28 Act value 2 PFC if ACT lt REF units set with parameter 28 30 These parameters are only displayed if the PI or PFC Control macro is selected Unscaled actual feedback signal no 2
63. e output current has exceeded 265 Ip This can be caused by a short circuit or earth fault in the motor motor cable or in the SAMI GS Too short an accelera tion time may also cause an overcurrenttrip DC bus voltage has exceeded 135 nominal voltage nom Volt 1 35 U1 nas U1 415 500 V Most common cause is over voltage static or transient in the mains supply Overvoltage can result also when the motor runs as a generator in drives where the load inertia is extremely high and the deceleration time is set low DC bus voltage has gone below 65 of U Start Up Data para D Most common reason for low voltage trip is failure in the mains supply loss of phase or brown out condition Analogue input less than 2V 4mA and minimum has been set to 2V 4mA The frequency converter software does not receive the optional board SNAT 7610 BAC identifica tion code card not connected or failed The drive stops according to the setting of parameter 26 3 STOP FUNCTION 15 Overcurr1 265 exceeded Overcurr2 3 Gate drive fault Overcurr4 Interference fault Refer to flowchart on page 79 Check the mains supply for static or transient overvoltages e g are there generating loads or large power factor correction capacitors upstream Use longer deceleration time or Use coasting stop function if it is compatible with the application If short decel time is needed use Dynamic Braking Device
64. eld weakening point The parameter differs from the TORQ BOOST option of the START FUNCTION in that it is always valid in the above mentioned speed range NO No compensation wanted MANUAL The compensation voltage and range are given by the user parameters 7 and 8 in this Group AUTOMATIC The IR Compensation voltage is automat ically controlled as a function of effective motor current This setting is suitable when the need for IR Compensation changes and manual control of the Compensation voltage is difficult Note If AUTOMATIC is selected then LINEAR should be selected in para 27 4 U F RATIO 58 SAMI GS U Vid Constantflux Field weak area d were _ al S b CG f Hz Figure 9 16 IR COMPENSATION is imple mented by applying extra voltage to the motor a IR COMP VOLTAGE b IR COMP RANGE c FIELD WEAKENING POINT d SAMI MAX OUT VOLT Speed 4 rpm Compensated speed 1000 9907 980 9707 Uncompensated speed 960 gt Load Figure 9 17 Slip compensation reduces Slip under load Example 6 pole motor 7 IR Comp Voltage The compensation voltage level in MANUAL IR COMPENSATION Keep the boost voltage as low as possible for the applica tion as the motor will overheat rapidly or an overcurrent fault may occur when a high level of compensation is applied Small motors can take higher compensation than larger mo
65. equency converter ceases to supply voltage and the motor coasts to a stop RAMP Note If the drive is stopped by the RUN ENABLE signal the Ramp deceleration as set in Group 21 SAMI GS will stop by coasting regardless of the STOP FUNC TION setting DC BRAKE DC injection braking stops the motor by applying DC voltage to the stator windings By using DC braking the motor can be stopped in the shortest possible time without the use of a dynamic braking device 4 Braking Chopper If a dynamic braking device is used the braking torque can be increased by setting this parameter to YES Genen DC Hold o oa t 1 5 Hz gt Figure 9 12 DC Holding 5 DC Holding If this parameter is set to YES the DC HOLDING feature is enabled When both reference and output frequencies drop below 1 5 Hz the frequency converter will stop generating rotating waveforms and inject a DC voltage to the motor The voltage value is set with the DC HOLD VOLTAGE When the reference frequency goes above 1 5 Hz the DC voltage will be removed and the frequency converter resumes normal operation DC Holding has no effect when the START signal is deactivated Note Injecting DC voltage into the motor may cause motor overheating In applica tions where long DC Holding times are required ensure the DC HOLD VOLTAGE is set at a low value avoiding motor over heating due to high motor current During
66. er signal chan nels The Communication board interface enables connection of an ABB high speed serial com munication board with an ISBX connector For further information please refer to the Installation and Operation Guide EN 58057835 Profibus Interface Card SNAT 7700 PRI SNAT 7700 is a serial communication board that enables a PLC or PC to control an ACS 500 series frequency converter through Profibus compatible communication channel For further information please refer to the Installation and Operation Guide EN 61096710 Dynamic braking device Effective motor braking and thus short decel eration times are achieved by using an internal braking chopper with an external resistor RFI filter An RFI Radio Frequency Interference filter should be used when extremely sensitive equipment is in the vicinity of the SAMI GS 90 SAMI GS 13 Glossary Brake control Ifthe deceleration time Group 21 is set very short and the motor load has high inertia the DC bus voltage will rise too high causing a fault indication during braking If the decelera tion time cannot be set longer an optional brake control device dynamic braking device must be used DC bus Intermediate DC link where the mains voltage is rectified and filtered The nominal DC bus voltage corresponds 1 35 UH Default Value provided for a parameter as a part of the program when the drive is started initially factory setting EEP
67. erence value AY1 and the actual value AX1 as a percentage Ales YA WI AER Calculation of the maximum actual value Xs and the minimum actual values as a percentage Xs of full reference scale Y0 100 YO 0 ACT1 2 MAX SCALE Ne KI 100 Y1 ACT1 2 MINSCALE Xs MI 0 Y1 ANITA AAT IA max E E E 3 gt 3 CO e o lt lt mA x 2 4 6 8 10 12 14 16 18 20 YO AN no 10 A A ie a a 10 y 4 es D e E E ae l S ei AYO g 5 e L 5 v 4 Ae 4 Y1 430 L3 Ya e 2 Yo 1 Ax1 1 Z YO _10 20 30 40 50 60 70 80 90 100 0 e o XX x lt gt X1 Figure 9 10 Basics of scaling factors 53 min 3 v Example SAMI GS The pressure of a pipe system is to be controlled between 0 and 10 bar Pressure transducer for 0 to 10 bar with output span 3 to 9 V output range 2 to 10 V Reference signal is 4 to 20 mA where 6 4 mA 0 bar and 16 mA 10 bar Reference value ACT1 2 MAX SCALE mA V mA V i e 118 75 20 10 2040 100 os 18 9 181990 i 1618 16 880 475 et 14 770 14 7 T 124660 12 6 10 550 1015 8 440 8 4 6 7330 15 el 4 220 i 2 1104 2277 4 2 g 125 87 5 Actual value ACT1 2 MIN SCALE 1 2 3 4 5 6 7 8 9 10 v 2 10 12 14 16 lis 20 mA 2 3 4 5 6 7 8 9 10 M T T T T 4 6 8 10 12 14 16 18 20 mA Figure 9 11 Scaling of ac
68. four Screws Figure 5 2 Standard Unit Figure 5 3 ACS 501 Motor Mains PE connection connection X1 v2 U1 V1 Wi PE L1 L2 L3 Mains ACS 501 Motor Brake Resistor Mains PE connection connection connection X3 u2 v2 w2 R R ui vi w1 R R PE Brake Resistor option PE L1 L2 D Unit with internal Braking Chopper A Mains WARNING The brake control terminals carry a dangerous DC voltage gt 500V Only an ABB dynamic braking device should be connected to terminal X2 Note If the motor cable has a separate screen in addition to the earth wire the screen is connected to the PE terminal at the frequency converter end and on the motor side 18 SAMI GS 6 Control Connections Figure 6 1 Control Interface Card SNAT 7640 The Analogue Input signal selection is done with jumpers S1 Al1 and S2 Al2 1 0 4 20mA V 0 2 10V X50 screw terminal X53 earthing connector X54 connection to Motor Control Card X55 and X56 option card connectors X51 for RS 485 connection Jumpers S3 and S4 are set to TERM in the last SAMI GS unit of a RS 485 chain The avail
69. g frequency f 3 kHz is 0 45 C except for ACS 501 006 3 and 009 50 40 C See fig 4 2 output current derating curves The ambient operating temperature for squared torque drives when the load current is isa and switching frequency f 3 kHz is 0 40 C except for ACS 501 006 3 and 009 50 35 C See fig 4 2 output current derating curves The cooling air must be clean and free from corrosive materials Where necessary the cooling air should be filtered If the cooling air contains dust clean the cooling surfaces of the unit regularly using compressed air and a brush Table 4 1 Required cooling air Type ACS 501 m h 004 3 006 3 005 5 009 5 51 009 3 011 3 011 5 016 5 102 016 3 020 3 020 5 025 5 406 025 3 060 3 030 5 070 5 560 If the cooling ability is reduced too much the thermal protection operates causing a fault indication and stopping the frequency con verter SAMI GS can be started again when the temperature ofthe cooling element has fallen below the tripping level 70 C The temperature of the cooling element can be read from the control panel display Oper ating Data parameter 8 SAMI TEMPERATURE for types ACS 501 050 3 060 3 060 5 and 070 5 the tripping level is 75 C 11 SAMI GS Figure 4 1 Power dissipation as a function of the switching frequency for different ACS 501 types Output power in the following curves is
70. h the insulation resist ance measurements make sure that the SAMI is disconnected from the mains 1 Check that the motor cable is discon nected from the SAMI output on terminals U V and W 2 Check that the motor cable is discon nected from the motor and remove bridg ing connections at the motor 3 Measure the insulation resistances from the motor The voltage range of the insulation resistance meter must be at least equal to the mains voltage but not exceeding 1000 V The insulation resist ance must be greater than 1 MQ 4 Measure the insulation resistance of the motor cable between the phases and between each phase and Protective Earth The insulation resistance must be greater than 1 MQ 5 4 Terminal Connections To connect the power motor and control cables remove the front cover of the unit by removing the four screws at the corners of the cover Then remove the front part of the cable entry insulator by removing the screws A at the ends of the insulator Remove the protective caps of the cable entry holes using a knife or a screwdriver In order to make the cable installation easier the cable entry insulator can be removed as one piece by unscrewing the screws B and pulling the insulator off the frame 17 SAMI GS Connect the power cables in accordance with the following drawings Attach the front part of the cable entry insulator with the screws A and attach the front cover of the unit by the
71. icate abnormal operation but do not cause the drive to stop If a fault occurs when a warning display is on the warning will be erased and the fault indication displayed Refer to the table on page 73 for warning and faultindications 10 2 Fault Resetting A fault can be reset either by pressing the Keypad Start Stop button activating the selected Digital Input parameter 11 9 via serial communication RS 485 or if neces sary switching the mains voltage off fora while If the fault has been removed the SAMI GS will resume normal operation If the fault has not been removed the SAMI GS will trip again For automatic fault reset refer to Group 33 on page 70 Note Fault resetting starts the drive if Start command is active If the fault persists it will trip the drive again resulting in a new fault indication However to allow parameters to be checked or altered after resetting a fault there is a 1 minute delay during which no new faults are dis played unless Start command becomes active During this delay the state of the fault relay output will follow the actual fault situa tion as will the fault registering into the Fault History If the autoreset function is selected these faults will also be reset Some faults require the user to cycle the power off then on before the fault can be cleared Proper fault reset action is given in the fault message Table on pages 73 77 10 3 Fault History When a fault is de
72. imes correspond to the time required for the output frequency to change from MINIMUM to MAXIMUM FREQUENCY and vice versa Regardless of the settings the maximum theoretical acceleration decelera tion is 120Hz 0 1s max slope 1200Hz s and the minimum 120 Hz 1800s min slope 0 067 Hz s The time required for the accel eration from zero to minimum frequency depends on the ACCELER TIME accelera tion fax f i acceleration time 48 SAMI GS Note The SAMI GS incorporates a bus controller that prevents overcurrent and overvoltage trips caused by too fast acceleration and deceleration for a given system by increasing the acceleration deceleration settings If a small number is entered for the acceleration time in a system with high inertia the acceleration time will be limited by the OUTPUT CURRENT parameter 22 3 Conversely if a small number is entered for deceleration time in such a system the deceleration time will be limited by the DC link bus regulator In some cases the motor will take a long time to come to a stop If a short deceleration time is critical to your application we suggest you add a dynamic braking device to your system 9 2 2 Group 22 Freq Cur Limits The maximum minimum recommended acceleration deceleration for the nominal size motoris 40 Hz in 1 second Ifthe motor rating is less than the nominal power of the SAMI GS smaller settings can be used If the reference signal changes
73. in units of se lected output signal Z the desired value in units of output signal which corresponds to Figure 9 4 Scaling value SAMI GS 9 1 7 Group 17 Ext Communication These values can be altered with the SAMI GS running Parameter Range Unit Description 1 SAMI ID Number 0 31 Identification of individual units connected to the serial link bus 2 Bit Rate Select 1200 2400 4800 9600 BIT s 0 5s 100 0s Speed of data transfer between the master and slave units The time which the SAMI GS waits for a response from a master before ending communication and giving a fault message 3 Time out Select None Fault Fault Stop 4Comms faultfunct Type of message and operation when a fault occurs in communication between the master and a slave unit 5 Bad messag counter a number Number of messages not accepted between the master and a slave unit 6 Good mess counter anumber Number of accepted messages between the 1 SAMI ID Number Each SAMI GS connected to the RS 485 bus has to be identified with an ID number 1 to 31 when remote controlled Each number can exist only once Number 0 disables remote control when physical connection has been made but remote control is not allowed 2 Bit Rate Select The bit rate can be set according to the device used to control connected units via the serial bus The bit rate may also depend on settings of the possible interface conver
74. indicate whether the nominal current of the motor is the same RATED 20 lower lt RATED 57 SAMI GS UI us 4 Constant flux range 100 t Linear U f ratio 50 Squared 10 U f ratio s 0 Field weakening point f Hz Figure 9 13 The voltage to frequency ratio in the frequency range 0 Hz to the field weaken ing point can be set to either LINEAR SQUARED or AUTOMATIC U A Constantflux Field weak area GE 50 Hz Field weakening points f Hz Figure 9 14 Field weakening point Umax A V Constantflux Field weak area 380 240 p 50 60 f Hz Figure 9 15 By adjusting the field weaken ing point and SAMI MAX OUT VOLT motors other than those of rated voltage can be used AUTOMATIC The motor voltage is automatically control led to minimise motor losses and noise This setting is suitable for a drive which has a slowly changing load torque and a motor that operates mainly below nominal load Note If SQUARED or AUTOMATIC is selected then para 27 6 IR COMPENSA TION shoud not be set to AUTOMATIC 5 Field Weak Point The Field Weakening Point is the frequency at which the output voltage reaches the max imum motor voltage para 27 2 Above this frequency the voltage remains at the set maximum value U x Also see Figure 9 15 6 IR Compensation This parameter allows extra torque at speeds between 0 1 Hz and the set fi
75. l Cont I Time 60s 3 Pl Cont Min Lim 25 Hz 4 Pl Cont Max Lim 50 Hz 5 Error Value Inv No 6 Actual Value Sel Act1 7 Actual 1 Input No 8 Actual 2 Input No 9 Actual1 Min Scale 0 10 Actual1 Max Scale 0 11 Actual2 Min Scale 0 12 Actual2 Max Scale 0 26 Start Stop 1 Start Function Ramp 2 Torque Boost Cur 3 Stop Function 1 5 1 A Coast 4 Brake Chopper No 5 DC Holding Off 6 DC Hold Voltage 0 01 U V 7 DC Brake Voltage 0 01 U V 8 DC Brake Time 34 Os MAIN 20 Drive GROUP 27 Motor Control 28 PFC Control Parameters available only if PFC control macro has been selected SAMI GS PARAMETER 1 Switching Freq DEFAULT 3 kHz CUSTOMER SETTING 2 SAMI Max Out Volt 100 U V 3 Motor Power Rated 4 U f Ratio Linear 5 Field Weak Point 50 Hz 6 IR Compensation 7 IR Comp Voltage No 0 01 U V 8 IR Comp Range 9 Slip Compensation 10 Nominal Slip 11 O U Volt Control 1 Pl cont gain 2 Pl cont I time 3 Reference step 1 4 Reference step 2 5 Reference step 3 6 Sleep delay 7 Sleep level 8 Wake up level 9 Start freq 1 10 Start freq 2 11 Start freq 3 12 Low freq 1 13 Low freq 2 14 Low freq 3 15 Aux mot start DLY 16 Aux mot stop DLY 1
76. l be 2040 2640 fixed to 70 current at 0 Hz 2220 2820 2400 3120 Note Motor thermal protection will not protectthe motorifthe A cooling efficiency of the motor is h reduced due to dust and dirt AA 7 Stall Func Stall region This parameter defines the operation NO WARNING FAULT of the Stall Protection The protection is activated if Stall current 1 the motor current exceeds the limit set in parameter 32 8 STALL CURRENT 2 the output frequency is below the level set in parameter 32 9 STALL TIME FREQ and 3 The motor current remains above and the output frequency below the set level longer than the period set in parameter 32 9 Because of the simple thermal model used for calculating temperature rise this tech nique of thermal protection may cause undesirable trips when the motor is run continuously at low frequencies If your application requires continuous running at frequencies lower than 25 Hz you may need to provide external cooling Stall frequency Figure 9 25 Stall Protection y 68 SAMI GS 10 Underload Func M A process malfunction can sometimes ap Underload Curve pear as a removal of motor load which is detected by underload protection The pro tection is activated if 1 the motor torque drops below the load curve selected in parameter 32 12 UNDERLOAD CURVE 2 the motor torque remains below the load curve longer than the period set in param eter 32 11 UNDERLOAD TIME a
77. ler frequency output The limit cannot be set greater than para 22 2 MAXIMUM FRE QUENCY 52 SAMI GS 5 Error Value Inv This parameter allows you to invert the Error Value and thus the operation of the PI Controller Error value Pl Controller output A Gain gt N o PI CONT I TIME Figure 9 9 Pl Controller 6 Actual value selection This parameter defines how the feedback for the Pl Controller is calculated Two analogue values Act1 and Act2 can be subtracted added or multiplied also Act1 can be selected on its own 7 Actual 1 Input 8 Actual 2 Input This parameter selects the input terminal for Act1 Act2 9 Act1 min Scale 10 Act1 max Scale 11 Act2 min Scale 12 Act2 max Scale Actual value signals can be scaled to correspond to the required regulation range with the minimum and maximum value scaling parameters Scaling values can be determined using the nomogram in figure 9 11 and the formulae as stated below Range of the reference value AYO and the actual value AX0 in units V mA AYO YO 0 AXO ND X0 m XS With the minimum and maximum values of the reference span Y1 Y1 and the min max actual span LAT X1 max in units V mA the values are transformed to percentages Iech YOn AYO 100 Ice Y1 YOn AYO 100 X1 an X1 X0O_ AXO 100 X1 nae X1 X0 AXO 100 Span of the ref
78. ler is active and the motor A Constant Frequency 1 7 is selected is running Uc REG LIM FAULT Voltage regulator is activated by Motor Any fault occurs See Fault History page 71 Control software fi tails or more details FREQ1 LIM FAULT 1 Output frequency has exceeded the supervi Reversed function of FAULT i e the relay is sion limit 1 parameter 31 2 normally activated and it releases on a fault See fault messages Section 10 4 FREQ2 LIM STALOEET Output frequency has exceeded the supervi sion limit 2 parameter 31 4 Stall protection has tripped CURLIM MHEAT FLT Motor current has exceeded the set current Motor overheat protection has tripped limit parameter 31 6 43 SAMI GS REF LIM Reference 1 has exceeded the set supervi sion limit parameter 31 8 REF2 LIM Reference 2 has exceeded the set supervi sion limit parameter 31 10 4 Relay RO2 Out This parameter allows you to select which information is indicated with Relay Output 2 Choices are identical as for para 14 3 RELAY RO1 OUT 9 1 5 Group 15 Analogue Outputs 5 Relay RO3 Out This parameter allows you to select which information is indicated with Relay Output 3 Choices are identical as for para 14 3 RELAY RO1 OUT Note IF PFC Control Macro has been selected the relevant relays for automatic exchange of motors will be
79. load rated current current current motor current current current motor LIA WA A PAK SA Iech A Pri KW ACS501 004 3 4 7 6 2 9 3 2 2 6 2 75 8 3 3 0 ACS501 005 3 6 2 75 11 3 3 0 8 1 10 0 11 0 4 0 ACS501 006 3 8 1 10 0 15 0 4 0 11 0 13 2 14 5 55 ACS501 009 3 11 0 13 2 19 8 5 5 15 0 18 0 19 8 75 ACS501 011 3 15 0 18 0 27 0 7 5 21 0 24 0 26 11 0 ACS501 016 3 21 0 24 0 36 0 11 0 28 0 31 0 34 15 0 ACS501 020 3 28 0 31 0 46 5 15 0 34 0 39 0 43 18 5 ACS501 025 3 34 0 39 0 58 0 18 5 41 0 47 0 52 22 0 ACS501 030 3 41 0 47 0 70 5 22 0 55 0 62 0 68 30 0 ACS501 041 3 55 0 62 0 93 0 30 0 67 0 76 0 84 37 0 ACS501 050 3 72 0 76 0 114 37 0 85 0 89 0 98 0 45 0 ACS501 060 3 85 0 89 0 134 45 0 101 112 123 55 0 Table 3 2 SAMI GS frequency converter types for 50 Hz and 60 Hz supplies Mains voltage 440 V 460 V 480 V 500 V Typedesignation SAMI s input current output current amp and motor powerP 8P y Constanttorqueapplications Squared torque applications Rated Rated Shortterm Max Rated Rated Shortterm Max input output overload rated input output overload rated current current current motor current current current motor LIA IIA A P KW hsa A Lig A A Puso KW ACS501 005 5 4 7 6 2 9 3 3 0 6 2 75 8 3 40 ACS501 006 5 6 2 75 11 3 4 0 8 1 10 0 11 0 5 5 ACS501 009 5 8 1 10 0 15 0 5 5 11 0 13 2 14 5 75 ACS501 011 5 11 0 13 2 19 8 7 5 15 0 18 0 19 8 11 0 ACS501 016 5 15 0 18 0 27 0 11 0 21 0 24 0 26 15 0 ACS501 020 5 21 0 24 0
80. long DC Hold periods the DC Hold function cannot prevent the motor shaft rotating when a constant load is applied to the motor 7 DC Brake Voltage When the stop function para 26 3 is set to DC BRAKE this parameter sets the DC voltage injected into the motor The factory setting is suitable for a nominal size motor If braking is too effective decrease this value If braking is not sufficient increase this value 8 DC Brake Time When the stop function is set to DC BRAKE this parameter sets the DC injection time in seconds If the braking time is too short the drive stops by coasting once the DC BRAKE TIME has elapsed 56 SAMI GS 9 2 7 Group 27 Motor Control These values can only be altered when the SAMI GS is stopped except those marked with I Parameter Range Unit Description 1 Switching Freq 1 0 12 0kHz Modulator frequency 2 SAMI Max Out Volt 0 15 1 05 U V Maximum motor voltage selection 3 Motor Power Rated lt Rated gt Rated motor SAMI ratio for Motor Controller 4 U f Ratio Linear Squared Voltage to frequency relationship in region Automatic below Field Weakening Point 5 Field Weak Point 30 500 Hz Threshold for nominal voltage 6 IR Compensation No Manual Automatic Low speed torque boost function 7 IR Comp Voltage 0 01 0 15 U V Voltage level in manual IR Compensation 8 IR Comp Range 0 FWP Hz Zero point in manual IR Compensation 9 Slip Compensation 1 Off On Automatic sli
81. meter values refer to the instructions in Sections 7 and 9 Use the parameter list in the Application Macro Manual or Table on pages 33 36 to record your settings Only selected macro parameters will be displayed e g Parame ter group 25 for Pl Control and group 28 for PFC Control 8 6 Keypad Control Test Without Motor 1 Ifthe motor is connected to the SAMI disconnect it after first making sure that the SAMI is disconnected from the mains 2 Connect the SAMI to the mains and switch power on 3 Set the DIRECTION par 11 8 to REQUEST 4 Select Operating Data 9 CONTROL PLACE KEYPAD R1 see Section 7 Control and Parameter Logic 5 Return to para 1 SAMI OUTPUT FREQ 6 Give a start command by pushing D The run status indicator on the display should show I 7 Use T key to change the rotation direction The rotation direction display should change accordingly 8 Change to the Setting Mode and control the reference frequency Return to Dis play mode by pressing 9 Check the Operating Data parameter values Parameter 7 SAMI OUTPUT VOLTAGE should increase with the frequency Pro grammed maximum voltage is reached at the field weakening frequency default is 50 Hz 10 If everything is operating normally turn off SAMI and disconnect it from the mains A N ter the display readout has disap peared before taking any further action within the SAMI For fault tracing information
82. more slowly than the acceleration or deceleration time the output frequency change will follow the reference signal If the reference signal changes faster than the acceleration or deceleration time the output frequency change will be limited by the parameters 6 Acceler Ref2 Time 7 Deceler Ref2 Time These times correspond to the time required for the reference to change from 0 to 100 and vice versa These values can be altered with the SAMI GS running Parameter Range Unit 0 120 500 Hz 0 120 500 Hz 0 5 2 0 A 1 Minimum Frequency 2 Maximum Frequency 3 Output Current 4 Max Freq Range 0 120 Hz 0 500 Hz Description Minimum operating frequency f n Maximum operating frequency f CR Output currentlimit Normal Extended Range for ACS 501 Max value is set automatically according to the setting of parameter 22 4 1 Minimum Frequency 2 Maximum Frequency The MINIMUM FREQUENCY represents the minimum output frequency available In a similar fashion the MAXIMUM FREQUENCY is the maximum output frequency available see para 13 1 and 13 2 3 Output Current This setting determines the max output cur rent the SAMI GS will supply to the motor If the rated current of the motor is lower than the rated current of the SAMI GS the current limit is recommended to be set in accordance with the motor rating in standard applications Note Current limitation time is not supervised
83. nd 3 the output frequency is more than 5 Hz 5 Hz f Figure 9 26 Underload Protection The protection function assumes that the drive is equipped with a nominal size motor T T 9 4 Select NO WARNING FAULT as desired Refer to Figure 9 27 for UNDERLOAD 1007 Constantflux Field weak area CURVE selection 80 4 IG 60 40 4 e 5 20 e i 0 T T T T T T T T T T T O 20 40 60 80 100 120 f Hz Figure 9 27 The five available curve types in parameter 32 12 UNDERLOAD CURVE 69 SAMI GS 9 3 3 Group 33 Automatic Reset These values can be altered with the SAMI GS running Parameter 1 Number of Trials 0 5 2 Trial Time 1 180s 3 Overvoltage No Yes No Yes No Yes No Yes Range Unit 4 Undervoltage 1 5 Overcurrent 6 Al signal lt 2 V 4 mA 1 Number of Trials 2 Trial Time The maximum number of faults per time period to keep the Automatic Fault Reset System active is given by parameters 33 1 and 33 2 If more faults occur within TRIAL TIME the drive stops The automatic fault reset system will reset the faults selected with parameters 33 3 33 6 3 Overvoltage 4 Undervoltage If you select YES the SAMI GS will resume 9 3 4 Group 34 Information Description Max number of trials for Autoreset logic Time limit for Autoreset logic Enable automatic fault reset Enable automatic fault reset Enable automatic fault reset Enable automatic fault reset
84. ng Parameter Range Unit Description 1 Filter Al1 0 01 10s Filter time constantfor Al1 2MinimumAl1 0V 0 mA or 2V 4 mA Analogue Input signal 1 minimum value 3 Invert Al1 No Yes Analogue Input signal 1 inversion 4 Filter Al2 0 01 10s Filter time constantfor Al2 5 Minimum Al2 0V 0 mA or 2V 4mA Analogue Input signal 2 minimum value 6 InvertAl2 No Yes Analogue Input signal 2 inversion 1 Filter AM 2 Minimum Al Filter time constant for Analogue Input 1 Analogue input signal can be set to a mini 63 percent of the change of the Analogue mum of either 0 VIO mora V A mA The Input value takes place within the time period latter value provides a living zero function given by this parameter If you select the see page 66 para 32 2 Al lt 2 V 4 mA minimum value 0 01 s the signal is not FUNC Refer to page 19 for selection filtered between current and voltage input 3 Invert Al1 A If you select YES the Analogue Input 1 Unfiltered signal signal is inverted minimum reference EN corresponds to maximum output frequency This can be used for example to invert the feedback signal to control a reference in liquid level control 4 Filter Al2 5 Minimum Al2 6 Invert Al2 100 63 Filtered signal EE FILTER Al1 Figure 9 2 Filter time constant Refer to parameters 12 1 12 3 41 SAMI GS 9 1 3 Group 13 Ref Value Scaling These values can be altered with the SAMI GS running
85. nt Relay Output 1 content Relay Output 2 content Relay Output 3 content OUT CUR Outputcurrent MOT TORQ Motor torque MOT POWER Motor power V DC LINK DC link voltage MOT VOLT Motor voltage 42 SAMI GS Additional selections available with the PFC SAMI HEATF Control Macro SAMI overheat protection has tripped The ERROR VAL Scaled difference of tripping level is 70 C 75 C for 050 060 3 ACT and REF values and 060 070 5 PICON OUTP Pl regulator output FAULT WARN ACTUAL 1 Unscaled actual value 1 Relay activated if any fault or warning oc ACTUAL 2 Unscaled actual value 2 eura 256 messages Geodon T0 PICON REF Reference of PI regulator WARNING Relay is activated if any warning occurs See warning messages Section 10 4 Refer to previous parameter SAMI HEATW 3 Relay RO1 Out 2 Analogue Out 2 The heatsink temperature has exceeded the This parameter allows you to select which warning level 65 C 70 C information is indicated with Relay Output 1 Relay Output 1 is activated according to the REMERSED setting if Reverse is selected NOT USED EXT CTRL No relay activity wanted External control selected READY REF2 SEL The SAMI GS is ready to function Reference 2 selected RUN CONST FREQ The motor control
86. oenee es a ani A T R a 17 5 4 Terminal CONNECtIONS eaae a a a s Ahe 17 6 Control Connections Loxa in red rita pai nnmnnn nnna 19 6 1 Control Cables eii E EA AA A TAREA 20 6 2 Connections of the Control Interface Card SNAT 7600 7640 aaaea 21 OPERATION 7 Control and Parameter LOGIC eseeccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeenseseeeeeeeeseeseeneees 22 VAE S pito E m il gt EE 22 7 2 Control Panel Operation oeseri iinternet eea e iieiea naanin oi inini 22 LIRA aMete Beie e E 23 7 4 Adjusting Display Contrast nor nnccnnnnnnn 25 4 9 OperatingDa a cmccctod lisina gd then EE EEE ET 25 ASS SA a a a a aa cede gh den ata iek 27 SAMI GS TT Eeer RE 28 TOENI CONTO EE 28 71 9 Parameter Lock neos ela 29 START UP S COMMISSIONING WE 29 8 1 Safety Pr cautions cni E EE EE AKE T 29 8 2 Sequence Of Operations se cnccrceccrercei a e i ia 30 8 3 Installation INSPECTION oooooonnnnnccccnnnnncocccocccononncccnccnonn no nccnnnnnn nn rcccnnnnnnnno 31 8 4 Start Up Data Parameters oooooooococcccccocoooncncconononnnnnccnnnnnnncnncnnnnnn nn nccnnnnnnn 31 8 5 Checking Selected Application Macro Parameters ooooooooooocoooocciiciccco 32 8 6 Keypad Control Test Without Motor oooooocccconnococccccnococoncccconannnnncncnnnnno 32 8 7 Keypad Control Test With Motor 32 8 8 Drive Parameters and Their Factory Settings Factory Macro 33 9 Drive Parameters id EE 37 9 1 Main 10 Control Connections cece ceceeceee
87. ol panel has disappeared before taking any measure ments Dangerous external control voltages may be present on the relay outputs of the Control Interface Card and Option Cards Pay attention to the following instructions Donotwork on the frequency converter when power is applied Neverconnect mains voltage to drive output terminals LU VM WX Do not make any voltage withstand tests on any part of the unit Disconnect motor cables before taking any measurements on the motor or motor cables Make sure that power factor correction capacitors are not connected between the drive and the motor Donottouch the IC circuits on the Control Interface and Motor Control Cards Static voltage may destroy the circuit ALWAYS CHECK THAT SAMI GS IS SAFE BY MEASURING THE DC LINK VOLTAGE AND MAINS INPUT VOLTAGE Refer to the figures 5 2 5 3 on page 18 SAMI GS Contents GENERAL Safety INStrUCtIONS cocidas 2 1 How To Use This Manual ccccsseseeeeeeseeneeeeeeeeeeneeeeeeseeneeeeeeeseeeeeeeeeaseseeeneeeenes 6 2 Delivery Chot kS ccoo dai 7 3 General Information About SAMI GS cseeeceeceeeeeeeeeeeeeeeneeeeeeneeseeeeeeenseeeeeeeeees 8 INSTALLATION 4 Mechanical Installation oooconnnnnnnonnnnnascccccnnnnnnncrrcnnnnn crecen 11 ATEO e EE 11 ALMA KE 14 5 Power Connections commmcccccnnnnnnccnnnnnnnnncrrr nan 16 5 Mains Cable lc de lO Perera ANI ET ee 16 52 Motor Cable iria E Nae 16 5 3 Insulation CHECKS n
88. ons of some less commonly used technical terms referred to in this manual are given in the Glossary pg 91 References to titles of the different sections of this manual are printed with a capital first letter SAMI GS parameter names and settings are printed in capital letters when mentioned in the text Parameters are also referred to by using a number which indicates the location of the parameter 32 1 means the first parameter in Group 32 of Main 30 Should there be any questions concerning SAMI GS please contact the supplier or the manufacturer The technical data and specifications are valid atthe time of printing We reserve the right to subsequent alterations SAMI GS 2 Delivery Checks Check that the device does not show any signs of damage and that the delivery is complete refer to the type designation code presented below In the event of damage please contact your insurance company or the supplier If the delivery is not in compli ance with the order please contact the supplier immediately ACS 501 004 3 00P20 AC AC drive Product type S Standard product Family 50 SAMIGS Sizes 1 004 to 070 wall mounted unit Rated power kVA Supply voltage 3 380V 400V 415V 5 440V 460V480V 500V Optional Control Card 1 O none 3 SNAT 7610 BAC Optional Control Card 2 O none 2 1 0 Extension Card Control panel P yes Enclosure class 2 P 21 5 IP 54 Braking Unit O
89. ontrol In addition R1 means Ref 1 and R2 Ref 2 Figure 7 1 Figure 7 5 Control places 7 7 Keypad Control When Keypad R1 or Keypad R2 is selected from Operating Data parameter 9 SAMI GS erate according to the commands penes given via the Keypad a START STOP button FORWARD REVERSE button Reference signal see parts Keypad Reference 1 and Keypad Reference 2 Keypad Reference 1 Operating Data parameter OKEYPAD REF 1 ell SEN nce To set the frequency reference select parameter 10 KEYPAD REF1 press the key and use the and keys to increase or decrease the keypad reference When in keypad control using reference 1 it is possible to change the keypad refer ence value while monitoring any of the measured values 1 8 For example you Xan monitor parameter 7 SAMI OUTPUT VOLT wie hanging the frequency To do this select the measured value you prefer press key and set the reference frequency with and keys Ifthe SAMI GS is running with an external reference and the CONTROL PLACE is changed to KEYPAD R1 it is possible to transfer the current value of the external reference to KEYPAD REF Example The SAMI GS is receiving a fre quency reference from a arc X50 Yolwant to temporarily override the external frequency reference Select CONTROL PLACE KEYPAD R1 and press and The SAMI GS puts the value of the external reference into KEYPAD REF1 may now control the drive manually by KEYPAD REF1
90. or will start The start frequency has a fixed 1 Hz hysteresis Output frequency at which the third aux motor will start The start frequency has a fixed 1 Hz hyster esis Frequency level for stopping the first aux motor Frequency level for stopping the second aux motor Frequency level for stopping the third aux motor Start delay for the auxiliary motors Stop delay for the auxiliary motors Number of auxiliary motors Elapsed time for automatic exchange of con nected motors 60 SAMI GS 19 Autochange Level O 0 100 0 20 Interlocks O On Off 21 Error Value Inv O No Yes No AI1 Al4 Std Commu No Al1 Al4 f ACT1 ACT2 1600 1600 1600 1600 1600 1600 1600 1600 No Yes No Unit 0 50000 0 5 22 Actual 1 Input O 23 Actual 2 Input O 24 Actual Value Sel O 25 ACT1 Min Scale 26 ACT1 Max Scale 27 ACT2 Min Scale 28 ACT2 Max Scale 29 Regul Bypass Ctrl 30 Display Unit 31 Displ Unit Scale 32 NBR of Decimals Actual value level for automatic exchange of connected aux motors Enables disables the interlocking function of aux motors Determines whether or not the Pl Controller error signal is inverted Actual 1 signal input selection Actual 2 signal input selection PFC Controller actual value selection Minimum scaling factor for actual 1 signal Maximum scaling factor for actual 1 signal Minimum scaling factor for actual 2 signal Maximum scaling factor
91. p level while the sleep function is active the SAMI GS will restart when the actual value goes below the new set refer ence value as shown in Figure 9 18 below Note Wake up level is calculated from the scaled actual value For example with 4 to 5 Actual value bar scaled actual value range a 10 wake up level corresponds to 4 1 bar Wake up level S para 28 8 Time Frequency Sleep delay time para 28 6 t Sleep time Sleep level para 28 7 Time Regulated pump Figure 9 18 Example of the sleep function 9 Start Freq 1 10 Start Freq 2 11 Start Freq 3 Output frequency at which the first second third auxiliary motor will start The start frequency has a fixed 1 Hz hysteresis 12 Low Freq 1 13 Low Freq 2 14 Low Freq 3 Minimum frequency to the regulated motor after start of the first second third auxiliary motor If the output frequency goes below this limit by 1 Hz the auxiliary motor will stop STOP START 15 Aux Mot Start DLY Start delay of auxiliary motors to prevent starting at a momentary crossing of the start limit e g due to pressure impacts in water supply systems 16 Aux Mot Stop DLY Stop delay of the aux motors to prevent stopping at a momentary crossing of the stop limit e g due to pressure impacts in water supply systems 17 NBR of Aux Motors Number of auxiliary motors 62 Frequency f max Start limit 1 para 2
92. p reduction 10 Nominal Slip 1 0 1 10 Nominal slip of the motor 11 O U Volt Control 1 Off On Over Undervoltage Controller 1 Switching Freq or higher gt RATED than the nominal current of the SAMI Motor noise can be minimised by adjusting the switching frequency to a value that does 4 U f Ratio not create resonances in the motor system The optimum switching frequency is the LINEAR lowest frequency at which noise is accept The velas are motor changes linearly able This frequency may not be the same with frequency in the constant flux area for identical motor systems near Ui ratio le normal used where thie load s torque characteristics is linear with As switching frequency increases inverter speed refer to Figure 9 13 efficiency goes down refer to Figure 4 1 on page 12 so itis best to use a low switching SQUARED frequency if the application can tolerate noise The voltage of the motor is maintained in the constant flux area less than in the case of 2 SAMI Max Out Volt Linear U f The motor is undermagnetised so noise and motor losses are reduced Squared Uff ratio is normally used in ap plications where the load torque character 3 Motor Power istic is proportional to the square of the speed such as centrifugal pump and fan drives This parameter sets the maximum output voltage fundamental of the SAMI To ensure accurate operation of the Motor Control Card it is important to
93. plete table of parameters is presented on pages 33 36 23 SAMI GS Figure 7 3 Example of control panel operation Let us suppose that you want to set the parameter 22 1 MINIMUM FREQUENCY to 3Hz The following example explains the procedure 1 SAMI OUTPUT FREQ 45 5 Hz R1 gt I gt Press to Main level CONT CONNECTIONS 10 MAIN Bi 1 Lt or l4 Select the required Main level DRIVE 20 MAIN Pi 1 gt Press to Group level ACCELER DECELER 21 GROUP R1 gt 1 LEI or y Select the required Group FREQ CUR LIMITS 22 GROUP R1 gt 1 gt Press to Parameter level 1 MINIMUM FREQUENCY Select the required Parameter 5 00Hz R1 gt 1 by and keys Change to Setting mode Brackets indicate that the parameter value can now be changed 1 MINIMUM FREQUENCY 5 00Hz R1 gt 1 Set the parameter value 1 MINIMUM FREQUENCY To cancel the change and return 3 00 Hz R1 gt 1 to Display mode press gt Save the selected value to permanent memory 1 MINIMUM FREQUENCY Brackets disappear indicating 3 00 Hz R1 gt 1 that the parameter value is gt stored in memory i Return to Operating Data 1 SAMI OUTPUT FREQ parameter 1 SAMI OUTPUT 45 5 Hz RIi gt 1 FREQ 24 SAMI GS 7 4 Adjusting Display Contrast The contrast of the LCD can be adjusted for optimal viewing This can be done when the display is at Main or Group level To adjust contrast hold do
94. plica tions where several motor cables are connected in parallel 77 Check mains supply If mains supply is adequate an internal failure has occurred Contact nearest SAMI service representative Check the insulation of the motor and motor cables If no earth fault or short circuit be tween phases exists contact the nearest SAMI service representative SAMI GS Flowchart 10 1 SAMI temperature warning fault SAMI temp warning fault No Reduce switching frequency to 3 kHz itching freq lt 3kHz Check cooling air flow Clear restrictions A to air flow Air flow OK Heatsink 1 Clean dust from fins dusty heatsink fins Ambien Yes temperature gt 40 C No Y Internal fault Re size SAMI GS d Restart system Contact SAMI GS for this applic or and check for service represent add extra cooling 4 faults j 78 SAMI GS Flowchart 10 2 Overcurrent fault Overcurrent trip j Motor stalled Yes Remove Disconnect mechanical SAMI GS from fault mains circuit Restart toi er system shortcircuit eart Yes i fault a Check for faults Replace motor Y Reconnect Repl bl SAMI GS SEH to mains Y Reconnect Restart SAMI GS
95. ptional Control Card The panel is mounted in the operator s control desk or cubicle Remote control panel SAGS 700 PAN A remote control panel can be used to control a maximum of 31 ACS 500 frequency converters individually or all together The panel is connected on Terminal X 51 to RS 485 interface In addition to Standard Control Panel functions the panel also has addi tional features such as network control up and down loading of parameters e g be tween drives and common drive control for all connected drives The panel functions as a master controller for bus connected drives but it can be set to a HOLD state where it cannot send or receive messages For further information please refer to the User Manual EN 58057584 Input Output Extension Card SNAT 7520 IOE SNAT 7520 IOE is an input output extension card with three digital and two analogue inputs two analogue and two relay outputs It can be used for example with PFC Control when more than 3 motors are to be control led In general it can be used in applications requiring galvanically isolated inputs and outputs For further information please refer to the Installation and Operation Guide EN 58057843 Bus Adapter and Pulse Tachometer Interface Card SNAT 7610 BAC SNAT 7610 BAC is a bus adapter and pulse tachometer interface card which includes a speed control Application Macro The Tachometer interface includes three gal vanically isolated tachomet
96. r The PI CONT GAIN is set to a small value e g default value 100 With small reference steps 1 the response motor frequency is monitored The PI CONT GAIN is increased until the drive ceases to be overcompensated see Figure 9 7 This should be done within the whole speed range approx 100 rpm steps Finally the reference steps are increased to suitable values for this application normal DTN ove rcompensated Peer undercompensated Figure 9 7 Frequency response to reference step with P Controller For operation with Pl Controller the value for PI CONT GAIN determined by the operation as P controller is divided by 2 and put to para 25 1 The PI CONT I TIME is set toa low value e g 10 s The drive response motor frequency to small reference steps is monitored The PI CONT I TIME is in creased until overshoot is observed This should be done within the whole speed range and with reference steps suitable for this application until drive response over shooting is within acceptable range oa normal l Time too short rm I Time too long Figure 9 8 Frequency response to reference step with Pl Controller Pl Controller fine tuning can be done by small changes of the above determined values 3 Pl Cont Min Lim The minimum value of the Pl Controller frequency output The limit cannot be set less than para 22 1 MINIMUM FRE QUENCY 4 Pl Cont Max Lim The maximum value of the Pl Control
97. run lt 10 m add 300 mm for every 10 m There should be no additional control components contactors or relays inside the SAMI GS and no control cables other than those of the SAMI GS The control connections of the SAMI GS are galvanically isolated from mains potential and have a 10 MQ resistance from the inverter frame e PE Because ofthis there is no need to connect X50 2 4 6 and 8 logic GND to TE or PE However it could prove useful to do this if EMC problems occur Analogue input and output signals A separate twisted pair must always be used for each individual signal Digital inputs It is strongly recommended to use screened cables for digital inputs DI An external 24V supply for the digital inputs DI1 to DI6 must not be used Relay outputs If relay outputs RO operate on 24 V DC the signals can be routed to the same cable used for the digital inputs If twisted cables are used digital output and input should never be in the same pair If 110 V 230 V AC is connected to a relay output a separate cable without screen can be used for these signals Note If the relay outputs are used to control inductive loads e g relays contactors they must be protected by using varistors or RC units AC or a diode DC The protection components should be installed onto the coil of the relay or contactor being controlled and not on the terminals of X50 When using an RC unit note that the leakage current
98. s because of reson ance problems With this Group it is possible to set up five different frequency ranges which the frequency converter will skip It is not necessary that for example 4 CRIT FREQ 2 LOW be greater than 3 CRIT FREQ 1 HIGH providing the LOW parameter of any one set is lower than the HIGH parameter of the same set Sets may overlap but the skip will be from the lower LOW value to the higher HIGH value The Critical Frequency settings are activated with parameter 1 CRIT FREQ SELECT Yes Example A fan system has severe vibration problems from 18 Hz to 23 Hz and from 46 Hz to 52 Hz The speed reference is set to 60 Hz Set the parameters as follows set the HIGH value first before setting the LOW value 2 CRIT FREQ 1 LOW 18Hz 3CRITFREQ1HIGH 23Hz 4 CRIT FREQ 2 LOW 46 Hz 5CRITFREQ2HIGH 52Hz If due to e g bearing wear another reson ance occurs at 34 36 Hz the critical fre quency table can be added to as follows 6 CRIT FREQ 3 LOW 34 Hz 7 CRIT FREQ3HIGH 36Hz Note Scale the range to 0 Hz for those Critical frequencies which are not used motor Hz 52 i TA 46 Te Tiet La Late 18 23 46 52 Hz Figure 9 6 Example of Critical Frequencies settings in a fan system with vibration prob lems at the frequency ranges 18 Hz 23 Hz and 46 Hz 52 Hz 50 SAMI GS 9 2 4 Group 24 Const Frequencies These values can be altered with the SAMI GS running Parameter
99. supervision Motor Current supervision limit Reference 1 supervision Reference 1 supervision limit Reference 2 supervision Reference 2 supervision limit Supervision messages on the display Max value is set automatically according to the setting of parameter 22 4 SAMI SUPERVISION R1 gt 1 2 ACT FREQ 1 Figure 9 21 Example of supervision display 1 Output Freq1 Func 3 Output Freq2 Func These parameters allow you to activate an Output Frequency supervision function A Relay Output para 14 3 14 5 and the dis play are used to indicate that the Output Fre quency has dropped below LOWLIMIT or exceeded HIGHLIMIT the supervision limit 65 5 Current Func Motor Current supervision Operation as in parameter 1 OUTPUT FREQ1 FUNC 7 Ref1 Func 9 Ref2 Func Reference supervision Operation as param eter 1 OUTPUT FREQ1 FUNC 11 Supervis Messages ON Supervision messages will be shown on the display OFF Supervision messages will not be shown on the display Relays operate if programmed for supervision signals SAMI GS 9 3 2 Group 32 Fault Function These values can be altered with the SAMI running Parameter 1 Serial Fault Func 2 Al lt 2 V 4 mA Func 3 Mot Temp FIt Func 4 Motor Therm Time 5 Motor Load Curve 6 External Fan 7 Stall Func 8 Stall Current 9 Stall Time Freq 10 Underload Func 11 Underload Time 12 Underload Curve 1 Serial Fault F
100. t t t 041 3 f E A S 2 2 041 5 PC NSQ 050 5 NSQ 030 5 NSQ E SAMI GS Cooling air outlet d see table 1 below e SAMI GS ANY E 50mm 50mm lt gt A Al e o Cooling air 50 mm inlet Type ACS501 004 011 3 ACS 501 005 016 5 ACS 501 016 060 3 ACS 501 020 070 5 Figure 4 3 Space requirement for adequate cooling 4 2 Mounting Note Do not handle or lift the drive using the front cover Use the bottom part for handling To ensure safe installation check that the surface mounting is flat Mark the fixing points of SAMI GS on the wall using the template printed on the protective cardboard package as a guide The maximum size of the fixing screws is 6 mm 15 64 for ACS 501 004 3 006 3 and ACS 501 005 5 009 5 units and 8 mm 5 16 for 009 3 060 3 and 016 5 070 5units Fix the screws to the marked positions Attach the unit by the fixing notches and tighten the screws Note If multiple units are installed adjacent or above each other the following minimum distances apply units side by side clearance 100 mm units above each other clearance 300 mm 14 MI ITT SAMI GS ACS501 004 006 3 ACS501 009
101. te In digital instruments the pole of the instru ment is positive when measuring resist ance In analogue instruments the pole is usually negative 13 Ifthe readings are different from the values given the rectifier module must be changed 12 Connect the positive measuring wire to the negative pole of the rectifier Repeat all the measurements against the negative pole 85 SAMI 10 6 Spare parts Component boards 60038554 Motor control SNAT 7030 SP2 compl 60038511 Motor control SNAT 7050 SP2 compl 60038546 Motor control SNAT 7070 SP2 compl 60036381 Motor control SNAT 7120 SP2 compl ACS 501 004 3 ACS 501 005 3 ACS 501 006 3 ACS 501 009 3 ACS 501 011 3 GS ACS 501 016 3 ACS 501 020 3 ACS 501 025 3 ACS 501 030 3 ACS 501 041 3 ACS 501 050 3 ACS 501 060 3 ACS 501 006 5 ACS 501 009 5 ACS 501 011 5 ACS 501 016 5 ACS 501 020 5 ACS 501 025 5 ACS 501 030 5 ACS 501 041 5 ACS 501 050 5 ACS 501 060 5 61027319 Ctrl interface Display cards 2Mb SNAT 7600 7640 SNAT 7680 cards 61052674 I O Extension Card SNAT 7520 61049614 Bus Adapt amp Pulse Tacho SNAT 7610 61042105 RS 232 20mA Comboard SNAT 7690 61096787 Profibus interface card SNAT 7700 Rectifiers 31128811 3 module 6 diodes V1 60008281 3 module 6 diodes V1 60008400 3 module 6 diodes V1 60008515 3 module 6 diodes V1 60024146 3 module 6 diodes V1 Transistor modules 60007357 IGBT mod 2
102. tected it is stored so that it can be reviewed at a later date The last three faults and warnings are stored in Operating Data parameters 20 LAST RECD FAULT 21 SECOND RECD FAULT 22 FIRST RECD FAULT The faults can be checked for trends that may be useful in preventing future faults For example if the last 2 out of 3 faults were overvoltage trips the deceleration time should be increased Scrolling through the Fault History parame ters does not erase the Fault History The oldest reset fault indication warning is auto matically erased when a new fault warning occurs To erase the Fault History each Fault History parameter must be set to zero Select param eter 20 LAST RECD FAULT and change to Setting mode Press or and the parameter value changes to zero Return to Display mode by pressing XK Re peat the same steps with parameters 21 and 22 Note Erasure of the Fault History is pre vented if the fault persists after it has been reset during the one minute delay discussed in Section 10 2 Note Whenever an Application Macro is selected Start up Data para BAPPLICA TION the Fault History will also be reset 71 SAMI GS SAMI WARNING 7 Al lt 2V 4mA Bil z 1 KI SAMI FAULT SE Figure 10 1 Examples of warning and fault displays Note Undervoltage faults are stored in the Fault History only when Automatic Reset is off Supervision limit indications are not stored in the Fault
103. ter Three Constant Speeds 1 3 are selected 26 1 is Flying Start or Flying TQB with two Digital Inputs as in DI1 2 9 Fault Reset Sel DI1 2 3 e Fault Reset signal resets faults warnings Seven Constant Speeds 1 7 are selected and supervision indications The reset is with three Digital Inputs activated by a transition from 24V to OV DI DD DI DI DI2 DI3 DI4 DIS DI6 0 0 0 No Constant Speed Reset signal can be connected to any of the 1 0 0 Constant Speed 1 Digital Inputs 1 6 0 1 0 Constant Speed 2 1 1 0 Constant Speed 3 eT oe 0 0 1 Constant Speed 4 The Fault Reset function is not activated 1 0 1 Constant Speed 5 0 1 1 Constant Speed 6 ON STOP 1 1 1 Constant Speed 7 Fault is reset by Stop command Start Stop DI3 4 5 is selected by DI1 DI1 2 or STD COMMU as Z selected by parameters 11 3 and 11 4 DI4 5 6 STD COMMU RefertoDI1 2 3 i ee Fault resetting via RS 485 serial link 40 SAMI GS 10 Acc Dec 1 or 2 Sel 11 Param Lock Sel This parameter defines which Digital Input This parameter selects the control place for 1 6 is used to select Acceleration Decel Parameter Lock eration Ramp 1 or 2 If you select KEYPAD Parameter Lock is 0 V DC Acc Dec Time 1 controlled with Operating Data parameter 23 24 V DC Acc Dec Time 2 PARAMETER LOCK If you select a Digital Input 1 6 0 V DC Open and 24 V DC Locked 9 1 2 Group 12 Analogue Inputs These values can be altered with the SAMI GS runni
104. ter which has to be used if a control device does not have an RS 485 communications port For the optional remote control panel SAGS 700 PAN the setting is 9600 bit s 3 Time out Select Minimum value which can be set depending on the number of connected units It is recom mended that this value is set as high as possible master and a slave unit If very fast information on communication faults is needed the value can be set lower Too short a time out setting may cause unnecessary time out errors 4 Comms fault funct The Mode of operation depends on the setting of this parameter when a fault has occurred in communications between the master and a slave unit NONE The SAMI GS continues running with the last set parameter values and reference FAULT The SAMI GS continues running and a fault message is displayed If an output relay RO1 RO3 is programmed as fault this relay is activated FAULT STOP The SAMI GS stops and a fault message is displayed If an output relay RO1 RO3 is programmed as fault this relay is activated 46 SA GS Communication via RS 485 terminal RS 485 serial communication is possible from an optional remote control panel SAGS 700 PAN or from aPC or a PLC PC and PLC applications require software utilising the protocol of the SAMI GS series A maximum of 31 units can be connected into a bus All units connected must have a different
105. tors because the winding resistance is higher If the load torque is high use just enough IR compensation to drive the load 8 IR Comp Range This parameter defines the frequency at which the Manual IR COMPENSATION reduces to zero The compensation voltage reduces linearly with increasing frequency 9 Slip Compensation A squirrel cage motor will slip under load This slip can be compensated by increasing the frequency as the current increases By setting this parameter to ON slip is reduced to approximately 10 of the original value If you require exceptionally precise speed control you may want to use a frequency controller with tachometer feed back control Contact your local SAMI representative for more information 10 Nominal Slip For the precise operation of the Slip Com pensation function itis necessary for the SAMI to know the nominal slip of the motor Nominal slip is given as a percentage of the synchronous speed Nominal slip of the motor s can be derived from synchronous speed n and nominal speed ny Sy 100 n n n 11 OU Volt Control This parameter allows you to turn off the Over Undervoltage Controller This may be useful for example ifthe supply network voltage varies more than 10 and the application will not tolerate the O U Controller controlling the output frequency in accord ance with the supply voltage An under overvoltage trip may occur instead 59 SAMI GS 9 2
106. ts 60018847 Cable entry IP21 60031461 Cable entry IP21 60031479 Cable entry IP21 60033854 Cable entry IP54 60018855 Base for Ctrl Interface card 60018863 IP 21 casing 60018871 IP 21 casing 60031436 IP 21 casing 60031444 IP 21 casing 60033897 IP 54 casing 60033901 IP 54 casing 60033919 IP 54 casing 60033927 IP 54 casing 60033935 Screw terminal set X1 X3 6 mm 60033943 Screw terminal set X1 X3 10 mm 60033951 Screw terminal set X1 X3 16 mm 60033960 Screw terminal set X1 X3 25 mm 60036403 Screw terminal set X1 X3 70 mm 60033978 Internal brake module SAGS 30BR 60033986 Internal brake module SAGS 50BR 60033994 Internal brake module SAGS 100BR 60034001 Internal brake module SAGS 200BR 87 SAMI GS 11 Technical Data Mains Connection Voltage ACS501 004 3 ACS501 060 3 3 phase 380 V 400 V and 415 V 10 permitted tolerance ACS 501 005 5 ACS 501 070 5 3 phase 440 V 460 V 480 V and 500 V 10 permitted tolerance Umax 415 V 500 V Frequency 48 63 Hz 1m Power factor for fundamental 0 98 0 95 at nominal point Motor Connection Output voltage 3 0 U at field weakening point Sech max Output frequency 0 120Hzor0 500 Hz Frequency resolution 0 01 Hz Switching frequency 1 12 kHz Continuous output current Constant torque SAMI GS rated
107. tual value AYO YO YO 20 4 16 mA AND X0 X0 10 2 8V Y1 Y1 X1 a Y1 YO AYO 100 6 4 4 16 100 15 Y1 YO Mal 100 16 4 16 100 75 ai X0 AX0 100 3 2 8 100 12 5 X1 a X1 X0 AX0 100 9 2 8 100 87 5 AYV Y 1 Y1 75 15 60 AX1 X1 X1 87 5 125 75 Xs X1 100 Y1 AX1 AY1 87 5 100 75 75 60 118 75 x Xs X17 0 Y1 n AX17AY1 12 5 0 15 75 60 6 25 ACT1 2 MAX SCALE 118 8 ACT1 2 MIN SCALE 6 3 The Result has been drawn in Figure 9 11 above 54 SAMI GS 9 2 6 Group 26 Start Stop These values can only be altered when the SAMI GS is stopped except those marked with I Parameter Range Unit Description 1 Start Function Ramp Flying Torq Conditions during motor acceleration Boost Flying TQB 2 Torque Boost Cur 0 5 2 0 A Torque Boost current level selection 3 Stop Function 1 Coast Ramp DC Brake Conditions during motor deceleration 4 Brake Chopper 1 No Yes Dynamic Braking Device activation 5 DC Holding Off On Enable DC Holding 6 DC Hold Voltage 0 01 0 1 U V Voltage set for DC Holding 7 DC Brake Voltage 0 01 0 1 U V Voltage set for DC injection braking 8 DC Brake Time 0 250s Duration of DC injection braking 1 Start Function TORQ BOOST This parameter determines how the SAM
108. un Enable signal the selected Digital Input must be connected to 24 V DC If the Digital Input comes to 0 V DC the drive will coast to stop STD COMMU Run Enable signal can be activated via RS 485 serial link 2 Ext Cont Place Sel This parameter defines how to select the external control place EXT REF1 EXT REF2 KEYPAD The selection is made with Operating Data parameter 12 EXT REF 1 OR2 DI1 DI6 Choose a Digital Input 0 V DC EXT REF1 and 24 V DC EXT REF2 STD COMMU Selection of external reference via serial link RS 485 3 Ext 1 I O Cont Sel 4 Ext 2 I O Cont Sel This parameter selects the Digital Inputs used for Start Stop and Reverse commands when using External Reference 1 External Ref 2 NOT SEL No Digital Input selected DI1 0 V DC Stop and 24 V DC Start Rotation direction is fixed to Forward DI1 2 Start Stop is connected to DI1 and Reverse to D2 DI2 0 V DC Forward and DI2 24 V DC Reverse DI1P 2P Start Stop commands are given separately using pulse signals Start is connected to DI 1 and is activated with 24 V DC pulse if Stop DI2 is connected to 24 V DC During normal operation DI2 is connected to 24 V DC If DI2 is disconnected with a pulse SAMI GS stops DI1P 2P 3 DI and DI2 as previously Reverse is connected to DI3 0 V DC Forwar
109. unc Range Unit Stop Const Freq No Warning Fault Const Freq No Warning Fault 300 10000s 50 150 No Yes No Warning Fault 0 2 1 5 Al 10s 15Hz or 20s 25Hz or30s 35Hz No Warning Fault 0 600s 1 5 This parameter allows you to select the preferred operation in case of a malfunction in the serial communication between the Control Interface and Motor Control Card STOP The SAMI GS stops according to the setting of parameter 26 3 STOP FUNCTION CONST FREQ The SAMI drives the motor at constant frequency selected with parameter 24 7 Note If the selected control place is KEYPAD the SAMI GS stops in case of a serial communication fault Description Operation following Serial Comm fault Operation following Al lt 2 V 4 mA fault Operation following motor overtemp Time for 63 motor temperature rise Motor current maximum limit Motor equipped with external cooling fan Operation following motor stall Current limit for Stall Protection logic Time Freq limit for Stall Protection logic Operation following Underload fault Time limit for Underload logic Torque limit for Underload logic 2 Al lt 2V 4mA Func This parameter allows you to select the pre ferred operation when the Analogue Input 1 or 2 signal drops below 2V 4mA and the minimum is set to 2V 4mA living zero NO No activity required WARNING Warning indication on display FAULT
110. utomatic exchange takes place at the frequency of 45 50 fa If auxiliary motors are connected the per centage value corresponding to the set max frequency is 1 1 motors 50 0 1 2 33 3 1 3 M 25 0 The exchange takes place if the following conditions are valid autochange interval time has elapsed actual value is below the set autochange level minimum one auxiliary motor is not running SAMI GS does not run at a constant fre quency see parameter 11 7 When all the conditions are valid the PFC stops all motors changes the order of the motors and restarts motors using the new start order The start order cannot be changed externally The start order and the elapsed run time remain in the memory during a mains inter ruption Note If only the regulated pump is used cancel the autochange operation para 28 18 00 h 00 min This releases relay outputs RO2 to RO4 for other use RO4 only available with UO Extension card SNAT 63 SAMI GS 7520 IOE 20 Interlocks If this parameter is set to ON and one of the interlocking signals disappears while in run status the SAMI GS stops and all output relays RO1 to RO4 are released If other motors are available the PFC con nects one of those instead and starts the SAMI GS again If this parameter is set to OFF the interlocking function is disabled and DI DI3 and DI4 DI7 can be pro grammed for other purposes available only
111. wer taken from the mains is almost entirely active power The power factor approaches unity The Inverter Stage forms symmetrical three phase AC voltage from the constant DC voltage supplied by the DC Intermediate Circuit A Motor Control Card controls the Inverter Stage and monitors the operation of the SAMIGS A number of charges within one minute is four Therefore in applications where frequent sequential Start Stops are required electronic Start Stop should be used while the unit is powered continuously Note The maximum permissible A Control Interface Card is the link between the operator and the SAMI It incorporates a control panel with an alphanumeric display and keypad A terminal block for external control connections is also located on the Control Interface Card Note The Control Interface Card A is galvanically isolated from the mains potential The card is connected to earth via a 10 MQ resistance If needed the card can be earthed by connect ing with a wire X50 terminal 8 to PE terminal on the unit frame see Figure 6 1 SAMI GS Table 3 1 SAMI GS frequency converter types for 50 Hz and 60 Hz supplies Mains voltage 380 V 400 V 415 V Typedesignation SAMI s input current output current 8 and motor power Pu amp Piso Constanttorque applications Squared torqueapplications Rated Rated Shortterm Max Rated Rated Shortterm Max input output overload rated input output over
112. wn 3K and press T orf y It may be necessary to adjust the display contrast ifthe SAMI has been installed in a location with high ambient temperatures The factory default setting is optimum for an ambient temperature between 15 C and 30 C Running data and keypad control parameters A complete description of the parameter Groups is given in chapter 9 Drive parameters Operating Data parameters are described here 7 5 Operating Data The monitored values are updated five times a second The accuracy figures given in brack ets are valid for steady state signals Actual reference signal is shown once a second if the frequency converter is stopped Note If measured value goes beyond the range of the parameter expression marks are shown on the display Parameter Range Unit Description 1 SAMI Output Freq Frequency to motor 2 Motor Speed Actual encoder calculated motor speed 3 Motor Current Motor current 5 4 Calcd Torque T Calculated motor torque 100 7 15 5 Calcd Power P Calculated motor power 100 P 15 T and P correspond to the motor data 6 DC Voltage V given in para E and G of Start up group 7 SAMI Output Volt V 8 SAMI Temperature C 9 Control Place Keypad R1 Keypad R2 External This parameter indicates small current value even though the motor cables and the motor is not connected Intermediate circuit DC voltage Calculated motor voltage 5 Temperatur

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