KaVo EWL 4452, Operating Instructions Manual

Page 1: ...ng Instructions Frequency inverter type EWL 4452 1 000 3172 WHD Ge Fk 03 01 GB 05 00 KaVo Elektrotechnisches Werk GmbH Wangener Straße 78 D 88299 Leutkirch Tel 0 7561 86 0 Fax 0 7561 86 371 STOP START Typ 4452 ...

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Page 3: ...nt aspects in brief 21 B 2 1 Connecting the inverter 21 B 2 2 Establishing factory default 21 B 2 3 Setting motor parameters 22 B 2 4 Setting remote control parameters 22 B 2 5 Operation 22 B 2 6 Reset 23 B 3 Configuration 24 B 3 1 Commissioning parameters examples 26 B 3 2 Examples of configuration 27 B 3 3 Special functions 27 B 3 4 SP1 Store and recall motor parameters 29 B 3 5 SP2 Test remote ...

Page 4: ...product described in this UM correspond to the state on going to press Modications and improvements to the product on the basis of new technical developments are possible This does not imply any right to retrofitting of existing devices KaVo assumes no responsibility for damage arising through external influences poor quality of the media or poor installation use of incorrect information improper ...

Page 5: ...se intended by the manufacturer Unauthorized modifications and the use of additional equipment not recommended by the manufacturer can cause fires electric shocks and injuries Definitions ASM motor 3 phase asynchronous motor BLDC 3 phase brushless DC motor without position sensors Motor The inverter performs the position synthesis by measuring the motor voltage e m f BLDCS 3 phase brushless DC mot...

Page 6: ...precautions are not taken A 1 4 Purpose and potential applications KaVo EWL frequency inverters type 4452 have been specially constructed for the operation of three phase asynchronous motors ASM and brushless DC motors BLDC as used in spindles e g for grinding cutting and drilling units on machine tools They can also be used for operating motors which are constructed from motor elements and serve ...

Page 7: ...ut power max 2500 VA continuous operation Output voltage 3 220 V at 8 A Output current max 8A per phase continuous operation 1 minute max 12A Output frequency 30 3000 Hz for ASM motors 180 000 min 1 30 2000 Hz for BLDC motors 120 000 min 1 Braking resistance internal 80 W external option rated resistance 27 100 Ω power 150 1000 W Efficiency 93 at 2500 VA cos phi motor 86 Motor sensors Motor temper...

Page 8: ...0V input protected up to max 40V Analogue outputs FB AOUT1 2 Ua 0 10V Iout max 10mA Output short circuit proof Frequency output FB OUT FREQ 3 times output frequency of the inverter pulse duty factor 50 open collector U_max 24V I_max 30 mA Supply and auxiliary voltages FB 10V Uout 10V 3 Iout max 15mA short circuit proof I_k max 40mA FB 24V X4 18 24V 15 5 I_a 0 80mA short circuit proof I_k max 300mA...

Page 9: ...r connection Mat No 0 223 1634 and metallized housing incl screw union Mat No 1 000 2790 Omitted in the case of delivery of the connection adapter accessory Mat No 1 000 2811 A 2 2 Accessories Connection adapter for 25 pin Sub D plug with screw connection incl metallized housing and screw union Mat No 1 000 2811 Mains cable with safety plug for Germany length 2 m Mat No 1 000 3263 ST OP ST AR T Ty...

Page 10: ...D Warnung LED Störung Operation Warning Fault grün green gelb yellow rot red Abbruch unten oben Enter Eingabe Stop Weiterschaltung down up Abspeichern Cancel transfer Enter input save LED Start grün green LCD Anzeige LCD display 16 Zeichen x 2 Zeilen 16 characters x 2 lines Start 8 ...

Page 11: ...641 7700 230 V 50 60 Hz 16 A Made in Germany Hersteller manufacturer Gerätetyp Device type Seriennummer Serial number Warnhinweis Begleitpapiere beachten Warning see accompanying documents CE Kennzeichnung CE mark Stromaufnahme Current consumption Max mögl Gerät Ver sorgungsspannung diese Angabe ist länder spezifisch und kann von der Abbildung abweichen Max possible device supply voltage this is c...

Page 12: ... m f voltage the motor inductance may not be too large A 4 3 Brushless DC motor with position sensors BLDCS The design of this motor is identical to that of the BLDC motor described above For position detection however 3 additional Hall sensors are installed in the motor This motor design is not supported in the basic version of the frequency inverter type 4452 and a firmware update is required fo...

Page 13: ...esponding parameters In order that the inputs perform the function prescribed in the parameters parameter P7 select func should be set to remote con or parallel Ansteuerung ohne Fremdspannung Control without external voltage FB REL1 FB REL2 FB REL3 FB 24V FB GND FB C REL R1 2k R2 2k FB C IN FB IN6 FB IN3 FB IN4 FB IN5 LED2 LED1 FB REL4 OE FB REL4 S FB OUT FREQ LED3 R5 2k R3 2k R4 2k LED5 LED4 _ 2k...

Page 14: ...ternal voltage FB C REL FB GND FB 24V FB REL3 FB REL2 FB REL1 FB IN5 FB IN4 FB IN3 FB IN6 FB C IN FB REL4 OE FB REL4 S FB OUT FREQ _ 2k Umrichter 4452 Inverter 4452 Fernbedienung remote control FB AIN2 FB AIN1 FB 10V FB AOUT1 FB AOUT2 FB AGND FB IN2 FB IN1 X4 D Sub 25 12 ...

Page 15: ...re and recall motor parameters The motor coding can be changed only when the motor is stationary Only the coding inputs H1 H3 actually required are evaluated and inputs not required are ignored A motor coding of up to 4 motors can be used in the case of motors with speed sensor motor coding of up to 8 motors cannot be used simultaneously with a speed sensor since the two functions share the input ...

Page 16: ...t first input a stop command followed by a start command A 4 8 Speed sensor For the ASM motor an external speed sensor can be connected and the number of pulses per revolution can be configured in the range 1 10 with parameter P59 speedsensor The measured actual speed is displayed in P14 f_motor The speed sensor is used for detecting motor stoppage f 1Hz see status signals P120 RELx for the catch ...

Page 17: ...L3 FB REL4 OE FB REL4 S FB C REL X7 PTC PGND P 12V H1 H2 H3 X1 N L1 X2 W V PE PE U X3 PE Motor 3 Bediensteuerung panel control unit Bedieneinheit control panel FB 10V X4 RXD F TXD F 7V F X5 RS232 9 pol 9 pin FB IN5 FB IN4 FB IN3 FB IN2 FB IN1 FB C IN FB IN6 FB REL1 FB REL2 FB AGND FB AOUT2 FB AOUT1 FB AIN1 FB AIN2 FB OUT FREQ FB 24V FB GND 15 ...

Page 18: ...net Fasten the mounting plate to the back panel of the switch cabinet by means of four screws Ensure good electrical contact with the protective conductor Information on cooling The inverter is cooled by an integral fan To ensure effective cooling at least the following clearances must be maintained around the inverter End surfaces 30 mm Longitudinal surfaces 10 mm STOP STA RT Typ 4452 10 mm 10 mm...

Page 19: ...3 variable speed electrical drives The above mentioned EMC product standard can be complied with only by means of shielded motor and control cables It should be ensured that the cable shields rest over a large area of the inverter housing and are surrounded by the cable clips A shielded mains cable is not required The control cables must be laid separately from not parallel with mains and motor ca...

Page 20: ... 3 W 4 black 5 black PTC cold conductor X7 1 B brown 4 brown PTC cold conductor X7 6 C white natural 2 white Protective conductor X3 PE 2 yellow green 7 yellow green Shield Pull relief terminal Housing braided not present Not connected A green 6 natural X4 Remote control connection Plug type 25 pole D Sub jack Note All connections of the 25 pole jack X4 are potentially isolated from the control an...

Page 21: ...ternen Bremswiderstandes Bridge plug for use of the internal brake resistance Anschluß externer Bremswiderstand Connection of external brake resistance Externer Bremswiderstand Brücke entfernen und R Brems anschliessen External brake resistance remove bridge and connect R brake X6 X6 R Brems R brake 20 650 Ohm 150 1000W Interner Bremswiderstand Brücke zwischen Pin 2 und Pin 3 Internal brake resist...

Page 22: ...e are not isolated from the mains potential 1 6 5 4 3 2 X7 X7 X7 X7 X7 12V max 50mA Zur Versorgung der externen Sensoren For supplying the external sensors Achtung Anschlüsse sind nicht potentialgetrennt vom Leistungsteil Note Connections are not potentially isolated from the power unit H2 H3 H1 ASM Motor Drehsensor an H1 Motor Codierung an H2 H3 Speed sensor at H1 motor coding at H2 H3 BLDC Motor...

Page 23: ...verter was already in operation and is to be configured for another application first establish the factory default Menu Special functions SP3 reset parameter all parameters Keys Display 2 x Special functions Enter SP1 2 x SP3 reset parameter Enter Reset parameter motor parameter top 1 Reset parameter remote control top Reset parameter all parameters Enter P1 P150 init YES Enter Function All param...

Page 24: ... 3 9 Stop the motor with the Stop key B 2 4 Setting remote control parameters If you wish to control the inverter via the remote control interface X4 additionally set the parameters P104 P136 and P7 select func See Section B 3 1 Commissioning parameters examples and from Section B 3 9 Description of the individual parameters B 2 5 Operation Operation concept for frequency inverter 4452 Parametrier...

Page 25: ...ilable With the key cancel transfer you can select between 1 Normal state Standard display or error display 2 Configuration Display of parameter P1 3 Special functions B 2 6 Reset If a serious error occurs LED H5 Fault lights up red a reset must be triggered in order to fetch the device from this state There are three possibilities for triggering a reset 1 Key combination cancel transfer Stop Firs...

Page 26: ...changed the Enter key is pressed The value can now be changed within the permissible range After the Enter key has been pressed the value is adopted by the control and is stored If the old value is to be retained the key cancel transfer is pressed If a parameter cannot be changed e g pure display values an eye symbol oo appears in the first position of the second line in the LCD display H1 This al...

Page 27: ...arameters Motorparameter für vordefinierte Spindeln Motor parameters for predefined spindles SP11 SP12 P100 P137 P150 P1 P38 P41 P96 autom Laden bei Netz ein Automatic recall at mains on EEPROM nichtflüchtiger Speicher Nonvolatile memory Motorparameter Werkseinstellung motor parameter factory setting KaVo Typ e xxxx SP 142 Diese Parameter können über das Bedienpanel an gezeigt und ver ändert werde...

Page 28: ... rating plate P93 I_mot_nom Rated motor current according to rating plate P94 cos phi Cosine phi under nominal load 85 P96 no of poles Number of motor poles 2 P85 motor prot Protection of the motor from excess temperature Brushless DC motors without position sensors BLDC Parameters which must be input P90 motortype Motor type BLDC P91 f_mot_nom Rated motor frequency according to rating plate P92 V...

Page 29: ... the normal state the standard display is output to H1 LCD panel During configuration the standard display can be selected under P4 display if the inverter is in an error state at this point the error number is displayed in the 1st line and a short text relating to the cause of the error is displayed in the 2nd line In the event of an error it is possible to switch back and forth between the error...

Page 30: ...2 SP11 SP13 recall store delete factory setting SP142 SP143 SP141 Kavo type 4060 factory default SP100 SP100 SP100 memory M1 M8 memory M1 M8 memory M1 M8 Up increase value exit memory entry Down decrease value previous memory entry SP121 overwrite SP22 SP0 SP4 SP3 TKD test progr Reset Parameter SP32 SP31 SP33 SP23 SP24 SP21 Test remote ctrl SP2 Special functions Standard display Normal state Confi...

Page 31: ...to the factory setting or to various predefined motors SP141 Special functions motor parameter factory setting factory default With this function motor parameters P41 P96 are set to the factory setting The configuration of the inverter P1 P8 and the configuration of the braking resistance and of the remote control P100 P150 remain unchanged SP142 Special functions motor parameter factory setting K...

Page 32: ...e control P104 P137 are set to the factory setting rendering the remote control inactive After confirmation of the safety inquiry SP300 with the Enter key the function is performed The other parameters remain unchanged SP33 Special functions reset parameter all parameters With this function all parameters P1 P150 are set to the factory setting After confirmation of the safety inquiry SP300 with th...

Page 33: ...20 motor code Motor coding and motor memory 1 8 N P24 Norm value Standardized display value 0 1500000 N P25 t_action Operating hours counter 0 65000 h 0 N P26 t_reset Switch on time from reset 0 65000 min 0 N P30 1st error Last error 0 N P31 2nd error Penultimate error 0 N P32 3rd error Third last error 0 N P33 4th error Fourth last error 0 N P34 5th error Fifth last error 0 N P36 Inverter Inverte...

Page 34: ... plate P90 motortype Motor design ASM BLDC BLDCS no motor S P P91 f_mot_nom Rated motor frequency 30 3000 Hz 50 S P P92 V_mot_nom Rated motor voltage 0 250 V 30 S P P93 I_mot_nom Rated motor current 0 5 8 0 A 1 0 S P P94 cos phi Cosine phi at nominal load 20 100 85 S P P96 no of poles Number of poles 2 4 6 8 2 S P Device parameters ext brake resistance P100 R_ext_brake Resistance of external brake...

Page 35: ...ection of the standard display in the normal state Values 0 Combi display Combination display consisting of actual motor values P14 f_motor P15 V_motor and P17 i_mot app 1 f_out_act Inverter output frequency P13 f_out_act 2 V_motor Voltage at motor P15 V_motor 3 I_mot_app Apparent current through motor P17 I_mot_app 4 I_mot_real Real current through motor P18 I_mot_real 5 V circ Voltage at interme...

Page 36: ...F1 P107 fixfreq FF4 of the remote control and the frequency limits for the analogue setpoint value input P135 f_rem_min P136 f_rem_max are effected Values 1 in Hz the display is in Hz 2 in min 1 the display is in min 1 revolutions per minute Factory setting 1 in Hz B 3 11 Display values P10 f_rated_act display value The valid rated speed value can originate from various sources depending on config...

Page 37: ... ms P19 P_real display value P_real is the current inverter output power corresponding to the real power consumed by the motor The value is updated every 500 ms P20 motor code display value Motor code is the current motor coding which is present at X7 4 and X7 5 In addition the currently used motor parameter memory M1 M6 is displayed If the parameters from the memory have been changed the dis play...

Page 38: ...SM motor serves for establishing the lower limit of the inverter frequency Minimum value 30 Hz Maximum value 100 Hz Factory setting 50 Hz P42 f_mot_max ASM BLDC BLDCS Absolutely maximum inverter frequency The output frequency of the inverter is limited to this value to protect the motor This value is set to the maximum rated frequency in the case of ASM motors in the case of BLDC and BLDCS motors ...

Page 39: ...at a motor stop after which DC braking is also performed see P55 t_DC_brake and P56 I_DC_brake If t_stop is set too short the inverter limits the generator current to the value of P44 I_limit and the actual stop time of the motor automatically increases but vibrations may occur during the braking process Specific values 0 3 DC brake At stop the system switches directly to DC brake there is no gene...

Page 40: ... selected only if P51 t_start 0 Low currents should be set for a soft and quiet start and higher currents for fast start and larger centrifugal masses Minimum value 0 4 A Maximum value 12 A Factory setting 0 4 A P53 f_start BLDC Startup frequency for microstep startup If P51 t_start is set to 0 4 without ramp the motor start begins at the frequency f_start if a ramp time is set in P51 t_start the ...

Page 41: ...o DC braking Minimum value 0 1 sec Maximum value 120 sec Factory setting 2 sec P56 I_DC_brake ASM Current for DC brake in ASM motor displayed only if P55 t_DC_brake is not set to off Minimum value 0 1 A Maximum value 12 A Factory setting 1 A P57 I_DC_stop ASM BLDC BLDCS Stop current this current flows in the stopped motor through 2 phases the 3rd motor phase is currentless and the motor is thus br...

Page 42: ...imum value 10 pulses revolution Factory setting 0 No sensor Motor U f characteristic ASM The voltage frequency table describes the key points of the motor voltage at specific frequencies for the ASM motor With the factory setting characteristic points KP1 KP3 are set to the nominal frequency and the nominal volt age of the motor With input from the table the following must be noted The frequencies...

Page 43: ...nom the value fo the rated motor voltage from P92 V_mot_nom is used Minimum value 1 V Maximum value 250 V Factory setting 0 V_nom P63 f2 ASM U f characteristic Frequency of characteristic point KP2 Specific values 29 f_nom the value of the nominal motor frequency from P91 f_mot_nom is used Minimum value 30 Hz Maximum value 3000 Hz Factory setting 29 f_nom P64 V2 ASM Specific values 0 V_nom the val...

Page 44: ...rease less sharply under load The I R factor corresponds to the ohmic resistance of the motor measured between two motor cables U P71 I R factor P18 I_mot_real P93 I_mot_nom P94 cos phi V_mot U_table U U_table corresponds to the U f table voltage calculated from the values P60 P66 Specific values 0 off I R compensation switched off Minimum value 0 1 V A slight rise Maximum value 30 V A Factory set...

Page 45: ...m value 2 Maximum value 200 Factory setting 40 P78 I limtr t_n ASM BLDC BLDCS Only in special cases should this parameter be changed from the factory setting P78 I limtr t_n influences the control PI for the motor current limitation it being possible to set the reset time I part here Longer times make the control slower If the times are too short the current control tends to oscillate Specific val...

Page 46: ... Factory setting 30 ms P84 N contr t_fil ASM BLDC BLDCS This parameter influences the control PID for the motor speed it being possible to set the filter before the D part here The filter makes the D part smoother and slightly slower In the case of longer times the tendency of the D part to oscillate is damped Minimum value 1 ms Maximum value 300 ms Factory setting 200 ms B 3 14 Monitoring P85 mot...

Page 47: ...um value 3000 Hz Factory setting 50 Hz P92 V_mot_nom ASM BLDC BLDCS Rated motor voltage according to rating plate Minimum value 0 V Maximum value 250 V Factory setting 30 V P93 I_mot_nom ASM BLDC BLDCS Rated motor current apparent current in one phase according to rating plate Minimum value 0 5 A Maximum value 8 0 A Factory setting 1 0 A P94 cos phi ASM BLDC BLDCS Motor power factor cosine phi acc...

Page 48: ...is possible only if no speed sensor is used since both functions share the input H1 X7 3 see P59 speedsensor Only the coding inputs H1 H3 actually required are evaluated Value Display Function Coding inputs used H1 X7 3 H2 X7 4 H3 X7 5 1 Motorcode OFF Motor code switched off 2 2 motors M1 M2 Coding with 2 motors x 3 3 motors M1 M3 Coding with 3 motors x x 4 4 Motors M1 M4 Coding with 4 motors x x ...

Page 49: ... has no function 1 stop Motor stop V_high stop V_low run enable 2 Reset Reset pulse at V_high trigger reset 3 fixfreq on Current nominal speed value is a fixed frequency and the input must be high for this purpose This selection of the fixed frequency FF1 FF4 is performed by inputs IN5 and IN6 The fixed frequencies themselves should be set with P104 P107 4 CCW rotation CCW motor operation U_high C...

Page 50: ...or brake and DC brake see P48 t_stop and P55 t_DC_brake After the inverter has been switched on or after a reset the motor stands signal is inactive If a speed sensor is configured with P59 speedsensor this signal becomes active at an actual motor stoppage f 1Hz BLDC motor The signal becomes active if the actual motor stoppage is detected from the e m f voltage 8 motor runs This is the inverted mo...

Page 51: ... 0 off P132 analogue AOU1 Function of the programmable analogue output 1 AOUT1 Werte 0 off The output has no function output voltage 0V 1 I_mot_real Real motor current P18 i_mot_real 10V P44 I_limit 2 f_motor 3000Hz Motor frequency P14 f_motor 0V 0Hz 10V 3000Hz 3 f_motor 1000Hz Motor frequency P14 f_motor 10V 1000Hz 4 f_out 3000Hz Inverter output frequency P13 f_out_act 10V 3000Hz 5 f_out 1000Hz I...

Page 52: ...r of poles of the motor P96 no of poles being taken into account Minimum value 0 Hz Maximum value 3000 Hz Factory setting 3000 Hz P137 f_stop_ana Stop frequency from analogue rated frequency signal this makes it possible to achieve an automatic motor stop with counterclockwise rotation of the nominal value potentiometer or analogue voltage 0 V The motor is automatically stopped if the rated freque...

Page 53: ...ither through the key combination or through a remote control reset With a reset a total initialization of the device is triggered If the error persists the error display immediately appears again The last 5 error messages are stored in the parameter P30 1st error to P34 5th error warning messages not being taken into account here This makes it possible to trace the error history B 4 1 Hold functi...

Page 54: ...coding 27 Motor coding more than 4 motors and speed sensor used conflict at input H1 B 4 4 Electronics errors on motor control 40 Communication of motor control to control panel broken 41 EEPROM on power circuit board faulty during self test data memory 42 Flash program memory on motor control circuit board faulty 43 EEPROM on motor control circuit board faulty in self test data memory 44 ID in me...

Page 55: ...all time too short Mains voltage too low Mains voltage too high Inverter overloaded motor short cir cuit or earth fault Device error in inverter Bridge at X6 2 3 for internal brake resi stance missing Bridge at X6 2 3 for internal brake resi stance connected but external brake resistance configured P1 f_rated or rated value of analogue input too high Mains voltage interruption or mains input volta...

Page 56: ...102 motorcoding contains more than 4 motors and a speed sensor is configured in P59 speedsensor Both functions share the input H1 X7 3 Loading of the motor para meter memory M1 M8 is not possible Hardware or software interruption of communication EEPROM on power circuit board faulty Flash memory on motor control circuit board faulty Rectification Set parameter P90 motortype presumably the inverter...

Page 57: ...on If the error persists in spite of re peatedly switching on and off a hardware error is present and the inverter should be sent for repair If the error persists in spite of re peatedly switching on and off or resetting a hardware error is present and the inverter should be sent for repair Warning indication is automatically reset after 10 seconds and motor continues to run Check parameter P90 mo...

Page 58: ... faulty Loss of data EEPROM on control circuit board faulty Loss of data flash on motor control circuit board faulty Internal communication of control circuit board to motor control circuit board broken since protocols do not match one another Strong EMC interference on control circuit board Rectification If the error persists in spite of re peated resetting a hardware error is present and the inv...

Page 59: ...s complies with the essential safety requirements in accordance with the provisions of the Directive s 89 336 EEC EMC Directive 73 23 EEC low voltage directive The following standards or normative documents were used for assessing the product EN 50178 Equipping of power current installations with electronic operating materials EN 61800 3 Variable speed electric drives Leutkirch 11 09 2000 M Mohr M...

Page 60: ... 23 Standard display 4 Standard factor 33 Standard value display 33 Standard value 35 Start pulse 47 Start Stop 47 Startup current 38 Startup frequency 38 Startup time 38 Startup voltage 41 Status 48 Current limit 48 Failure 48 f_rated reached 48 Motor runs 48 Motor stands 48 Motor temperature 48 Operation 48 Stop current 39 Stop current 39 Stop delay time 37 Switch cabinet 16 Switch off time 39 T...

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Page 62: ...3 Frequency 2 f2 x Hz f_mot_nom O 64 Voltage 2 V2 x V U_mot_nom O 65 Frequency 3 f3 x Hz f_mot_nom O 66 Voltage 3 V3 x V U_mot_nom Control O 70 Control U f I R slip N Control x U f table O2 71 I R comp rise factor I R factor x V A off O2 72 Load comp rise factor Loadkomp x off O2 73 I R and load comp filter time comp T filt x ms 20 O2 75 Slip comp P factor Slipkomp x Hz A off O2 76 Slip comp filte...