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Blast-e manuals part1

1. a S OT A E A f U J Jo No Uc POS Uc nf U zs nN Ly UM U a uii 0 1 U U 4 A m ll i UU x am Eu U E9 n JU E ns U pig o UJ U U 280 SYNERGY IN MOVEMENT SIZE E 350 400 660 22 SYNERGY IN MOVEMENT 2 6 Operating description BLAST E can be divided into two sections e POWER SECTION e CONTROL SECTION 2 6 1 Power section gt On this section the mains voltage applied to terminals L1 L2 L3 three phase is rectified by three phase bridge and filtered through electrolytic capacitors The dc voltage is tuned by 6 IGBT Thus three alternate phase voltages are obtained on terminals U V W to which the motor is connected All BLAST E drives up to 22 kW are provided with a built in brake Symbols used to define the power terminals Power Terminal BLAST E Board Input Phase MAINS Input Phase MAINS
2. torque TORQUE LOOP 200 loop Y SPEED LOOP set ig ati NJ e CURRENT LOOP y f Vq vq Nu vu i p D A W ssp m A TAN FLUX LOOP vg Vd N pw FLUX SET r 0 SVM op qe a A position rating torque rating 0 Lid iq 9 speed rating dich Low o SPEED SWITCH The SSP motor does not have electromagnetic brush and magnets so it has the same liability of an asynchronous motor it does not need programmed maintenance except for the bearings Its inertia moment compared to the one of a classical asynchronous motor is very inferior thanks the major specific power at parity with the mechanical quantity and the lighter motor The torque ripple is comparable to the servomotor one d 1 PWM It shows the working modulation frequency of the drive 1 5KHz 1 2KHz 2 3KHz 3 4KHz 4 8KHz 5 12KHz Current 5E In this way SVC the drive in case of too high temperature of IGBT reduces automatically the working currents It is possible to decide to use a fix modulation frequency not changeable automatically This choice could lead in certain cases dependent by the size and chosen modulation frequency to a derating of the drive with consequent decrease of the nominal curr
3. Se 19 SYNERGY IN MOVEMENT SIZE C 2 v Start sme wer U O 20 SYNERGY IN MOVEMENT SIZE D 250 310
4. eo epa cass ee eenscestesoosvoeecsessssssoudecessssssessseeCosteeseisessesecoesesses 40 4 1 SAFETY REQUIREMENTS 40 4 2 CHECKING BEFORE INSTALLATION vua des 40 5 ELECTRICAL INSTALLATION noe eee ea EE ob eae uoa Ea pho FR Ue Ere pe ER EUH e ero 42 5 1 SAFETY REQUIREMENTS RR 42 5 2 CONNECTION DIAGRAM RR 43 5 3 CABLE SIZE WIRING NOTES ON USE cccccccesssscecssseeceesceecsesaeccecseceececsueeecsesaececseaeessaeeecesseeeceeaeeessueesessaeeesseaaess 44 6 DATA DISPLAY AND PROGRAMMI NQG eee eese eren nennen eene eren ones setae eese esae 47 6 1 FACTORY SETTING 47 6 2 MODIFYING PARAMETERS 47 6 3 DESCRIPTION OF THE INTEGRAL KEYPAD CRUEL URS 48 6 3 1 Programming With Keypad 48 6 4 CONTROL FROM KEYPAD MOTOPOTENTIOMETER ssccesscecsseceeeeeceseeeencecsaeeeceeeseeeseneeceaeesenaecereseaaeceareeeneeeeea 51 6 4 1 Start Run Command us cese 51 6 4 2 Reference Increase Decrease Command 5l 6 4 3 Forward Reverse 52 ENG iT ees 52 6 45 Res
5. 2 DIN 2 Active Low 4 DIN 3 Active Low 8 DIN 4 Active Low 16 DIN 5 Active Low 32 DIN 6 Active Low 256 DOUT 1 Active Low 512 DOUT 2 Active Low 16 DINI 6 Digital programming inputs Value set by meaning Value set by meaning keypad keypad 0 DISABILITATO 11 SPEED TORQUE 1 DRIVE ON 12 RESET ALARMS 2 DRIVE ON CCW 13 DISABILITA RAMPE 3 EN 1 14 SONDA TERMICA MOTORE SOLO DIN 1 4 4 EN 2 15 FREQUENCY INPUT SOLO DIN 5 5 CW CCW 16 START CW 6 SETPOINT UP 17 START CCW 7 SETPOINT DOWN 18 SELECT O 8 JOG 1 19 SELECT 1 9 JOG2 20 SELECT 2 10 JOG 3 21 OUT AN SELECTION 80 SYNERGY IN MOVEMENT me 1 8 Off Rif1 Parameter indicating the offset on the analog input 1 Range 20 20 of scale end 1 9 Off Rif2 Parameter indicating the offset on the analog input 2 Range 20 20 of scale end OQ O1 D 1 DO2 Set Value Meaning disabled min speed relay brake speed set reached rotation sense motor alarm thermal warning motor thermal waming drive ok pre warning motor 9 oo o l2 O The function motor pre warning thermal pre alarm permits to distinguish the thermal problems that come from the drive motor advancing the alarm f intervenes the thermal sensor placed in protection of the motor the output is suddenly disabled the alarm is delayed 10 seconds If the drive protects the motor with th
6. WARNING 8 Avoid handling the electronic components of the control board without taking adequate measures preventing from damages caused by electrostatic discharges 9 If a contactor is installed on the inverter output make sure that opening and closing occur only with disabled drive 10 Do not connect the capacitors to the drive output 11 While grounding more inverters avoid ring connections Fig 5 4 2 45 SYNERGY IN MOVEMENT BLAST BLAST BLAST BLAST BLAST BLAST Proper connection b Wrong connection OK NO 12 Plan to place a choke between mains and drive in the following cases a a thiristors converter or other inverters are planned on the same line b a power factor correction is planned on the same line c the unbalance of the supply voltage exceeds 3 or the mains is very disturbed for example Vrs 400V Vst 407V Vtr 390V Vrs Vst Vt VM rs Vst 390 3 In this example no deviation from VM 9 reactance is needed Fs 100 max deviation fr 0 _ 23 399 d the power of the supplying line and the inverter power comprehend the evidenced zone in the following picture KVA Supplying power line 2500 Decoupling required 500 Not required Inverter size 50 250 KVA 13 In case one drive supplies more motors and or the distance between motor and drive is relevant see chart 3 3 5 5
7. 0 0 Freq Hz 0 00 0 Ref 1 Ref 2 0 nz 1 0 0 COMMANDS Drive ON EN ON w EN2 UN Speed Ref Commissioning Drive OFF ow EN2 OFF Torque Rel 27 08 04 16 20 00 CAC error Dataexchange P Astor cn cpm 5 031 Blocco 6 xBlast EARP 1 1702 XBLAST beside the supervision permits through TOLLS CHANNEL the channels to be monitored There are 8 channels associable to different dimensions 54 EARP Spa First of all it must be configured through TOLLS CHANNEL the channels to be monitored There are 8 channels associable to different dimensions Channel setup DC Link Voltage Torque Process Deviation Process PID Feedback 7 Aux signal 1 Lau 55 Now SCOPE under menu TOOLS can be selected With key START acquisition begins with STOP itis stopped The sampling can now be checked by changing the Time BASE 56 2 wz E m Em m a D Blast EARP Spa and then by using SCROLL the whole stored Time Base Menu HELP About there are the XBLAST applicable version and information about EARP SPA 57 SYNERGY IN MOVEMENT AxBlost EARP Spa BEE File Drive Automation Tools Window Hel
8. Speed Rel Alarm Alam Cur A 00 Speed rpm Freq Hz 0 00 Ref 2 Ref 1 Setpoint T 0 COMMANDS UNE piveon enton enzon quem Dive OFF EN1 OFF cew EN2 OFF Toque Pet AN2 CLC Data exchange coni 9600 Picture 1 85 SYNERGY IN MOVEMENT Ma 7 5 Commissioning Motor Parameter for AC Motor 7 5 1 Meanings In nominal current of the motor nominal voltage of the motor referred to the nominal voltage Nn nominal revolutions of the motor this is the value obtained reducing to the synchronism speed the nominal flowing of the motor Costi cosfi Rs phase stator resistance Lm magnetization inductance sLs leakage inductance TaurR rotor time constant Introduction The auto tuning is a function which permits to obtaining automatically the main electrical parameters of the motor This is possible in two ways 1 Off line Tuning Drive pad on Xblast STARTING FROM THE PLATE DATA OF THE MOTOR IN ULN NN COSFI THERE IS THE MATHEMATIC CALCULATION OF THE FOLLOWING ELECTRICAL PARAMETERS RS LM SLS TAUR IT CONCERNS A METHOD WHICH DOES NOT ADMIT THE CURRENT INJECTION IN THE MOTOR AND CAN BE DONE WITH DISABLED DRIVE 7 5 2 On Line Tuning Commissioning pad on XBlast Anyway it is necessary to log the plate data of the motor In nN cosfi but the calibration admits an
9. _ Back up 1 Pa B positive pole for backup supply 24vdc_ Only with optional BlastOPTO110 _ 0 Power ground and negative pole back up supply OV I O Digital inputs AN I O Configurable Differential anal Input configurable 10 40 impedance or 0 20mA 5000 4 Configurable Differential anal Input Impedance Configurable Differential anal Input 10Vdc 30kQ impedance Del mm Reference OV for P4 7 0 100kHz 10mA cw emer 0t 2 m cmd CANL With signal TAST Connector for keypad or OPTIONALS connection According to the installed optional OPT boards 27 SYNERGY IN MOVEMENT 2 7 Description of the control signals 2 7 1 Digital Commands The BLAST E inverter has command signals with PNP logic The commando operates when the related terminal is closed on a 24Vcc supply through a relay contact static The six digital inputs 11 I2 3 I4 I5 I6 are configured as follows Digital Inputs DENOMINATION Drive ON CW Drive ON CCW EN1 With Speed Reference EN2 CW CCW SETPOINT UP SETPOINT DOWN JOG1 JOG2 EN1 With Torque Reference RESET ALARMS DISABLE RAMPS FREQUENCY INPUT for I5 only THERMAL PROBE for 11 14 only SPEED TORQUE START CW START CCW SELECT NOTES Enable input for clockwise motor rotation Enable input for anti clockwise motor r
10. 3 4 10 The connections both of signal and power are the most sensible because the first can not be filtered to obtain an elevate control speed e g an encoder input and the following are sensible to the wiring typology and the applied load signals 1 to limit the electromagnetic susceptibility the EARP Drives are provided by differential analog inputs filtered analog outputs logic input and outputs filtered The tests performed in our laboratory demonstrate a sporadic sensibility only towards disturbing events generated within 50cm from the converter CPU It is necessary to focus the attention on not generate electrostatic loads of important intensity next to the converters or on involved conductors is required the implementation of recycling diodes on relays directed to dc RC groups on relays and mains contactors directed to ac is always suggested the installation of toroid on the signal connection cables next to the I O connectors 38 SYNERGY IN MOVEMENT back 0 Power 2 All the driver are protected in output against possible external short circuits by electronic devices able to recognize quickly the circuital anomalies the using of a long cable could cause the protection intervention To avoid inconveniences there are two possibilities Insert in output a dV dt limitation filter Insert an output reactance between drive and motor next the Drive Choose a cable at low parasitic capacity
11. Delta f d24 Hz Frequency hop quantity Tab V Hz 27 It selects the LOOP kind for SVC 0 open speed ring sensorless 1 closed speed ring with encoder 63 SYNERGY IN MOVEMENT NAME KEYPAD CODE UNIT RANGE DESCRIPTION SVC FVC SFT INPUT OUTPUT CONFIGURATION Polarity 10 0 21 Inputs outputs polarity 0 positive 1 negative Din 0 21 Settable digital input function 0 disable 1 drive ON CW 2 drive ON CCW 3 4 EN2 5 CW CCW 6 Reference UP 7 Reference DOWN 8 9 Jog2 10 Jog3 11 Speed Torque not available 12 Reset ALARMS 13 Bypass ramps 14 Thermal probe only for 11 14 15 Frequency input only for I5 16 Start CW 17 Start CCW 18 Select 0 19 Select 1 20 Select 2 21 Out AN Selection Din2 0 21 Come Din Din3 0 21 Come Din Din4 0 21 Come Din Din5 0 21 Come Din Din 0 21 Come Din OFF R l 20 analog input offset OFF R 2 20 AN2 analog input Offset e e ej ejej e e e e ej ejej e e e e ejejej e e e e ej eje e e 002 0 8 Functions associable to the settable digital output 07 disable enabled analog out 1 msr 2 brake 3 speed set reached 4 direction 5 alarm 6 7 drive thermal warning 7 7 motor thermal warning 8 dri
12. Set the first gear with the IMAX parameter equal to 1 2 of the nominal current of the motor to limit the suppliable torque verify ihe general behaviour drive and mechanics and set again the proper value The speed loop calibration is to be performed after the current loop calibration as described in the Commissioning Current Loop Gain paragraph 1 Monitor the motor speed signal with the tools SCOPE of the application 2 Doseveral speed steps with progressive amplitude 3 Optimize the dynamic behaviour managing the variables Kpw Kiw Kdw Tdw with the consequent progression Increase the KDw variable to cancel the eventual speed overshoot Increase the TDw if the KD increment has introduced instability to the constant speed regime Increase the KP variables and or KI to increase the dynamic performances Decrease the KP variables and or KI to obtain the stabilizing effect The graphic below evidences the action to be chosen depending on the dynamic behaviour to obtain a correct speed behaviour CW speed Overshoot increase KD Excessive compensation increase KP Decrease KD Increase KI ES CCW speed Picture 4 time n 1 1 Ls Undershoot increase KD n 1 Optimal behaviour Oscillation modify KI or KD decrease KP Speed set Motor speed Set again the acceleration ramps to the wanted value and verify the behaviour in all the speed
13. 45 90 180 8 80 85 90 90 80 80 0550 D 55 112 224 8 85 112 112 90 0600BDH D 60 Kw 120 240 4 85 120 112 90 0750BDH D 75 150 300 4 85 150 120 0900BEH 90 Kw 8 85 90 1100 D 110 Kw 200 240 4 85 180 160 90 1320 132 Kw 4 85 IMIIII 90 1600 160 4 MM 85 90 In development 14 SYNERGY IN MOVEMENT 2 4 4 Blast E General Features gt BLAST E GENERAL CHARACTERISTICS Control system PWM Frequency Speed Feedback Resolver Input Configuration parameters The default parameters are referred to a standard asynchronous motor 380V 50Hz Frequency control Torque control Acc decel ramps Ramp type Current control Overload Frequency Derating Frequency Control Input Analog Control Inputs Configurable commands Alarm signalling Cofigurable signalling PID Control Auxiliary output configurable through dip switch Protections Basic programming Parameter Visualization Display electric data machine status Serial port Net connection with optional board Dynamic brake chopper Brake resistor SFT Stator Flux Torque Control SB Sinusoidal Brushless Control FVC Flux Vector Control SVC Space Vector Control SSP Sensorless Speed and position Random 1 1 5
14. SIZE 18 SYNERGY IN MOVEMENT a SIZE B 24
15. Scale factor of the processing feedback Feedbac 10 00 k Process Loop 65 SYNERGY IN MOVEMENT KEYPA UNIT RANGE DESCRIPTION gt D code Gain P9 0 00 Processing regulator gain elelelele 100 0 Ti P10 0 00 Integrative rime constant elelele 10 00 PID Proc P12 0 2 0 1 positive correction 2 negative correction FB val P13 0 01 Visualization scale factor 10 00 Display CONTROL SSP amp EVC CONFIGURATION 15 Proportional Constant of the compensator from DC link KP cmpV 14 Integral constant of the DC link compensator StartKlq 17 rpm 1 5 Starting of outflow torque limiter NMAX break 16 Limit from the torque limiter in outflow dwn X RAM Reserved parameters 1 Debug X RAM 2 Reserved parameters shift P31 Reserved parameters SSP CONTROL Kfil Ldest 18 reading only it shows the filter on the Kfil_Lqest P19 Reading only it shows the filter on the flow KLS P20 Model gain at low speed KHS P21 Model contribute at high speed in the operation at low speed KHH P22 Gain of the model at high speed Ky P23 Reading only adapting constant of the curves Injection P24 Size of the injection signal max track P25 Reading only tracking max speed Ld set P26 Size of the flow r
16. The resistor value and its power are basing on the drive type the inertia of the moving masses the resistor torque and deceleration time n RPM N1 N2 Td tbrake s 103 SYNERGY IN MOVEMENT Symbols used for the formulas M brake torque to take the motor speed from N1 to N2 within time tb Nm J inertia to the motor axis resistor torque to the motor axis Nm P averageresistor power IW W brake energy J R brake resistor MN nominal motor torque in 2z N n nominal motor speed in RPM P nominal power W _2 y 60 tbrake 2 0 10472 M N1 1 2 brake UJ W Td IW Data needed by the resistor manufacturer ohm value chosen according to the max current allowed by the drive brake energy J duty cycle 11 4 Opt 10 v board A simple adding file supplies the dual supply 10 useful for the supply of the external circuits for example potentiometers or transducers where it is required the possibility to control Blast e with an analogical way 104 SYNERGY IN MOVEMENT Exit connector DESCRIPTION CHARACTERISTICS 10V 10 10 max OS OV of signal 10V 10 10 max The chart is not supplied with the product and it allows the direct clutch on the control board 57003 Thanks to the 5 poles streep connecto
17. When conditions go back to normality the PWM goes back to the set max frequency To choose the suitable BLAST with FPWM derating refer to chart 2 4 3 1 Fix PWM The function with fix PWM means that the drive operates with set PWM until the max allowed case temperature is reached After that the thermal alarm is switched and the drive is stopped See chart 2 4 3 1 to choose the In referring to the PWM value Chart 2 4 3 1 Quick drive choice according to the operation mode PWM deratin fix PWM F max CODE Pot In is a E er yn A Inat Inat SIZE 380V A A kHz 12kHz 8kHz 4kHz 2kHz 4kHz 8kHz 12kHz case 0007 BAH 0 75 Kw 2 5 5 12 80 2 5 2 5 2 5 80 0011 BAH A 1 1 Kw 3 5 7 8 80 3 5 3 5 3 85 0015 1 5 4 8 9 6 12 4 8 4 8 4 8 80 0022 2 2 6 12 12 85 6 6 6 85 0037 3 7 9 5 19 12 85 9 5 9 5 9 85 0055 5 5 13 26 8 75 80 13 11 9 85 0075 7 5 16 5 33 8 70 16 5 16 5 14 70 0110BBH B 11 Kw 25 50 4 70 80 25 21 16 5 80 0150 15 31 62 8 70 80 31 25 20 85 0180 18 5 39 78 8 70 80 39 33 25 80 0220BBH B 22Kw 45 90 4 75 85 45 39 31 85 0300BCH C 30 Kw 62 125 12 80 85 62 62 62 80 0370BCH C 37 Kw 76 152 8 75 80 76 76 70 80 0450
18. so the sum of the phase phase and phase ground capacity does not exceeds the 5nF 3 4 11 Grounding It is important the Tunnel is appropriately connected to the ground The starry connection system is perfect to such purpose the drives have been provided of an own connection point The following picture evidences the connection typology to be done BLAST BLAST BLAST BLAST BLAST BLAST pee Proper connection b Wrong connection OK NO Focus on the following directions 1 It is necessary to provide in the electrical cabinet 2 copper ground bars of adequate size to which all system grounds are connected separating the power grounds from those of signal these bar has to be connected to the ground in only one point Connect the electric board to the ground systems of the supplying mains 2 The ground connections of the drives to the copper bar must be kept as short as possible 3 To increase the immunity it is important to have a big surface of contact of the various ground connections 3 4 12 Conclusions The right application of EARP converter as component of system grants the feedback to the normative limits of electromagnetic compatibility It is to memorize that the results with the converters are not determinant but of help because the whole system must be subjected to directives and CE making 39 SYNERGY IN MOVEMENT gt 4 MECHANICAL INSTALLATION 4 1 Safety requirements produ
19. 1 1 Specification of basic requirements e 1EC146 1 2 Semiconductor converters General requirements and line commutated converters Part 1 2 Application Guide e 1EC146 2 Semiconductor converters Part 2 Self commutated semiconductor converters e 1 664 1 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests e EC22G 24 CDV Power electronics Semiconductor power converters for adjustable speed drives Part 1 Low voltage variable frequency driver for general purpose for alternating current motors e EN60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements e EN60204 1 Electric equipment for industrial machines e 529 Degrees of protection provided by enclosures IP Code e 50178 Electronic equipments used in electrical power installations e 1EC61800 3 Immunity and emission conducted and irradiated CE Marking BLAST E was developed according to the European Low Voltage Regulations 73 23 CEE and 98 68 CEE and EMC 89 336 CEE The BLAST E drives are CE marked as far as EMC is concerned and regarding the inverter use according to the instructions contained in this manual 17 SYNERGY IN MOVEMENT 2 5 Overall Dimensions Weight and Terminal Boards BLAST E SIZE A b c d E quotes in mm BLAST E SIZE E TYPE WEIGHT Kg BLAST E SIZE A 2 5 BLAST E SIZE B 10 BLAST E SIZE C 21 BLAST E SIZE D 25
20. 2 4 8 12 kHz min 4kHz for SB mode 2 pole resolver 2 equal phases encoder top of zero line driver Supply Frequency 4 kHz resolution 11 bit rev Nominal current Motor current at the nominal voltage without load Nominal frequency Nominal speed nominal slip Nominal voltage Nominal Power Nominal COS PHI pole torques 0 1000Hz resolution 0 02Hz From 2 to 200 of the nominal motor value for SB and FVC 0 to 999 9 Trapezoidal and physiological S form Up to 20096 of the nominal current 15096 of the nom current 1 every 10 20096 of the nom current 10 every 10 1 Automatic 2 Manual with current reduction Analog 0 10V frequency0 100 kHz Resolution 8 bit sign 0 10 kHz Current or alarm limit Thermal Motor protection limit or Pt at choice Under voltage 400V DC Overvoltage gt 800 DC Thermal protection drive with displayed temp Short circuit between phases and toward ground Brake resistor thermal protection Congruence error for feedback control only Digital programming through 4 keys on optional keypad And through PC with free applicative with RS 232 option 4 seven segment displays on optional keypad or PC monitor with free applicative with RS 232 option DEVICE NET not opto insulated CAN BUS Device net PROFIBUS SERCOS RS485 Modbus RS 232 for PC connection Built in up to 22 Kw Buil in up to 11 Kw 15 SYNERGY IN MOVEMENT gt 2 4 5
21. 3 3 chapter Application of CEE law on the EMC directive 42 SYNERGY IN MOVEMENT 5 2 Connection Diagram SZ mains switch dimensioned for Current gt 1 5 In F fusestype gG chart 5 4 1 CM contactor dimensioned in AC1 current gt 1 5 In RFI filter at radio frequency L decoupling reactor MH x 10 20 Inom line thermal current gt Inx 1 15 chart 3 3 5 3 RF brake resistor if needed see chapter 7 P1 Feedback connector encoder resolver SR feedback device resolver encoder Lu see chart 3 3 5 5 M squirrel cage asynchronous motor or BLAST brushless or SSP motor INVERTER WARNING DO NOT MOUNT THE FILTER ON THE DRIVE OUTPUT a instead of switch SZ and fuses it is possible to use an automatic switch having nominal current gt 1 2 l an adjustable magnetic releaser 5 10 1 b when a protection to ground is used a less sensible to high frequency values should be chosen to avoid anomalies the current threshold should be gt 200mA and the intervention time at least 0 15 see charts 3 3 5 1 and 3 3 5 2 In case decoupling reactor is planned it should be dimensioned for current gt 1 2In 43 SYNERGY IN MOVEMENT m 5 3 Cable Size Wiring Notes on Use 1 the power cables must be dimensioned for 600 Va c 1000 Vd c In the same way the motor cables as well as those for the brake resistor Power cables and wiring must be far away from the control one
22. Intermediate alarms 9 Oldest alarm 98 SYNERGY IN MOVEMENT 10 2 Error description Removing causes Overload of the E 24 LOW supply available supplies Verify the entity of 24V dc too low voltage for the to the P3 ihe load in use of correct system operation connector the maximum available supply Missing of a supplying phase Verify the mains voltage E Uu Min Voltage Mains with wrong the presence of all the Not sufficient DC LINK supply nominal voltage phases Check the integrity of the fuses 99 SYNERGY IN MOVEMENT Wrong mains Verify the mains is within supply 15 of the nominal value E ou Max voltage DC LINK voltage beyond its limits Control the working turnover Wrong mains and eventually increase the supply deceleration time ramp Verify the right operation within the braking if implemented disconnected braking resistance if available set again the wiring Increase the deceleration ramps increase the braking resistance Verify the working turnover Hyperactivity of and or the dynamic charge the dynamic Eventually power the dynamic braking braking killer resistance and resistance increase the homonym variable setting E br KILLER Short circuit on the Verify the electrical Excessive use of dynamic braking connections the dynamic killer resistance braking Wrong Have a look on the relative parameter par
23. a procedure to be followed or avoided so to properly carry out an installation repair or replacement without damaging the device NOTE It is used to further clarify an instruction repair or any item The indications will be provided with the following symbols Situations that may cause serious danger to the operator always going along with CAUTION Cases when voltage can generate danger for the operator Always going along with CAUTION Means that operations are being carried out where electrostatic discharges are given Always going along with WARNING gt gt SYNERGY IN MOVEMENT gt 1 3 General Safety Requirements This section contains information regarding the safety of the personnel operating with BLAST E The general information regards the risks around operations and servicing of the devices Operators and personnel in charge of service must be informed on all dangers related to high voltage and frequency as well as know all related safety procedures CAUTION All maintenance and installation operations on BLAST E must be carried out by trained and therefore qualified electricians AN 1 BLAST E and connected devices must be adequately grounded 2 Do not mount the EMC filter when BLAST E is connected to a floating supply If BLAST E with integrated EMC filter is connected to the mains without ground the supply would be connected to the ground frame through the filter s capacitors Such configu
24. again Auto Tuning Error Alarm during the resolver tuning 3233913232123 Over speed Over speed passing of the maximum programmed speed 96 SYNERGY IN MOVEMENT Param Config Wrong parameters Brake Overcurrent Brake Overcurrent Default 160ms 10s E AS Irreversible alarm Reference 4 20mA HW problems PLL x TAL not hooked FAULT active during startup Ref x3mA m Not pre charged DC LINK Capacitor charging failed Detached resolver Error in the resolver connection in SB mode Missed phase SSP configuration Missing of one of the three supplying phases only for size gt 22kW Missing of the motor chart for SSP control 333558 Wrong SSP chart Motor chart for SSP control incongruent if compared to the BLAST size in use 97 SYNERGY IN MOVEMENT 10 1 2 Alarm Memory Display To enter the alarm memory press keys DOWN STOP and ENTER together The last 10 occurred events can be displayed Alarm number from 0 to 9 is shown on the display s left side alarm 9 oldest alarm followed by the alarm code see code chart e UP START displays the next less new alarm e Key DOWN STOP display the following oldest alarm e Key FUNC SPEED goes back to the main page ESCAPE Alarm memory chart 5 2 5 1 ALARM NUMBER ALARM CODE 0 Latest most recent alarm 1 8
25. are extremely compact reliable and cost attractive as well as easy to use they can find application in all application fields for sinusoidal brushless servomotors three phase asynchronous and SSP motors The DSP control system allows high programming flexibility The PWM modulation and the low loss semi conductive devices grant the drive s high efficiency SYNERGY IN MOVEMENT mt 2 2 Use of BLAST E The BLAST E drives are suitable for single or multi motor systems with asynchronous or sinusoidal brushless motors and can satisfy any need for most different simple or complex applications compressors pumps centrifuges centrifugal pumps for central heating stations and water sources Machines for textile and paper industries Ventilation systems Conveyors conveyor belts and packaging machines Textile machines machines for wood and marble manufacturing Liffs goods elevators hoist cranes Separators fans and feedstuff companies mills Printing machines and typographic presses Presses supplies steel cut positioners and other machines for the metal manufacturing Extruders boiler plants 23 Identification Code and Plate BLAST E is encoded as follows 0 0 2 2 B B H Product type Size in kW See electric data charts Nominal Supply Voltage A 220 240 Vac B 380 480 Vac SIZE 0 75kW 5 5kW 7 5kW 22kW C 30kW 45kW 55kW 75kW 90kW 160kW Duty H Standard o
26. at O the filter is bypassed P 6 Proportional constant of the flux PI control Acts in flux reduction only and for the FVC control mode Range 3000 P 7 Kiflx Integal constant of the flux PI control Active in flux reduction only and for the FVC control mode Range 3000 P 8 K Feedback Feedback scale in case of processing PMS using Range 0 0 to 10 0 e g if at 1 with 2V at the analog input AN2 it is read a feedback level of 1076 of the scale end value P 9 Gain Proportional constant used by the processing PID control Range 0 00 100 0 P 10 TI Time Constant in seconds associated to the integral action of the PID Range 0 00 1 00 sec If at O it disables the integral action and its effect increases for small values 0 1 max effect P 11 Td Time constant in seconds associated to the PID derivative action Range 0 00 1 00 sec If at 0 it disables the derivative action 0 1 gt max effect 1 gt min effect P 12 PROC PID Abilitation setting of processing PID there are 3 selections available and precisely 0 disabled the drive operates in the standard way 1 5 positive correction 5 if the feedback decreases its value as the setpoint the output frequency increases Vice versa a feedback increase will cause a decrease of the output frequency 2 Negative correction 5 if the feedback increases as the setpoint the output frequency will increase Vice versa if the feedback decre
27. current injection in the motor and shaft revolution till the 8076 of the nominal speed WARNING The drive shaft must be free from mechanical constraints The absence of this advert damages the results and could cause damages to the people or things because of the revolution which is automatically controlled 7 5 3 On Line calibration procedure with SFT 1 Logon the plate data In nN Cosfi 2 first of all do the pre calibration in off line tuning pushing the Drive pad on the Xblast interface mode 1 3 enable the drive and verify that the idling motor without load rotates correctly If necessary use the speed optimizing the constants eventually penalize the performances till a stable rotation Disable the drive 4 With the free drive shaft push the Commissioning pad on Xblast and select the DRIVE ON command On the interface there is a yellow led to notice that the calibration is in process It is possible to interrupt the procedure in every moment inviting the DRIVE OFF command The auto tuning finishes with the shutting down of the yellow led on Xblast it is necessary to send the DRIVE OFF command 5 Enable the drive and verify the rotation stability If necessary act on the PID constants to optimize the passband of the speed ring 86 SYNERGY IN MOVEMENT 7 6 Commissioning of the resolver position for sb 7 6 1 Start of the Commissioning with Xblast Select the drive supervision item Push the tune reso
28. frequency that guarantees an adequate current resolution An adequate min FPWM has obviously to be selected e Acceleration deceleration time depends on the torque delivered by the drive system motor inverter related to the load torque and the system inertia A too short time especially for the SVC mode can cause the intervention of the max voltage and or max current protection the automatically adjusting acceleration deceleration function increases the time in order to avoid the protections 13 4 Motors e APPLICATION WITH STANDARD OR ALREADY EXISTING MOTORS The continuous torque delivered by the motor due to the reduced ventilation fan on motor shaft decreases according to the typical law The motor performances have to be previously checked with the manufacturer Typical curves Torque C Cn 2 00 1 75 1 50 1 25 1 Motor with self ventilation permanent torque 2 Motor with ext ventilation permanent torque 3 Transitory overtorque 1 4 Overspeed torque at constant power 1 0 95 0 75 0 50 0 25 0 0 50 100 150 200 Frequency 1 Overtorque limited at 1 1 Cn applied at variable N B Exceeding the motor s nominal speed must always be allowed by the manufacturer due to the necessary checks from a mechanical point of view bearings balancing etc e APPLICATIONS exceeding F nom The manufacturer must be contacted There may be vibration problems unbalance of the rotor load vibrations the moto
29. further information about the XBLAST software refer to chapter n 6 93 SYNERGY IN MOVEMENT 9 SOFTWARE update WITH RS232 9 1 Firmware programming in short Operations to carry out in order to download the software update 1 Disable the drive 2 Enter variable Select through program XBlast inside parameter group DRIVE and set 1 The set value is automatically zeroed by the positioning function If that does not happen the drive is not disabled yet Close XBlast and execute HyperTerminal Switch BLAST off and then on again On the HyperTerminal the message sent by the positioner will appear RO EARP SpA S Record loader Version 1 1 Waiting for data in 30s 6 Select Send text file under menu Transfer then enter updating FILE S anyway within 30 sec Wait for transfer end and close HyperTerminal After transfer ends the new program is carried out automatically The wait time out for the new update sending is 30 seconds After this time the program already stored is executed In this case the cycle has to be repeated starting from point 2 Oo ON Instructions for a detailed programming are available in the cd attached with the product 9 1 1 Available modes The DRIVE BLAST grows configured as inverter for asynchronous motors but it can be configured with the following software FVC SVC SB SFT BR POSITIONER SSP SSP POSITIONER For further re
30. inserted PWM dl 0 5 Modulation frequency for SVC and FVC 1 5KHz 1 2KHz 2 3KHz 3 4KHz lt 4 8KHz 5 12KHz per SB 4KHz 1 8KHz 2 12KHz Random 2 0 10 Random frequency Size on set PWM ee 61 SYNERGY IN MOVEMENT NAME Keypad Code UNIT RAN GE DESCRIPTION svc FVC SFT SB SSP Setup d3 Hex Drive commands designation to the serial door 0 hardware commando Possible Selections Drive enabling Reference enabling CW CCW auxiliary reference enabling alarm reset Torque Speed selection 1 HW SW reference Hw sw auxiliary reference moto potentiometer analog frequency auxiliary OUT 10 10V 4 20mA reference Setup2 d4 Hex Configuration of the current supplied managing possible selections Re entry in overvoltage Overload alarm in overcharge PWM re entry in over calibration fix PWM declassing in function of the selected PWM SFT with 1 8 outflow SFT with 1 4 outflow Size d5 max size Module size see Sizes chart Killer d26 0 10 Limited by the duration of the intervention of the braking resistance 0 160ms max in 105 1 250ms max in 10s 2 500ms max in 10s 3 750ms max in 10s 4 1000ms max in 10s 5 1500ms max in 10s 6 2000ms max in 10s 7 3000ms max in 10s 8 4000ms max in 10s 9 6000ms max in 10s 102
31. integral keypad The keypad is an optional part allowing the parameters input and display as well as the display of occurring alarms and operating status The inverter visualization unit consists in 4 displays with 7 segments UP START Increasing the displayed variable DOWN STOP Decreasing the displayed variable or alarms RESET FUNC SPEED Function selection or ESCAPE ENTER F R Confirms the selected operation CONFIRM KEY INCREASE KEY or rotation sense or Run inversion DECREAS KEY FUNCTION KEY or Stop and Reset or speed These key functions are active when the drive is controlled through keypad d3 setup 6 3 1 Programming With Keypad Three main operations are selected through the keypad 1 Parameter setting 2 Resolver setting 3 Alarm memory Some examples are shown below 48 SYNERGY IN MOVEMENT mt PARAMETER SETTING PASSWORD 1099 press 3sec ALARMS MEMORY RESOLVER ADJUSTMENT ress 3sec ready program starting condition digit password USING pads scroll from O ae 9 press to display ulterior errors in the same position confirm with keep pressed start 3sec With program in function set d3 87 choose the parameter to be modified daca taratura resolver confirm with press back to STOP display and setting 49 SYNERGY IN MOVEMENT mt To use the drive quickly the keypad has a motopotent
32. it may be necessary to place a reactance between drive and motor This is recommended for all multi motor applications more motors connected to the same drive 14 Respect the directions of 3 3 chapter Application of the CEE normative on the EMC directive 46 SYNERGY IN MOVEMENT 6 Data display and programming 6 1 Factory Setting gt BLAST E is set for SVC mode as default which means to control asynchronous motors through Hiper Terminal by Windowse the other control modes can be downloaded SFT VFT from the attached CD After setting the mode the user can visualize and set parameters either per keypad option or with software XBLAST though a normal PC having windows 95 or later versions installed Option BLAST OPT0031 is needed as well see 2 3 2 6 2 Modifying Parameters The parameters can be modified through keypad or software XBLAST delivered along with the product The parameters displayed by the keypad or through the XBLAST menu are shown below DISPLAY DESCRIPTION XBLAST MENU parameters MOTOR r parameters RUN d Control parameters DRIVE Parameters of the drive s inputs and outputs Parameters of the drive s outputs Communication parameters COMM P P 1 D parameters 1 Parameters for the option cards OPT CARD 47 SYNERGY IN MOVEMENT 6 3 Description of the
33. measuring their phase shift calculates the instant cos finds mathematically the current components estimates the induction to the rotor estimates the supplied torque and decides in real time which current component is to be changed to obtain the necessary speed and torque Measuring furthermore the instant speed and finds the flowing compensating it entirely 72 SYNERGY IN MOVEMENT Ma FIELD ORIENTATION CONTROL SCHEME ORQUE LOOP Tox RQUE rque set PI SPEED LOOP CURRENT LOOP vd ib j i D H SVM N ic A iq rin Q ao we 13 id PAN FLUX LOOP vq io gt 4 id L d m 4 N err ap 1 da im ab E in S Ome On The estimate precision is directly linked to the knowledge of some parameters as the stator resistance phase phase the rhetoric time constant the dispersion inductance the curve of the motor magnetization All of these limits the application to a single motor because it is impossible to compensate independently more motors connected in parallel In order to do precisely the compensations above BLAST is able to auto acquire the motor parameters following An automatic procedure that expects the current injection
34. not limited intervention Off DCLink 21 100 450 Offset voltage DC Link accessible only by pad reserved calibration Enc Out dl imp rev Encoder simulation revolution pulses 9 Enc In 17 imp rev Nominal revolution pulses of the feedback encoder Feedback 18 Feedback type 0 no one 1 encoder 2 2 poles resolver 62 SYNERGY IN MOVEMENT back 5 adaa UNIT RANGE DESCRIPTION gt 2151919 Off res dig Resolver offset timing Q Num of d20 Index number in the encoder revolution Index TOP ZERO number 1 index 1 2 indexes 2 4 indexes Select 25 Available only from XBlast DIG RUN GEAR CONFIGURATION Jogl d Hz 1 pulses speed elelelele Jog2 d7 Hz 2 pulses speed elelelele Jog3 d8 Hz 0 00 3 pulses speed elelelele Fmax Dig d9 76 100 0 Fmax Dig Ref 2 100 0 Fmax Digital reference To enable it selection Dig Ref 3 dll 100 0 Select 0 1 2 on the settable input Fmax DIN 1 6 to which it is associated the Dig Ref 4 12 100 0 hardware command for the digital elelelele Fmax activation see also digital speed Dig Ref 5 d13 100 0 function Fmax Dig Ref 6 14 2 100 0 Dig Ref 7 15 100 0 Skip f1 d22 Hz Frequency hop N 1 Skip f2 23 Hz Frequency hop N 2
35. oO N Input Phase MAINS Ground Shields Output Phase MOTOR Output Phase V MOTOR Output Phase W MOTOR Motor ground Shields U External brake resistor External brake resistor External brake unit External brake unit 23 SYNERGY IN MOVEMENT iag 2 6 2 Terminal Boards For case A and B up to 11kW For case B 15 to 22kW PE PE For case C PE 24 SYNERGY IN MOVEMENT gt 2 6 3 Control section The control section consists of several interfaces and one microcontroller unit The control board receives and operates the motor current and filter capacitor voltage signals and sends six command signals to the IGBT modules The access to the inverter control is given by the command and programming keys as well as the interface circuits connected to the control terminal board 2 6 4 Control Board Blast e regulation board description ME S S 0000000000006 o0000000 0000000000000 1 Connector for options Display serial ports etc 2 P3 Digital in out connector P4 Analog in out connector and Device Net P5 Encoder resolver input connector P6 Connector optional back up Switching 7 F1 Supply Connector SW1 OD analog output selection frequency SW2 Dipi setIn 0O 10V 4 20mA Dip2 Can bus term if Can bus is not used it must be ON p U3 DSP micro
36. of the motor Range 0 50 0 99 M 10 Poles Number of pole pairs on the motor Range 1 5 pole pairs 2 10 poles M 11 Rs Stator resistor of the motor starry connected or 1 3 of the phase resistance for triangle connections expressed in 1 100 Ohm In case of SFT control mode this parameter must be entered to improve he motor s performance at low speed There are more ways 1 motor parameters auto acquisition with injection of current 2 automatic calculation of the resistor basing on the plate data being entered In the second or third case the sequence to follow with XBLAST applicative to do the automatic calculation is described in COMMISSIONING paragraph 12 515 Typical stator inductance of the motor being used in 1 100 mH as RJ this value is automatically available with some distance automatisms in the COMMISSIONING paragraph M 13 TauR Rotor time constant in ms M 14 Lm Magnetization inductance expressed in 1 100mH 7 3 2 RUN parameters To such group belong all typical RUN parameters parameter group r 0 S Ramp Easier quote arrival on the reference set r Acc Time indicated in 1 10 sec needed to carry out a positive speed variation from zero to max value set with parameter no 8 Range 0 0 s 999 9 s r 2 Dec Time in 1 10 sec needed carry out a negative speed variation from the max value set with parameter no 8 nMax to zero Range 0 0 s 999 9 5 69 S
37. operating revolutions number Cosfi M9 0 30 0 99 Power factor Qoo Poles MIO 1 5 Number of poles couples e olo go Rs M11 Ohm Phase resistor for star connected motors or 1 3 of the phase resistor connected in triangle SLs M12 Stator inductance TauR M13 ms Time constant of the stator Rd circuit Qe Lm M14 mH Magnetization inductance 60 SYNERGY IN MOVEMENT prag UNIT RANGE DESCRIPTION gt 25219 RUN PARAMETRI DI MARCIA S Ramp ro 0 100 Variation time on the speed set ACC rl 10 0 Accelerating time at the start 999 9 DEC r2 S 0 0 Decelerating Time at the stop 999 9 Timax r3 0 1 10 0 Motor s overload limit time 121 Msr r4 Hz 0 3 Min speed relay threshold in Hz Fmax T cong r5 S Congruence error limit time for SVC only if e ele cie feedback S cong r rpm Window for congruence error handling for SVC only if feedback ee ere lt r7 Hz START UP stored reference elelele VO r8 O Voltage Boost for RI compensation 30 UIn fO r9 Hz 0 0 Frequency level at which VO stops 6076FIn Tbrake 10 00 Rif abilitation delay for parking brake e ele ce 10 00 Ftw rll Hz Low filter cutting on the speed observer In elelele SSP control it works as filter for speed Pid r12 Unused DRIVE DRIVES PARAMETERS Type SVC SB Indicates the drive depending on FVCSSP the Fw
38. resist 10kQ V WARNING 1 The drive contains components which suffer from electrostatic charges and can be damaged if handled in a not proper way In case of replacement or servicing on the electronic boards the following has to be taken into account 2 The boards should be touched only when strictly necessary in order to do the planned job Anyway a service set against electrostatic discharges has to be used grounded metallic strip to be applied on the operator s wrist along with a piece of conductive material to put the board on 3 The boards may not touch high insulating materials such as plastic sheets insulating surfaces synthetic cloth parts 1 4 Documentation The documentation of Blast e inverter as well as providing this manual it supplies also publications for specific applications or system optional they can be found in the CD supplied with the product NOTE Requirements regarding transport storing and unpacking are contained in this manual IN MOVEMENT a 2 Drive DESCRIPTION 2 1 Introduction EARP spa has developed BLAST as Servo Drive able to 1 Control brushless and asynchronous motors 2 Be configured and updated anytime from a PC NB the product is actually available with SVC FVC SB SFT SSP mode The BLAST E drives were conceived for most different industrial applications and allow a continuous speed control of brushless and asynchronous from 0 to a max value They
39. 130A 26 0A 130A 11 0A 9 0 5 5 kW 0075 16 5 33 0 16 5 16 5 14 7 5 kW 0110 25 0 50 0 25 0 21 0 16 5 11 kW 0150 31 0 62 0 31 0 31 0 22 0 15 kW 0180 39 0 780A 39 0 33 0 25 0 18 kW 0220 45 0 90 0 45 0 39 0 31 0 22 kW 0300 62 0 124 0 30 kW 0370 760A 1520A 37 kW 0450 90 0 1800A 45 kW 0550 1120A 224 0 A 55 kW 0600 200 240 0A 60 kW 0750 150 0 300 0A 75 kw 0900 180 0 360 0 90 kW 1100 2200A 440 0 110 kW 1320 260 0 5200A 132 kW 1600 300 0A 600 0A 160 kW M 3 Uln Nominal motor voltage in Volt Range 280 V 600 V 4 Nominal motor frequency Hz Range 25 Hz 999 Hz M 5 Fmax Max output frequency of the inverterin 1 10 Hz Range 0 1 Hz 999 9 Hz M 6 Fmin Parameter in 1 10 Hz indicating the min frequency for the drive to start operating to the motor which is If the parameter is set at 0 0 proportional to the value set under variable r 9 Range 0 0 Hz Fmax M 7 nN Nominal motor speed in rom Range rpm 30 000 rom 8 Scale end speed reference rpm Range 1 rpm 30 000 rpm the drive delivers a continuous current gt 68 SYNERGY IN MOVEMENT Ma donot exceed the motor s plate data NOTES Besides 9999rpm the keypad changes automatically the display in Krom rpm x 1000 E g 20 000 20 00K M 9 Cosphi Power factor
40. A 0 Opt Keypad Display Set value Control selection 0 CURRENT A 1 SPEED RPM 2 VOLTAGE V 3 TEMPERATURE 4 PROC PID feedback CAN DeviceNet A 2 MAC ID Baudrate 02125 12250 2 500 A 4 OutPut inst 5 inst Profibus 6 Slave Address 7 Ident No 84 SYNERGY IN MOVEMENT RS485 A 8 Protocol 9 Baudrate A 10 Address 0 Reel W3 1 ModBus RTU 0 9600 1 19200 2 38400 3 57600 4 76800 5 115200 6 230400 A 11 Parity none 1 ODD 2 EVEN 7 4 Commissioning gt Blast has been developed to automatically perform the main calibrations of the various controls to ease and accelerate the starting operations First of all the process is about the acquisition of the intrinsic motor parameters the current ring calibration when implemented The starting operations of the auto calibration process are common to all the variables of the commissioning menu and could come from the XBLAST applicative software According to the requested commissioning the procedures change Commissioning Starting with PC from the supervision menu select drive supervision push the commissioning pad select the wanted available function push the start pad AxBlast EARP Spa Dive Automation Jools Window Help Wow DC Link Temp C amp Drive Supervision INPUT ENT OFF ENZOFF
41. EARP S p A Via Riviera Berica 44 36024 Ponte di Nanto Vicenza Tel 39 0444 730508 Fax 39 0444 738546 SYNERGY IN MOVEMENT e mail earp earp it http www earp it SERVODRIVE BLAST E INSTRUCTION AND USER MANUAL Code BLAST MNU 0000 ING Revision 1 7 Issue November 2007 SYNERGY IN MOVEMENT INDEX Io qe 2 L FORE W ORD 5 1 1 NOTES ABOUT THE MANUAL ee 5 1 2 DESCRIPTIONS AND SYMBOLS 6 1 3 GENERAL SAFETY REQUIREMENTS 7 1 4 DOCUMENTATION E eee 8 2 OX 9 2l INTRODUCTION 9 2 2 UIN NIMI E EE S E E A 10 2 3 IDENTIFICATION CODE AND PLEATE E AEE E ESS 10 How To Read e E A aN a 11 2 32 Option COMES EH 11 2 4 GENERAL FEATURES AND TECHNICAL DATA OF THE BLAST E 12 2 4 1 General Inverter Features eese a basses saei tese asses 12 2 4 2 Technical Data Blast E range eie od eT UE BE Hus ere pete Renee 13 24 3 PWM Frequency Of Blast E 14 2 4 4 Blast E General Featur
42. Environmental conditions for Blast E operations Protection Degree IP20 IEC 529 Operating Environment Conditions for BLAST E installed in a fix and protected place Weather protection according to IEC 721 3 3 e Room Temperature for BLAST E 0 40 In case of room temperature higher than 40 C derate the nominal output current of 2 5 for each exceeding degree max 50 or PWM derating can be set Relative Humidity 5 85 96 non condensing e Altitude of the installation place up to 1000 m above the sea level beyond 1000 m a s l the nominal output current is derated of 1 every additional 100 max 2000 Storing Storing environment conditions for BLAST E inside its package environment protected according to IEC 721 3 1 e Room Temperature BLAST E 25 70 Relative Humidity 5 95 without condensing or freezing Transport Transport conditions for BLAST E inside its package according to IEC 721 3 2 Temperature 25 70 Relative Humidity 95 at 40 16 SYNERGY IN MOVEMENT 2 4 6 Cooling BLAST E has a fan inside with air flow upwards m h Ventilation Fan flow BLAST SZEA BLAST E SIZE B BLAST E SIZE C 340 BLAST E SIZED 480 BLASTESIZEE 2 4 7 Regulations BLAST E was developed according to the regulations mentioned below as far as applicable e EC146 1 1 Semiconductor converters General requirements and line commutated converters Part
43. OVEMENT 2 control system is the torque flow regulator which decides the commutations according to what has been elaborated at the same time The result is a drive able to answer to torque couple in few milliseconds with a speed precision lower than 0 576 according to the motor nominal flowing without speed feedback to reach the 0 1 with a sufficient speed feedback This special modulation technique permits to save the IGBT commutation number the middle modulation frequency is lower also of the 30 in comparison to a normal PWM control with consequent reduction of the thermal dissipation losses of the drive This kind of control is damaged only at very low revolutions lower to 1Hz for a motor of 50 2 where the working frequency particularly low and the commutation pulses because of the low voltage to be applied to the motor limit the precision degree of electrical measures Anyway it is not kept a limit in the 95 of the applications because it is considered transitory Scheme of torque direct control Motor parameters A Calculation Switch o gontrol Inverter T Calculation 74 SYNERGY IN MOVEMENT SINUSOIDAL BRUSHLESS CONTROL SCHEME Inverse Park Transformation O j O P AH iq A Speed calculation Park Clarke Transfomation Transfomat on p polar torques Om motor angular position Ome electrical angle
44. RESOLVER POSITION FOR 5 87 7 6 1 Start of the Commissioning with 87 7 7 COMMISSIONING CURRENT LOOP PIN EEE E E kee 88 TIA 88 Experimental 88 7 8 CONTROL CALIBRATIONG ccccccssssscecsessececssececessececcsessececsneeeeessaeeecsssaececseeeeceesaeecsesaececueeessesaeeecsesaeeeceeeeeeesaeeeeeseaaes 88 L8 T Parameters AESP UON 88 7 8 2 Modulator SVC SFT SB controls esses eret nennt nnns 89 7 8 Speed loop calibration des 91 Sy e sj S 92 8 1 INTRODUCTION T 92 8 2 SERIAL INTERFACE WITH DEVICENET PROTOCOL 93 9 SOFTWARE UPDATE WITH 9232 kava 94 9 1 FIRMWARE PROGRAMMING IN SHORT 2 94 OTT Available moules 4 94 ETE 95 SYNERGY IN MOVEMENT IRFORE P 95 LOD Alarm Display ede eie tede esed ter 95 10 1 2 Alarm Me
45. SVC W3 control uses the V Hz relation in the vectorial way in the calculation algorithm the voltage parameter is like a vector in rotation to the required frequency In this way the compensations actuated by the control to the various speeds grant an elevate level of torque already at very low revolutions At a supply frequency of 1Hz there is the nominal torque of the motor supplying the only plate current 71 SYNERGY IN MOVEMENT gt The voltage vectorial control is especially indicated for applications where more motors are connected in parallel and piloted by the same drive not accepted condition by other controls as the pure vectorial inverter The major advantage of this control is that it does not require the speed feedback only to compensate precisely the increase of the flowing according to the load condition not always required because a partial compensation is already sensorless V Hz CONTROL SCHEME Speed calculation Ome Om Polar torques Om Motor angular position Electrical angle e FVC pure vectorial inverter It is in absolute control and performing for drive with asynchronous motors Differently from the impressed voltage inverter it is able to manage the supplied current to the motor distinguishing the flow component from the examined one to the torque The electronics examines constantly all the phase currents it compares them to the applied voltage by
46. Sensorless control pf SSP speed and position It is a Drive Motor system focused on the estimate of the rhetoric position to permit always the correct orientation of the filed and the maximum torque An algorithm based on the perfect knowledge of motor parameters BLAST is able to control the rotation corner position of SSP motor and then its speed with absolute precision SSP Sensorless Speed and Position is bound to change and substitute the great part of the handlings realized with controls with closed ring and not The drive observe analytically the flowing of the current supplied to the SSP motor which thanks to its special construction brings the necessary information to find the drive shaft position The position is reached reading the same motor as it is a sensor to obtain Speed precision absolute in absolute SENSORLESS for all the regimes Control of the position or the space done WITHOUT THE FEEDBACK AUXIL The granted speed is the set one with an error margin of 0 01 1 10 000 which is comparable to the declared error by a good control with closed ring feedbacked by a speed transducer of good technology the position error of the drive shaft position is 1 5 mechanical degrees the availability on the same position is 0 1 0 2 75 SYNERGY IN MOVEMENT
47. YNERGY IN MOVEMENT Ma r 3 Timax Maximum delivery time of the current set under parameter Imax The drive measures the current delivered beyond nominal current lan carries out the integral and compares the value to the threshold which is equal to Timax Imax lan Once exceeded the current is limited to the lan value in SB controls SSP and FVC or intervenes the E alarm The Thermal Alarm in SVC SFT control Range 0 05 10 0 s 4 msr Hz and msR rpm Min speed relay threshold in Hz and rpm in accordance of the used control Range 0 3 Hz Fmax Hz and 5rpm Nmax r 5 T cong Max operating time in presence of a congruence error It is linked to parameter S cong with which alarm congruence error is handled Range 0 0 s 2255 0 s r 6 5 cong This parameter handles the congruence error alarm together with T cong Range rpm Nmax This alarm occurs when the motor speed does not follow the speed set correctly if for a longer time than the set one with the parameter r 5 T cong the error between the set speed setpoint and the feedback exceeds the value set with parameter 6 S Cong there is the congruency alarm The alarm is not handled when one or both parameters is 0 The control is useful both in case of overload on the motor shaft and in case of failure of the feedback transducer 7 memo Parameter saving the initial digital speed reference r 8 VO Voltage value applied to the motor
48. abinet parts free from command or control devices 8 In the application in which more motors are connected to only one drive and because of a derivation terminal board of each cable it is not possible to perform the shielding for the drive output provide output toroids Anyway minimize the distance between drive output and terminal and shield the cable below from the terminal towards the motor 9 In pluri motor applications and or with power shielded cables or also with lengths gt 25m 50m for non shielded cables to compensate the capacitive dispersion current towards ground and reduce the voltage gradient on the motor additional reactance are necessary or drive output filters These directions help the attenuation of RFI phenomenon v NOTE The use of ferrite rings or reactances does not satisfy the limits prescripted by the EMC The use of a long shielded cable for the inverter motor connection and or input filter may lead to the intervention of some differential switches caused by the dispersion current to the ground due to the switching frequency and the capacitors inside the filter Solutions Replace the differential switch with a less sensitive one Feed the inverter through an insulation transformer ES For shielded cables with lengths superior than 10m verify the parasitic capacity WARNING does not induce to much phase phase dispersion or towards mass It can causes the block of the converter Anyway it can not be connecte
49. agraph 100 SYNERGY IN MOVEMENT Disabling for Defected module or protection of the declassed capacitors Have capacitors charge look on the assistance circuit service E dc failed pre charge Failed attempt of capacitor modules pre charge Failured pre charge Look the assistance service circuit up Control The line fuses integrity E mF Missing of a Missing of one of the Line insertion mains contactor supplying phase power phases integrity The tensions levels of the three line phases 101 SYNERGY IN MOVEMENT Ma 11 BRAKE UNIT 11 1 Foreword The drives up to 22kW are provided with a brake unit which is needed when the required brake torque is about 2095 than the motor s nominal torque related to the drive brake torque values gt 150 are not allowed class 2 The drive is delivered with built in brake resistor up to 11kW with brake unit up to 22kW optional ext resistor from 30kW upwards the brake unit is an ext option It is possible to ask for a special configuration in the code from the letter F adding because of this for the user there is the possibility to connect an external braking resistance also for the size up to 11kW E g BLAST E 0022 standard method which has the resistance inside the DRIVE BLAST E 0022 BAHF special method which has the exit B1 and B2 for the connection with an external resistance Chart 11 1 1 Max currents for modules with extern
50. al braking Resistance PRODUCT I MAX BRAKE BLAST E 0007 BAH 10A BLAST E 0011 BAH 10A BLAST E 0015 BAH 10A BLAST E 0022 BAH 10A BLAST E 0037 BAH 10A BLAST E 0055 BAH 10A BLAST E 0075 BBH 17A BLAST E 0110 BBH 25A 11 2 Installation The external brake resistors must be installed in a position not damaging the drive Under normal conditions the resistor duty cycle does not exceed 2096 and their power is chosen according to this data They must therefore be protected an adequate thermal relay whom intervention must open the supplying line of the inverter and not the resistance supply CAUTION EACH RESISTOR NEEDS ADEQUATE THERMAL RELAY PROTECTION A OPENING THE MAINSCONTACTOR IN CASE OF INTERVENTION 102 SYNERGY IN MOVEMENT 11 3 Resistor Choice When the speed frequency of an asynchronous motor decreases very quickly the motor itself acts as asynchronous generator and recovers energy to the drive Part of that energy is dissipated as losses 10 20 of the motors nominal power while the rest is charged on the capacitor of the intermediate circuit with consequent voltage increase at its ends To avoid the voltage on the capacitor to reach too high levels the dynamic brake unit is used An electronic circuit detects the voltage on the capacitor when the voltage exceeds a certain value a command is given to a transistor activating the brake resistor in parallel to the capacitor
51. ally modify the values 88 SYNERGY IN MOVEMENT Ma 7 8 2 Modulator SVC FVC SFT SB controls FPWM modulation frequency kHz It is possible to choose the modulation frequency between the following 2kHz 3kHz 4kHz 8kHz 12kHz Notice that at the frequency increasing the thermal dispersions of the IGBT module increase because of the greatest number of commutations For modulation frequencies of 8kHz and 12 kHz the suppliable current from the module is decreased as shown in the Blast manual chart Nevertheless consider that a modulation frequency of at least 4KHz is indispensable for the control of a motor with thrust outflow gt 2 or with high frequency gt 80 Hz Current regulator SVC FVC SFT SB controls Kpl proportional part of the current regulator Kil integral part of the current regulator Speed regulator FVC SFT SB SSP controls Kpw proportional part of the speed regulator Kiw integral part of the speed regulator Kdw derived part of the speed regulator Taud time constant of the derived action Flux regulator FVC SFT SSP controls Kpflux proportional part of the flux regulator Kiflux integral part of the flux regulator DC Link Compensation FVC control KpVCmp proportional part of the DC Link compensation KiVCmp integral part of the DC Link compensation This regulator reduces the magnetization flux maintaining the counter electric motor power fcem bemf in the limit allowed by the dc
52. ases there will be an other decrease of the output frequency 82 SYNERGY IN MOVEMENT back 5 P 13 FB VAL DISP Values from 0 01 to 10 000 Scale factor referred to the keypad display of the feedback signal useful for the conversion of the measure unit displayed with HZ or Rpm and other scales as meters minutes etc E g if placed at 2 and feedback 1076 it will display 20 7 3 6 Control parameters This parameters category optimizes the behaviour with the SSP and FUC controls vectorial control DC LINK Compensation for TVC control p 15 cmpV Proportional constant of the Dc link compensator p 14 KP cmpV integral constant of Dc link compensator p 17 StarKig deflowing torque starting limitation p 16 break Limit of the deflowing torque limitator DEBUG reserved parameter 2 reserved parameter 31 SHIFT reserved parameter SSP Control P 18 Kfil idest Filter on the flux feedback P 19 Kfil iqest Flux feedback Filter Value P 20 KLS Gain of the low speed model P 21 KHS Gain of the high speed model in the operation at low speed P 22 KHH Gain of the high speed model P 23 Ky Curves adapting constant P 24 Injection Amplitude of the injection signal for the position recognition The control modifies the current sinusoid with a disturb to recognize the corner position This disturb if could be heard if it is possible to decrement it penalizing the precision of the cont
53. at 0 speed To obtain the maximum performances it is available a special asynchronous motor different for the square shape of the housing This motor apposite applications with inverter is servo ventilated when it is required the permanence at low speed regimes The meeting between pure vectorial control and square motor realizes as status a drive which permits the enabling to elevated handlings both for dynamic answer and for high level of torque at revolutions e Inverter at direct control of the SFT torque It is the result of mathematical models of the application to the industrial handling The SFT control disturbs the classical system of IGBT modulation for the stator current control also if the structure of the power bridge is common to all the controls The supply of current is the result of mathematic elaboration able to control constantly the magnetization flow parameters and developed torque without need of a speed feedback The control with the only measure of the phase currents can calculate precisely all the variables of the motor Regarding a program cycle that lasts few dozens of microseconds it is examined the status of the motor and decided which IGBTs to be changed to satisfy the instant request of torque speed Resuming if in the normal systems at pulse modulation PWM a current ring requires to the modulator the supply and it deals with the commutation of the IGBTs in the torque direct 73 SYNERGY IN M
54. at frequency This parameter has a value only for the SVC control mode Range 0 Volt 30 r 9 10 the meaning of the two previous parameters is in the example in figure r 10 Tbrake Managing time of the handbrake if programmed 70 SYNERGY IN MOVEMENT Vnom fo fnom frequency r 11 FIW Speed observation filter It determines the cut frequency of the low filter useful to minimize the feedback disturbs for the sensorless it acts on the feedback estimate It has to be calibrated at lower values than 50Hz in sensorless vectorial controls SFT and SSP 7 3 3 DRIVE Parameters To this group belong the drive related parameters group d d 0 Type Indicates the control mode installed in the drive and it is not changeable reading only The modes are Inverter standard SVC They apply a linear law of the voltage frequency ratio to an asynchronous motor Fixed the nominal points e g 50Hz 400V the drive imposes a voltage and a frequency to the motor at 25Hz the motor is supplied at 200V at 15Hz 120V etc Only at low regimes the ratio changes to deliver the voltage drop on the internal motor resistance which limit the suppliable current and the torque For frequency value superior than the nominal the voltage is constant e g 70Hz 400V with consequent decrease of the torque to be obtained at current parity this tract is called constant power or for analogy deflowing The Blast
55. cabinet SPEED j START STOP ENTER roc sw 001 41 SYNERGY IN MOVEMENT gt 5 ELECTRICAL INSTALLATION 5 1 Safety Requirements CAUTION N Electrocution risk Disconnect the drive and wait at lest 10 minutes before removing the protecting cover of the control and power terminal boards and touch internal parts to work on the drive The drive must be protected by placing adequately dimensioned fuses on the mains supply The connection to the mains supply has to be carried out with a switch or contactor and protected with fuses Follow regulations in force as far as fuse size and cables are regarded See chart 5 4 1 for cable section The drive must be grounded before start Oversize cables better flat ones are recommended Ground terminal PE according to the regulations in force Do not mount the RFI filter on the drive output Make sure the drive has the correct size and is set for the motor to be connected otherwise both may seriously damaged or cause bad working of the machine plant they are part of Follow all the directions of
56. controller K2 000000000 2 6 5 Control Dip Switches SW1 1 2 Frequency Out 2 3 Analog Out SW2 dip 1 ON 4 20 mA input OFF 0710 V input SW2 dip 2 ON Can bus term on OFF Can bus term Off 25 gt 2 6 6 Description of the control terminal board P3 cour 2 rrr 01 FOULT 02 PROG 5 24 DIGITAL IN PROG 4 15 _ HIGH SPEED 6 SPEED BACK UP 24VDC 4B 10 9 0 2 11 110yo 10V El pa m IN2 OA 10y I Q NCC FREQ V lt CANSHIELD 8 CANH 19 CAN BUS PORT CANL 10 26 SYNERGY IN MOVEMENT gt RL1 relay contact DRIVE 1A 110 Vac AC1 RL2 configurable relay contact Line driver encoder supplying output 5V 150mA max Zero encoder supplying OV 150mA max input 0 5V line driver CHB input 9 Ps e input 1TOPO input Resolver 5 P5 SIN sin input 0 3V Impedance eff 20kQ REF supplying Resolver 4kHz 3V 80mA max GND shield connection P5 24Vdc output 24Vdc 100mA max ON215 30Vde OFFs3Vdc Pa imutiZ SWeomguabe Impedance2K 7 Pa ipuisSWeofguabe mane sw conga Fast mpatie SW configurable ON25 30Vdc OFF lt 2Vdc Fmax 100kHz
57. ct is constructed to be used according to the installation and CAUTION servicing procedures described in this manual and carried out by skilled personnel The user has to take care for the installation to be carried out according to laws in force on plant and workplace safety correct installation and connection only ensure good drive operating and performances All sections of the user manual must be read and understood before using the drive 4 2 Checking before installation A Avoid installing the drive on walls subject to vibrations B The environment for installation should be free from dust metallic parts oil gas and corrosive liquids C The drive is conceived for wall mounting and must be installed in vertical position only Horizontal assembling has to be avoided the maximum allowed inclination under operating conditions is x 30 D The drive easily operates at temperatures 0 50 A good ventilation must be ensured when the drive is installed inside a cabinet E When several drives are installed inside the same cabinet they have to be mounted one beside the other and not on top of each other F The cooling of the power components of the drive is obtained per external ventilation Enough space around the drive must be provided allowing adequate air circulation as well as wiring it must also be possible to operate for maintenance or service 40 SYNERGY IN MOVEMENT back Drawing assembling inside the
58. cted control mode are disabled The parameters have the same sequence asin the XBLAST software under menu MOTOR To such group belong all typical motor parameters parameters of keypad group Version available only from keypad The control and automation software version installed is indicated as follows SS AA SS is the software version in hexadecimal AA is the automation software version that could be installed also in hexadecimal If no automation is installed the two SS figures will be 00 see also parameter d 0 M 1 lan Nominal motor current plate data in Ampere The range for this parameter is from 0 1 A to a max value depending on the drive size and in case of SB control mode on the modulation frequency also see d 19 setup2 See chart 7 1 M 2 Imax Max current delivered by the drive in Ampere 67 SYNERGY IN MOVEMENT The range covers values from 0 1 A to a value twice the module s nominal current See char 7 1 Chart 7 1 shows the ratio between the nominal and maximum current for each drive size Variable FFWM Fix FFWM Size lan Imax Inom 4kHz Inom 8kHz Inom 12kHz POTENZA 0007 25 5 0 A 2 5 2 5 2 5 0 7kW 0011 3 5A 70A 3 5A 3 5A 3 0A 1 1 kW 0015 48A 9 6A 48 4 8 4 8 1 5 kW 0022 60A 12 0 6 0 6 0 6 0 2 2 kW 0037 9 5 19 0 9 5 9 5 9 0 3 7 kW 0055
59. d in the drive output a capacity superior than 5nF 3 4 5 I O The drive emissions through I O are the most negligible It is necessary to pay attention to mass connections and to shielding It is also necessary to use mostly differential analogical inputs and digital inputs provided of optocouplers 3 4 6 Converter casing It is important to focus on the irradiated disturbs they have an action area very limited The adoption of the chassis of the metallic inverter is sufficient to obtain a satisfying attenuation and also the dimensions of the drive are small in comparison to the RFI wave lengths so this can not be considered a very efficient antenna It is necessary to grant a good ground connection It is to be reminded that there is already a small tract of this connection could reduce a lot also the by pass effect of a mains filter The direct mounting in the same metallic panel of the converter and filters is always suggested Respect the principle of the starry connection of the grounds 37 SYNERGY IN MOVEMENT gt 3 4 7 RFI Compatibility Most of problems of EARP converter have been already solved in project phase Anyway it is necessary to respect some details The susceptibility of a drive could come from Power connection Environment O Grounding 3 4 8 Power connections The using of RC groups and varistors in the line input with the help of the input inductance suppress the great part of the pertu
60. d in the factory before shipment After opening the package check the following e Data on the label must correspond to the purchase order e Check for transport damages e Check for the quick guide CD to be inside the package In case of damages and or missing parts ask the freight forwarder and or the manufacturer for immediate info basing on the code and the ID plate 32 SYNERGY IN MOVEMENT mt 3 2 1 WARRANTY AND RELIABILITY ON THE DRIVE EARP S P A guarantees perfect quality and construction on the own products and shall repair or replace free of charge within shortest time those parts that should prove as detective except for those cases of failure due to wrong behaviour lack of experience of the purchaser or wrong use beyond the agreed limits not authorized interventions hazard or major force The warranty period is 24 months from delivery date provided the goods are stored with care and in adequate environment Nothing is due to the purchaser for the period of the plant s non activity nor will the purchaser claim for indemnity or compensation for suffered direct or indirect damages Freight costs for all devices repaired at the EARP Technical Centres are on purchaser s charge In Case of technical support on spot by specialized technical personnel related to the above mentioned events support and out of pocket expenses will be on purchaser s charge The work will be invoiced basing on the ANIE tariffs in force at th
61. ding household and non domestic uses which are directly connected without any intermediate transformer to a low voltage mains supply feeding buildings of the non domestic type SECOND ENVIRONMENT Environment including all plants different from the ones directly connected to a low voltage mains supply feeling domestic buildings RESTRICTED DISTRIBUTION Means that the constructor limits the delivery of the equipment to suppliers customers or users having technical experience and skill regarding EMC requirements on drive applications NON RESTRICTED DISTRIBUTION In this case the equipment is supplied independently from the customer s experience and skill in this field The conformity of BLAST E regarding the emission for the first environment restricted distribution or first environment non restricted distribution driver with nominal current Inom gt 25A according to EN 61800 3 is achieved by placing filters between mains and inverter and taking care of the measures mentioned in this chapter Since the installation of the RFI filter in the second environment is not strictly necessary it is up to the installer who shall evacuate e The supply source being common to other devices or dedicated e Immunity degree of other devices composing the cabinet 35 SYNERGY IN MOVEMENT gt EARP proposes a mains filters range which installed with Blast e reduces the disturbs within the normative limit Beyond the proposed filters g
62. e product The available controls are SB Sinusoidal Brushless as standard setting SFT Stator Flux Torque Direct Torque Control SVC Space Vector Control Voltage vector control FVC Flux Vector Control Pure vector control SSP Sensorless Speed and Position Position and Speed Sensorless control Positioner Posiblast Positioner available in BR and SSP modes The user once programmed the Drive with the dedicated SW can display and set alll parameters through the optional keypad optional or through a 232 serial door optional and software XBLAST with a PC provided with windows 95 or later versions 7 2 List of Parameters Each control Typology is divided into groups to be easily handled by the user MOTOR RUN DRIVE DIGRUN I O P I D CONTROL COMUNICATION and AUXCARD The keypad displays a short form every type of control expects a parameter specific set see below NAME ela UNIT RANGE DESCRIPTION gt gt 55 5 MOTOR MOTOR PARAMETERS 1 0 0 In Nominal motor current elelelele size Imax M2 A 0 0 Imax Allowed overload current elele size Uln M3 V 280 600 Nominal motor voltage Fin M4 Hz 25 1000 Nominal motor frequency Fmax M5 Hz 0 0 999 9 Max operating frequency Fmin M6 Hz 0 0 Fmax Min operating frequency 7 rpm 0 30000 Motor nominal revolutions 8 rpm 0 30000 Max
63. e moment Not covered by warranty are parts subject to consumption wear 3 3 EMC Conformity Electro Magnetic Compatibility 3 3 1 Foreword A motors converter if phase control with thyristors technology or impulse modulation PWM with IGBT or transistors considering according to the EMC directive a component and not a device it does not belong to the present normative application The reference lows are for the product EN 61800 3 for the converters redacted by a IEC commission It is compulsory for the components manufacturers converters for our case to supply an applicative guide to help the system and or installation manufacturer to obtain the correspondence of the application system installation to the electromagnetic compatibility problems relative to the application Radio frequency interference is the name for electromagnetic emissions EM produced by electric and electronic devices for home or industrial use whenever such emissions disturb interfere with transmission signals of telecommunication Such noises are given in any case of someway disturbed transmission signal The distortion can show up as not correct receiving due to the intermingling of alien signals or as partial or total suppression ofthe transmission signal 3 3 2 Electromagnetic Noise Sources Any electric electronic device able to generate EM can be a radio frequency noise source Common signal sources are circuits p
64. e by one of the following cases 1 wrong cyclic sense of the U V W exit phases of the drive check the right correspondence of the U V W phases of the drive with the U V W of the motor 2 wrong feedback connection check the wiring of the feedback NOTES cable 3 oscillations of the drive shaft during the resolver timing due to the load presence put the motor in free shaft 4 oscillations of the drive shaft during the resolver timing due to the current ring instability calibrate the current ring 5 Non suitable resolver characteristics check the hardware compatibility of the resolver WARNING oscillation of the drive shaft during the automatic timing could compromise the right result The FEEDBACK alarm indicates the resolver connection lack also partial 87 SYNERGY IN MOVEMENT Ma 7 7 Commissioning current loop 4 pin The variables involved are Kpl and Kil the calibration could be done experimentally or automatically 7 7 1 Automatic method Insert in the RS SLS variables the value of the resistance and stator inductance taken from the data sheet of the motor in use Start the Drive Supervision function from the programming applicative Push the Drive pad from the Tune menu Verify the value checking the variables KPI and KII after pressed the Refresh pad 7 7 2 Experimental method 1 Reset the speed ramps 2 Block mechanically the motion of the drive shaft The drive once
65. e intervention of the electronic thermal see R3 parameter ti max the output pre warning is activated in advanced of 5 seconds O 4 Off DAC Offset adjustment on analog outputs Outl Resolution 10 bit 5 1 Analog output gain calibration e 0 5 Space Vector Control SVC combines the IGBT vector driving with the traditional V Hz control Considering the voltage applied to a three phase motor as sinusoidal and not taking the voltage drop due to the stator resistance into account at normal conditions we have OUT AN1 Parameters for the analog output programming Set value Meaning 0 Disabled Speed output 10V Current output 10V DC LINK voltage output 10V 1000Vdclink Proc PID deviation Proc PID feedback 81 SYNERGY IN MOVEMENT Ma 7 3 5 PID parameters To this category belong all current PI speed PID auxiliary reference PID and flux PI group P P 0 Kpl Proportional constant of the current PI control Range 3000 P 1 Kil Integral constant of the current PI control Range 0 3000 2 Proportional constant of the speed PID control Range 0 9999 P 3 Kiw Integral constant of the speed PID control Range 0 9999 P 4 Kdw Derivative constant of the speed PID control Range 0 9999 5 tdw Time constant of the PB filter on the speed PID derivative function Range ms 30000 ms If set
66. e limited In case a high starting torque is needed a bigger drive size should be chosen The drive s nominal current does not change with the operating quadrants The brake switch needed in case the braking energy is dissipated is dimensioned for duty factor 20 Connections The drive may be damaged if the supply voltage is applied to the output terminals the RF filter is connected between drive and motor capacitors are connected on the drive output Frequent switch handling on the drive input reduce the lifetime of the filter capacitors and can cause the burning of the pre charge resistor with heavy damages to the drive In case a contactor is needed on the drive output this should be done with disabled drive Provide an auxiliary contact NA on the contactor to disable the drive with at least 500 m s anticipation If the drive trips due to a protection or in case of mains failure the motor is left by the drive and stops per inertia In case this is not supposed to happen or should be dangerous for any reason a mechanical brake has to be added If the drive supplied by a generator the harmonic distortion generated by the drive has to be checked with the manufacturer regarding the acceptability 108 SYNERGY IN MOVEMENT mt 13 3 Calibration e The drive output delivers max frequency 1000Hz which means possible dangers at high speed Select the max speed compatible with the application and the machine choose a modulation
67. e makes a calculation of the resistor switching time sum on a 10 second base The thermal resistor protection switches as soon as the time reaches the limit value set under parameter d20 with 12 160ms 102 1 6 5 If set at 0 variable d20 selects the brake resistor missing d 21 Off Dclink Parameter set in the testing phase at EARP Needed to compensate measure tolerances on the dc link voltage This parameter cannot be edited d 16 Enc Out Pulses per revolution of the encoder simulation output on board Range 2048 1024 512 256 ppr d 17 Enc In Selects the ppr for the encoder connected to board Range 64 pulse rev to 8192 ppr d 18 Feedback Selects the kind of feedback used for the position speed detecting Set Value feedback 0 Sensorless 1 Bidirectional Encoder 2 Resolver d 19 Off res Offset for the Resolver tuning Usually this data is calculated automatically by the drive on the command Through this parameter it is possible to set it also by hands The range of variation is 0 65535 Such parameter to be displayed on the option board is divided per 8 and so a value displayed on PC of for example 3412 on the keypad will be displayed equal to 3412 87426 78 SYNERGY IN MOVEMENT back 9 d 20 Num of index Number of synchronization pulses also called index or zero top pulses given on the feedback encoder In case no pulse should be available or the related channel should not be connected
68. eatures IGBT Frequency converter for three phase asynchronous motors brushless motors and SSP motors with supplying possibility for three phase net also with integrated dissipative brake SFT Control Stator Flux Torque control SB Control Sinusoidal Brushless control FVC Control Flux Vector Control SVC Control Space Vector Control 55 Control Sensorless Speed and Position control Automatic identification for motor parameters Running with programmable intermediate speeds QGcceleration deceleration time in a field 0 1 999 9 sec frequency 1000Hz Change possibility of the modulation frequency 12kHz 8kHz 4k Hz 2kHz 1 5kHz 1kHz PWM Frequency of random type to reduce the noise Monitoring and control of monitoring soeed and current torque control Failures indicator Torque and speed operation SW moto potentiometer Overcharge limitation Rotation sense setting Acceleration on fly 5 Characteristic of the acceleration deceleration function 0 02Hz frequency digital reference resolution Analog digital frequency meter output Password for parameters modification for keypad System functions positioning Aspo tension adjustment Fast PLC Traverse PID Regulator Switch braking integrated up to 22kW Speed retroaction with encoder resolver Resolver auto timing 12 SYNERGY IN MOVEMENT 2 4 2 Technical Data Blast E range Technical data of Blas
69. eference Kp track P27 Reading only proportional constant of flow PI Ki track P28 Reading only integral constant of PI flow 29 Hz It filters the speed visualization in the display start P30 Increasing of the starting torque Speed min P32 rpm Threshold under which it is halved the speed PID c ON SYNERGY IN MOVEMENT Ma AUXILIARY BOARDS COMUNICATION COMUNICATION SETTING pic UNIT RANGE DESCRIPTION 525 4 8 Protocol CO 0 1 PROPRIETARY BUS W3 Reel on board 12 MODBUS RTU RS 232 Baudrate Cl bps 0 3 9600 1 19200 2 38400 Seti cal cdl 3 57600 Parity C2 0 2 0 none 1 ODD 2 EVEN solo in MODBUS Address C3 1 247 e Display AO 0 4 0 CURRENT A 1 SPEED RPM 2 VOLTAGE V 3 7 3 Parameter Description The BLAST E parameters are divided in to different groups for easy use MOTOR RUN DRIVE DIGRUN CONTROL COMUNICATION and AUXCARD To enter to the parameters from the integrated keypad press seconds digit the password 7305 using A and Y increase decrease the value or start the X BLAST available in the CD supplied with the product 7 3 1 MOTOR Parameters The motor parameters are used for the motor s correct setting The parameters not used for the sele
70. enabled will supply the maximum current set on the Imax variable with maximum torque Assure the enabling of the system can not damage the mechanics especially if there are parking brakes Take the appropriate precautions 3 Do several time the running with reset speed ramps looking at the current signal with the tools SCOPE of the Xblast applicative The monitored signal has to be a step without overshoot At the presence of overshoot or with too slow answers modify the Kpl variables and Kpl 4 Leave out the forcings already done 7 8 Control calibrations Below there are some notes for the optimization of the dynamic characteristics in the various available controls 7 8 1 Parameters description Motor Parameters SVC FVC SFT controls Rs phase resistance 95 leakage inductance mH TauR rotor time constant mS Lm magnetization inductance mH These parameters could be calculated automatically by the plate data of the motor to have a starting point useful to optimize the control as already described in the Commissioning Motor Parameter paragraph It is necessary to insert correctly FLn poles Nnom and push the drive pad on Xblast It concerns an Off line mathematic calibration to be done exclusively with disabled drive it does not include the shaft revolution and so it can be also with blocked constrained shaft To obtain higher control performances it can be necessary to manu
71. enerally mains filter available in the market if certified could satisfy the necessity Where it is necessary to reduce not only the perturbations towards high frequency mains but also those with low frequency to 1 1 5 kHz it is necessary the installation of tuned harmonic filters Inverter RFI Filter BLAST E RO LI L1 50 12 L2 TO L3 L3 tot LOAD In every situation it is always necessary to install at the top of the drive a decoupling inductance dimensioned in accordance with the installed size A simple formula helps the dimensioning MH phase nominal ampere gt 20 for size A voltage drop equal to 396 to nominal current 215 for size B voltage drop equal to 296 to nominal current 210 for size C voltage drop equal to 1 596 to nominal current Thereactance nominal current has to be equal to the nominal one of the drive increased of 15 suggested saturation current is 3lnom 3 4 4 Towards motor The main mechanism of propagation of disturbs of the inverter is the conduction through connection cables The converter di dt especially if impulses modulation PWM with IGBT creates important emissions especially irradiated There are 2 possible solutions Adoption of power shielded cables Metallic path for cables where it is not possible to use shielded cable use piping metallic wireway with 80 minimum cover without interrup
72. ent and maximum suppliable from the module 76 SYNERGY IN MOVEMENT back 9 d 2 Random Set amplitude of Random frequency possible on PWM it permits to have a variable PWM within the limits imposed by this parameter reducing the acoustic emission of the motor d 3 Setup the parameter selects the possibility to command the drive with hardware or software controls The choice of the command mode of the drive happens through the selection of the keypad value in the parameter Setup d 3 see chart 7 3 3 1 Chart 7 3 3 1 Keypad value Function Drive 0 HW 1 SW 2 Reference On 0 HW 1 SW 1 4 Direction O HW 1 SW 8 Reference2 On 0 HW 1 5W 2 16 Alarm Reset O HW 1 SW 32 Torque Control O HW 1 SW 64 Reference 1 Value 1 SW 128 Reference 2Value O HW 1 SW 256 Enable Motopotentiometer 512 Analog out O analog 1 freq 0 200kHz 1024 1 Type 0 0 10V 1 4 20 The drive can be controlled both through 6 digital inputs HW and through the Keypad or the use of a pc or an extemal supervisor connected via serial port to the drive SW or both at the same time So it is possible to decide from where the various commands have to be heard For example it can be possible to control the start and stop of the motor and its speed through serial port but to e sure disable completely the modulation through an hardware command connected to a digital input To do so it is necessar
73. es ccccccccccccccssssssccsccsscsssssccssccsesssssscescessesssssssssccsessssssscssecsssssssssessscsssssssssasessseesesssaass 15 2 4 5 Environmental conditions for Blast E operations eese eene nre rennes 16 VE SUIT E 17 DAs ICI 17 2 5 OVERALL DIMENSIONS WEIGHT AND TERMINAL 18 2 6 OPERATING DESCRIPTION em 23 261 Power SCCLION 23 2 6 2 Terminal 24 2 6 3 CORIFOLSECHOTA 25 2 6 4 Control Board 25 2 6 3 Control Dip Switches Sou 25 2 6 6 Description of the control terminal board eese rennen nennen rennes 26 2 7 DESCRIPTION OF THE CONTROL SIGNALS ket 28 VISIO 28 27 2 Digital Outputs 29 VIS 29 2 7 cT 30 RECEIVING THE DRIV E ivessecccscccscpsdeccsevecostssessaucessssostessescedsess
74. et Command 52 6 5 RESET OF SAVED DATA 53 6 6 DATA DISPLAY amp PARAMETERIZATION THROUGH XBLAST SOFTWARE enne 53 TD PARAMETERS 60 7 1 FACTORY SETTING etas t ore RE OR EE 60 7 2 LIST OF PARAMETERS T C 60 7 3 MAIN PARAMETER DESCRIPTION teeth RE LER REEL AEn eee THER REEF Yee 67 7 3 1 MOTOR Parame S eu trice aee ERE eee pa eda 67 73 2 RUN Darameteks eet e oes opt eps qus pee dete tope 69 7 2 3 DRIVE Parameters E 71 nO ML 80 7 3 5 PID TT 82 7 3 6 Control eR Dd 83 3 7 OPT CARD Parameters cnie E E EN E 84 TACOMMISSIONIN Geinn 1 eevee 85 7 5 COMMISSIONING MOTOR PARAMETER FOR AC MOTOR s cccssssseesssscecessececssceececeseeeecseaeeecseaeesecseeecsesaeesenseees 86 MOCGNIN 86 7 5 2 On Line Tuning Commissioning pad on XBlast esee eene eere 86 7 5 3 Line calibration procedure with SFT 86 7 6 COMMISSIONING OF THE
75. evesseaseetecuoscesseopecsscsecesdetsossuesescevedecesbvooutedsseontestssessessee 31 3 1 TRANSPORT PEE 31 34 1 Handling 31 DID EE 31 3 1 3 Opening the Package oii Eee Eon EEG RUDI QUI UNE 32 3 2 CHECK AT DELIVER Yoco R E E EE EE RECS 32 3 2 1 WARRANTY AND RELIABILITY ON THE 33 3 3 EMC CONFORMITY AE E E E E EE 33 1 MEA EEEE EEEE cess TE E AE E M I ML ME 33 3 3 2 Electromagnetic Noise SOUTCES AEGEE HR Eraikita 33 3 4 SPEED CONVERTER APPLICATION FOR BLAST E 34 3 4 1 EMI nianie 55 34 342 Towards MOINS sic d 35 3 4 3 Mains filter application i a vax a co eo eC 35 33 4 Towards motOoF oise 36 37 3 4 6 Converter COSTING 37 347 asennad 38 34 6 Power connect ons 38 38 38 SYNERGY IN MOVEMENT be MEET EET 39 EE DAS 39 4 MECHANICAL
76. field Repeat the tests with the maximum load and the current breaks of acceleration 91 IN MOVEMENT 8 SERIAL INTERFACE 8 1 Introduction The serial interface connects BLAST to an external device to control and monitor the system BLAST has as standard a DeviceNet interface on user terminal board not optocoupled 500kB Further options for net communication e PROFIBUS DP e RS485 e CANBUS with DeviceNet protocol optocoupled e RS232 Interface RS232 is very useful for the drive handling with PC and software XBLAST as well as to download the firmware for a personalization of the product The available firmware are supplied in the CD attached with the product 92 SYNERGY IN MOVEMENT 8 2 mt Serial Interface CAN With DeviceNet Protocol With the XBLAST software it is possible Enter in all the BLAST parameters The parameters have been divided in groups according to their characteristics Display of all the working parameters current speed alarms DC link voltage IGBT temperature Alarms reset The alarm reset is possible only if the drive has been disabled Storage the PC the parameters and double them into another BLAST Oscilloscope function to display up to 8 selectable traces among the following positioners working parameters motor speed absorbed current by the motor real position position set point linear speed DC LINK voltage gt For
77. g Inputs DENOMINATION NOTES IN1 IN1 Diff Input reference 1 10 0 20 mA IN2 OAN Input auxiliary reference 2 10V CET Do not connect voltage generators of equal value or higher than 13V to the WARNING analog input terminals 29 SYNERGY IN MOVEMENT gt SW2 dip 1 SW2 dip 1 ON ON Current input 0 20 Voltage input 0 10V NB in case the internal CAN BUS communication is not used SW2 dip 2 must be ON SW2 dip 2 nm 2 7 4 Analog Outputs BLAST E has one analog output configurable through switch SW1 and dip switch SW2 shown in the 2 6 4 paragraph OUT AN OAN analog output or frequency 0 100kHz 10mA SWI Analog output in SWI Voltage current analog output 30 SYNERGY IN MOVEMENT 3 RECEIVING THE DRIVE 3 1 Transport 3 1 1 Handling The handling is different according to the size SIZE A B Manual handling weight below 10 Kg SIZE C D E Handling with fork truck only weight superior than 20Kg 3 1 2 Storage If the unit is stored before installation check for environmental condition to be adequate chap 2 4 5 Ee Do not place the packages one on the other WARNING Do not load weights on the packages Do not damage the package to avoid device damages and therefore warranty decay 31 SYNERGY IN MOVEMENT a 3 1 3 Opening the Package Follow the indications as per image below 3 2 Check at Delivery BLAST E is fully teste
78. harge of installation assembling commissioning and service for BLAST E Such persons must definitely e Know all specific safety regulations regarding the switching of electric circuits grounding and electric circuit device and system identification Know all main physical aspects of electric system e Have a full knowledge of the symbols used for electric diagrams e Know all criteria regarding cabling and electric components Neither do the operators need previous experience in the specific field of frequency converters nor have received a training on operations all steps from installation to service on the device The data contained in this manual are not binding and are related to the device reflecting the actual state of art at the moment of selling This document describes the BLAST E performances The product might be further developed so that higher performances would be integrated later on This manual has to be considered as part of the device and must therefore kept for future reference as long as the device is used The instructions may not be copied without previous written agreement by EARP SPA claiming all rights SYNERGY IN MOVEMENT m 1 2 Descriptions and Symbols The manual contains three different kinds of indication CAUTION Shows not correct actions or behaviours that may generate danger for the operators It also stresses dangers that may occur during service operations WARNING Shows
79. iometer function to use by setting parameter 43 87 obligatory for the resolver setting As follows there is the modification of d3 variables for the Motopotentiometer function selection Press at the same time Select parameter d3 Enter with Set value 87 Confirm with Exit with NOTE the way of programming is common to all the variables 50 SYNERGY IN MOVEMENT gt 6 4 Control From Keypad Motopotentiometer The functions of the keypad set on Motopotentiometer are shown below 43 87 The Motopotentiometer function is useful during commissioning since it allows an immediate start up from keypad start stop increases or decreases the reference Forward and Reverse 6 4 1 Start Run Command The Start key pressed during 3s enables the drive for the READY status by pressing START again the RUN mode is selected RUN and the drive reaches the latest set reference in the example the Hz of the asynchronous motor STOP READY Press during 35 m NB If the set reference is zero in RUN mode the motor does not start Increase the reference as described in the following paragraph 6 4 2 Reference Increase Decrease Command The RUN mode mentioned above can increase decrease the reference through key SPEED followed by A to increase SPEED V to decrease The variation will be displayed Increase reference Decrease Reference The latest set reference is stored in the memo
80. link voltage In this way even if the DC link voltage decreases the effect of voltage saturation will be limited Suggested values 100 KiVcmp 5 Example Vnom 400Vrms Available line voltage 380V The regulator permits to maintain the sinusoidal current even if the voltage requested passes the maximum available one NOTE The sil Dc link compensators KPUCnp e KiV Cnp are developed at Earp Torque limitation FVC control IqBreakdwn 10 100 rom 1 5 89 SYNERGY IN MOVEMENT Ma q limit i nom startKlq Omax C612 Picture 2 These two last parameters permit the limitation of the Iq current responsible of the torque generation to avoid to pass the breakdown threshold Such threshold depends on the motor typology and shows the maximum suppliable torque limit THE LQ LIMIT FOLLOWS THE PROCEDURE SHOWN IN PICTURE 2 BUT STARTING FROM THE SET SPEED STARTKLQ THERE IS AN ULTERIOR REDUCTION OF THE COURSE SHOWN IN PICTURE 3 TO IMPLY LQ BREAKDOWN IN A MAX It is recommended to set the IqBreakdown 100 parameter in the way to disable the compensation using it only in case of necessity 1007 q breakdown range 0 100 startKlq Picture 3 90 SYNERGY IN MOVEMENT 7 8 3 Speed loop calibration AN Ma The motor will begin to rotate if the converter does not control the revolutions invert
81. lver pad Push the drive on pad after selecting the software enabling setup variable The drive controls the drive of the drive shaft in more different positions reads the mechanical position of the resolver phase motor The OFFSET is automatically saved in the Off res variable The variation is anyway directly available both to do eventual verifications and to OFFSET setting already known Procedure WARNING During the commissioning there is a direct current to the motor which will lead it to place in a specific mechanical point to do then a series of movements it is equal to the current set the variable resolver timing is to be done with free shaft Assure that the set current with the INOM parameter does not exceed the plate current of the motor At the end of the calibration note the eventual changed parameters to the predetermined value 1 the timing procedure started with the commissioning starting according to the modes described before 2 the motor is positioned by the drive in a certain mechanical point with the injection of direct current it follows a series of spring movements 3 the control backups automatically the Poles and Off res variables it is possible to control the new value pushing the Refresh pad from the Xblast applicative or with the access of the variables from the option Keypad The intervention of the AUTO TUNING ERROR alarm during the resolver commissioning is caus
82. mory 98 10 2 ERROR DESCRIPTION REMOVING nennen ee eres ee enses eene esse nns 99 11 BRAKE UNIT 102 11 1 FOREWORD ep 102 11 2 INSTALLATION 102 11 3 IRESIS TOR GHOICE 103 11 4 BOARD ient onere teer ton bn e 104 115 OPT BACK UP tenete te E 106 12 MAINTENANCE amp CHECKS eese 107 12 1 INTRODUCTION cccccccccceceesesseseeecececeesuacaesecececeesuueseeececsensuaesecececeeseaseececececseaueseeececsessaaeseeececeeeauasaeseeseeeseneea 107 12 2 ORDINARY MAINTENANCE 107 TS NOTES 108 SSBEEGTION recie EE MEME E ME 108 13 2 CONNECTIONS i cete cue RIEN RIED EMI E M 108 13 3 109 134 MOTORS 109 13 4 1 Applications with Special 1 110 SYNERGY IN MOVEMENT me 1 FOREWORD 1 1 Notes about the Manual This manual informs on details regarding the frequency inverter BLAST E in all steps such as transport installation disassembling as well as all requirements to be considered and measures to be taken to grant full safety for the persons taking care of simple operating This manual was written thinking of trained personnel persons in c
83. otation Enable Input Speed Reference 1 P4 24 Enable Input Reference 2 P4 65 Input for motor rotation inversion Increase moto potentiometer Decrease moto potentiometer Enable input for previously set 1 speed values Enable input for previously set 2 speed values Enable input for previously set 3 speed values Enable Input torque Reference Alarm reset input Disable ACC DEC ramps Programmable input for frequency reference Thermal Motor protection 5k Enable torque speed selection Enable the start in clockwise rotation Enable the start in anti clockwise rotation gt 28 SYNERGY IN MOVEMENT 2 7 2 Digital Outputs BLAST E is provided with two relay outputs one of them is used as run enable and the other one as programmable DENOMINATION NOTES 01 fix output Run enable output Drive OK Disable Minimum speed relay Brake handling Speed quote reached Rotation direction Alarm Drive thermal warning Motor thermal warning Drive OK Motor Pre warning 02 programmable output 2 7 3 Speed set signals In case the speed frequency reference from terminal board is chosen there are several possibilities 1 From potentiometer 10 kQ supplied with OPT 0120 2 External voltage signal 0 10V 3 External current signal 0 20mA 4 Enabling through contacts enabling the JOGs 5 Through frequency input on 15 0 100 2 6 Moto potentiometer configuring the inputs Analo
84. owards the supply they modify phase phase and phase earth impedance conditions using passive components as inductances and fast capacitors they create a filter linked to proper frequencies realizing an easy way of leak of the noises toward the ground The RFI reduction through the filter and the application of other indicated item enable the W3 serial drives to be in accordance with the European low for EN 61800 3 drives During the installation of the filter take care of the following advises The filter must be placed as close as possible to the Supply Module input clamps with connecting wires with lengths lower than 30cm If it is impossible to respect this distance use only the shielded cable filter has to be placed on the same panel on which the drive has been installed and connected to the earth of the system not wire the filter input connection cables at the side of filter output cables in parallel the high frequencies filtering could vanish filter must be connected to ground before supplying the system for the first time integrity of the earth connection must be verified periodically filter can be used only on supplying mains balanced to the ground type mains TN and TT because it expects a capacitive coupling to dispel the generated disturbs CET Do not connect the drive output filter motor side WARNING 3 4 3 Mains filter application FIRST ENVIRONMENT Environment inclu
85. p ENABLED ALARN DCLink N 493 Temp 39 2 Module Type i About XBlast Blast Vers 4 2 Beta 20 07 2004 SYNERGY IN EARP Via Riviera Berica 44 36024 PONTE D NANTO VI ITALY Technical support Tel 39 0444 730508 39 0444 738546 E mait earp earpit Web hitp www eerp i 27 03 04 16 20 00 error l Dataenchange COM1 9600 v MStart amp mu Lettore CD 03 Blast ini Blocco B XBlast EARP US 1704 XBlast EARP Spa ME x Ele Drive utomation Tools Window Help ENABLED ALAR DCLirk N 483 Temp C 39 2 Module Type Version is available only via on board communication port Blast vers BLAST SVC__v005_260804 8001 SVNERGY IN MOVEMENT 27 03 04 16 20 00 CRC error Data euchange 1 9800 amp m s Lettore CD 03 Q Blastini Blocco B XBlast EARP Dosumertot 1705 Ma 58 SYNERGY IN MOVEMENT 2 To exit XBLAST select EXIT from file menu View Tools Help 59 SYNERGY IN MOVEMENT Ma 7 PARAMETERS 7 1 Factory Setting BLAST E is in SVC mode so it is suitable for Asynchronous motors nevertheless through Hyper Terminal by Windows the other control modes which are inside the attached CD with th
86. r noise may increase fan fitted on the axis e NOISE The motor noise increases compared to the operating through mains supply The noise is reduced and neutralized by using output reactors sinusoidal filters or by activating random modulation frequency USE OF A MOTOR WITH A A CONSTANT TORQUE UP 87 104Hz A 400V 50Hz motor with A connection can be used at constant torque up to 173 Vnom 109 SYNERGY IN MOVEMENT 2 if connected in this case the initial motor and related drive power multiplicated by the drive size must be adequate and check with the manufacturer of the motor that the mechanical parts support the high speed 100 173 H 13 4 1 Applications with Special Motors MOTOR WITH BRAKE The brake needs separate supply The brake supply must be derived above the drive When the brake is inserted the drive must be disabled MOTORS WITH CONICAL ROTOR The brake is controlled by the motor s magnetic field the boost has to be set adequately and in some cases a bigger drive size will be necessary MOTORS WITH DOUBLE WNDING The drive s output current must be higher than the nominal cu
87. r s nominal current is lower than half the nominal input voltage of BLAST E or if the motor s nominal current is lower than 1 3 of the nominal output current of BLAST E BLAST E was developped to control brushless or standard squirrel cage asynchronous motors 3 The BLAST E output consists of short but voltage pulses not related to the output frequency Such voltage can reach the double value if the motor cable is too long and can cause serious damage to the motor SYNERGY IN MOVEMENT 4 All insulation tests must be carried out after disconnecting BLAST E from the cables Do not try and use the system beyond d its nominal capacity Not respecting the rules might damage BLAST E seriously 5 Handle the device carefully so that no parts can be damaged 6 The drive must be protected against not allowed conditions temperature humidity blows etc 7 No voltage may be applied to the drive s output terminals U2 V2 and W2 It is not allowed to connect inverters in parallel on the output no direct connection of the input to the inverter output is allowed By pass 8 No capacitive load over 5nF may be connected to the drive output terminals U2 V2 W2 9 Always carry out the ground connections PE from the related terminal to the round bar of the cabinet or plant 10 No electric strength tests may be carried out on drive parts In order to measure the signal voltage adequate instruments have to be used min inner
88. r the mechanical fixing is assure by an insulator support Mechanical fixing Electrical clutch Control board 105 SYNERGY IN MOVEMENT mt 11 5 OPT BACK_UP board An adding board produces the back up supplies for all the internal circuits starting from 24V to supply on the mother terminal board 57003 Clutch connector The board is supplied separately from the product and allows the direct clutch on the control board 57003 Thanks to a 5 poles streep connector the mechanical fixing is assured by an insulator support Mechanical ane LA Electrical clutch Control board 106 SYNERGY IN MOVEMENT Ma 12 MAINTENANCE amp CHECKS 12 1 Introduction The drive can be inspected by trained personnel only The access to internal parts may cause damage to the electronic components IGBT CMOS and afterwards wiring mistakes during reconnection No claim can be laid on EARP for failures or accidents in case this warning is not observed 12 2 Ordinary maintenance Blast needs a programmed maintenance for the fans and capacitors only It is enough to grant a clean and without dust environment especially if conductive The maintenance period is in accordance with the environment quality where the drive operate especially for the ventilation Because of the ageing of the mechanical and electronic components it is recommended to substitute The boards capacitors inside the sys
89. ration may bring lightning risk for the operator as well as damage to the drive Disconnect the EMC filter before connecting BLAST E to a not grounded mains supply 3 Do not act BLAST E under voltage After disconnecting the mains wait at least 10 minutes before operating on drive motor or motor cable for the capacitors of the dc circuit to unload Before any operation check the drive not to be under voltage with a voltmeter 4 The output terminals BLAST E motor connection have dangerous voltage values when the drive is supplied not depending on the motor s running or not 5 Even when BLAST E is not under voltage mains supply open and capacitors not loaded there could still be dangerous voltage inside coming from the auxiliary circuits connections and external control circuits Working on the unit must happen with utmost caution after cutting all connections This to avoid any danger for persons meaning even death risk 6 When the drive is not running but is not cut off from the mains through the switch or other device there might be an accidental motor shaft movement in case of failure or bad running 7 It is not allowed to change the insulation distances or remove insulating materials or covers 1 BLAST E allows electric motor and driver machines to operate on wider field It WARNING 3 is therefore necessary to check for all devices to fulfil such requirements 2 No operating is allowed if the moto
90. rbations which could come from the external The line reactance and the RFI filter reduce the harmonic content of the absorbed current by the drives and they decouple them from the other equipments connected to the same line Only for mains with particular problems for example the possible presence of lightings in line and big welding machines or compensation plants without decoupling reactances or working badly could be necessary to protect the converter the application of overvoltage suppressors In the Drive installation it is necessary to consider 1 the placement of the Tunnel is preferable to be done in a metallic cabinet in which the panels have to be connected electrically together realizing low impedance contacts leaving out the eventual insulating paint from the ground interconnecting points 2 the reactance causes a voltage drop proportional to the absorbed current and the same inductance value it has to be calculated for a voltage drop in correspondence to the nominal current absorbed by the inverter of 2 4 of the supplying nominal voltage 3 4 9 Environment The using of metallic structures in the power section coming from the EARP converters construction creates a suitable protection from EMI problems Anyway it is necessary to build a good ground connection The tests performed evidence only a sensibility to electrostatic loads directly on the from protection of the converters at few cm from the control microprocessor
91. roducing voltaic arcs switches relays etc conversion circuits having non sinusoidal or not direct output voltage choppers inverters etc e devices absorbing non sinusoidal current All other than sinusoidal waveforms are potential RFI generators due to the contained high frequency harmonics The PWM principle on which inverter are based offers several technical practical and function advantages Since the drive uses the quick voltage commutation and high current values to obtain high efficiency and a low noise level inside the motor radio frequency energy is generated that may interfere with other systems nearby 33 SYNERGY IN MOVEMENT The signal level generated by an installed drive depends on several variables such as e drive power e output frequency range switching frequency e mains impedance mechanical and construction features of the drive assembling internal shields mechanical and construction features of the electrical cabinets containing the drives wiring e mechanical and construction features ofthe plant in which the drive is installed The above described above is generally known as electromagnetic compatibility EMC the word RFI is often used as well as the radio receiving noises are better known as common EMC form 3 4 Speed Converter Application for Blast e motors The purpose of these notes is to help the systems engineers and drives installation plant engineers in systems in
92. rol It determines the signal with medium null heat on the supplied current useful for the determination of the rhetoric position at low speed A calibration very low cause a decrease of the available torque at low revolutions a calibration too high cause an increase of the noise linked to the injection P 25 max track Max value of Tracking PI It determines also the max speed allowed 83 SYNERGY IN MOVEMENT Ma P 26 Ld set Amplitude of the reference of the motor flux it is function of the SSP motor typology P 27 Kp track Proportional constant of the Tracking PI of the sensorless corner P 28 Ki track Integral constant pf Tracking PI of sensorless corner P 29 Ftw Parameters that defines the time constant of low filter placed in the output of the speed information It has effect in the display of the keypad in the speed analog output when programmed and in the information expressed by the master to the user program P 30 Iq start Percentage of Iq torque current for the motor starting with high load P 32 Speed min Speed level under there are automatically reduced the constants of the speed PID to obtain a better linearity stability of the revolution 7 3 7 OPT CARD Parameters To this category belong all the parameters proper of the display and communication C 0 Protocol 0 Reel W3 1 Modbus RTU C 1 Baudrate 9600 1 19200 2 36400 3 57600 C 2 Parity 0 1 2 EVEN C 3 Address
93. rrent of each winding The winding commutation has to be carried out with stopped motor and drive disabled for atleast 500 msec CLASSIFIED MOTORS The drive cannot be assembled where there is explosion or fire risk since is not explosion proof The motor must be certified together with the feeding drive GEARED MOTORS the lubrication method and rotation limits vary according to the manufacturer in case of oil lubrication continuous operations at low speed may cause overheating due to lacking lubrication Speed values corresponding to frequency values higher than the nominal one must be checked with the constructor SYNCHRONOUS MOTORS An output reactance on the drive output is recommended as such motors have a low inductivity The slip compensation must be disabled MOTORS FOR UNDERWATER 5 The nominal current of such motors is higher than the standard one so an adequate drive size is necessary SINGLE PHASE MOTORS They cannot be supplied by inverter NOT do notuse VFC and SFT 110
94. ry 51 back 6 4 3 Forward Reverse Command On RUN mode key F R changes the rotation sense RUN Mode Press for 3 sec Press for 3 sec The motor changes The motor goes back direction to the initial direction Caution The sudden rotation sense change of the motor may damage persons and things Make sure that the operation is carried out with care and by qualified personnel 6 4 4 Stop Command The Stop key allows two kinds of stop 1 With STOP double command START disabled the reference uu 2 With lasting STOP STOP Press during 3s ee 5 27 ERRORE mode STOP 6 4 5 Reset Command Press during 3s 52 SYNERGY IN MOVEMENT Ma 6 5 Reset of Saved Data In case of error E set disconnect the DRIVE wait 5s and connect the drive again 6 6 Data Display amp Parameterization through XBLAST software Data and modification parameters through XBLAST are easy thanks to Windows interface Cklick on to start the program which will open the first page EARP 523 Dh Yes Imk de bosm ew SYNERGY IN MOVEMENT latex wd eso ABE eee cater mos EGP Spe BA Through Menu VIEW it is possible to enter to Menu DRIVE SUPERVISION and DRIVE PARAMETERS Im 5 File Tools Help ri Xu Supervision Drive Parameters with DRIVE SUPERVISION the drive is entered direc
95. s keeping a distance of at least 30cm between each other It should not be possible to avoid crossing of the power and signal cables a 90 angle should be kept The control signal conductors must be shielded and the shield must be connected on the inverter side only It is recommended not to exceed a length of 10m for the control signal connections in case of highly disturbed industrial environment from en electric point of view exceeding lengths may cause bad working of the devices Should the application require bigger distances between the drive and the control system adequate devices optocouplers interface circuits etc should be used in order to reduce noise sources as much as possible 2 All contactors and relays must be provided with R C on the winding 3 In case of working conditions different from the nominal ones especially for low speeds an adequate external ventilation for the motor has to be planned Do not use the drive with motors of bigger size than the indicated 4 The drive is anyway protected against exceeding loads The current protection Eoc may intervene in the following cases a motor failure b failure toward ground drive re start while the motor is turning by inertia d too short acceleration time e Excessive parasitic capacity in the drive output max 5nF 5 Inverter feeling from an independent generator generator The current harmonics produced by the inverter ma
96. stallations avoiding problems of electromagnetic interferences EMI and helping to reach the conformity to the EMC 89 336 CEE Directive and next modifications 92 31 CEE 93 68 CEE Two basic EMC aspects are the emission of energy being a noise source for other devices and immunity which means that a device is not sensible to noises generated by external electromagnetic interferences Related to the latter is the concept of susceptibility level which means the level at which a device loses the mentioned immunity 3 4 1 EMI Compatibility Due to the high power and speedy commutation an inverter is able to generate EMI Noises generated by inverters are divided into the following groups low frequency noises transmitted on mains cables conducted emissions high frequency radiated noises radiated emissions The emission occurs mainly per mains and motors cable as well as ground circuit conduction in differential or common mostly common way Small inverters usually generate more noise than big ones since they have quicker switching and therefore a different emission range The emissions are linked to four essential blocks highlighted in the picture Connection towards mains Connection towards motor Converter casing 34 SYNERGY IN MOVEMENT iag 3 4 2 Towards mains The best solution to avoid or reduce the troubles towards mains is the application of a EMI filter The main filters reduce the emission of disturbs t
97. t e range Three phase supplying Three phase supplying mains kW 380 V 15 480 V 5 45 65 Hz 400V KW 380 V 15 480 V 5 45 65 Hz Inverter power at 400V Three phase supplying 0300 BCH 0370 BCH 0450 BCH 380 V 15 480 V 5 45 65 Hz Inverter power at 400V Three phase supplying 0550 BDH 0600 BDH 0750 BDH 380 V 15 480 V 5 45 65 Hz Three phase supplying power indins at 400V KW 1320BEH 1600 BEH in development 380 V 15 480 V 5 45 65 Hz Inverter power at 400V Inverter power at Output A Nominal current OutputO2 A nominal current Output 2 A nominal current Output A nominal current Output A nominal current Output A maximum current Output A maximum current Output A maximum current Output A maximum current Output A maximum current Converter kVA apparent power Converter kVA apparent power Converter kVA apparent power Converter kVA apparent power Converter kVA apparent power 13 SYNERGY IN MOVEMENT gt 2 4 3 PWM Frequency of Blast E BLAST E has 2 options regarding the PWM 1 with Derating 2 Fix PWM Derating By setting parameter d2 at 1 BLAST works derating the set PWM and keeping Inom and Imax constant while temperature varies Such option is recommended for applications in which the drive must grant continuous duty
98. tem every 5 years after the eventual inspection The fuses after 10 years 107 SYNERGY IN MOVEMENT 2 13 13 1 13 2 Selection The drive size has to be chosen according to the current and not power The drive s output current must be x 10 than the nominal current of the controlled motor When one single drive supplies motors in parallel it is necessary to choose a drive having output current IN 1096 higher than the 496 of the sum of the current of all motors A single thermal motor protection has to be planned The built in protection is not significant The selection of a vector control mode FVC SFT SSP and SB excludes the possibility of controlling motors in parallel with one inverter If just one inverter controls motors in parallel for a system needing to switch on off the single motors during operating A drive has to be chosen having max current 1 1 IN for cl 1 and 1 5 IN for cl 2 higher than the sum of the nominal currents of the switched motors and the start currents of the motors to be switched during operating A decoupling reactor is needed between drive and motor N B The electromechanical coupling decoupling of the motors is allowed when the motor current is lt 10 ofthe drive s nominal current The starting torque and acceleration of a motor controlled by inverter is limited by the drive s maximum current as regards the direct start from the mains the performances ar
99. tions connecting the side close to the drive to internal earth bar to the electric board separate the powers from other signals The first solution is the best for connections with limited power cable section inside The second one in all other cases The shielded cable makes the leakage current both high frequency and normally through the parasitic capacities circulates from the ground motor casing or among the cables and ground it follows an obliged path through the shielding instead of following the metallic structure of the machine or alternative ways Pay more attention to the following directions 1 The cable shield must be continuous and connected to ground on both ends using the related ground terminal do not connect to the cabinet s common ground bar The connections should be carried out at 360 2 No signal cable may be laid in parallel to the motor drive supply cables with distance below 0 3m Anyway use wireways separated both for the power and signals 3 In case it should not be possible to avoid signal and power cable crossing there should be an angle of 90 36 SYNERGY IN MOVEMENT 4 No signal cable should be placed at a distance from the drive lower than 0 3m 5 The cable shield prevents from radiated noises further The shield must be connected to the ground on one point only 6 The inverter installed inside a cabinet allows very effective shielding 7 Distribute the power components over the c
100. tly so the START STOP RESET command can be given the reference can be changed alarms and DRIVE status are displayed 53 SYNERGY IN MOVEMENT Ma XBlast EARP Spa Ele Drive Automation window Help ENABLED No ALARM ms DC Link 484 Temp C 39 2 Module Type E Blast e Parameters Space Vector Control SVC SW version 0800 Drive setup Feedback 4 0 Type 9 16 Enc imp rev 41 PWM E d 17 Enc In inp rev 4 2 Random 0 4 18 Feedback 4 3 Setup mjfosz Hex d 19 Off res 7767 _ 4 4 Setup2 0000 4 20 o indak 3 Four Index 4 5 Size 220 4 25 Killer 0 4 21 ff DCLink 395 4 25 Select 0 Retesh Load from tile Update Save to Bl 27 08 04 16 20 00 error Dataenchange COM1 9600 m ALettore co 021 XBlast EARP Documentol Mi Eia 1701 Menu DRIVE PARAMETER displays the control mode and all parameters their values can be changed The parameters are displayed in the sequence shown in chapter 7 PARAMETERS and organized in different folders for applicative typology Blast EARP 5 x Drive Tool Window Help ENABLED NO ALAFM 484 Temp C 38 2 Module Type Drive Supervision INPUT ENABLED OFF EN OFF CW set ENZ2UFF mSRON Cun 00 0 Alarm Speed
101. to the input this parameter has no influence on the correct operating Ser Vale ZERO top NUMBER 0 1 1 2 2 4 49 25 Select This parameter available only for BLAST is exclusively for a request for re programming of the firmware inside the DSP Dig Run Parameters d 6 JOG1 Value of the first settable fix soeed d 7 JOG2 Value of the second settable fix soeed d 8 JOG3 Value of the third settable fix soeed d 9 4 15 Dif Ref 1 Dif Ref 7 Digital speeds is a function which permits to fix 8 speed levels liable through the activation of 3 hardware inputs associable to Din 1 Din 6 settable inputs according to the chart below Select 0 Select 1 Select 2 Activated selection 0 0 0 0 0 Dif Ref 1 0 1 0 Dif Ref 2 0 1 1 Dif Ref 3 1 0 0 Dif Ref 4 1 0 1 Dif Ref 5 1 1 0 Dif Ref 6 1 1 1 Dif Ref 7 d 22 Skip F1 NO used d 23 Skip F2 NO used 79 SYNERGY IN MOVEMENT d 24 Delta f No used d 27 Tab vhz It enables the managing at closed ring of the SVC control 7 3 4 Parameters Set Value Control selection 0 Open ring SVC 1 Closed ring SVC Ma To this category belong all the parameters proper of inputs and drive outputs parameters of group and group 1 0 Polarity Input output polarity Keypad value Function 1 DIN 1 Active Low
102. ve OK in Development 64 SYNERGY IN MOVEMENT a NAME pois UNIT RANGE DESCRIPTION gt gt 21 DAC O3 1 6 Settable analog output Analog 0 disable Output 1 10V Out 2 current 0 10V DC Link voltage 0 10 1021000Vdc 4 52 Proc PID deviation 0 10V elelelele 6 Proc PID feedback 0 10V Off_Out_ O4 analog output Offset AN DAC e eoe kOut AN O5 0 01 Analog output range scale factor DAC 99 99 pere e e Out DAC O9 0 6 Auxiliary analog output active with Din e ele cie Anaux input configuration kOut DA 0 01 Auxiliary analog output scale factor C 99 99 Fw Out Hz 1 100 Analog output filter AN DAC PID LOOPS CALIBRATION Kpl PO 0 9999 Constant proportional to the current Current regulator SVC current hook Kil P1 0 9999 Integral Constant of the current regulator elelelele current hook for SVC Kpw P2 Proportional constant of the speed Speed regulator Kiw P3 Integral constant of the speed regulator 4 Constant from the speed regulator Tdw P5 Limit of the filter passband on the ele feedback for the Kdw constant Kpflx P6 Proportional constant of the flux regulator Kiflx P7 Integral constant of the flux regulator egeo 8 0 0
103. verload L Reduced Overload Special Versions No letter Standard version F External brake resistor for units of power 0 75 11kW 10 SYNERGY IN MOVEMENT 2 3 1 How To Read the Plate SYNERGY IN MOVEMENT MODEL BLAST E 0011 D AEDEM S N C012001050258 Ponte di Nanto VI www earp it e mail earp earp it drive abbreviation nom Power absorbed in kVA Supplying voltage in Volt nom max output current output frequency serial number 2002 2003 123456789 10 11 12 VOLTAGE Q 380 15 480 5 Vac INPUT FREQUENCY 45 65Hz KVA 25 VOLTAGE 3Ph 380 480 Vac OUTPUT CURRENT 3 5 7 0 1000 Hz 2 3 2 Option Codes Also available CODE DESCRIPTION BLAST E OPT 0000 Cover for option card mounted as standard BLAST E OPT 0010 7 segments display keypad BLAST E OPT 0030 Option Card RS232 BLAST E 0031 Option Card RS232 cable L 1 5 m BLAST E OPT 0040 Option Card RS485 BLAST E 0041 Option Card RS485 cable L 1 5m BLAST E 0050 Option Card CAN BUS with DeviceNet BLAST E OPT 0060 Option Card PROFIBUS DP BLAST E OPT 0110 Option Back UP Card 24V BLAST E 0120 10 supplying optional card for external potentiometer 11 SYNERGY IN MOVEMENT gt 2 4 General Features and Technical Data of the BLAST E range 2 4 1 General Inverter F
104. views it is recommendable to look at the firmware books supplied in the CD attached with the product 94 SYNERGY IN MOVEMENT 10 ALARMS 10 1 Foreword In case of one or more alarms occurring the system stores and signals them with E The letter means alarm followed by the alarm code The alarms are stored in a alarm memory in chronological order up to 10 alarms Several alarms occurred at the same time are stored in an order which depends on the priority assigned to each of them 10 1 1 Alarm Display The alarms are automatically displayed on the keypad The alarm is displayed in short form with a 2 letter code and E e ENTER alarms e Key DOWN STOP pressed for 3 sec makes RESET of all the alarms The alarm reset is carried when the drive is disabled only Furthermore the last 10 alarms are stored in ALARM MEMORY 95 SYNERGY IN MOVEMENT ALARM CODES CHART 10 1 1 1 Alarm Code Alarm DISPLAYED ON PC DescriPTion Short circuit Short Circuit Thermal alarm Pt Low 24 Volt Electronic supply low drive reset Power thermal alarm Drive Overtemperature Motor thermal probe Drive Thermal probe Min Voltage DC Link low voltage Max Voltage Max voltage limit exceeded 2800V Over Current If measured current Imax Congruence Incongruence between real speed and commanded speed The positioning automatic setting must be carried out
105. y modify the generator s voltage and cause the overheating or a deformation of the output voltage The generator s power should therefore be at least 5 times higher than the inverter s power in kVA 6 Repeated on off switching within short time through the remote control switch reduce the life time of the filtering capacitors 44 SYNERGY IN MOVEMENT WARNING gt Never use this solution to start and restart the motor For BLAST E 0007xxx to BLAST E 0055xxx cycles having more than three mains on off operations per minute may cause the switching of the protection device placed above BLAST due to the NTC overheating For BLAST E 0075xxx to BLAST E 0220xxx cycles having more than ten mains on off operations hour may cause the burning of the pre charge resistor and so heavy damages on the inverter CHART 5 4 1 Fuses gG type and cable section 20 21 Ta 40 Mains Inputwithout Inputwith reactance BLAST E 0007 BLAST E 0011 BLAST E 0015 BLAST E 0022 BLAST E 0037 BLAST E 0055 BLAST E 0075 BLAST E 0110 BLAST E 0220 BLAST E 0300 BLAST E 0370 BLAST E 0450 BLAST E 0550 BLAST E 0750 BLAST E 0900 BLAST E 1100 BLAST E 1320 BLAST E 1600 MCM Section of the control signal cables 0 75 mm 18 AWG Section of the signalling relay cables 0 75 mm 18 AWG 7 Check for the mains supply to be connected to terminals L1 L2 L3 and the motor to terminals U V W and not
106. y to set the bit 0 Drive 0 HW the bit 1 reference 1 On 1 SW and the bit 6 reference 1 Value 1 SW 0 2 1 2 41 25 0 2 64 66 the bit 12 decides if is to be generated the speed output in analogical way bit 1220 or through a frequency from 0 to 100KHz bit 12 21 To obtain the operation desired it will be also necessary to set the dip switch SW1 correctly The bit 13 permits to choose if use the main reference controlled in voltage range 10 10V or in current range 4 20mA This setting imposes the will to use such input in analogical mode and excludes the possibility to set the bit 6 Also in this case beside to set such bit it will be necessary to set the dip switch SW2 T1 SYNERGY IN MOVEMENT Ma d 4 Setup 2 Configuration of the managing of the supplied current possible selections Behaviour in overload re entry to the nominal in overload overload alarm in overcharge PWM re enter in over calibration PWM operating derating of the selected PWM SFT with deflowing 1 8 SFT with deflowing 1 4 d 5 Size the parameter identifies the size of the module in kW In chart 7 1 chapter 7 paragraph 3 there are the characteristics of the various available sizes Such parameter can not be changed by pc but only by keypad with EARP reserved code d 26 killer Thermal protection constant of the brake resistor Setting range 0 10 In case the brake circuit is switched the driv

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