CAT425

BULLETIN 425
ADJUSTABLE FREQUENCY CONTROL

Using Inverter No. R46333
OPERATION and MAINTENANCE MANUAL CATALOG 425-1
CATALOG 425-1 PUBLICATIONS DEPARTMENT OAK CREEK, WI 53154 0701
Dangers, Warnings, Cautions, Notices

Dangers, Warnings, Cautions, and Notices are used throughout this manual to emphasize important and critical instructions. Dangers, Warnings, and Cautions always precede the paragraph or item to which they apply; Notices always follow the paragraph or item to which they apply. For the purpose of this manual Dangers, Warnings, Cautions, and Notices are defined as follows: DANGER Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.
WARNING Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION Caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also beused to alert against unsafe practices.
NOTICE
Notice is used to notify people of installation, operation, or maintenance information which is important but not hazard-related.
COPYRIGHT
Under the copyright laws, this document may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine readable form, in whole or part, without the prior written consent of Morris Material Handling. Copyright 2000 Morris Material Handling, Oak Creek, Wisconsin, USA 53154. All rights reserved. Printed in the United States. Published by: MMH Publications Department
Morris Material Handling
PREFACE
Operators, inspectors, and maintenance personnel of overhead traveling cranes, gantry cranes, monorail and underhung cranes, storage/retrieval machines, overhead hoists, and overhead stacker cranes should be read and be familiar with the Safety Standard as listed below. Copies of these publications are available, at a nominal cost, from the American Society of Mechanical Engineers at 22 Law Drive, Box 2300, Faireld, NJ 07007-2300, Phone: (800) 843-2763 or the American National Standards Institute at 11West 42nd Street, New York, NY 10036, Phone: (212) 642-4900.
ANSI/ASME B30.2 ANSI/ASME B30.9 ANSI/ASME B30.10 ANSI/ASME B30.11 ANSI/ASME B30.13 ANSI/ASME B30.16 ANSI/ASME B30.17 ANSI/ASME B30.18 ANSI/ASME B30.21 ANSI Z244.1 Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist) Slings Hooks Monorail and Underhung Cranes Storage/Retrieval (S/R) Machines and Associated Equipment Overhead Hoists (Underhung) Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoist) Stacker Cranes (Top or Under Running Bridge, Multiple Girder, Top or Under Running) Manually Lever Operated Hoists Lockout/Tagout of Energy Sources
This manual is provided as a guide to personnel involved with the installation and testing procedure of this equipment. We recommend that such personnel review and become familiar with general procedures and information contained within this manual. In addition we recommend that this manual be kept readily available for reference before beginning installation or testing of this overhead crane. Throughout the manual are safety precautions and instructions for awareness and information on potential hazards. Due to the complexities of this crane and the environment in which it operates, situations may arise which are not directly discussed in detail in this manual. If there is ever a question regarding safe operation of this equipment immediately contact: Morris Material Handling Inc., Telephone: 1-800-933-3001 www.morriscranes.com
INTRODUCTION TO THIS MANUAL
This section describes the purpose and the contents of this manual. The purpose of this manual is to provide detailed information on the installation and start-up of the BUL 425 AC inverter drive system. Included are detailed descriptions of the functions, installation, and start-up of the unit. Fault diagnosis information, technical data, dimensional drawings, and glossary are included. The sections with footers highlighting BUL 425 are applicable for the whole BUL 425 AC drive product range. Individual sections may be specic to certain frame sizes and are marked where applicable. This manual is intended for people who are responsible for installing, commissioning, and servicing the BUL 425 AC drive. The audience is expected to: Have a basic knowledge of physical and electrical fundamentals, electrical wiring practices, electrical components and electrical schematic symbols.
INTENDED AUDIENCE
Revised 6/25/01 Have prior experience on P&H products. Have prior experience on ac drives.
Have prior experience on the BUL 425 product family. Have prior experience on installing, commissioning, operating, and servicing the BUL 425.
WHAT THIS MANUAL CONTAINS
This manual contains basic information required to safely store, transport, and unpackage the BUL 425 AC drive system. Included is a detailed product description with ratings, dimensioning, and other details for mechanically and electrically installing the BUL 425 and planning start-up of your crane/hoist ac drive application. (See Sections 1 through 7)
NOTICE
Safety Instructions are placed on the rst pages of this manual. The safety instructions describe the formats for various warnings and notations in use in this manual. The section also states the general safety instructions that are intended for all work on the BUL 425 inverters. Section 8, has a detailed explanation in using the on-board PMU (parameter-meteringunit) keypad, and details for reading and writing parameter values, control actual values. Detailed steps involved in start-up, conguration, and the tuning of the BUL 425 inverter for your application are included Section 9. The remaining sections of this manual contain detailed information needed in troubleshooting, servicing, and maintaining your BUL 425 AC inverter drive. Included is a glossary listing with denitions of common terms used with BUL 425. (Sections 10 through 16)
MATERIAL SAFETY DATA SHEETS (MSDS)
In order to transfer MSDS information from our suppliers to our customers, P&H will provide this service upon customer request. All customer requests need to be specic because of the volume and complexity of the MSDS system. To correctly identify the appropriate MSDS, one of the following pieces of information must be included: P&H part number, vendor trade name or vendor name. Inquiries concerning MSDS information can be addressed to our Sales or Service representatives by calling our Toll-Free number (800) 933-3001 or visit our website: http://www.morriscranes.com When performing inspection, maintenance or repair work on Morris Material Handling equipment, always follow lockout/tagout procedures as required by OSHA 29 CFR Part 1910.147 and outlined in ANSI Z244.1. Lockout/tagout procedures are intended to protect personnel working on or around the equipment by preventing accidental start up or exposure to hazardous energy release such as electrical shocks. The procedure requires that individual locks and tags are placed on controls, shutoff switches, valves or other devices to prevent usage until the person who installed the lock or tag removes it. Never attempt to operate any control, switch, valve or other device when it is locked or tagged out. OSHA required lockout/tagout procedures include: 1. A documented and established site policy on the steps to follow for lockout and tagout such as: Notify all affected people including supervisors before lockout or tagout is used. Shut off the affected machine, equipment, system or function. Disengage, isolate or release energy supply or source.
LOCKOUT/ TAGOUT PROCEDURES
ii
BUL 425 Operation and Maintenance Manual
Morris Material Handling Apply individual locks and/or tags on controls, switches, valves or other devices to prevent usage. Try or test the machine, equipment or system to check that the energy has been removed before service or maintenance. 2. Employee training about the facilitys lockout/tagout procedures. 3. Identication and location of shutoff switches, controls, valves or other devices that isolate hazardous energy are predetermined at the site facilities. 4. After maintenance and service is nished and each lock and/or tag has been removed by the appropriate individual and all affected people are notied then restore energy or power.
GENERAL SAFETY INSTRUCTIONS
These safety instructions apply to all work on the BUL 425. Many tests and procedures outlined in this manual involve exposure to components that operate at potentially lethal voltage levels. To eliminate this danger, service personnel must ensure that the incoming three-phase ac power has been disconnected, locked out, and tagged. After removing power, allow at least ve minutes to pass, then verify that the dc bus capacitors have discharged to a level below 50 VDC before contacting internal components. Test by connecting a dc voltmeter across the dc bus + and - terminals. Start with the meter on the highest scale and progressively switch to a lower scale as the indicated voltage falls below the maximum value of the scale used. Only trained qualied electricians should be allowed to test or service this equipment. Do not work on "live" equipment alone. The output of the BUL 425 inverter is composed of short high voltage pulses (approximately 1.35 to 1.41 times line voltage) regardless of output frequency. This voltage can be almost doubled by unfavorable motor cable properties. Neglecting these instructions concerning the motor can result in permanent damage to the motor. All insulation tests must be carried out with the BUL 425 inverter disconnected from the cabling. Operation outside the rated capacities should not be attempted. Neglecting these instructions can result in permanent damage to the inverter. There are several automatic reset functions in the BUL 425. If selected, they reset the unit and resume operation after a fault. These functions should not be selected if other equipment is not compatible with this type of operation. This control contains ESD (electrostatic discharge) sensitive components. Observe the following static control precautions when testing, servicing, or installing the control to avoid component damage. Do not touch the pins of the chip. If any circuit board is removed from the control, immediately place it in conductive packaging. For additional information on static control procedures, refer to "Electro-static Discharge Control Handbook for Protection of Electronic Parts, Assemblies, and Equipment," available from the U.S. Department of Defense (DOD-HDBK-263). The BUL 425 crane drive system introduces electric motors, drive train mechanisms, and driven machines to an extended operating range. It should be determined from the outset that all equipment is capable of operating under these conditions. Operation is not allowed if the motor nominal voltage is less than one-half of the inverter nominal input voltage, or if the motor nominal current is less than 1/6th of the BUL 425 nominal output current. The insulation of the inverter is dimensioned for standard squirrel cage motors with rated voltage of at least 380 Volts. Motors with rated voltage of 220/380 Volts and no phase-to-phase insulation are not to be used with the BUL 425 inverter.
iii
Revised 6/25/01
! WARNING DANGER
Disconnect ac power, use lockout and tagout procedures, and test circuits for stored voltage before conducting maintenance, service, or inspection. Only authorized and qualied personnel with proper equipment should attempt diagnostics of the central processing unit.
! WARNING DANGER
Two-blocking the bottom block against the hoist drum or trolley frame can fail the wire rope and drop the loading, resulting in severe injury or death. Inspect the upper limit switches for proper operation and slowly raise the block to test the upper limit switches. Never permit anyone to stand or work under the block or load.
! WARNING DANGER
Unexpected hoist or crane movement can occur during the auto-tuning operation of the inverter, and can result in equipment damage, severe personnel injury, or death. The Dynamic auto-tuning operation releases the hoist, bridge, and trolley holding brakes and disables stop limit switches for the same motions. Chock the hoist drum to prevent lowering rotation. For the trolley and bridge, disconnect the output shaft on the motor from the drive machinery and chock the bridge and trolley wheels. Use barricades and tags to restrict access of personnel to the material handling equipment during the auto-tuning operation.
! WARNING DANGER
Unexpected hoist or crane movement can occur during the auto-tune operation of the inverter, and may result in equipment damage, severe personnel injury, or death. The Dynamic auto-tuning operation, causes traverse motion and hoist to raise. Remove hoist rope from the hoist drum before performing the Auto-tune operation. For the trolley and bridge, jack up the driven wheels so they are not in contact with the crane rail. Use barricades and tags to restrict access by personnel to the material handling equipment, during the Dynamic auto-tuning operation.
! DANGER
Touching or contacting energized high voltage connections or terminals will cause severe injury or death, and equipment damage. Disconnect power, use lockout and tagout procedures, and allow at least 5 minutes for voltage discharge before checking the electrical contacts, connections, or terminals of the SMARTORQUE system and components. Only authorized and qualied personnel with proper equipment should attempt to work on energized equipment.
! WARNING DANGER
Travel movement beyond limits or stops can cause unexpected two-blocking or collisions resulting in equipment damage, severe injury, or death. Increasing the deceleration times of the SMARTORQUE Control can permit the host or crane to over-run the established limits or end stops, Always re-adjust the upper stop and end zone limit switches after increasing the deceleration times. Contact your Morris Material Handling Inc., representative for additional information or assistance.
iv
! DANGER
Falls from heights can result in death or serious injury. OSHA / ANSI fall protection requirements must be followed when working at heights.
! WARNING DANGER
OPERATING THIS MOTION CONTROL FROM THE DIGITAL OPERATOR OR CHANGING THE SETTINGS FOR THE CONTROL CAN CAUSE SERIOUS INJURY OR DEATH. LOSS OF CONTROL CAN RESULT IF OPERATING FROM THE DIGITAL OPERATOR OR IS SETTINGS ARE CHANGED. DO NOT ATTEMPT TO OPERATE FROM THE DIGITAL OPERATOR OR ALTER THE CONTROL SETTINGS UNLESS YOU HAVE BEEN INSTRUCTED AS TO THE EFFECTS. CONSULT THE OPERATIONS MANUAL.
! WARNING DANGER
HAZARDOUS VOLTAGE WILL SHOCK, BURN, OR CAUSE DEATH... HAZARDOUS VOLTAGE WHICH CAN SHOCK AND BURN MAY BE PRESENT AFTER POWER HAS BEENN TURNED OFF. DISCONNECT, LOCK OPEN, AND TAG THE POWER SOURCE BEFORE SERVICING. HIGH VOLTAGE CAPACITORS IN ADJUSTABLE FREQUENCY DRIVE MAY STAY CHARGED BEYOND 5 MINUTES. DO NOT ATTEMPT TO SERVICE UNIT WITHOUT UNDERSTANDING SERVICE MANUAL AND CIRCUITRY. DO NOT OPERATE WITHOUT COVER IN PLACE.
! WARNING DANGER
Any hoist motor that is being used in an open loop conguration and has had its motor rewound or changed out for any reason, must have the input parameters for current EFF speed and RPM rerun in the optimization.
Revised 6/25/01
vi
Contents
PREFACE.......................................................................................................................
DEFINITIONS AND WARNINGS ............................................................................... 1-1
DESCRIPTION .......................................................................................................... 2-1
FIRST START-UP ..................................................................................................... 3-1
TRANSPORT, STORAGE, & UNPACKING ............................................................... 4-1
TECHNICAL DATA FOR BUL 425 INVERTERS ....................................................... 5-1
6 6.1 6.2 6.2.1 6.2.2 6.2.3 6.3
INSTALLATION......................................................................................................... 6-1 Pre-installation Planning............................................................................................. 6-1 Installing the BUL 425 AC Inverter.............................................................................. 6-1 Installation of Frames A, B, C, & D ............................................................................. 6-2 Installing units of Frame sizes E, F, & G ..................................................................... 6-4 Installing units of Frame size K................................................................................... 6-6 Installing the control and option boards....................................................................... 6-7
7 7.1 7.1.1 7.1.2 7.1.3 7.2 7.2.1 7.2.2 7.2.3 7.2.4
CONNECTING-UP..................................................................................................... 7-1 Power connections for the BUL 425 Inverter............................................................. 7-10 Terminal strip X-9 Frames A, B, C, & D (380-460 & 500-600 VAC) ........................... 7-12 Terminal strip X-9 Frames A, B, C, & D (200 - 230 VAC) ......................................... 7-12 Terminal strip X-9 Frames E, F, G, & K ................................................................... 7-13 Control Connections for the BUL 425 Inverter .......................................................... 7-14 RB-2 Board Connections (115VAC Control Interface - P/N R46885D2) ................... 7-14 CUVC Board connections (Main Processor Control - P/N R46888D1)...................... 7-16 EB-2 Board Connections (I/O extension Board - P/N R46887D1)............................. 7-21 (OPTIONAL) DTI (Digital Tachometer Interface Kit - P/N R46886D1) ....................... 7-24
Rev 10/20/00
7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.4 7.4.1 7.4.2
Description of crane terminal inputs (CUVC board)................................................... 7-26 Binary Input #7 : Run Enable.................................................................................... 7-26 Binary Inputs #6 & #5 : Raise / Forward and Lower Reverse .................................... 7-26 Binary Input #4 Brake Answer-back.......................................................................... 7-26 Binary Input #3 Accelerate (In 2-Button mode) ......................................................... 7-27 Binary Inputs #2 & #1 .............................................................................................. 7-27 Analog Input #1 (Speed reference #1) ...................................................................... 7-27 Analog Input #2 / Vector Speed reference #2 ........................................................... 7-28 Analog Input #3 (EB-2 Board) Torque reference ....................................................... 7-28 Analog Output #1 / CUVC: Speed Actual Value........................................................ 7-28 Analog Output #2 / CUVC: Torque Actual Value ....................................................... 7-28 Fusing For Heatsink Fans & Line Voltage Selection.................................................. 7-29 Cooling Fan fusing selection table ........................................................................... 7-29 Fan line voltage tap selection table........................................................................... 7-30
8 8.1 8.2 8.3
PARAMETERIZATION .............................................................................................. 8-1 Parameter input via the PMU ..................................................................................... 8-1 BUL 425 User Level Parameter List (P60=0) .............................................................. 8-5 BUL 425 Commissioning Level Parameter List (P60=5).............................................. 8-7
9 9.1 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.3 9.3.1 9.3.2 9.3.3
PARAMETERIZING STEPS FOR BUL 425 ............................................................... 9-1 Power definition reset of BUL 425 (for changes in CU board) ..................................... 9-2 Crane or Hoist Motion Commissioning........................................................................ 9-5 Factory Settings and Operation Modes Overview ....................................................... 9-6 BUL 425 Setup For a Closed-Loop Hoist Control...................................................... 9-13 BUL 425 Setup For an Open-Loop Hoist Control ...................................................... 9-15 BUL 425 Setup For Bridge / Trolley Control.............................................................. 9-17 BUL 425 Setup For Bucket Crane Control ................................................................ 9-19 Drive Optimization (Tuning) of BUL 425 inverter drive .............................................. 9-21 Drive Optimization (Tuning) of BUL 425 Inverter....................................................... 9-22 Manual adjustments to improve BUL 425 performance............................................. 9-23 Notes regarding "Automatic Parameterization" ......................................................... 9-24
10 10.1 10.2
BUL 425 CONTROL WORD AND STATUS WORD................................................. 10-1 Description of the control word bits........................................................................... 10-1 Description of the status word bits .......................................................................... 10-11
11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20 11.21 11.22
MAINTENANCE ...................................................................................................... 11-1 Replacing the fan ..................................................................................................... 11-2 Replacing the fan fuse (frame size K) ...................................................................... 11-5 Replacing the fan transformer fuse -F3, -F4 frame size K) ........................................ 11-6 Replacing the fan transformer .................................................................................. 11-6 Replacing the starting capacitor ............................................................................... 11-7 Replacing the capacitor battery ................................................................................ 11-7 Replacing the SML and the SMU ............................................................................. 11-8 Removing and installing the module busbars (frame size G).................................... 11-8 Replacing the balancing resistor............................................................................... 11-9 Replacing the PCU (frames E to G).......................................................................... 11-9 Replacing the PCC (frames E to G).......................................................................... 11-9 Replacing the rectifier module ................................................................................ 11-10 Replacing the IVI.................................................................................................... 11-10 Replacing the VDU and the VDU resistor ............................................................... 11-11 Replacing the PSU................................................................................................. 11-12 Replacing the IGD.................................................................................................. 11-12 Replacing the TDB (frame size K) .......................................................................... 11-13 Replacing the IGBT module ................................................................................... 11-14 Replacing the thyristor modules (V1 to V3, frame size K)........................................ 11-15 Replacing the PMU ................................................................................................ 11-16 Replacing the pre-charging resistors (R1 - R4, frame size K).................................. 11-18 Replacing the circuit resistor .................................................................................. 11-18
12
FORMING................................................................................................................ 12-1
13
COMMISIONING PARAMETER LIST FOR BUL 425............................................... 13-1
Rev 10/20/00
14 14.1 14.2 14.3
BUL 425 FAULTS AND ALARMS ........................................................................... 14-1 Faults....................................................................................................................... 14-1 Alarms ................................................................................................................... 14-17 Fatal errors (FF)..................................................................................................... 14-25
15 15.1 15.2 15.3
BUL 425 INVERTER SPARE PARTS LISTS .......................................................... 15-1 230 Volt AC Inverters Parts ...................................................................................... 15-1 460 Volt AC Inverters Parts ...................................................................................... 15-6 575 Volt AC Inverter Parts...................................................................................... 15-25
16
BUL 425 CRANE AND HOIST CONTROL DIAGRAMS........................................... 16-1
17
GLOSSARY OF TERMS.......................................................................................... 17-1
Definitions and Warnings

In reference to this document and BUL 425 inverter product warning labels, a "Qualified person" is someone who is familiar with the installation, mounting, start-up, operation, and maintenance of the product. He or she must have the following qualifications: Trained or authorized to energize, de-energize, ground and tag circuits and equipment in accordance with established safety procedures. Trained or authorized in the proper care and use of protective equipment in accordance with established safety procedures. Trained in rendering first aid. With reference to this document and BUL 425 inverter product warning labels, "Danger" indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.
Qualified personnel
DANGER
WARNING
With reference to this document and BUL 425 inverter product warning labels, "Warning" indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
With reference to this document and BUL 425 inverter product warning labels, "Caution" indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
NOTICE
With reference to this document and BUL 425 inverter product warning labels, "Notice" indicates important information about the product, installation, maintenance, or about the respective part of the documentation which is important but not hazard-related.
COPYRIGHT
Under the copyright laws, this document may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine readable form, in whole or part, without the prior written consent of Morris Material Handling. Copyright 2000 Morris Material Handling, Oak Creek, Wisconsin, USA 53154 All rights reserved. Printed in the United States. Published by: MMH Publications Department
1-1
Rev 10/20/00
WARNING
Hazardous voltages are present in this electrical equipment during operation. Non-observance of the warnings can thus result in severe personal injury or property damage. Only qualified personnel should work on or around the equipment The servicing personnel must be thoroughly familiar with all warning and maintenance procedures contained in this documentation. The successful and safe operation of this equipment is dependent on correct transport, proper storage and installation as well as careful operation and maintenance.
NOTICE
This documentation does not purport to cover all details on all types of the product, or to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes, the matter should be referred to the local Morris Material Handling sales office.
NOTICE
For safety considerations, this documentation does not recommend the control or operation of any BUL 425 inverter using the PMU or OP1-S keypads. Keypads are not as responsive as the conventional control, and often are located where it is difficult to observe the load and crane movement. For these reasons, MMH proprietary crane and hoist software has, by design, control by keypads totally deactivated and not allowed.
WARNING
The energization of the BUL 425 with ac line power or the starting of a unit with a failed Dynamic Braking Unit (DBU) can result in serious electrical discharge. This discharge can cause in serious damage to the equipment that can result in serious injury and or death. Inspect the condition of BDU wiring, overloads, and test for shorted outputs before energizing the BUL 425 inverter. Only authorized and qualified personnel with proper equipment should attempt diagnostics of the DBU.
1-2
CAUTION
Components that can be destroyed by electrostatic discharge (ESD) The board contains components that can be destroyed by electrostatic discharge. These components can be easily destroyed if not carefully handled. If you have to handle electronic boards, please observe the following: Electronic boards should only be touched when absolutely necessary. The human body must be electrically discharged before touching an electronic board. Boards must not come into contact with highly insulating materials - e.g. plastic parts, insulated desktops, articles of clothing manufactured from man-made fibers. Boards must only be placed on conductive surfaces. Boards and components should only be stored and transported in conductive packaging (e.g. metalized plastic boxes or metal containers). If the packing material is not conductive, the boards must be wrapped with a conductive packaging material, e.g. conductive foam rubber or household aluminum foil. The necessary ESD protective measures are clearly shown again in the following diagram: a = Conductive floor surface b = ESD table c = ESD shoes d = ESD overall e = ESD chain f = Cubicle ground connection
b e
d b e f f c a f f c a f d
c Sitting
Figure 1-1
Standing
ESD protective measures
Standing / Sitting
1-3
Rev 10/20/00
Safety and Operating Instructions for Drive Converters

(in conformity with the low-voltage directive 73/23/EEC)
1. General In operation, drive converters, depending on their degree of protection, may have live, uninsulated, and possibly also moving or rotating parts, as well as hot surfaces. In case of inadmissible removal of the required covers, of improper use, wrong installation or maloperation, there is the danger of serious personal injury and damage to property. For further information, see documentation. All operations serving transport, installation and commissioning as well as maintenance are to be carried out by skilled technical personnel (observe IEC 364 or CENELEC HD 384 or DIN VDE 0100 and IEC Report 664 or DIN VDE 0110 and national accident prevention rules). For the purposes of these basic safety instructions, "skilled technical personnel" means persons who are familiar with the installation, mounting, commissioning and operation of the product and have the qualifications needed for the performance of their functions. 2. Intended use Drive converters are components designed for inclusion in electrical installations or machinery. In case of installation in machinery, commissioning of the drive converter (i.e. the starting of normal operation) is prohibited until the machinery has been proved to conform to the provisions of the EC directive 89/392/EEC (Machinery Safety Directive MSD). Account is to be taken of EN 60204. Commissioning (i.e. the start of normal operation) is admissible only where conformity with the EMC directive (89/336/EEC) has been established. The drive converters meet the requirements of the lowvoltage directive 73/23/EEC. They are subject to the harmonized standards of the series prEN 50178/DIN VDE 0160 in conjunction with EN 60439-1/DIN VDE 0660 Part 500 and EN 60146/DIN VDE 0558. The technical data as well as information concerning the supply conditions shall be taken from the rating plate and from the documentation and shall be strictly observed. 3. Transport, storage The instructions for transport storage and proper use shall be complied with. The climatic conditions shall be in conformity with prEN 50178.
4. Installation The installation and cooling of the appliances shall be in accordance with the specifications in the pertinent documentation. The drive converters shall be protected against excessive strains. In particular, no components must be bent and/or isolating distances altered in the course of transportation or handling. No contact shall be made with electronic components and contacts. Drive converters contain electrostatic sensitive components that are likely to be damaged through improper use. Electronic components must not be mechanically damaged or destroyed (potential health risks). 5. Electrical connection When working on live drive converters, the applicable national accident prevention rules (e.g. VBG 4) must be complied with. The electrical installation shall be carried out in accordance with the relevant requirements (e.g. cross-sectional areas of conductors, fusing, and PE connection). For further information, see documentation. Instructions for the installation in accordance with EMC requirements, such as screening, grounding, location of filters and wiring, are contained in the drive converter documentation. They must always be complied with, also for drive converters bearing a CE marking. Observance of the limit values required by the EMC law is the responsibility of the manufacturer of the installation or machine. 6. Operation Installations which include drive converters shall be equipped with additional monitoring and protective devices in accordance with the relevant applicable safety requirements, e.g. Act respecting technical equipment, accident prevention rules, etc. Changes to the drive converters by means of the operating software are permissible. After disconnection of the drive converters from the voltage supply, live appliance parts and power terminals must not be touched immediately because of possibly energized capacitors. In this regard, the corresponding signs and markings on the drive converter must be respected. During operation, all covers and doors shall be kept closed. 7. Maintenance and servicing The manufacturer's documentation shall be followed. Keep these safety instructions in a safe place!
1-4
Description
BUL 425 is a three-phase AC inverter drive system for squirrel cage electric motors. The BUL 425 employs sophisticated microprocessor circuitry for monitoring the motor electromagnetic status. This data and motor modeling control techniques enable either scalar V/HZ or state-of-the-art Sensor-less Vector traverse motor control. Optional Pulse encoder feedback will be employed in hoist and other motions that require precision speed control, or long time operation near zero speed. Controlling many motors with one inverter is possible with a slight reduction in control accuracy. BUL 425 ac drives are equipped with advanced communication features for local and remote control. Every BUL 425 controller is supplied with an RS-485 communication port as standard. This port allows for networking up to 31controllers to a common PC or PLC Controller. Making multiple control startup easy, as parameters can be duplicated by simply downloading data from one inverter to another. The BUL 425 inverter is fitted with hardware and software protection features to guard against faults and damage due to improper operating conditions and equipment malfunctions. BUL 425 AC frequency converter is available in the output range from 2.2 KW frequency of 50/60 Hz and a voltage in the range of the values indicated on the rating plate (200...230 / 380...480 / 500...600V). The 3-thru 50 hp, Thru frame size D are housed in IP20 protected Compact enclosures. The 60 thru 400 HP units are housed in IP-20 protected wall-mounted Chassis enclosures. Inverter parameterizing is via the PMU (See Section 8 for information on the use of the PMU interface). Machine operator control is via the terminal strip or the serial interfaces of the bus system. For this purpose, the unit is provided with a number of interfaces and six slots for the use of optional boards. (See Sections 6 and 7 for additional information.) The three-phase current from the system is rectified, smoothed and fed onto the capacitor DC link (See Figure 2-1). The inverter enables a variable output frequency between 0 Hz and a maximum of 120 Hz to be generated from the DC current with the pulse width modulation method (PWM). The internal 24 V DC voltage is supplied through an integral power supply unit from the DC link. The unit is controlled by the internal closed-loop control electronics. The software of the unit provides the control functions.
General Information
2-1
Rev 10/20/00
Optional boards
Terminal strip Control electronics Internal power supply
PMU Serial interface
24 V == ==
U1/L1 V1/L2 W1/L3 PE Rectifier Pre-charging DC link Inverter
U2/T1 Motor connecW2/T3 tion V2/T2 PE2
C / L+ D/LPE1
Figure 2-1
Circuit principle of the frequency converter
BULLETIN 425
Morris Material Handling Part # R46333D3-2-10 Mot. Rat. HP 3
200VAC 230VAC Constant Torque Inverter Drive Controller

Output Current (Amps) 9.6 Unit Rat. KW 2.2 Unit Enclosure Dimensions H x W x D (Inches) 16.73x 3.54x13.78 Unit Weight (lbs.) 17.6 Unit Frame Size A KWatts Loss@ 2.5kHz 0.13 Input Class J Fuse MMH Part # Rated Amps R23968D12 12A (Qty. 3) Req. R23968D25 25A (Qty. 3) Req. R23968D40 40A (Qty. 3) Req. R23968D70 70A (Qty. 3) Req. R23968D90 90A (Qty. 3) Req. R23968D100 100A (Qty. 3) Req. Unit Input Fuse-Block MMH Part # R23969D6
R46333D5-2-16
16.1
4.0
16.73x 5.31x13.78
26.4
0.18
R23969D6
R46333D10-2-29
7/10
29.3
7.5
16.73x 5.31x13.78
26.4
0.32
R23969D9
R46333D15-2-49
15
49.1
15
23.62x10.63x13.78
77.0
0.58
R23969D11
R46333D20-2-63
20
62.8
18.5
23.62x10.63x13.78
77.0
0.74
R23969D11
R46333D25-2-74
25
73.7
22.0
23.62x10.63x13.78
77.0
0.83
R23969D11
Table 2-1
Smartorque 200 - 230VAC Inverter Ratings & Input Fuse Selection
2-2
BULLETIN 425
380 460VAC Constant Torque Inverter Drive Controller

Unit Rat. KW 2.2 Unit Enclosure Dimensions H x W x D (Inches) 16.73x 3.54x13.78 Unit Weight (lbs.) 17.6 Unit Frame Size A Kwatts Loss@ 2.5kHz 0.11 Input Class J Fuse MMH Part # Rated Amps R23968D8 8A (Qty. 3) Req. R23968D15 15A (Qty. 3) Req. R23968D20 20A (Qty. 3) Req. R23968D25 25A (Qty. 3) Req. R23968D35 35A (Qty. 3) Req. R23968D45 45A (Qty. 3) Req. R23968D50 50A (Qty. 3) Req. R23968D60 60A (Qty. 3) Req. R23968D80 80A (Qty. 3) Req. R23968D90 90A (Qty. 3) Req. R23968D125 125A (Qty. 3) Req. R23968D175 175A (Qty. 3) Req. R23968D200 200A (Qty. 3) Req. R23968D250 250A (Qty. 3) Req. R23968D300 300A (Qty. 3) Req. R23968D400 400A (Qty. 3) Req. R23968D500 500A (Qty. 3) Req. Unit Input Fuse-Block MMH Part # R23969D6
Output Current (Amps) 5.6
R46333D5-4-9
9.3
4.0
16.73x 3.54x13.78
17.6
0.16
R23969D6
R46333D7-4-12
7.5
12.0
5.5
16.73x 5.31x13.78
26.4
0.16
R23969D6
R46333D10-4-16
10
15.9
7.5
16.73x 5.31x13.78
26.4
0.21
R23969D6
R46333D15-4-23
15
23.2
11.0
23.62x 7.09x13.78
52.8
0.34
R23969D9
R46333D20-4-31
20
30.9
15.0
23.62x 7.09x13.78
52.8
0.47
R23969D9
R46333D25-4-34
25
34.1
18.5
23.62x10.63x13.78
77.0
0.60
R23969D9
R46333D30-4-43
30
42.8
22
23.62x10.63x13.78
77.0
0.71
R23969D9
R46333D40-4-54
40
53.7
30
23.62x10.63x13.78
77.0
0.85
R23969D11
R46333D50-4-65
50
65.5
37
23.62x10.63x13.78
77.0
1.06
R23969D11
R46333D60-4-84
60
84
45
41.34x10.63x13.78
121
1.18
R23969D12 (Qty. 3) Req. R23969D12 (Qty. 3) Req. R23969D12 (Qty. 3) Req. R23969D13 (Qty. 3) Req. R23969D13 (Qty. 3) Req. R23969D13 (Qty. 3) Req. R23969D14 (Qty. 3) Req. -
R46333D75-4-113
75
113
55
41.34x14.17x13.78
143
1.67
R46333D100-4-133
100
133
75
41.34x14.17x13.78
143
1.95
R46333D125-4-169
125
169
90
41.34x14.17x13.78
143
2.17
R46333D150-4-191
150
191
110
57.09x20.00x18.11
341
2.68
R46333D200-4-287
200
287
160
57.09x20.00x18.11
363
4.30
R46333D250-4-337
250
337
200
57.09x20.00x18.11
396
5.05
R46333D300-4-464
300
464
250
68.11x31.50x22.24
882
7.10
R46333D400-4-537
400
537
315
68.11x31.50x22.24
882
8.20
Table 2-2
Smartorque 380 460 VAC Inverter Ratings & Input Fuse Selection
2-3
Rev 10/20/00
BULLETIN 425
500VAC 600VAC Constant Torque Inverter Drive Controller

Output Current (Amps) 4.1 Unit Rat. KW 2.2 Unit Enclosure Dimensions H x W x D (Inches) 16.73x 5.31x13.78 Unit Weight (lbs.) 26.4 Unit Frame Size B Kwatts Loss@ 2.5kHz 0.10 Input Class J Fuse MMH Part # Rated Amps R23968D6 6A (Qty. 3) Req. R23968D10 10A (Qty. 3) Req. R23968D15 15A (Qty. 3) Req. R23968D20 20A (Qty. 3) Req. R23968D30 30A (Qty. 3) Req. R23968D40 40A (Qty. 3) Req. R23968D45 45A (Qty. 3) Req. R23968D60 60A (Qty. 3) Req. R23968D80 80A (Qty. 3) Req. R23968D90 90A (Qty. 3) Req. R23968D150 150A (Qty. 3) Req. R23968D200 200A (Qty. 3) Req. R23968D300 300A (Qty. 3) Req. Unit Input Fuse-Block MMH Part # R23969D6
R46333D5-5-7
7.1
4.0
16.73x 5.31x13.78
26.4
0.12
R23969D6
R46333D7-5-10
7.5
10.0
5.5
16.73x 5.31x13.78
26.4
0.16
R23969D6
R46333D10-5-14
10
13.7
7.5
16.73x 5.31x13.78
26.4
0.21
R23969D6
R46333D15-5-20
15
20.0
11.0
23.62x 7.09x13.78
52.9
0.32
R23969D6
R46333D20-5-26
20
26.4
18.5
23.62x10.63x13.78
77
0.59
R23969D9
R46333D25-5-31
25
30.9
22
23.62x10.63x13.78
77
0.69
R23969D9
R46333D40-5-42
30/40
42.3
30
23.62x10.63x13.78
77
0.87
R23969D9
R46333D50-5-55
50
55
37
41.34x10.63x13.78
121
0.91
R23969D11
R46333D60-5-71
60 75 / 100 125 / 150 200
71
55
41.34x14.17x13.78
143
1.26
R23969D11
R46333D100-5-98
98
75
41.34x14.17x13.78
143
1.80
R23969D12 (Qty. 3) Req. R23969D12 (Qty. 3) Req. R23969D13 (Qty. 3) Req.
R46333D150-5-142
142
110
57.09x20.00x18.11
341
2.58
R46333D200-5-205
205
160
57.09x20.00x18.11
396
4.02
Table 2-3
Smartorque 500 600VAC Inverter Ratings & Input Fuse Selection
2-4
First Start-up
After removing the packaging, check that the unit is See Section 4 intact and undamaged. Only intact units may be started "Transport, up. Please also check that all the necessary option Storage, & boards are present and correct. Unpacking"
Unpack and check the units
Mount the unit and install optional boards which have not yet been fitted
See Retrofit any optional boards which have not yet Sections 5&6 been installed, if necessary. Then install the units "Tech Data & taking into account the requirements at the point of Installation" installation.
Form the DC link capacitors, if necessary
If the DC link of the unit was de-energized for more than See Section 12 one year, you have to newly form the DC link capacitors "Forming"
Connect the protective conductor, the power cables or buses and, if present, the ext. 24 V supply
Connect, ground conductors and power cables and, if present, the external 24 V supply. At this stage don't connect any control, communication, encoder, and motor cables.
See Section 7 "Connectingup"
Power up the external 24 V supply or the line voltage
After checking that the cabling has been correctly connected, power up the external 24 V supply or the line voltage. After the electronics power supply has been started, the unit initializes itself. The action can take several seconds. The drive status is subsequently shown on the PMU. After downloading the Crane Function Macro (or factory setting)for your required motion it is necessary to load the remaining motor data, machine data.
111
Set the factory setting containing the Crane Motion Macro & set required features.
See Sections 8 & 9 "Parameterization"
Connect remaining control and motorcables and prepair for optimization
After loading the motor and machine data for your See Section 9 "Parameterrequired motion it is necessary to reconnect the ization" motor and control and prepare for control optimization.
3-1
Rev 10/20/00
Optimize the system performance
Using the BUL 425 Static & Dynamic autotuning proceedures, optimize the control system for optimum performance in both Static & Dynamic modes.
See Section 9 "Parameterizatio and Drive Optimization"
After optimization test the crane or hoist control and make necessary adjustments to obtain the desired performance
After checking and rechecking cabling and connections power up the line voltage and perform a functional test according to your application needs.
WARNING
siehe "Anschlieen" und "EMVgerechter Aufbau"
It must be ensured that no danger for persons and equipment can occur by energizing the power and the unit. It is recommended not to couple the driven machine until the function test has been successfully completed.
Further start-up and parameterization according to your specific requirements
siehe "Ans
3-2
Transport, Storage, & Unpacking

This section explains the delivery check, storage, transportation, nameplate identification, and ratings of the BUL 425 AC drives. The units and components are packed at the factory. A packing label is located on the outside of the packaging. Please observe the instructions on the packaging for transport, storage and professional handling.
Transport
Vibrations and jolts must be avoided during transport. If the unit is damaged, you must inform your shipping company immediately. Check that there are no signs of damage. Check the information on the BUL 425 inverter nameplate to verify that the unit is of the correct make, model, and rating before attempting installation and operation. Contact your insurance company or device supplier in case of damage. Contact the supplier in case of incorrect hardware or incomplete delivery.
NOTICE
The BUL 425 inverter weighs a considerable amount, and should not be handled by the front cover. The unit should only be placed on its back side. Exercise appropriate care when maneuvering the unit to avoid damage. The units and components must be stored in clean, dry rooms. Temperatures between -13 F (-25 C) and +158 F (70 C) are permissible. Temperature fluctuations must not exceed more than 54F (30 C) per hour.
Storage
NOTICE
If the storage period of exceeds one year from manufacture or from operation, the BUL 425 bus capacitors must be reformed. See example below and Section 12 Forming before powering unit across the line. The date of manufacture of the unit can be read from the serial number. Example: A-L60147512345 = Manufacture date of June 1999
Digit Example Meaning
How the serial number is made up to determine date of manufacture.
1 and 2 3
AL M N O 1 to 9 O N D
Place of manufacture 1999 2000 2001 2002 January to September October November December Not relevant for dating unit
5 to 14
Table 4-1
---
Using serial number to determine date manufacture
4-1
Rev 10/20/00
Unpacking
The packaging comprises board and corrugated paper. It can be disposed of corresponding to the appropriate local regulations for the disposal of board products. The units and components can be installed and commissioned after they have been unpacked and checked to ensure that they are the correct rating, everything is complete, and that they are not damaged. Only then should the shipping containers be disposed of.
4-2
Technical Data For BUL 425 Inverters

EN 50178 *
EU low-voltage directives 73/23/EEC and RL93/68/EEC * EU directive EMC 89/336/EEC * EU machine directive 89/392/EEC * Approval Switching at the input Type of cooling Permissible ambient and coolingmedium temperature during operation during storage during transport Installation altitude
( * = Documents available on request )
EN 61800-3 * EN 60204-1 * UL: E 145 153 * CSA: LR 21 927 * 2 switching operations per minute Air cooling with built-in fan or air-cooling with additional water cooling
Permissible humidity rating
Climatic class Degree of pollution Overvoltage category Degree of protection Class of protection Shock protection Radio interference suppression Standard Options Interference immunity Paint finish Mechanical specifications Vibrations During stationary use: Constant amplitude of deflection of acceleration During transport: of deflection of acceleration - Shocks - Drop and topple
Table 5-1
0 C to +40 C ( 32 F to 104 F) (up to 50 C see Fig. Derating curves) -25 C to +70 C (-13 F to 158 F) -25 C to +70 C (-13 F to 158 F) 1000 m above sea level (100 % load capability) > 1000 m to 4000 m above sea level (for load capability. see Fig. Derating curves) Relative humidity 95 % during transport and storage 85 % during operation (moisture condensation not permissible) Class 3K3 to DIN IEC 721-3-3 (during operation) Pollution degree 2 to IEC 664-1 (DIN VDE 0110. Part 1). * Moisture condensation during operation is not permissible Category III to IEC 664-1 (DIN VDE 0110. Part 2 ) * IP20 EN 60529 * Class 1 to EN 536 (DIN VDE 0106. Part 1 ) * To EN 60204-1 and DIN VDE 0106 Part 100 (VBG4) * To EN 61800-3 * No radio interference suppression Radio interference suppression filter for Class B1 or A1 to EN 55011* Industrial to EN 61800-3 * For interior installation To DIN IEC 68-2-6 *
0.075 mm in the frequency range 10 Hz to 58 Hz 9.8 m/s in the frequency range > 58 Hz to 500 Hz 3.5 mm in the frequency range 5 Hz to 9 Hz 9.8 m/s in the frequency range > 9 Hz to 500 Hz to DIN IEC 68-2-27 / 08.89 * 30 g. 16 ms half-sine shock to DIN IEC 68-2-31 / 04.84 * on a surface and on a corner
General data for BUL 425 Inverters
5-1
Rev 10/20/00
Permissible rated current in % 100
75
50
7
25
0 0 2,5 3 5 6 7,5 9 12 15 16 Pulse frequency in kHz Permissible rated output voltage in % acc. to VDE 0110 / IEC 664-1 (not necessary acc. to UL / CSA) 100 <2> <1> <1> The derating curve only applies to the following units: - Sizes B to G with a rated input voltage of 380 - 480 V only in the case of an actual input voltage of 380 - 400 V - Sizes J to Q with a rated input voltage of 500 - 600 V <2> The derating curve only applies to the following units: - Sizes J to Q with a rated input voltage of 380 - 480 V - Sizes J to Q with a rated input voltage of 500 - 600 V only in the case of an actual input voltage of 500 V
75
50 0 1000 2000 3000 4000 Installation altitude above sea level in m Permissible rated current in % 100
Temp [C] 75 50 25 0 0 10 20 30 40 50 Cooling-medium temperature in C Permissible rated current in % 100 Altitude [m] 90 1000 80 70 4000 60 0 1000 2000 3000 4000 2000 3000 50 45 40 35 30 25
Derating factor K2 0,76 0,879 1,0 1,125 * 1,25 * 1,375 * * See the following Note
Derating factor K1 1,0 0,9 0,845 0,8
Installation altitude above sea level in m
Figure 5-1
Derating curves for BUL 425 inverters
5-2
The derating of the permissible rated current for installation altitudes of over 1000 m and at ambient temperatures below 40 C is calculated as follows: Total derating = (Derating altitude) x (Derating ambient temperature) K = K1 x K2
NOTICE
It must be kept in mind that total derating must not exceed 1.0! Example: Altitude: 3000 m Ambient temperature: 35 C K1 = 0.845 K2 = 1.125
Total derating = 0.845 x 1.125 = 0.95
NOTICE
Complete fulfillment of the degree of protection IP20 in accordance with EN 60529 is dependent on the number of incoming and outgoing control cables cover the opening area on the lower section of the unit. If degree of protection IP20 also has to be met in operation, the opening may have to be subsequently reduced.
5-3
Rev 10/20/00
Designation MMH Part No. R46333D... Rated voltage [V] Input Output Rated frequency [Hz] Input Output: V/f = constant V = constant Rated current [A] Input Output DC link voltage [V] Rated output [kVA] Auxiliary current supply [V]
Max. aux. curr. requirement[A] Standard version at 20 V Max. aux. curr. requirement[A] Maximum version at 20 V
Value 3-2-10 5-2-16 3 AC 200 (- 10 %) to 230 (+ 15 %) 3 AC 0 up to rated input voltage 50 / 60 6 % 0 to 600 8 to 300 11.7 9.6 3.7 to 4.2 14.6 12.1 4.7 to 5.2 19.5 25.2 16.1 20.8 270 (- 10 %) to 310 (+ 15 %) 6.0 to 6.9 8.0 to 9.1 DC 24 (24 - 30) 1.5 2.5 35.4 29.3
11.2 to 12.8
10-2-29
48.6 40.2
15.4 to 17.6
Derating curve (see Fig. 5-1) Load class II to EN 60 146-1-1 Base load current [A] 1.00 x rated output current Base load duration [s] 240 Overload current [A] 1.50 x rated output current Overload duration [s] 60 Load class II to EN 60 146-1-1 (additional) Base load current [A] 1.00 x rated output current Base load duration [s] 270 Overload current [A] 1.75 x rated output current Overload duration [s] 30 Losses, cooling, power factor Power factor Line cos1L 0.98 Converter cosC < 0.92 ind. Efficiency (rated operation) 0.97 Power loss (at 2.5 kHz) [kW] 0.13 0.16 0.20 0.25 Cooling-air requirement[m/s] 0.009 0.009 0.022 0.022 Pressure drop p [Pa] 10 10 32 32 Sound pressure levels, types of construction, dimensions, weights Sound pressure level[dB(A)] 60 60 60 60 Type of construction A A B B Dimensions [mm] Width 90 90 135 135 Height 425 425 425 425 Depth 350 350 350 350 Weight approx. [kg] 8.5 8.5 12.5 12.5
Table 5-2 Air-cooled BUL 425 converters (Frames A - D part 1)
0.32 0.022 32 60 B 135 425 350 12.5
0.41 0.028 30 60 C 180 600 350 21
5-4
Value 15-2-49 20-2-63 25-2-74 3 AC 200 (- 10 %) to 230 (+ 15 %) 3 AC 0 up to rated input voltage 50 / 60 6 % 0 to 600 8 to 300 59.4 49.1
18.8 to 21.5
75.9 62.8
24.0 to 27.4
89.1 73.7 270 (- 10 %) to 310 (+ 15 %)

28.1 to 32.2
DC 24 (24 - 30) 1.5 2.5
Derating curve (see Fig. 5-1) Load class II to EN 60 146-1-1 Base load current [A] 1.00 x rated output current Base load duration [s] 240 Overload current [A] 1.50 x rated output current Overload duration [s] 60 Load class II to EN 60 146-1-1 (additional) Base load current [A] 1.00 x rated output current Base load duration [s] 270 Overload current [A] 1.75 x rated output current Overload duration [s] 30 Losses, cooling, power factor Power factor Line cos1L 0.98 Converter cosC < 0.92 ind. Efficiency (rated operation) 0.97 Power loss (at 2.5 kHz) [kW] 0.59 0.74 0.81 Cooling-air requirement[m/s] 0.054 0.054 0.054 Pressure drop p [Pa] 230 230 230 Sound pressure levels, types of construction, dimensions, weights Sound pressure level[dB(A)] 65 65 65 Type of construction D D D Dimensions [mm] Width 270 270 270 Height 600 600 600 Depth 350 350 350 Weight approx. [kg] 32 32 32
5-5
Rev 10/20/00
Value 3-4-6 5-4-9 7-4-12 10-4-16 15-4-23
3 AC 380 (- 15 %) to 480 (+ 10 %) 3 AC 0 up to rated input voltage 50 / 60 6 % 0 to 600 8 to 300 6.7 5.6 4.1 to 5.0 8.8 7.3 5.3 to 6.6 11.2 14.5 9.3 12.0 510 (- 15 %) to 650 (+ 10 %) 6.8 to 8.4 8.7 to 10.9 DC 24 (24 30) 1.5 2.5 19.3 15.9
11.6 to 14.5
28.1 23.2
16.8 to 21.2
Derating curve (see Fig. 5-1) Load class II to EN 60 146-1-1 Base load current [A] 1.00 x rated output current Base load duration [s] 240 Overload current [A] 1.50 x rated output current Overload duration [s] 60 Load class II to EN 60 146-1-1 (additional) Base load current [A] 1.00 x rated output current Base load duration [s] 270 Overload current [A] 1.75 x rated output current Overload duration [s] 30 Losses, cooling, power factor Power factor Line cos1L 0.98 Converter cosC < 0.92 ind. Efficiency (rated operation) 0.97 Power loss (at 2.5 kHz) [kW] 0.11 0.12 0.16 0.16 Cooling-air requirement[m/s] 0.009 0.009 0.009 0.022 Pressure drop p [Pa] 10 10 10 32 Sound pressure levels, types of construction, dimensions, weights Sound pressure level[dB(A)] 60 60 60 60 Type of construction A A A B Dimensions [mm] Width 90 90 90 135 Height 425 425 425 425 Depth 350 350 350 350 Weight approx. [kg] 8.5 8.5 8.5 12.5
0.98 0.24 0.022 32 60 B 135 425 350 12.5
0.36 0.028 30 60 C 180 600 350 21
5-6
Value 20-4-31 25-4-34 30-4-43 40-4-54 50-4-65
3 AC 380 (- 15 %) to 480 (+ 10 %) 3 AC 0 up to rated input voltage 50 / 60 6 % 0 to 600 8 to 300 37.4 30.9 22.4 to 28.2 51.7 64.9 79.2 42.8 53.7 65.5 510 (- 15 %) to 650 (+ 10 %) 24.7 to 31.1 31.0 to 39.0 38.9 to 49.0 47.4 to 59.8 DC 24 (24 - 30) 1.5 2.5 41.3 34.1
Derating curve (see Fig. 5-1) Load class II to EN 60 146-1-1 Base load current [A] 1.00 x rated output current Base load duration [s] 240 Overload current [A] 1.50 x rated output current Overload duration [s] 60 Load class II to EN 60 146-1-1 (additional) Base load current [A] 1.00 x rated output current Base load duration [s] 270 Overload current [A] 1.75 x rated output current Overload duration [s] 30 Losses, cooling, power factor Power factor Line cos1L 0.98 Converter cosC < 0.92 ind. Efficiency (rated operation) 0.98 0.97 0.98 Power loss (at 2.5 kHz) [kW] 0.49 0.58 0.73 0.86 Cooling-air requirement[m/s] 0.028 0.054 0.054 0.054 Pressure drop p [Pa] 30 230 230 230 Sound pressure levels, types of construction, dimensions, weights Sound pressure level[dB(A)] 60 65 65 65 Type of construction C D D D Dimensions [mm] Width 180 270 270 270 Height 600 600 600 600 Depth 350 350 350 350 Weight approx. [kg] 21 32 32 32
1.05 0.054 230 65 D 270 600 350 32
5-7
Rev 10/20/00
Value 3-5-4 5-5-7 7-5-10 10-5-14 15-5-20
3 AC 500 (- 15 %) to 600 (+ 10 %) 3 AC 0 up to rated input voltage 50 / 60 6 % 0 to 600 8 to 300 5.0 4.1 3.9 to 4.6 8.6 12.1 7.1 10.0 675 (- 15 %) to 810 (+ 10 %) 5.4 to 6.4 6.8 to 8.1 9.6 to 11.4 DC 24 (24 30) 1.5 2.5 6.8 5.6 16.6 13.7
13.1 to 15.6
24.2 20.0
19.1 to 22.8
Derating curve (see Fig. 5-1) Load class II to EN 60 146-1-1 Base load current [A] 1.00 x rated output current Base load duration [s] 240 Overload current [A] 1.50 x rated output current Overload duration [s] 60 Load class II to EN 60 146-1-1 (additional) Base load current [A] 1.00 x rated output current Base load duration [s] 270 Overload current [A] 1.75 x rated output current Overload duration [s] 30 Losses, cooling, power factor Power factor Line cos1L 0.98 Converter cosC < 0.92 ind. Efficiency (rated operation) 0.97 0.98 Power loss (at 2.5 kHz) [kW] 0.09 0.14 0.12 0.15 Cooling-air requirement[m/s] 0.022 0.022 0.022 0.022 Pressure drop p [Pa] 32 32 32 32 Sound pressure levels, types of construction, dimensions, weights Sound pressure level[dB(A)] 60 60 60 60 Type of construction B B B B Dimensions [mm] Width 135 135 135 135 Height 425 425 425 425 Depth 350 350 350 350 Weight approx. [kg] 12.5 12.5 12.5 12.5
0.23 0.022 32 60 B 135 425 350 12.5
0.33 0.028 30 60 C 180 600 350 21
5-8
Value 20-5-26 25-5-31 40-5-42 3 AC 500 (- 15 %) to 600 (+ 10 %) 3 AC 0 up to rated input voltage 50 / 60 6 % 0 to 600 8 to 300 31.9 26.4 25.2 to 30.1 51.2 42.3 675 (- 15 %) to 810 (+ 10 %) 29.5 to 35.3 40.3 to 48.3 DC 24 (24 30) 1.5 2.5 37.4 30.9
Derating curve (see Fig. 5-1) Load class II to EN 60 146-1-1 Base load current [A] 1.00 x rated output current Base load duration [s] 240 Overload current [A] 1.50 x rated output current Overload duration [s] 60 Load class II to EN 60 146-1-1 (additional) Base load current [A] 1.00 x rated output current Base load duration [s] 270 Overload current [A] 1.75 x rated output current Overload duration [s] 30 Losses, cooling, power factor Power factor Line cos1L 0.98 Converter cosC < 0.92 ind. Efficiency (rated operation) 0.97 0.98 Power loss (at 2.5 kHz) [kW] 0.62 0.70 0.87 Cooling-air requirement[m/s] 0.054 0.054 0.054 Pressure drop p [Pa] 230 230 230 Sound pressure levels, types of construction, dimensions, weights Sound pressure level[dB(A)] 65 65 65 Type of construction D D D Dimensions [mm] Width 270 270 270 Height 600 600 600 Depth 350 350 350 Weight approx. [kg] 32 32 32
5-9
Rev 10/20/00
Designation MMH Part No. R46333D... Rated voltage [V] Input Output Rated frequency [Hz] Input Output: V/f = constant V = constant Rated current [A] Input Output DC link voltage [V] Rated output [kVA] Auxiliary power supply [V]
Max. aux.-curr. requirement[A] Standard version at 20 V Max. aux.-curr. requirement[A] Max. version at 20 V
Value 60-4-84 75-4-113 100-4-133 125-4-169 150-4-191
3 AC 380 (- 15 %) to 480 (+ 10 %) 3 AC 0 to rated input voltage 50 / 60 6 % 0 to 600 8 to 300 101 84 61 to 76 1.7 2.7 136 113 82 to 103 160 205 133 169 510 to 650 (- 15 % / + 10 %) 97 to 121 123 to 154 DC 24 (24 - 30) 2.1 3.2 1.7 to 7.5 231 191 139 to 174 2.3 3.5 1.7 to 7.5 286 237 172 to 216
Pulse frequency [kHz] 1.7 to 16 1.7 to 16 1.7 to 9 1.7 to 9 Derating curve (see Fig. 5-1) Load class II to EN 60 146-1-1 Base load current [A] 1.00 x rated output current Base load duration [s] 240 Overload current [A] 1.50 x rated output current Overload duration [s] 60 Load class II to EN 60 146-1-1 (additional) Base load current [A] 1.00 x rated output current Base load duration [s] 270 Overload current [A] 1.75 x rated output current Overload duration [s] 30 Losses, cooling, power factor Power factor Line cos1N 0.98 Converter cosU < 0.92 ind. Efficiency (rated operation) 0.97 Power loss (at 2.5 kHz) [kW] 1.18 1.67 1.95 2.17 Cooling-air requirement[m/s] 0.10 0.14 0.14 0.14 Sound-pressure levels, types of construction, dimensions, weights Sound-pressure level IP00 [dB(A)] 69 69 69 69 Type of construction E F F F Dimensions [mm] Width 270 360 360 360 Height 1050 1050 1050 1050 Depth 350 350 350 350 Weight approx. [kg] 55 65 65 65
Table 5-8 Air-cooled BUL 425 converters (Frames E - K part 1)
0.98 2.68 0.31
3.4 0.31
80 G 508 1450 450 155
80 G 508 1450 450 155
5-10
Designation
Value
MMH Part No. R46333D... 200-4-287 250-44-337 300-4-464 400-4-537 Rated voltage [V] Input 3 AC 380 (- 15 %) to 480 (+ 10 %) Output 3 AC 0 to rated input voltage Rated frequency [Hz] 50 / 60 6 % Input 0 to 600 Output: V/f = constant 8 to 300 V = constant Rated current [A] Input 346 407 561 649 Output 287 337 464 537 DC link voltage [V] 510 to 650 (- 15 % / + 10 %) Rated output [kVA] 208 to 261 244 to 307 336 to 424 389 to 490 455 to 573 Auxiliary power supply [V] DC 24 (24 30) Max. aux.-curr. requirement[A] 2.3 3.1
Standard version at 20 V Max. aux.-curr. requirement[A] Max. version at 20 V
759 626
3.5
4.3 1,7 to 2.5
Pulse frequency [kHz] 1.7 to 6 1.7 to 6 1.7 to 6 1.7 to 5 Derating curve (see Fig. 5-1) Load class II to EN 60 146-1-1 Base load current [A] 1.00 x rated output current Base load duration [s] 240 Overload current [A] 1.50 x rated output current Overload duration [s] 60 Load class II to EN 60 146-1-1 (additional) Base load current [A] 1.00 x output current not additional Base load duration [s] 270 not additional Overload current [A] 1.6 x output current not additional Overload duration [s] 30 not additional Losses, cooling, power factor Power factor Line cos1N 0.98 Converter cosU < 0.92 ind. Efficiency (rated operation) 0.98 0.98 Power loss (at 2.5 kHz) [kW] 4.3 5.05 7.1 8.2 Cooling-air requirement[m/s] 0.41 0.41 0.46 0.46 Sound-pressure levels, types of construction, dimensions, weights Sound-pressure level dB(A)] 82 82 77 77 Type of construction G G K K Dimensions [mm] Width 508 508 800 800 Height 1450 1450 1750 1750 Depth 450 450 551 551 Weight approx. [kg] 155 155 400 400
10,2 0,6 80 K 800 1750 551 460
5-11
Rev 10/20/00
Value 50-5-55 60-5-71 100-5-98 150-5-142
3 AC 500 (- 15 %) to 600 (+ 10 %) 3 AC 0 to rated input voltage 50 / 60 6 % 0 to 600 8 to 300 67 55 53 to 63 1.7 2.7 73 60 58 to 68 87 119 72 98 675 to 810 ( 15 %) 69 to 82 94 to 112 DC 24 (24 30) 2.1 3.2 1.7 to 7.5 141 117 111 to 133 2.3 3.5 1.7 to 6 172 142 136 to 162
Pulse frequency [kHz] 1.7 to 16 1.7 to 16 1.7 to 9 1.7 to 7.5 Derating curve (see Fig. 5-1) Load class II to EN 60 146-1-1 Base load current [A] 1.00 x rated output current Base load duration [s] 240 Overload current [A] 1.50 x rated output current Overload duration [s] 60 Load class II to EN 60 146-1-1 (additional) Base load current [A] 1.00 x rated output current Base load duration [s] 270 Overload current [A] 1.75 x rated output current Overload duration [s] 30 Losses, cooling, power factor Power factor Line cos1N 0.98 Converter cosU < 0.92 ind. Efficiency (rated operation) 0.97 0.98 Power loss (at 2.5 kHz) [] 0.91 1.02 1.26 1.80 Cooling-air requirement[m/s] 0.10 0.10 0.14 0.14 Sound-pressure levels, types of construction, dimensions, weights Sound-pressure level IP00 [dB(A)] 69 69 69 69 Type of construction E E F F Dimensions [mm] Width 270 270 360 360 Height 1050 1050 1050 1450 Depth 350 350 350 450 Weight approx. [kg] 55 55 65 65
0.97 2.13 0.31 2.58 0.31
80 G 508 1450 450 155
80 G 508 1450 450 155
5-12
Value 200-5-205 3 AC 500 (- 15 %) to 600 (+ 10 %) 3 AC 0 to rated input voltage 50 / 60 6 % 0 to 600 8 to 300 211 174 167 to 199 2.3 3.5 248 205 195 to 233 327 400 270 322 675 to 810 ( 15 %) 258 to 308 307 to 367 DC 24 (24 - 30) 3.1 4.3 1.7 to 2.5 497 411 392 to 469
Pulse frequency [kHz] 1.7 to 6 1.7 to 6 1.7 to 3 1.7 to 3 Derating curve (see Fig. 5-1) Load class II to EN 60 146-1-1 Base load current [A] 1.00 x rated output current Base load duration [s] 240 Overload current [A] 1.50 x rated output current Overload duration [s] 60 Load class II to EN 60 146-1-1 (additional) Base load current [A] 1.00 x output current not additional Base load duration [s] 270 not additional Overload current [A] 1.75 x output current not additional Overload duration [s] 30 not additional Losses, cooling, power factor Power factor Line cos1N 0.98 Converter cosU < 0.92 ind. Efficiency (rated operation) 0.98 0.97 0.98 Power loss (at 2.5 kHz) [kW] 3.4 4.05 5.80 6.80 Cooling-air requirement[m/s] 0.41 0.41 0.46 0.46 Sound-pressure levels, types of construction, dimensions, weights Sound-pressure level IP00 [dB(A)] 82 82 77 77 Type of construction G G K K Dimensions [mm] Width 508 508 800 800 Height 1450 1450 1750 1750 Depth 450 450 551 551 Weight approx. [kg] 155 155 400 400
Table 5-11 Air-cooled BUL 425 converters (Frames E K part 4)
8.30 0.46
77 K 800 1750 551 400
5-13
Rev 10/20/00
5-14
6
6.1
Installation
Pre-installation Planning
This section explains the appropriate steps to take before and during the mechanical installation of the BUL 425 inverter. The most important part of the mechanical installation is pre-installation planning. Neglecting this planning often results in extra work during and after installation in order to compensate for the insufficient preparation. The purpose of pre-installation planning is to select the best possible operational site for the inverter. Aspects to consider in this planning include: Proper attention to cooling and ventilating the inverter. Ambient operating conditions may require derrating of the inverter. Note proper mounting, positioning, and handling of the inverter. Note adjoining equipment and routing of cabling. Note proper retrofitting of unit options.
6.2
WARNING
Installing the BUL 425 AC Inverter

Safe operation of BUL 425 inverter requires that the equipment is mounted and commissioned by qualified personnel taking into account the warning information provided in these Operating Instructions. The general and domestic installation and safety regulations for work on electrical power equipment must be observed as well as the professional handling of tools and the use of personal protective equipment. Death, severe bodily injury or significant material damage could result if these instructions are not followed.
Clearances
When positioning the units (right side up mounting only), note that the Line Input (mains) connection is located at the top section of the unit, and the Output motor connections, are at the lower section of the unit. The units can be mounted flush side to side with each other. When mounting the inverter in enclosures, you must leave a clearance at the top and the bottom of the units for cooling. Refer to the dimension drawings on the following pages regarding airflow minimum clearances. Note also that the cabinet cooling must be properly sized to dissipate the watts loss. Requirements of the installation are that are necessary to observe include: BUL 425 inverters must be protected against the ingress of foreign particles from drilling etc. that may occur at time of installation. Equipment rooms must be dry and dust-free. Ambient and cooling air must not contain any electrically conductive gases, vapors and dusts which could diminish the functionality. If necessary, filters should be used or other corrective measures taken. Continued on next page...
Requirements at the point of installation
6-1
Rev 10/20/00
The ambient climate of the units must not exceed the values of DIN IEC 721-3-3 class 3K3. For cooling air temperatures of more than 40C (104F) and installation altitudes higher than 3300ft (1000 m), derating is required. See Section 5 for allowable ambient conditions and derating curves for temperature and altitude.
6.2.1
Installation of Frame Sizes A , B, C, & D
Mounting surface
Cooling air 250 mm
Figure 6-1
Minimum clearances for cooling
Mounting
The unit is mounted directly to a mounting surface, for which you require the following: G-type mounting rail according to EN50035 with screws for fixing at the top of the unit. One M6 screw for types A to C, two M6 screws for type D, for fixing at the bottom of the unit. Dimensional drawing for frames A, B, C, and D.
6-2
100 mm
G-type rail according to EN50035
Mounting surface
425 mm
425 mm
Cutouts for M6 screws
350 mm
45 mm 90 mm
67.5 mm 135 mm
Type A Side view

Figure 6-2
Type B
Front view (without front panel)

Dimension drawings for installation of Frame Sizes A & B
G-type rail according to EN50035
Mounting surface
600 mm
600 mm
Cutouts for M6 screws
350 mm
90 mm 180 mm
45 mm 180 mm 270 mm
Type C Side view

Figure 6-3
Type D
Front view (without front panel)

Dimension drawings for installation of Frame Sizes C & D
6-3
Rev 10/20/00
6.2.2
Installing units of Frames Sizes E, F & G

Mounting surface
Cooling air
350 mm Type
E,F
Clearances 400 320 [mm]
Figure 6-4
Minimum required clearances for cooling air (Frame Sizes E, F & G)
The following are required for mounting: Dimension drawing for the relevant construction type. M8 or M10 screws, refer to dimension drawing for the quantity.
Mounting surface
1050 mm
1025 mm
Cutouts for M8 screw
350 mm
10 mm
180 mm 270 mm Type E
10 mm
1025 mm 270 mm 360 mm Type F
Side view
Front view
Figure 6-5
Dimension drawing for Frame Sizes E & F
6-4
Mounting surface
1450 mm
1375 mm
Cutout for M8 screw
350 mm Side view
25 mm 119 mm 270 mm 508 mm Front view
Figure 6-6
Dimension drawing for Frame Size G
6-5
Rev 10/20/00
6.2.3
Installing units of Frame Size K

Mounting surface Cutout for M8 / M10 screw
1730
1675
Oblong holes 9 x 15 for M8 screw
25
213 483 708
550 Side view
800 Front view
Figure 6-7
Dimension drawing for Frame Size K
6-6
6.3
WARNING
Installing the control and option boards

Only a qualified technician may replace BUL 425 inverter option boards. It is not permitted to withdraw or insert the boards while BUL 425 unit is energized. A maximum of six (6) slots is available in the electronics box of the BUL 425 inverter Used for installing the main control and option boards these slots are designated with the letters A thru G. See Figure 6-8. BUL 425 inverters are supplied with an LBA (Local Bus Adapter). The LBA adapter is used for mounting, aligning, and connecting control option boards to the main microprocessor (CU) board back-plane, and up to two full-size or four half-sized option boards in slot positions D, E, F, & G. BUL 425 inverters are supplied with a 115 VAC I/O Interface RB-2 mounted in slot positions D & E, (Slot B is not provided or used by BUL 425.) and has control boards supplied from the factory in the following positions: Slot A CU Main Microprocessor 1 Left top w/ daughter EB-2 I/O Expansion Board 1 Left top Board mounted to CU (Installed) Slot C CU Main Microprocessor Board 1 - Left Bottom Daughter board is reserved for Profibus 1 - Left Bottom Slot D 115 VAC I/O Board RB-2 (Installed) 2 - Right top Slot E 115 VAC I/O Board RB-2 (Installed) 2 - Right Bottom Slot F Option Board Position 3 (Not Used) 3 - Center top Slot G Option Board Position 3 (Not Used) 3 - Center Bottom
Electronic box slot positions
Mounting position 1 Mounting position 3
Mounting position 2
Figure 6-8
Position of the slots for Compact and chassis type units
NOTICE
Position 3 cannot be used with 115VAC I/O Interface Board in Position 2 (slots D & E). Mounting position 2 can also be used for technology boards (T100, T300, T400, & TSY). Mounting positions 2 and 3 can also be used for communication boards SCB1 and SCB2.
6-7
Rev 10/20/00
WARNING
The BUL 425 inverter drives have hazardous voltage levels that can last for up to 5 minutes after it has been powered down, this is due to the discharge time of DC link capacitors. The unit must not be opened, until this time has elapsed.
CAUTION
The BUL 425 inverter control boards contain components that could be damaged by electrostatic discharge. These components can be very easily destroyed if not handled with caution. You must observe the ESD cautionary measures when handling these boards.
Disconnecting the unit from the supply
Disconnect the unit from the incoming power supply (AC or DC supply) and deenergize the unit. Remove any external 24 VDC controls supply for the electronics. Open the door panel on the electronic box of the BUL 425 inverter. Remove the CUVC board or the option board from the electronics box as follows: Disconnect the connecting cables to the CUVC board or to the option boards. Undo the two holding screws on the handles above and below the CUVC board or the option board. Pull the CUVC board or option board out of the electronics box using the handles. Place the CUVC board or option board on a grounded working static-free surface. Insert the control board from the right onto the 64-pin connector on the CUVC board. The view shows the installed state. Affix the option board tight at the fixing points in the front section of the optional board using the two screws attached. Re-install the CUVC board into Slot 1 (original position) reaffix to card rack, and reconnect cabling. Connect new cabling to daughter or option board(s) per details in Control Connections in Section 7.2.
Preparing installation of daughter boards
Installing daughter boards to CU
NOTICE
The optional board must be pressed tightly onto the plug connector; it is not sufficient to simply tighten the screws! Check that all the connecting cables and the shields are properly terminated.
6-8
Section 7: Connecting Up
! WARNING DANGER
Inverters are operated at high voltages. The equipment must be in a no-voltage condition (disconnected from the supply) before any work is carried out! Only professionally trained, qualied personnel must work on or with the units. Death, severe bodily injury or signicant property damage could occur if these warning instructions are not observed. Hazardous voltages are still present in the unit up to 5 minutes after it has been powered down due to the DC link capacitors. Thus, the appropriate delay time must be observed before working on the unit or on the DC link terminals. The power terminals and control terminals can still be live even when the motor is stationary. If the DC link voltage is supplied externally, the converters must be reliably isolated from the DC link voltage! When working on an opened unit, it should be observed that live components are at hazardous voltage levels and can be touched presenting a serious shockhazard. The user is responsible for seeing that all the BUL 425 units are installed and connected-up according to recognized regulations in that particular country, as well as, other regional and local regulations. Practices for cable dimensioning, fusing, grounding, shutdown, isolation, and overcurrent protection, should be particularly observed.
OVERVIEW
This section discusses the electrical installation of the BUL 425 inverter drive. These instructions cover ground, input line and motor power, and control connections. Due to the large number of available options, only the default properties are covered. Some general information is given on the Option Modules and other options in order to simplify their electrical installation later in this manual. This manual introduces electric motors, drive train mechanisms, and driven machines to an extended operating range. It should be conrmed that all equipment is capable of operating under these conditions. Operation is not allowed if the motor nominal voltage is less than one-half of the BUL 425 nominal input voltage, or if the motor nominal current is less than 1/6 of the BUL 425 nominal output current.
EMC FILTERS
If external EMC lters are added to the BUL 425 inverter, the EMC lter capacitors increase ground leakage current, which may be detected by fault current breakers in the supply. If the BUL 425 inverter is connected to ungrounded ac lines, the line will be connected to ground potential through the EMC lter capacitors. In this situation, if another inverter is connected in parallel with the BUL 425 inverter, and if a ground fault occurs on the output of this other inverter, the capacitor voltage can rise and this can lead to capacitor failure. BUL 425 inverters are equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and the motor cable. (This is not a personnel safety feature.) The EMC lter if added to the inverter increases ground leakage currents. Fault current circuit breakers in the line might detect these currents.
GROUND FAULT PROTECTIVE FUNCTION
Rev. Date 6/25/01
7-1
Revised 6/25/01
GROUNDING
The BUL 425 inverter and the motor must be properly grounded at the installation site to ensure personnel safety in all circumstances, and, in addition, to reduce electromagnetic emission and pick-up.
! WARNING DANGER
When possible, rigid metallic conduit is recommended for input and output power wiring to provide better electromagnetic interference suppression and capacitive leakage current reduction at high frequencies. Four wires (three phase wires and a ground wire) are required for the input. Connect the ground wires for the input power and output motor power. The ground wire for the input power is connected to the separate input terminal marked PE1. The ground wire for the output power and the shield, if shielded cable is used, is connected to the separate ground terminal marked PE2 by the output terminals. See Figure 7-1 through Figure 7-6 for the Recommended Grounding, Line, and Motor Cable Connections and DC Link Bus Connections.
NOTICE
The BUL 425 inverter ground terminals should not be connected in series in the case of a multiple installation. Incorrect grounding can cause increased electromagnetic interference. For additional information on grounding of a drive system refer to the National Electrical Code.
INPUT FUSES
If the BUL 425 inverter is not equipped with input fuses, they must be added externally. Class J Fuses are needed to protect the input and motor cables from overload and the input bridge of the inverter in case of an internal short circuit. Fuses sizes and part numbers are listed in Tables 2-1 through 2-3. To help protect the bridge of BUL 425 inverters, non-standard, ultra-rapid fuses, can be supplied by Morris. Contact your local Morris dealer for details. BUL 425 inverters are rated for use on a symmetrical 50 Hz and 60 Hz three-phase electrical systems with the selected voltage. BUL 425 is suitable for use on a circuit capable of delivering not more than 50,000 rms symmetrical Amperes. Input power wiring must be sized according to local regulations to carry the inverters total rms input current. Motor wiring must be sized according to local regulations to carry the inverters nominal output current. The motor wires can, in most cases, be of the same size as the input power wires, where a single motor is connected to an inverter . Table 7-1 gives the maximum input and output power wire sizes allowed by the power terminals of the inverter. The voltage rating has a signicant effect on the selection of drive components. Operation outside the nominal voltage range should not be attempted, as overvoltage can result in permanent damage to the unit.
INPUT BRIDGE PROTECTION POWER CABLES
INSULATION CHECKS
Every BUL 425 unit has been high-voltage tested for insulation between main circuit and chassis (1000 VDC rms for 2 seconds) at the factory. Therefore there normally is no need to check the insulation on the inverter.
7-2
! CAUTION DANGER
Insulation checks must be performed before connecting the BUL 425 inverter to the line. Before proceeding with the insulation resistance measurements make sure that the inverter is disconnected from the line. Connect a volt/ohm meter between the following Dynamic Brake Unit (DBU) terminals. Use a times 1K scale or higher measure the following. 1. Terminal P+ to terminal N. 2. Terminal N+ to terminal P. 3. Terminal B+ to N. 4. Terminal N+ to B. 5. Terminal P+ to B. 6. Terminal B+ to P. In steps 1 thru 4, the meter should deect to the right, then move back to the left indicating capacitor charging. In step 5 measure the ohmic value of the DBU. Typically 167 ohms for 3 hp inverters down to 12 ohms for larger inverters. In step 6, read through the diode in the DBU (in step 6, if a digital voltmeter is used, you will again read the value of the DBU resistor). If these results are not obtained, re-check the wiring. Failure to observe this procedure can result in destruction of the precharge resistor upon power up.
INPUT POWER CONNECTION
Only a qualied electrician should only carry out input power connections. No work on the line should be attempted with power applied.
! WARNING DANGER
If there are power factor compensation capacitors in parallel with the BUL 425 inverter, be sure that the capacitors and the inverters dc bus are charged simultaneously to avoid voltage surges that might damage the unit. Never connect the line to the BUL 425 inverter output. If frequent bypassing is required, mechanically connected switches or contactors should be employed. Line voltage applied to the output can result in permanent damage to the unit. The input power connects to the input terminal blocks of the BUL 425 inverter at the upper part of the frame in accordance with Figure 7-1 through Figure 7-6.
CABLE ENTRY
The following gures (Figure 7-1 through Figure 7-6), show the different frame sizes for the BUL 425 inverters. Separate feeds are required for the top entry input power, bottom exit output power, 115VAC control signals, low-voltage analog and encoder control signals, and the dynamic braking power. The motor cable should be installed away from other cable routes. Long parallel runs of motor cables with other cables should be avoided in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage. Motor cables in rigid metallic conduit, or the shielded motor cables of several drives can, however, be installed next to each other, as long as they are routed away from all
MOTOR CABLE ROUTING
7-3
Revised 6/25/01 other cables as recommended. Where control cables must cross power cables make sure this is done with an angle as near to 90 degrees as possible.
NOTICE
As a general rule motor power cabling and low power signal cables should always be run separately. In cases where these runs are parallel it is necessary to follow a simple rule of thumb to minimize the effects of induced noise to your control cables Rule#1 - Keep 12 inches of parallel separation, for every 10 Meters of parallel cable length up to 150 ft of total length.
MOTOR CABLE LENGTH
The BUL 425 employs a synchronized high-speed output current measuring system. This places no limitations on the length of the motor cable. The motor cable should, however, be kept as short as possible in order to avoid electromagnetic emission as well as capacitive current. The rapid voltage changes of the BUL 425 inverter output causes stray capacitive currents to occur in the motor cable. The cable length increases the capacitive current and electromagnetic emission. It is recommended that the motor cable length not exceed 300 m (990 ft) without special provisions.
MOTOR THERMOSTAT
The BUL 425 inverter control can be interlocked with thermostats located in the motor windings, to prevent excessive heating. The thermostats, when provided, should be wired into the control circuit, which disables the inverter and sets the brake, whenever motor temperature exceeds the allowable setting. Power factor correction capacitors and surge absorbers must not be connected to the motor cables. These devices are not designed to be used with AC drives, and will degrade motor control accuracy. They also can cause permanent damage to the BUL 425 inverter or themselves due to the rapid changes in the BUL 425 output voltage. It is not recommended that output contactors be used with the BUL 425 inverter. If a contactor is used between the output of the inverter and the motor, a Stop command must be given to the BUL 425 inverter before the contactor is opened. Otherwise the inverter will be damaged.
POWER FACTOR CORRECTION CAPACITORS OUTPUT CONTACTORS
! DANGER
Touching or contacting energized high voltage connections or terminals will cause severe injury or death, and equipment damage. Disconnect power, use lockout and tagout procedures, and allow at least 5 minutes for voltage discharge before checking the electrical contacts, connections, or terminals of the SMARTORQUE system and components. Only authorized and qualied personnel with proper equipment should attempt to work on energized equipment.
POWER CABLE CONNECTING PROCEDURE
To connect the power cabling, follow the procedures below: (Reference Figure 7-1 through Figure 7-6 for terminal locations on the different frame sizes of BUL 425 inverters) Disconnect, lock out, and tag the input power. Wait for 5 minutes.
7-4
Morris Material Handling Open front door or on frames a through D or on larger units ( 60 HP and above) remove the front cover. After removing power, allow at least 5 minutes to pass and verify that the dc bus capacitors have discharged to a safe level (below 50 VDC) before contacting internal components. Connect a DC voltmeter across the dc bus + and - Terminals. Start with the meter on the highest scale and progressively switch to a lower scale as the indicated voltage falls below the maximum value of the scale used. Whenever possible, never work on "live" equipment alone. Note the maximum allowable power cable sizes as shown in Table 7-1. Incoming line power connections should be brought in through the top of the unit. Connect phase conductors U1, V1, and W1 (L1, L2, & L3) to their respective terminals. Connect the power system ground conductor(s) (and shields if shielded conductors are used) to terminal PE1. DC link power connections for the dynamic braking unit(s) should be brought in through the top of the unit. Connect phase conductors C and D (L+ & L-) to their respective terminals. Motor wires should be brought in through the bottom of the unit. Connect phase conductors U2, V2, and W2 (T1, T2, & T3) to their respective terminals. Connect the motor ground conductor(s) (and shields if shielded conductors are used) to terminal PE2. Replace the front cover if no other cables are to be connected to the inverter. Figure 7-1: Recommended Grounding, Line, and Motor Cable Connections and Brake Resistor Connections
CUVC SHIELDED CABLE PE U1 V1 W1 U2 V2 W2 L+ L-
PE 1 1 INPUT FUSES DBU TRANSISTOR
CONTROL SIGNALS
PANEL GROUNDINGL1 L2 L3 WIRE
V1 U1 W1 3~ If shielded Motor cable is used on output leads
P N
PO DBU RESISTOR
DBU DYNAMIC BRAKING UNIT DBU OVERLOAD
NOTICE
See Section 6 for BUL 425 Dimensional Drawings. See Section 7 for terminal location of each frame size
7-5
Revised 6/25/01
CONTROL CONNECTIONS NOTICE
The BUL 425 inverter can be controlled from four control locations: Parameterization Metering Unit PMU
Do not use the digital PMU keypad to control crane and hoist motions. The digital keypad is not as responsive as the conventional control, and can be located where it is difcult to observe load and crane movement. For these reasons, MMH proprietary crane and hoist software has, by design, control by keypads totally deactivated and not allowed. External devices that connect to the standard analog and digital I/O terminals of CU, EB-2, and/or RB2 option boards. Personal Computer (PC) or Personal Logic Controller (PLC) connected to the X300 Serial Interface on the PMU. Option Boards that are not normally supplied with BUL 425. These include CBP Probus board or other Serial interfaces, I/O, and technology option boards. T h e B u l l e t i n 4 2 5 i nve r t e r e m p l oy s c o n n e c t o r s t h a t a r e w i d e l y u s e d i n telecommunication applications. The use of shielded control cables is highly recommended and should be properly grounded directly at the inverter end by connecting the shield to the provided grounding rail. The other end of the shield should be left ungrounded. The control cables should be installed as far away from the motor cabling as possible. Long parallel runs with the motor cable should be avoided in order to suppress electromagnetic interference. The control cables should be run directly downwards underneath the drive to allow for service and maintenance. It is not allowed to install control instruments (contactors or relays) or control cables other than those provided with the inverter inside the frame. The control connections are displayed later in Section in 7.2.
7-6
Morris Material Handling Figure 7-2: Connection overview of Frame Sizes A, B, and CMorris Material Handling
7-7
Revised 6/25/01 Figure 7-3: Connection overview for Frame Size D
NOTICE
A 230 V fan is installed in drive converters, for Frame Size D units. The fan transformer as shown below powers this fan. To supply the fan with 230 V, the primary side of the fan transformer must be adjusted to the existing line voltage via the plug connector (Connection 2). (For supply voltage range, see terminal).
Figure 7-4: Transformer location (only for Frame Size D Converters)
7-8
Morris Material Handling Figure 7-5: Connection overview for Frame Sizes E and F
NOTICE
Due to the 230 V fan a transformer is integrated into the converters The terminals on the primary side of the transformer may have to be reconnected corresponding to the line voltage.
7-9
Revised 6/25/01 Figure 7-6: Connection overview for Frame Sizes G & K
NOTICE
Due to the 230 V fan a transformer is integrated into the converters. The terminals on the primary side of the transformer may have to be reconnected corresponding to the line voltage
7-10
7.1 Power Connections for the BUL 425 Inverter

Grounding terminations available on the inverter are labeled PE1 & PE2. While at the same potential, ground connections can be made to either or both terminals. The grounding (PE) conductor should be the same size as that of the supply-cable conductor. See Table 7-1 below for maximum cable sizing: Table: 7-1 : Bulletin 425 Input Fusing & Power Wire Sizing
MMH Drive Part # Motor Rated HP Req. Input Fuse MMH Part # 200VAC 230 VAC R23968D12 R23968D25 R23968D40 R23968D70 R23968D90 R23968D100 380VAC 460 VAC R23968D8 R23968D15 R23968D20 R23968D25 R23968D35 R23968D45 R23968D50 R23968D60 R23968D80 R23968D90 R23968D125 R23968D175 R23968D200 R23968D250 R23968D300 R23968D400 R23968D500 --500VAC - 600VAC R23968D6 R23968D10 R23968D15 R23968D20 R23968D30 R23968D40 R23968D45 R23968D60 R23968D80 R23968D100 R23968D150 R23968D200 R23968D300 Max. Input Wire Size (AWG) 14 8 4 2 0 00 16 14 14 10 6 4 4 2 2 00 1x000 2x0 2x00 2x00 2x00 2x300 2x300 2x800 4x800 16 15 14 10 6 6 4 2 1x0 1x00 1x000 1x300 2x4/0 MAX. Output Wire Size (AWG) 16 14 6 2 2 0 16 16 14 14 6 6 4 4 4 2 1x0 2x2 2x2 2x0 2x00 2x4/0 2x4/0 2x800 4x800 16 16 14 14 10 6 6 4 1x2 1x2 2x4 1x4/0 2x00 7-11
R46333D3-2-10 R46333D5-2-16 R46333D10-2-29 R46333D15-2-49 R46333D20-2-63 R46333D25-2-74 R46333D3-4-6 R46333D5-4-9 R46333D7-4-12 R46333D10-4-16 R46333D15-4-23 R46333D20-4-31 R46333D25-4-34 R46333D30-4-43 R46333D40-4-54 R46333D50-4-65 R46333D60-4-84 R46333D75-4-113 R46333D100-4-133 R46333D125-4-169 R46333D150-4-191 R46333D200-4-287 R46333D250-4-337 R46333D300-4-464 R46333D400-4-537 R46333D3-5-4 R46333D5-5-7 R46333D7-5-10 R46333D10-5-14 R46333D15-5-20 R46333D20-5-26 R46333D25-5-31 R46333D40-5-42 R46333D50-5-55 R46333D60-5-71 R46333D100-5-98 R46333D150-5-142 R46333D200-5-205
3 5 7.5 / 10 15 20 25 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 400 3 5 7.5 10 15 20 25 30 / 40 50 60 75/100 125/150 200
Revised 6/25/01
! WARNING DANGER
Recommended Class J fusing only provides reliable protection to the cables, and not to the semiconductors. If the units are connected to the incoming supply without a main contactor that can interrupt the incoming supply in the event of a fault, BUL 425 inverters may suffer further damage.
NOTICE
Frame Size E - G Due to the 230 V fan a transformer is integrated into the converters. The terminals on the primary side must be connected corresponding to the rated input voltage.
NOTICE
Frame Size K Due to the 230 V fan a transformer is integrated into the converters. The terminals on the primary side have to be reconnected according to the rated input voltage, if necessary. If this is not done, the fuses F3, F4 or F101, F102 may blow. See Figure 7-7 below. Figure 7-7: Fan transformer (-T10), fan transformer fuses (-F3, -F4)
7-12
7.1.1 Terminal strip - X9 (BUL 425 Frames A, B, C, & D with 3 Phase, 380 -480 VAC and 500 - 600 VAC inputs only) X9- Connector External 24 VDC supply and main contactor control
Although not normally used by the BUL 425 inverter, the 9-pole terminal strip can be used for connecting to an external 24 VDC voltage supply and for connecting a drive controlled main or bypass contactor. Note: The BUL 425 inverter normally requires a jumper on terminals 5&6. The external 24VDC supply is required if the converter is connected via a main or bypass contactor. The connections for the contactor are oating. Table: 7-2 : Connection of external 24 VDC control supply and inverter controlled main contactor and control connections.
Terminal Designation Meaning Rating
9 8 7 6 5 4 3 2 1 Notes:
Main contactor control Not connected Main contactor control Safety Off Interlock Safety Off Interlock Safety Off Intlk Chkbk Safety Off Intlk Chkbk 0V +24 V (in)
Main contactor control Not used Main contactor control Safety Interlock Safety Interlock Not used Not used Reference Common 24 V voltage supply
AC 230 V, 1.8kVA AC 230 V, 1.8kVA Jumper to 5 not used Jumper to 6 not used Interlock answer-back Interlock answer-back 0V DC24 V 2.5 A
1) Maximum terminal wire size (AWG 16) 2) Terminal 1 is located closest to the front when properly installed.
7.1.2 Terminal strip - X9 (BUL 425 Frames A, B, C, & D with 3 Phase, 200 -230 VAC inputs only) X9 Connector External 24VDC supply and main contactor control
Although not normally used, the 5-pole terminal strip can be used for connecting to an external 24 V voltage supply and for connecting a drive controlled main or bypass contactor. The voltage supply is required if the inverter is connected via a main or bypass contactor. The connections for the contactor control are oating. Table: 7-3 : Connection of external 24 VDC control supply and inverter controlled main contactor control connections
Terminal Designation Description Rating
1 2 3 4 5 Notes:
+24 V (in) 0V Not connected Main contactor control Main contactor control
24 V voltage supply Reference Common Not Used Main contactor control Main contactor control
DC24 V 2.5 A 0V 1.8 kVA AC 230 V
1) Maximum terminal wire size (AWG 12) 2) Terminal 1 is located closest to the front when properly installed.
7-13
Revised 6/25/01
7.1.3 Terminal strip - X9 (BUL 425 Frames Sizes E, F, G, & K) X9 - Connector External 24 VDC supply and main contactor control
Although not normally used by the BUL 425 inverter, the 5-pole terminal strip can be used for connecting to an external 24 V voltage supply and a main or bypass contactor. The voltage supply is required if the inverter is connected via a main or bypass contactor. The connections for the contactor control are oating. The position of the terminal strip can be seen from the connection overviews. Table: 7-4 : Connection of external 24 VDC control supply and inverter controlled main contactor and control connections.
5 4 3 2 1 Notes:
Main contactor control Main contactor control Not connected 0V +24 V (in)
Main contactor control Main contactor control Not Used Reference Common 24 V voltage supply
AC 230 V 1.8 kVA 0V DC24 V 3.5 A
1) Maximum terminal wire size (AWG 12) 2) Frame Size K requires a 24VDC source of at least 4.3 amperes 3) terminal #1 is located closest to the front when properly installed
NOTICE
The excitation coil of the main contactor has to be damped with overvoltage limiters, e.g. RC element.
7-14
7.2 Control Connections for the BUL 425 Inverter

Standard control connections
The standard control connections of the BUL 425 inverter (Printed in Bold Print in Section 7.2) are made to three factory-mounted circuit boards installed in the card rack or Electronic Box of the inverter package (See Figure 6-8 for an illustration of the card rack and slots). These installed boards are described as follows: The RB-2 option board, or 115 VAC Control interface board, is mounted in position #2 (right position) of the card rack which includes slots D & E). The purpose of this board, is to provide an isolated interface of the low-voltage (24VAC) control inputs of the CU board and control outputs of the EB-2 board, with the 115 VAC control signal inputs and outputs of the crane or hoist control circuits. See Section 7.2.1 for more details on the RB-2 board. The CUVC or main microprocessor board, is mounted in position #1 (left position) of the card rack and includes slots A & C. See Section 7.2.2 for more details on the CUVC board. The EB-2 option-board, is a daughter board that mounts directly onto the above CUVC board via a 64-pin connector, and also occupies slot A (upper slot). The purpose of this board is that of an I/O extender. EB-2 increases the number of programmable control inputs and outputs, both analog and digital, available to control BUL 425. See Section 7.2.3 for more details on the EB-2 board.
7.2.1 RB-2 Board Connections (115VAC Control Interface - P/N R46885D2)

BUL 425 drive system has designed to operate as standard, using externally supplied 115VAC control input signals and provides output relays for switching 115VAC externally supplied power to the holding brake and fault relay circuits of the crane or hoist control circuits.
NOTICE
All external 115VAC digital crane or hoist control connections will be made to this board using X901 and X-902 terminal connectors and are shown in Bold print on the following Tables 7-5 & 7-6. Figure 7-8: RB-2 115 VAC I/O Board
7-15
Revised 6/25/01
X-900 Control Connections (Factory Connected)
The X-900 connector of the RB-2 (115 VAC control interface board) See Figure 7-8, is a factory wired plug connection that sends converted 115VAC to 24VDC crane control inputs to the X-101 connector of the CU board. In addition, 24VDC control signal outputs of the X-490 connector of the EB-2 I/O extender board, are sent to drive relays on the RB-2 board, thereby providing 115 VAC outputs for the Fault and Holding Brake functions of the crane. Only factory-made connections are to be made on the X900, X-101, or X-490 connectors. The X-901 plug-in connector of the RB-2 option board provides the connection point for the 115VAC crane control inputs. (See table 7-5 below). Table: 7-5 : Control terminal strip X-901
X-901 Control terminal strip
Binary In 1
Slowdown Lower/Reverse Hoist & Bridge/Trolley Mode Speed-matched torque follower Bucket Mode Slowdown Raise / Forward Hoist & Bridge/Trolley Mode Speed-follower Bucket Mode Accelerate (Active only in Pushbutton Mode) Brake Answer-back Lower / Reverse Raise / Forward Run Enable 115VAC Ground
115 VAC Input (Jumper to 115 VAC if not used) 115 VAC Input (Jumper to 115 VAC if not used) 115 VAC Input 115 VAC Input 115 VAC Input 115 VAC Input 115 VAC Input Neutral
Binary In 2
3 4 5 6 7 8 Notes:
Binary In 3 Binary In 4 Binary In 5 Binary In 6 Binary In 7 Common
1) Maximum terminal wire size (AWG 16) 2) Terminal 1 is at the top when installed.
The X-902 plug-in connector of the RB-2 option board provides the connection point for the 115VAC crane control outputs. (See table 7-6 below) Table: 7-6 : Control terminal strip X-902 Terminal 9 10 11 12 13 14 15 Notes: Designation Binary Out 1 Binary Out 1 Binary Out 1 Binary Out 2 Binary Out 2 Binary Out 3 Binary Out 3 Meaning Fault (N.O. Contact) Contact Common N0-Fault (N.C. Contact) Brake (N.O. Contact) Contact Common Not Used (N.O. Contact) Contact Common Rating 115 VAC 115 VAC 115 VAC 115VAC
1) Maximum wire size (AWG 16) 2) Terminal 9 is at the top when installed.
7-16
7.2.2 CUVC Board Connections (Main Processor Control - P/N R46888D1)

The CUVC Board is the heart of the BUL 425 inverter drive system. In addition to providing the main control algorithms, it also provides: Qty (7) Binary Inputs of which Qty (4) are convertible to Outputs Qty (2) Analog Inputs Qty (2) Analog Outputs w/ switches for voltage/current selection Qty (2) Serial communications ports Qty (1) Encoder feedback frequency input Qty (4) Regulated dc voltage sources Figure 7-9: View of the CUVC Main Processor Board
X-108 Control terminal strip (Factory Connected)
The X-108 is used for connecting the PMU operator keypad assembly that is mounted on the card rack door to the CUVC control board. This is a factory made connection. No external connections are to be made on control terminal strip X-108. This connector hardwires the PMU pushbuttons, the display, as well as the 9-pin Type D serial port connections.
7-17
Revised 6/25/01
X-101Control terminal strip (Factory Connected)
The X-101 terminal strip includes programmable digital inputs used for the control of the crane or hoist motion. The following connections are provided on the X-101 connector of the CUVC board. These terminals are factory connected via plug-in cable to the RB-2 option board (115VAC I/O control interface see section 7.2.1) and in standard congurations, there are no other external connections to be made to the X101 connector. For additional details see Table 7-7 below. Table: 7-7 : Control terminal strip X-101 Terminal 1 2 3 Designation +24 AUX -24 AUX Binary In 1 Meaning Auxiliary voltage supply Auxiliary supply common Slowdown Lower/Reverse Hoist, Bridge/Trolley Modes Speed-matched Torque Follower in Bucket Mode Jumpered High if not used Slowdown Raise/Forward Hoist, Bridge/Trolley Modes Speed Follower in Bucket Mode Jumpered High if not used Accelerate In 2-Button Mode Only (Or Not Used) Brake Answer Back Lower / Reverse Raise / Forward Run Enable Not Used Not Used Not Used Rating DC 24 V / 150 mA 0V 24 V, 10 mA
Binary In 2
24 V, 10 mA
5 6 7 8 9 10 11 12
Binary In 3 Binary In 4 Binary In 5 Binary In 6 Binary In 7 RS485 P RS485 N M RS485
24 V, 10 mA 24 V, 10 mA 24 V, 10 mA 24 V, 10 mA 24 V, 10 mA RS485 RS485
Notes:
7-18
X102-Control terminal Strip
The BUL 425 inverter has the following analog reference connections provided on the X102 connector of the CUVC board. This removable connector plug has control terminal connections for analog inputs and outputs and reference supplies. For additional details see Table 7-8 below. 10 VDC bi-polar regulated reference supply (max. 5 mA) for the supply of an external reference potentiometer. These supplies are not used by BUL 425 ac drives as standard. 2 analog inputs, selectable as current (4-20mA) or voltage (0-10 VDC) input. BUL 425 inverters use voltage the standard factory setting. 2 analog outputs, selectable as current or voltage output. BUL 425 inverters use voltage as standard factory setting. Table: 7-8 : Control terminal strip X-102 Terminal 13 Designation + 10 VDC Meaning +10 V regulated reference supply for potentiometer (Not used by BUL 425) -10 V regulated reference supply for potentiometer (Not used by BUL 425) Analog Speed Setpoint (Used in all master crane / hoist motions except Two Button Inf. Adj. Control) Reference Common A I-1 Analog Speed Setpoint (Used by Bucket Slave only, signal from Bucket Master Drive allows up to 200% rated speed) Reference Common A I-2 Actual Speed output (Used by Bucket Master only to Slave as reference in both directions to 200% of rated speed). Reference Common A O-1 Actual Torque/Current (Used by all Vector Master Sections for Torque share input to Slave drives. Torque reference is in both directions to 200% rated.) Reference Common A O-2 Rating +10 VDC 1.3 %, I max = 5 mA -10 V DC 1.3 %, I max = 5 mA 0 to +10 VDC (10VDC = 100% Speed)
14
-10 VDC
15
Analog In 1
16 17
A I-1 Com Analog In 2
0 VDC -10 to +10 VDC (5VDC = 100% Speed)
18 19
A I-2 Com Analog Out 1
0 VDC -10 to +10 VDC (5 VDC = 100% Speed) I max = 5 mA 0 VDC -10 to +10 VDC (5VDC = 100% Torque) I max = 5 mA
20 21
A O-1 Com Analog Out 2
22 Notes:
A O-2 Com
0 VDC
7-19
Revised 6/25/01
X103-Control Terminal Strip
When applications require closed-loop speed feedback control is required on the BUL 425 inverter, the connection for a pulse encoder (HTL unipolar) is provided on the control terminal strip X-103. Since MMH as a standard only uses differential type encoders for additional noise immunity. The BUL 425 requires an additional interface called the digital tachometer interface board or DTI and power supply. This interface is wired between the differential encoder and the unipolar input connections below. See section 7.2.4 for additional details on the DTI optional differential encoder interface and power supply. Connector X-103 also provides for motor thermistor or thermostat input (PTC) for providing motor thermal overtemperature protection when supplied in motor. For additional details see Table 7-9 below. Table: 7-9 : Control terminal strip X-103 Terminal 23 24 25 26 27 28 29 30 Notes: Designation - V SS Track A Track B Zero pulse CTRL + V SS - Temp + Temp Meaning Encoder supply ground Connection for track A Connection for track B Connection for zero pulse Connection for control track Encoder power supply Minus (-) connection KTY84/PTC Plus (+) connection KTY84/PTC Rating 0 VDC HTL unipolar HTL unipolar HTL unipolar HTL unipolar +15 VDC Imax = 190 mA KTY84: 0...200 C PTC: R cold 1.5 kW Ohm
1) Maximum terminal wire size (AWG 16) 2) Terminal 23 is at the top when installed. Figure 7-10: DTI Board Wiring
7-20
CUVC board switch settings
Table: 7-10 : CUVC Board Analog and Communication Switch Selections Switch S1 Open Closed S2 Open Closed S3 (1,2) Open Closed S3 (3,4) Open Closed S4 (1,2,3) Jumper 1, 3 Jumper 2, 3 S4 (4,5,6) Jumper 4, 6 Jumper 5, 6 Meaning Scom1 (X300): Bus terminating resistor Resistor open Resistor closed ( Not required by BUL 425) Scom2 (X101/10,11): Bus terminating resistor Resistor open (Not required by BUL 425) Resistor closed AI - 1: Changeover current/voltage input Voltage input (Required BUL 425 Setting) Current input AI - 2: Changeover current/voltage input Voltage input (Required BUL 425 Setting) Current input AO 1: Changeover current/voltage output Voltage output (Required BUL 425 Setting) Current output AO 2: Changeover current/voltage output Voltage output (Required BUL 425 Setting) Current output
X-300 Serial interface of PMU (PMU is factory connected to CUVC via X-108 connector)
BUL 425 inverters are supplied with an RS232/485 interface, located on the PMU mounted on the drive chassis face. This standard 9-pin Sub-D socket can be used for connection to a PC, usually used by qualied service engineers during commissioning or troubleshooting of the drive system. This port allows access to reading, writing, and cloning of parameters (sets) as well as retrieving online operating data. This port can also be congured to operate as a slaved node in an RS485 PLC network. See Table 7-11 below for pin-out details. Table: 7-11 : Serial interface X-300 Connector Pin 1 2 3 4 5 6 7 8 9 Name n.c. RS232 RxD RS485 P Boot 5V P5V RS232 TxD RS485 N n.c. Meaning Not connected Receive data via RS232 Data via RS485 Control signal for software update Reference Common to +5VDC 5 VDC regulated voltage supply Transmit data via RS232 Data via RS485 Not connected Rating RS232 RS485 Digital signal, low active 0V +5 V, Imax = 200 mA RS232 RS485
7-21
Revised 6/25/01
7.2.3 EB-2 Board Connections (I/O Extension Board - P/N R46887D1) Range of application
The EB-2 board is a supplied as standard in the BUL 425 inverter drive system. This option board provides additional digital and analog inputs and outputs to the base unit. This board is required in motions provided by Morris Material Handling except in some applications where PLC type automation is supplied. The EB2 I/O Expansion Board adds the following functions to the base drive: 24 VDC supply for the digital inputs Qty (2) digital inputs Qty (1) relay output with changeover Form C contacts Qty (3) relay outputs with NO contact Qty (1) analog input with differential signal, which is selectable via jumper as a current input or as a voltage input Qty (1) analog output which is selectable via jumper as a current or as a voltage output Figure 7-11: View of the EB-2 I/O Expansion Board
7-22
X-490 Control terminal strip (Factory Connected)
The X-490 connector of the EB-2 I/O Expansion board has connections that are prewired internal factory connections only and are provided with the plug-in terminal strip as shown in Table 7-12 below. Table: 7-12 : Control terminal strip X-490 Terminal 38 39 40 41 42 43 44 45 46 Notes: Designation Binary Out 1 Binary Out 1 Binary Out 1 Binary Out 2 Binary Out 2 Binary Out 3 Binary Out 3 Binary Out 4 Binary Out 4 Signicance Relay output 1, NC contact No Fault Output (60 VAC max) (Not used by BUL 425) Relay output 1, NO contact Fault Output (60 VAC max) Relay output 1, reference contact Relay output 2, NO contact Brake Output (60VAC max) Relay output 2, reference contact Relay output 3, NO contact Programmable Spare Relay output 3, reference contact Relay output 4, NO contact (Not used by BUL 425) Relay output 4, reference contact
The X-491 connector of the EB-2 I/O Expansion board has connections that are provided on the plug-in terminal strip as shown in Table 7-13 below. Table: 7-13 : Control terminal strip X-491 Terminal 47 48 49 Designation Analog Output 3 Com Analog Output 3 Analog Input 3 Signicance Analog output (Not used by BUL 425) Common analog Out 1 (Not used by BUL 425) Analog input Positive (Used by BUL 425 as Torque Reference on Vector controlled load sharing in Bucket and Hoist Slave Modes Only) Analog input Negative Ground digital input (Not used by BUL 425) +24 VDC supply (Not used by BUL 425) Binary Input 8 (Not used by BUL 425) Binary Input 9 (Not used by BUL 425) Rating 10 VDC 5 mA Signal Common 0 VDC 10 VDC 40 kW OHM (Differential Input)
50 51 52 53 54
Com Analog Input 3 Binary Input Common AUX +24VDC Binary Input 8 Binary Input 9
0 VDC Analog Input 3 Differential Common 0V +24 VDC @ 150 mA 24 VDC 4 kW 24 VDC 4 kW
Notes:
7-23
Revised 6/25/01
7.2.4 (OPTIONAL) DTI (Digital Tachometer Interface Kit - P/N R46886D1)

As discussed earlier the DTI interface board is used typically in Hoist or Bucket Crane modes where closed-loop speed feedback is required. This board converts a differential encoder output to match the unipolar (non-differential) signal input accepted by the X-103 connector of the CU board. See Table 7-9 above and Figure 7-12 and Figure 7-13 following for more details. The DTI kit P/N R46886D1 consists of two DIN-Rail mountable components that are panel mounted external to the BUL425 inverter drive and includes the following items: Qty (1) conformal coated DTI Interface board (P/N R46886D2) Qty (1) 24 Volt, 1 amp, external DC power supply (P/N R46886D3)
NOTICE
The DTI-board (Digital-Tachometer-Interface) is a board that allows differential encoder inputs with inverted tracks to be connected to the control unit. It is externally mounted and requires an external power supply 24V/300mA min.
External 24 VDC supply
The following diagram shows the following electrical connections: (L) Line Supply (External Control Power 115 VAC, 50-60 hertz, 55VA) (N) Line Supply (External Control Power 115 VAC Neutral) (+) Positive Output 24 VDC, 1.0 ampere max. (connect to the DTI board X-404 connector terminal 2). () Negative Supply Ground (connect to the DTI board X-404 connector terminal 1).
Figure 7-12: Wiring diagram for the External DTI tachometer power supply
7-24
Morris Material Handling Figure 7-13: Wiring diagram for the External DTI tachometer interface boardRev 10/20/00
NOTE: the control track is a signal, that feeds back the 15V-supply to the drive. This signal is permanent HIGH. A low level will cause immediate trip with F052
7-25
Revised 6/25/01
DYNAMIC BRAKING UNIT DBU
The dynamic braking module provides controlled gating of excess energy on the dc bus due to regenerative feedback during dynamic braking to a bank of resistors which dissipate the energy. The dynamic braking unit is connected across the dc bus circuit and consists of transistor/resistor circuit (see Figure 7-1). The transistor base is controlled from the dynamic braking module control circuits. The braking resistor connects to the terminal block supplied with the braking unit and to the thermal OL mounted next to the DBU. The thermal OL heater has been sized to open in the event that the DBU transistor fails closed. When this occurs the drive is shut down and the brake sets.
EXTERNAL BRAKING RESISTOR NOTICE
If the thermal OL relay trips the DBU transistor has failed closed. If this occurs do not reset the OL without replacing the failed DBU. Failure to observe this warning can result in burning out the precharge resistor when power is reapplied, which can lead to further inverter damage.
MOTORS
BUL 425B system is designed to operate with three-phase, ac squirrel cage, NEMA design A or B, induction motors. Squirrel cage motors are asynchronous induction machines whose speed depends upon applied frequency, number of poles, and to a small extent, load torque. They are uncomplicated and rugged, offer low initial cost and high reliability, and are very efcient. Squirrel cage induction motors have only stator windings; rotor windings consist of solid encapsulated bars. Thus, slip rings are not required. Rotor current, which produces motor torque, is induced in the rotor because the rotor operates at an rpm that is less than the synchronous speed of the electrical eld in the stator. This difference in speed is called slip, and is the basic factor that determines torque at any specic time. Characteristically, the slip of a NEMA class B or D squirrel cage induction motor is relatively constant at about 3 percent. Thus, torque is constant (i.e., motor will provide 100 percent of the torque required by the load) over a speed/ frequency range of 1 to 60 Hz. Since the squirrel cage induction motor basically runs at xed slip, relative to synchronous speed, it develops retarding torque as soon as an overhauling load drives the motor to exceed synchronous speed. During operation, when the operator releases the control pushbutton, the frequency of the applied voltage is reduced, resulting in a change of slip. Rotor speed would then be greater than synchronous speed, producing a retarding torque in the rotor. This is known as regenerative braking. Because of the changing horsepower characteristics of this type of application, motor parameters change rapidly to t the hp requirements. While many constants need to be adjusted to accommodate the changing parameters, this is all accomplished by the BUL 425 microprocessor and software.
MOTOR HOLDING BRAKE
The holding brake is a spring-applied, magnetically released brake located on the motor shaft. The brake is actuated whenever the motor approaches zero speed, or whenever the base drive signals to the inverter are blocked. Unlike other controls, brake application and release is controlled by the BUL 425 control system and not by application of power to the motor. The holding brake coil may be of either ac or dc conguration, depending upon application. A typical schematic diagram for the power and disc brake conguration is shown in Figure 7-14.
7-26
Morris Material Handling R-C type (not MOV type) surge absorbers are used to suppress the coils of ac electromechanical brakes. This will minimize nuisance faults. These brakes are an important feature, especially on hoist motions, and must therefore be properly maintained. Specic maintenance instruction for the brakes are provided in another care and operation manual. Since these are friction devices, wear and heating are associated with their use. The P&H system, using the induction motor, reduces brakes wear and heating because the dynamic braking reduces motion to very slow speeds before the brake activities. The motor brake is, in fact, a parking brake. Figure 7-14. Power and Brake Connections
NOTE: FUSES AND DISCONNECT SWITCH MAY BE USED IN PLACE OF CIRCUIT BREAKERS BRAKE CONTACTOR BC BRAKE
Precharge resistor/diode combination used on 25 HP and larger. FUSES R14 V14 U1 460 VAC/3 PH/60HZ V1 W1 460 VAC H1 H3 H2 H4 + P Po B DBU OL N 2 BC X2 BRAKE CONTACTOR 3 X1 SURGE ABSORBER NOTE: SURGE ABSORBER MUST BE RC TYPE, NOT MOV TYPE Precharge resistor and bypass contact used on 20 HP and smaller. X25 DBU U2 V2 W2 PE DBU RESISTOR MOTOR
DC BRAKE COIL ARRANGEMENT BC2 BC1
X1
X2
K11
R14
BC
HOIST UPPER LIMIT SWITCH
The hoist upper limit arrangement consists of a geared limit switch and either a control circuit weight-operated limit switch or a power circuit switch as a back up to the geared limit switch. The function of each switch is to open the power to the raising circuit, and to set the motor brake, causing the hoist raise motion to stop. BUL 425 control system can be operated as a variable speed control or ve-step pushbutton control. Innitely adjustable speed control can be obtained from a pushbutton induction master or a SIR induction master. Depending upon how far the pushbutton is depressed or how
OPERATOR CONTROL
Variable Speed Control
7-27
Revised 6/25/01 far the master is moved away from the off position, determines the magnitude of the output voltage. This voltage is fed to an interface card (see Figure 7-15) which converts the ac induction master signal to a 0-10Vdc signal. This signal ultimately is applied to the inverter input terminal 15 and 16 of terminal block X102. Innite adjustable speed control can be obtained with a 2 step P.B. see parameter 11.04. Five-Step Pushbutton Control The multi-speed pushbutton element, used for 3, 4, and 5 speed steps, requires a depression of only 3/4 inch for full operation, with a movement of 1/8 inch between each speed point. It is enclosed in a molded-plastic housing, and only the terminal screws are exposed for external connections. The movable contact member is an assembly of six copper-carbon brushes, mounted radically in an alkyd molding fastened to the button. The pushbutton circuit is made in steps as the button is pressed, moving the brushes down to contact, in successive order, the phosphor segments of varying length mounted in grooves in the barrel of the housing.Beryllium copper springs exert contact pressure on the brushes, and two return springs maintain the button in the OFF position. The output from the 5 step pushbutton is applied to the 5 step interface card (see Figure 7-15). The card has 5 potentiometers to set the 0-10Vdc output signal. The output from this card is applied to inverter terminals 15 and 16 of terminal block X102.
NOTICE
Typically, a 1/4 W, 10k ohm loading resistor is added across terminals 7 and 8 of the 5-step interface card TB2 output (see Figure 7-15). Terminal 7 is tied to the inverter ground PE. Figure 7-15. Interface Cards
NOTE: POTENTIOMETERS P1 AND P2 MUST BE ADJUSTED TO PRODUCE 10.2 VDC OUTPUT SIGNAL, WHEN THE SIR MASTER IS IN THE FULL ON POSITION. 10
GND
Note: Terminal 7 must be grounded to the inverter PE ground located just below the NIOC card. A 10k, ohm 1/4W loading resistor may also be needed across output terminals 7 and 8 to stabilize the voltage at the first step.
P5
1 TB2
LED 5 P4 LED 4 P3 LED 3 P2 LED 2 P1 LED 1
P5 OUTPUT ADJUSTMENT P4 OUTPUT ADJUSTMENT P3 OUTPUT ADJUSTMENT P2 OUTPUT ADJUSTMENT P1 OUTPUT ADJUSTMENT 10K 1/4W RESISTOR 0-10 VDC TO INVERTER INPUT INVERTER F/R CONTACTS INVERTER RUN CONTACTS
016VAC REV K2 SIGNAL (INPUT) + 010V OUTPUT
FWD K1 REVERSE (K2) FORWARD (K1) 3 AMP LOW VOLTAGE CONTACTS P2 MAX SPEED REVERSE P3 MIN SPEED P1 MAX SPEED FORWARD 3 AMP REV 120VAC FWD CONTACTS
3 AMP FWD 120VAC REV CONTACTS
K1
K2
L1 L2 TB1 1 2 3
10
L2 L1
+ 8 7 6 5 2 4 3 1 2 1 TB-2
K2
K2
K1
K1
FORWARD CONTACT
REVERSE CONTACT
1 2 3 4 5 6 7 8 9 10 1112 TB1 120 5 VAC 4 3 FWD 2 1 1 2 REV 3 4 5 AUX RUN CONTACTS OUTPUT
STEP 5 STEP 4 STEP 3 STEP 2 FWD REV
INDUCTION MASTER CARD 79R649
5-STEP MASTER CARD (TC-IMS, 79U2488D2)
7-28
7.3 Description of crane application terminal inputs (CUVC board) 7.3.1 Binary Input #7: Run Enable HIGH LOW
The Run Enable command has to be HIGH for any operation. A LOW signal (coast) will cause the converter to: Inhibit the inverter output pulses immediately Close the brake Remain in the status 008 (SWITCH-ON INHIBIT), until both: 1. RUN ENABLE is high again 2. The RAISE / LOWER command is withdrawn
7.3.2 Binary Inputs #6 and #5: Raise / Forward and Lower / Reverse HIGH
A HIGH signal will cause the inverter to: Enables the inverter output pulses Excites the motor Releases the brake Rotates the machine according to the speed-reference polarity, in the clockwise rotating eld (RAISE / FORWARD) or counterclockwise rotating eld (LOWER / REVERSE)
LOW
A LOW signal will cause the inverter to: Ramps the drive down to zero-speed Sets the brake Disables the inverter output pulses In the 2-button-innite-adjustable-mode a LOW signal causes the drive to ramp down until it is HIGH again.
NOTICE
RAISE / FORWARD and LOWER / REVERSE may not be high at the same time. This will cause ALARM A035 or F055.
7.3.3 Binary Input #4: The Brake Answer-back

The Brake Answer-back signal, is evaluated in the brake-control function block, and veries that the brake is working as commanded.
HIGH LOW
The brake is released The brake is set
7-29
Revised 6/25/01
7.3.4 Binary Input #3: Accelerate (2-button mode)

This binary input is only used in the 2-button innitely adjustable mode in the factory settings for the hoist and bridge / trolley controls.
HIGH LOW
ACCELERATE MAINTAIN CONSTANT SPEED OR DECELERATE
7.3.5 Binary Inputs #2 and #1

These two inputs provide automatic slowdown functions (Binary Input #2 = SlowdownRaise / Forward and Binary Input #1 = Slowdown Lower / Reverse) when used on the following factory settings: Factory Setting Hoist closed-loop vector control (P366 = 11) Hoist open-loop vector control (P366 = 12) Bridge / Trolley scalar volts/hertz control (P366 = 13)
HIGH LOW
A HIGH signal to both inputs, causes the drive to operate normally A low signal to one of the inputs, reduces the speed reference to a preset percentage of the setpoint value set in P400 (factory default is 20% of setpoint) when the drive is commanded to rotate in the same direction after activation. SLOWDOWN RAISE / FORWARD Binary Input # 2 is LOW SLOWDOWN LOWER / REVERSE Binary Input #1 is LOW The drive can operate at normal speed if the opposite direction is selected with its corresponding slowdown input HIGH.
Factory Setting Binary Input # 2 is HIGH Binary Input # 2 is LOW
Bucket Crane vector control (P366 = 14) With Binary Input #1 HIGH Fault F148 (wrong external signals) Drive operates as a speed-matched torque follower With Binary Input #1 LOW . Drive operates as a speed follower Normal operation (Manual control via Master Speed Switch)
7.3.6 Analog Input #1 / CUVC: Speed reference #1

This unipolar 0-10V input is the standard input for the speed reference, except the 2-Button-innite-adjustable-mode is selected the drive is in the slave mode The resulting %-value can be observed in r637.1. 10V equals 100%
7-30
7.3.7 Analog Input #2 / CUVC: Speed reference #2

This speed reference is a bipolar 10 - + 10V input and only used, when factory setting bucket operation is preset. The resulting %-value can be observed in r637.2 (10V is displayed as 100%, in this case the speed scaling is made after the display parameter). 5V equals 100% speed in order to allow speed commands up to 200%.
7.3.8 Analog Input #3 (Analog Input #1 on EB2 board): Torque reference
The torque reference is a bipolar 10 - + 10V input and only evaluated, when torque follower or speed-matched torque follower is selected. The resulting %-value can be observed in r682.1. 5V equals 100% in order to allow torque commands up to 200%
7.3.9 Analog Output #1 / CUVC: Speed Actual Value
The speed output is a bipolar 10 - + 10V signal. 5V equals 100% in order to see speed values up to 200%
7.3.10 Analog Output #2 / CUVC: Torque Actual Value
The torque output is a bipolar 10 - +10V signal in the vector control mode. 5V equals 100% in order to see torque values up to 200%Morris Material Handling
7-31
Revised 6/25/01
7.4 Fusing For Heatsink Fans & Line Voltage Selection

7.4.1 Cooling Fan Fusing Selection Table
BUL 425 drives in frame sizes D, E, F, G, & K, all have cooling fans that include protective fusing that may require replacement. Table 7-14 below provides replacement fuse information. Motor Rated HP Req. Fan Fuse F101 / F102 MMH Part # 200VAC 230 VAC R46889D76 R46889D76 R46889D76 380VAC 460 VAC R46889D77 R46889D77 R46889D77 R46889D77 500VAC 600VAC R46889D77 R46889D77 R46889D77 Req. Fan Fuse F1 / F2 MMH Part # R46889D77 R46889D76 R46889D76 R46889D76 R46889D80 R46889D78 R46889D78 R46889D78 R46889D78 R46889D77 R46889D81 R46889D81 R46889D80 R46889D80 Req. Fan Fuse F3 / F4 MMH Part # R46889D79 R46889D79 -
MMH Drive Part #
R46333D15-2-49 R46333D20-2-63 R46333D25-2-74 R46333D25-4-34 R46333D30-4-43 R46333D40-4-54 R46333D50-4-65 R46333D60-4-84 R46333D75-4-113 R46333D100-4-133 R46333D125-4-169 R46333D150-4-191 R46333D200-4-287 R46333D250-4-337 R46333D300-4-464 R46333D400-4-537 R46333D20-5-26 R46333D25-5-31 R46333D40-5-42 R46333D50-5-55 R46333D60-5-71 R46333D100-5-98 R46333D150-5-142 R46333D200-5-205
15 20 25 25 30 40 50 60 75 100 125 150 200 250 300 400 20 25 30 / 40 50 60 75/100 125/150 200
Table: 7-14 : Fusing for Heatsink Cooling Fans
7-32
7.4.2 Fan Line Voltage Selection Table

Fan voltage tap table for frame sizes D thru K only During commissioning of BUL 425, if the measured line voltage is higher or lower than the nominal nameplate rating of the drive it is necessary to adjust transformer taps energizing the cooling fan of the power section of the drives to be assured of adequate ventilation. The following Table 7-15 show what taps should be used for the nearest measured line voltage. BUL 425 Rated Input Line Voltage Measured Phase to Phase Line Volts 3-Phase 170 V 3-Phase 200 V 3-Phase 220 V 3-Phase 230 V 3-Phase 264 V 3-Phase 325 V 3-Phase 380 V 3-Phase 400 V 3-Phase 415 V 3-Phase 425 V 3-Phase 440 V 3-Phase 460 V 3-Phase 480 V 3-Phase 500 V 3-Phase 525 V 3-Phase 575 V 3-Phase 600 V 3-Phase 230 Volt AC 200 V 200V 220V 230V 230V 380V 380V 400V 400V 400V 440V 460V 460V 460V 460V 3-Phase 3-Phase 460 Volts AC 575 Volts AC
Fan Transformer Tap Connections
500 V 500 V 500 V 500 V 500V 525 V 575 V 575 V
Table: 7-15 : Connecting the fan transformer taps on frame sizes D thru K Only
7-33
Section 8
Parameterization
The functions stored in BUL 425 inverters are adapted to your specic crane or hoist application by the setting of parameters. Every parameter is clearly identied by its parameter name and its parameter number. In addition to the parameter name and number, many parameters also have a parameter index. These indices enable several values to be stored for a parameter under one parameter number for several setups. Parameter numbers consist of a letter and a three-digit number. The upper-case letters P, U, H and L represent the parameters which can be changed, and the lowercase letters r, n, d and c represent the visualization or read-only parameters which cannot be changed.
NOTICE
BUL 425 almost always uses the rst index (.001) of most indexed parameters P000 - P999 P parameters changeable, r000 r999 r read only U000 U999 U parameters (2000s) changeable, n000 n999 n read only The H, L, d, and c parameter sets are not normally used by BUL 425
Parameter Examples:
DC Bus Volts r006 = 541
Parameter name: Parameter number: Parameter index: Parameter value: Parameter name: Parameter number: Parameter index: Parameter value:
DC Bus volts r006 Does not exist 541 V Source ON/OFF1 P554 2 20
Source ON/OFF1 P554.002 = 20
Parameters can be input or changed by using the PMU (parameterizing metering unit) which is permanently mounted on the front cover of the inverter. The parameters in the BUL 425 inverters can only be changed under certain conditions. The following conditions must be satised before they can be changed: The parameter must be a changeable parameter. (Designated by upper-case letters in the parameter number). Parameter access must be granted and the default setting P053 = 6 then turns on the PMU for parameterizing. BUL 425 inverter must be in a menu (or status), which allows parameters of a particular type to be changed. (i.e. P60=0000, or 0001, or 0002...) The lock and key mechanism must not be activated. The use of KEY parameter P358.1 may be required to allow parameter access.
8.1
Parameter input via the PMU

The PMU (parameterizing metering unit) enables the readout and changing of parameter values, and metering of BUL 425 control functions, directly on the unit itself. It is an integral part of the basic unit, and consists of a four-digit seven-segment display and several keys. In some cases during commissioning or service the PMU can be programmed to provide operator control functions.
8-1
Revised 6/25/01
Table: 8-1 : Operator control elements on the PMU Key Meaning ON key OFF key Function For energizing the drive (normally disabled in BUL 425). If there is a fault: For returning to fault display For de-energizing the drive by means of OFF1, OFF2 or OFF3 Stop Modes(P554 to 560) depending on setting of parameters For reversing the direction of rotation of the drive. This function is turned off and not used by BUL 425 For switching between parameter number, parameter index and parameter value in the sequence indicated (command becomes effective when the key is released). If fault display is active: For acknowledging the fault For increasing the displayed value: Short press = single-step increase Long press = rapid increases exponentially with time For lowering the displayed value: Short press = single-step decrease Long press = rapid decreases exponentially with time If parameter number level is active: For jumping back and forth between the last selected parameter number and the operating display (r000) If fault display is active: For switching over to parameter number level If parameter value level is active: For shifting the displayed value one digit to the right if parameter value cannot be displayed with 4 gures (left-hand gure ashes if there are any further invisible gures to the left) If parameter number level is active: For jumping directly to the operating display (r000) If parameter value level is active: For shifting the displayed value one digit to the left if parameter value cannot be displayed with 4 gures (right-hand gure ashes if there are any further invisible gures to the right)
Reversing key Toggle key
Raise key
Lower key
Hold toggle key and depress raise key
Hold toggle key and depress lower key
8-2
Toggle key (P key)
As the PMU only has a four-digit seven-segment display, the 3 descriptive elements of a parameter: Parameter Number Parameter Index (if parameter is indexed) Parameter value All cannot be displayed at the same time. For this reason, you have to switch between the individual descriptive elements by depressing the toggle P key. After the desired level has been selected, adjustment can be made using the raise key or the lower key. With the toggle key, you can change over in the following order: From the parameter number to the parameter index From the parameter index to t h e p a r a m e t e r va l u e ( i f indexed) From the parameter value to the parameter number If the parameter is not indexed, you can jump directly to the parameter value.
NOTICE
If you change the value of a parameter, this change generally becomes effective immediately. It is only in the case of acknowledgement parameters (marked in the parameter list by an asterisk * ) that the change does not become effective until you change over from the parameter value to the parameter number. Parameter changes made using the PMU are always safely stored in the EEPROM (protected in case of power failure) once the toggle key has been depressed.
8-3
Revised 6/25/01
Example
The following example shows the individual operator control steps to be carried out on the PMU for a parameter reset to factory setting. Set P053 to 0002 and grant parameter access for PMU P
P053 0000 0001 0002
P
P053
Select P060
P053
P060
Set P060 to 0002 and select Fixed settings menu P

P060 1 2
Set P366 to 11 and set Closed Loop Hoist control P

P060 P366 0 11
P
P366 P970
Set P970 to 000 and start parameter reset P

P970 1 0
P
008 or 009
8-4
8.2
BUL 425 User Level Parameter List (P60=0)

Table: 8-2 : User Level Parameter Default Listing part 1 Parameter Description * = Changable in User Level Access ** = Manually entered Commissioning Access required Drive Status Rotating Frequency (Hz) Output Volts (V) Output Amps (A) Output Power (% Rated) DC Bus Volts (V) Active Motor Data Set Active BICO Data Set Active Function Data Set Setpoint Speed (RPM) Speed Actual Value (RPM) Source of Display Binector Display Binector Source of Display Connector Display Connector Incoming Line Voltage (V) Motor Type Control Mode Selection Motor Rated Voltage (V) Motor Rated Current (A) Motor Magnetizing Current (%) Motor Rated Power (HP) Motor Rated Efciency (%) Motor Rated Frequency (Hz) Motor Rated Speed (RPM) n/f Regulator Gain (actual) Torque Static (%) Torque Dynamic) (%) Access Key (commissioning) Main Setpoint (actual) n/f max. Forward speed (RPM) n/f max .Reverse speed (RPM)
Selected Macro Default Value Closed Loop Hoist Open Loop Hoist Bridge/Trolley Drive Bucket Crane Drive Range of Adjustment
Parameter Number r001 r002 r003 r004 r005 r006 r011 r012 r013 r014 r015 P030 r031 P032 r033 P071 P095 P100 P101 P102 P103 P105 P106 P107 P108 r237 P278 P279 P358 r447 P452 P453
* B0 * K0 ** ** ** ** ** ** ** ** ** ** 125.0 20.0 * 0000 0 0
* B0 * K0 ** ** ** ** ** ** ** ** ** ** 125.0 20.0 * 0000 0 0
* B0 * K0 ** ** ** ** ** ** ** ** ** ** 125.0 20.0 * 0000 0 0
* B0 * K0 ** ** ** ** ** ** ** ** ** ** 125.0 20.0 * 0000 0 0
Binector List Connector List 90-1320 0-13 0-5 100-2000 0.6-6553.5 0.0 - 95.0 0.1-2000.0 50.0 - 99.9 8.00 - 500.00 0.0 - 36000.0 0.0 - 200.0 0.0 - 200.0 0 - 2700 -2700 - 0
8-5
Revised 6/25/01
BUL 425 User Level Parameter Listing (P60=0) Continued

Table: 8-3 : User Level Parameter Default Listing part 2 Parameter Description * = Changable in User Level Access Parameter (1) = Plug Mode Deceleration Number Ramp
(2) = Bucket Crane Follower Ramp
Selected Macro Default Value
Closed Loop Hoist
Open Loop Hoist
Bridge/Trolley Drive
Bucket Crane Drive
Range of Adjustment
P457 P462.1 P462.2 P462.3 P462.4 P464.1 P464.2 P464.3 P464.4 r550 r551 r552 r553 r637 r646 r673 r682 P804 r812.1 r812.2 P813 P901.1 P901.2 P902 P905 P907 r947 r949 U842 n911 n912
Minimum speed setpoint (%) Accel Time Raise / Forw. (Sec) Accel Time Lower / Rev. (Sec) Fast Accel Raise / Forw. (Sec) Fast Accel Lower / Rev. (Sec) Decel Time Raise / Forw. (Sec) Decel Time Lower / Rev. (Sec) Fast Decel Raise / Forw. (Sec) Fast Decel Lower / Rev. (Sec) Control Word 1 Control Word 2 Status Word 1 Status Word 2 Analog Input (setpoint) Status if Digital Inputs EB2 Digital I/O Status Display EB2 Analog Input Setpoint Overspeed Hysterisis (%) Overload Monitor ( n/T %) Overload Monitor ( n/T %) Overload Counter Allowable Speed Deviation (%) Allowable Speed Deviation (%) Delay time Fault F152 (sec) Max speed as zero F154 (%) Delay time for F154 (sec) Fault Mem. 8 faults / 8 events Fault Value assigned to faults Start Pulse height (%) Board Identication VCS Software Information
0.5 * 2.0 * 1.5 * 1.5 * 1.5 (1) * 0.8 (1) * 0.8 10.0 0 13.0 15.0 0.50 0.05 0.20 0.0 -
2.0 * 2.0 * 1.5 * 1.5 * 1.5 (1) * 1.1 (1) * 1.1 10.0 0 13.0 15.0 0.50 0.05 0.20 0.0 -
0.5 * 5.0 * 5.0 * 5.0 * 5.0 (1) * 2.5 (1) * 2.5 10.0 0 13.0 15.0 0.50 0.05 0.20 0.0 -
0.5 * 2.0 * 1.5 (2) * 0.8 (2) * 0.8 * 1.5 * 1.5 (2) * 0.8 (2) * 0.8 10.0 0 13.0 15.0 0.50 0.05 0.20 0.0 -
-200.0 - 200.0 0.0 - 999.9 0.0 - 999.9 0.0 - 999.9 0.0 - 999.9 0.0 - 999.9 0.0 - 999.9 0.0 - 999.9 0.0 - 999.9 0.0 - 20.0 0 0.0 - 50.0 0.0 - 50.0 0.0 - 1.00 0.0 - 1.00 0.00 - 0.50 -100.0 - 100.0 -
8-6
BUL 425 Commissioning Level Parameter List (P60=5)

Table: 8-4 : Commisioning Level Parameter Default Listing part 1 Parameter Description **= Manually entered values requires Commissioning Access *** = v Drive Status Active Motor Data Set PMU Operating Display Parameter Access Parameter Menu Select Output Filter Select Software Version Order Number MFLB # Line Voltage (V) Rated Drive Amperes (A) Motor Type Control Mode Selection Motor Rated Voltage (V) Motor Rated Current (A) Motor Magnetizing Current (%) Motor Rated Power Factor (%) Motor Rated Power (HP / KW) Motor Rated Efciency (%) Motor Rated Frequency (Hz) Motor Rated Speed (RPM) Motor Number of Pole Pairs Motor Rated Torque (Nm) Technology Cond. Calculate Motor Model Startup Time I max Func. Paramerter (A) Select Motor Encoder Setpoint Encoder Cong. Setpoint Encoder PPR Encoder Frequency (Hz)
Selected Macro Default Value Closed Loop Hoist Open Loop Hoist Bridge/Trolley Drive Bucket Crane Drive Range of Adjustment
Parameter Number r001 r011 P048 P053 P060 P068 r069 P070 P071 P072 P095 P100 P101 P102 P103 P104 P105 P106 P107 P108 P109 P113 P114 P115 P116 P128 P130 P139 P140 P141
2 0 0 ** ** ** ** ** ** ** ** ** ** ** ** *** *** 0 1.00 *** 12 0x0 1024 10000
2 0 0 ** ** ** ** ** ** ** ** ** ** ** ** *** *** 0 1.00 *** 12 0x0 1024 10000
2 0 0 ** ** ** ** ** ** ** ** ** ** ** ** *** *** 0 1.00 *** 12 0x0 1024 10000
2 0 0 ** ** ** ** ** ** ** ** ** ** ** ** *** *** 0 1.00 *** 12 0x0 1024 10000
0 - 3999 0 0-2 90 - 1320 4.5 - 6540.0 0 - 13 0-5 100 - 2000 0.6 - 6553.5 0.0 - 95.0 0.500 - 1.000 0.1 - 2000.0 50.0 - 99.9 8.00 - 500.00 0.0 - 36000.0 1 - 99 .01 - 899999.98 0-7 0-7 0.10 - 327.67 0.1 - 6553.5 0 - 16 0x0 - 0x8499 60 - 20000 500 - 1000000
8-7
Revised 6/25/01
BUL 425 Commissioning Level Parameter Listing (P60=5) Continued

Table: 8-5 : Commisioning Level Parameter Default Listing part 2
Parameter Description *** = Values that are measured or calculated automatically Selected Macro Default Value Closed Loop Hoist Open Loop Hoist Bridge/Trolley Drive Bucket Crane Drive Range of Adjustment
Parameter Number P151 P235 P236 P240 P278 P279 P290 P325 P326 P336 P339 P340 P350 P351 P352 P353 P354 P357 P380 P381 P382 P383 P400 P452 P453 P457 P467 P471 P536 P602
Feedback Encoder PPR n/f Regulator Gain 1 n/f Regulator Gain 2 n/f Integral Reset Time (msec) Torque Static (%) Torque Dynamic (%) Flux Raise (%) Boost Volts (V) Boost End Frequency (Hz) Slip Compensation Gain Modulation System Release Pulse Frequency (kHz) Reference Amperes (A) Reference Volts (V) Reference Frequency (Hz) Reference Speed (RPM) Reference Torque (Nm) Sampling Time (msec) Motor Thermal Warning (oC) Motor Thermal Fault (oC) Motor Cooling Motor thermal time const (sec) Auto slowdown speed (%) n/f max forward speed (RPM) n/f max reverse speed (RPM) Minimum speed setpoint (%) Protective ramp gen. gain Scale torque precontrol (%) n/f Regulator Dyn. Resp. (%) Motor Excitation Time (sec)
1024 3.0 3.0 400 125.0 20.0 0.000 9.8 12.00 0.0 0 2.5 *** *** *** *** *** 1.5 0 0 0 700 20.0 0 0 0.5 2.0 0.0 65 ***
1024 3.0 3.0 400 125.0 20.0 0.000 9.8 12.00 0.0 0 2.5 *** *** *** *** *** 1.5 0 0 0 700 20.0 0 0 2.0 2.0 0.0 65 ***
1024 3.0 3.0 400 125.0 20.0 0.000 9.8 12.00 0.0 0 2.5 *** *** *** *** *** 1.5 0 0 0 700 20.0 0 0 0.5 2.0 0.0 65 ***
1024 3.0 3.0 400 125.0 20.0 0.000 9.8 12.00 0.0 0 2.5 *** *** *** *** *** 1.5 0 0 0 700 20.0 0 0 0.5 2.0 0.0 65 ***
60 - 20000 0.0 - 2000.00 0.0 - 2000.0 25 - 32001 0.0 - 200.0 0.0 - 200.0 0.000 - 50.000 0.0 - 500.0 0.00 - 300.00 0.0 - 400.0 0-5 1.5 - 16.0 0.1 - 6553.5 100 - 2000 4.00 - 600.00 1 - 36000 .10 - 899999.98 0.8 - 4.0 0 - 200 0 - 200 0-1 0 - 16000 0 - 100.0 0 - 2700 -2700 - 0 -200.0 - 200.0 1.0 - 100.0 0.0 - 200.0 10 - 200 0.01 - 10.00
8-8

Table: 8-6 Commisioning Level Parameter Default Listing part 3
Parameter Number P605 P606 P607 P611 P616 P617 P618 P781 P804 P807 P811 P820 P821 r826 r827 r828 P900 P901.1 P901.2 902 P903.1 P903.2 P904 P905 P906.1 P906.2 P907 P912 P915 P916
Parameter Description
Closed Loop Hoist
Open Loop Hoist
Bucket Crane Drive
Range of Adjustment
Brake Control Type Brake Open Time (sec) Brake Close Time (sec) Brake Threshold (%) Brake Theshold 2 (%) Brake Theshold 2 Time (sec) Flux Off Delay (sec) Fault Off Delay (sec) Overspeed Hysterisis (%) OFF 3 after alarm ULE torque limit Enable Alarm A035 Fault listing PCB Board Codes Generated date (mware) Software ID code Smoothing speed dev (msec) Allowed Speed Deviation (%) Allowed Speed Deviation (%) delay time F152 (sec) Faults 152 & 153 enable 1 Faults 152 & 153 enable 2 Smooth 0-spd dev.F154 (ms) Max spd as zero F154 (%) Enable Fault 154 Enable Fault 154 Delay time F154 (sec) Allowed current deviation (%) Enable pushbutton mode Enable eld-weakening
2 0.35 0.50 25.0 3.0 0.10 0.00 0.0 10.0 1 100.0 B1 0 0 13.0 15.0 0.50 B1 B104 100 0.05 B277 B1 0.20 20 0 0
2 0.35 0.50 25.0 3.0 0.10 0.00 0.0 10.0 1 100.0 B1 0 0 13.0 15.0 0.50 B1 B104 100 0.05 B277 B1 0.20 20 0 0
2 0.35 0.50 25.0 3.0 0.10 0.00 0.0 10.0 1 100.0 B1 0 0 13.0 15.0 0.50 B1 B104 100 0.05 B277 B1 0.20 20 0 0
2 0.35 0.50 25.0 3.0 0.10 0.00 0.0 10.0 1 0.0 B641 0 0 13.0 15.0 0.50 B1 B104 100 0.05 B277 B1 0.20 20 0 0
0-2 0.00 - 10.00 0.00 - 10.00 0.0 - 200.0 0.0 - 15.0 0.00 - 100.0 0.00 - 600.00 0.0. - 101.0 0.0 - 20.0 0-1 0.0 - 200.0 Binector List 0 - 65535 0 - 100 0.0 - 50.0 0.0 - 50.0 0.00 - 1.00 Binector List Binector List 0 - 100 0.00 - 1.00 Binector List Binector List 0.00 - 0.50 0 - 100 0-1 0-1
8-9
Revised 6/25/01

Table: 8-7 Commisioning Level Parameter Default Listing part 4
Parameter Number r947 r949 U842 n911 n912
Parameter Description
Closed Loop Hoist
Open Loop Hoist
Bucket Crane Drive
Range of Adjustment
Fault memory 8 faults 8 events Fault value Start Pulse (%) Board Identication VCS Software Information
0.0 -
0.0 -
0.0 -
0.0 -
-100.0 - 100.0 -
8-10
Section 9
Parameterizing steps for BUL 425

This section entitled "Parameterizing Steps" describes the proper programming steps that are necessary for the startup, motion conguration and adjustment, and tuning of the BUL 425 drive system for the required crane or hoist motion. In addition to this chapter, you should also refer to Chapter 3 The First Start-Up of BUL 425 and Chapter 8 Using the PMU Operator Interface. The parameterizing or programming steps are divided into different categories: Power Denition Reset of BUL 425 (Section 9.1) Crane or Hoist Motion Commissioning (Section 9.2) Drive Optimization (Tuning) of BUL 425 Inverter Drive (Section 9.3)
Parameter P060 the Menu Selection parameter
The menu structure of BUL425 has designed clusters or groups of parameters into Menus. These menus limit access to only those parameters that are needed for certain specic functions or tasks at hand and reducing the possibilities of making unintentional changes to unrelated parameters, and allow quicker scrolling to related parameters using the PMU operator keypad. Parameter P060 has the following ve menu settings that can be used during commissioning: 0 = User operational menu 2 = Fixed factory settings menu (Crane/Hoist application macros) 4 = Option board conguration menu Not used by BUL 425 5 = Drive setting menu 8 = Power section denition
Parameter P358 the MMH Access Key parameter
BUL 425, as standard, is supplied with parameter access protection to help protect against unauthorized program changes that can result in failure to the crane or hoist equipment and create hazardous situations to operating personnel or others near the machinery. Parameter P358.1 is the Key parameter that will be given, by MMH to authorized personnel that have been properly trained on BUL 425 and its use. This key will allow parameter access at the commissioning level for inverter startup and tuning.
9-1
Revised 6/26/01
9.1
Power denition reset of BUL 425 (for changes in CUVC board)

The power denition of BUL 425, is a programmed setting that tells the main microprocessor control unit CUVC board, the size of the power converter section that it is controlling. This power section denition has already been completed at the factory in the as-delivered new condition.
NOTICE
The procedure described in Figure 9-1 below only needs to be carried out if the originally supplied main control board (CUVC board) has been replaced. This step is necessary for all frame sizes of BUL 425.
! WARNING DANGER
If a new CUVC (main control board) is installed or reinstalled from another unit without the power section being re-dened, the BUL 425 inverter can be destroyed when it is connected up to the voltage supply and energized with a command to run. To redene the power section, the unit has to be switched to the "Power Section Denition menu before any change to the Power Section Denition setting is allowed. The procedure for doing this is as follows: Gain parameter access to Commissioning Level using Key Parameter. Set the Menu Select parameter P060 to the "Power Section Denition" menu. Read the 6SE70xx-xxxx Order Number of MLFB# on the nameplate of the unit and match with the numbers those supplied on the following Table 9-1 to obtain the PWE # (Power section size). Load the PWE# number in parameter P070. Return to the user parameter menu using P060 =0 Figure 9-1: Sequence for performing the power section denition
P358 = ??? If Parameter P060 cannot be changed, Set Access Key Parameter P358.1 given to you by MMH to unlock.
P060 = 8
Select Power section definition menu
P070 = ?
Input the code number for the unit concerned The code number (PWE #) is allocated to the order number. The order number can be read off the units rating plate. The list of units is on the following pages.
P060 = 0
Return to user parameter menu
9-2
Power Denition selection chart Frame Sizes A D
Table: 9-1 Power denition PWE sizing chart for frames A, B , C , & D
3AC 200 V to 230 V
Order No. (MLFB) 6SE7021-1CA60 6SE7021-3CA60 6SE7021-8CB60 6SE7022-3CB60 6SE7023-2CB60 6SE7024-4CC60 6SE7025-4CD60 6SE7027-0CD60 6SE7028-1CD60 6SE7016-1EA61 6SE7018-0EA61 6SE7021-0EA61 6SE7021-3EB61 6SE7021-8EB61 6SE7022-6EC61 6SE7023-4EC61 6SE7023-8ED61 6SE7024-7ED61 6SE7026-0ED61 6SE7027-2ED61 6SE7014-5FB61 6SE7016-2FB61 6SE7017-8FB61 6SE7021-1FB61 6SE7021-5FB61 6SE7022-2FC61 6SE7023-0FD61 6SE7023-4FD61 6SE7024-7FD61
In [A] 10.6 13.3 17.7 22.9 32.2 44.2 54.0 69.0 81.0 6.1 8.0 10.2 13.2 17.5 25.5 34.0 37.5 47.0 59.0 72.0 4.5 6.2 7.8 11.0 15.1 22.0 29.0 34.0 46.5
PWE # 14 21 27 32 39 48 54 64 70 3 9 11 18 25 35 42 46 52 56 66 1 5 7 16 23 30 37 44 50
3AC 380 V to 480 V
3AC 500 V to 600 V
Notes:PWE# (Power denition) that should be set in parameter P070 Rated Output (In) on nameplate should be set in parameter P072
9-3
Revised 6/26/01
#Power Denition selection chart Frame Sizes G K
Table: 9-2 : Power denition PWE sizing chart for frames E, F , G , & K
3AC 200 V to 230 V
Order number 6SE7031-0CE60 6SE7031-3CE60 6SE7031-6CE60 6SE7032-0CE60 6SE7031-0EE60 6SE7031-2EF60 6SE7031-5EF60 6SE7031-8EF60 6SE7032-1EG60 6SE7032-6EG60 6SE7033-2EG60 6SE7033-7EG60 6SE7035-1EK60 6SE7036-0EK60 6SE7037-0EK60 6SE7026-1FE60 6SE7026-6FE60 6SE7028-0FF60 6SE7031-1FF60 6SE7031-3FG60 6SE7031-6FG60 6SE7032-0FG60 6SE7032-3FG60 6SE7033-0FK60 6SE7033-5FK60 6SE7034-5FK60
In [A] 100.0 131.0 162.0 202.0

3AC 380 V to 480 V
PWE # 13 29 41 87 74 82 90 98 102 108 112 116 147 151 164 60 62 68 78 84 94 100 104 136 141 143
92,0 124,0 146,0 186,0 210,0 260,0 315,0 370,0 510,0 590,0 690,0
3AC 500 V to 600 V
61.0 66.0 79.0 108.0 128.0 156.0 192.0 225.0 297.0 354.0 452.0
Notes:PWE# (Power denition) that should be set in parameter P070 Rated Output (In) on nameplate should be set in parameter P072
NOTICE
To check the input data, the values for the converter supply voltage in P071 and the converter current in P072 should be checked after returning to the parameter menu. They must agree with the data given on the unit rating plate.
9-4
9.2
Crane or Hoist Motion Commissioning

The factory setting, is the dened initial state of all parameters of a unit for a particular crane or hoist motion. Since the units are delivered without these settings activated, it is the responsibility of the commissioning engineer to activate the required crane or hoist motion factory setting, then select the required features or adjustments for that motion.
Factory settings menu
NOTICE
You can restore this initial state at any time by resetting the parameters to a factory setting, thus canceling all parameter changes that were made since the unit was delivered. The parameters for dening the power section and for releasing the technology options and the operating hours counter and fault memory are not changed by a parameter reset to factory setting. Additional parameters that are not affected are listed in the Table 9-3 below: Table: 9-3 arameters that are not changed by the factory setting
Parameter number Parameter name
P070 P072 P073 P366
Order No. 6SE70.... Rated Drive Amps Rated Drive Power Select Factory Setting
Drive Commissioning Procedure
The setup procedure for commissioning the BUL 425 inverter drive to a crane or hoist application is relatively simple as listed below: Review Section 9.2.1 for an overview of the different factory settings and the possible features for each and note the functions that will be required. Next go to the appropriate owchart for the required crane or hoist motion (See Sections 9.2.2 thru 9.2.5 for the motion setup owcharts). The owcharts consist of easy-to-follow parameterizing steps that are clearly explained. A different owchart is given for each of the possible crane or hoist motions. Each of the owcharts will walk you through the setup procedure and adjustments for that motion. Once the crane or hoist motion is setup, it is then necessary to optimize, or tune the system. Flowcharts in Section 9.3 will guide you through the Static ID and Dynamic autotuning procedures of the BUL 425 inverter. Additionally this section offers some additional manual adjustments that can be performed to further improve the performance of your BUL 425 inverter drive system.
9-5
Revised 6/26/01
9.2.1 Factory Settings and Operation Modes Overview

The following table shows the four different pre-configured factory settings in the drive and the availability of the selectable functions: Table: 9-4 : Overview of Factory Setting features for BUL 425 Crane and hoist macros
conguration hoist closed loop hoist open loop bridge / trolley bucket operation
factory setting (P366=?) control mode tachometer slave operation
#11 closed loop vector yes torque follower
#12 open loop vector no not possible, only single drive 2.0% standard possible yes possible not possible yes not possible 2.0 sec 1.5 sec 1.5 sec 1.5 sec 0.8 sec 0.8 sec 2.0 sec 1.5 sec 1.5 sec 1.5 sec 1.0 sec 1.0 sec preset
#13 V/f no Volts / Hertz, speed references are in parallel 0.5% standard possible yes not possible not possible yes not possible 5.0 sec 5.0 sec 5.0 sec 5.0 sec 2.5 sec 2.5 sec preset
#14 closed loop vector yes speed follower, torque matched speed follower 0.5% standard not possible no not possible not possible no possible 2.0 sec 1.5 sec 1.5 sec 1.5 sec 0.8 sec 0.8 sec not possible
preset min. speed (P457) analog speed reference push-button mode plug-mode express speed overload detection speed limit switches start pulse preset ramp times accel. raise / forw. (P462.1) accel. lower / rev. (P462.2) decel. raise / forw. (P464.1) decel. lower / rev. (P464.2) plug-decel. raise / for. (P464.3) plug-decel lower / rev. (P464.4) follower accel. (P464.3) follower decel. (P464.4) mechanical friction
0.5% standard possible yes possible possible yes possible
preset
9-6
9.2.1.1 Factory Setting #11: Closed Loop Hoist Macro

This factory setting pre-congures the drive for hoist operation. The selected control mode is closed loop vector, and a feedback encoder is required. Possible functions are express speed (eld-weakening) overload detection pushbutton mode plug-mode slowdown speed initiation by switches (i.e. binary inputs) torque-follower The follower is in this case, is a 100% torque regulated follower of the master without any speed reference. Figure 9-2: hoist closed loop with torque follower
Masterswitch or pushbuttons
MASTER speed ref#1
SLAVE
torque act AO#2
torque ref Al#3
10V = 100%
5V = 100%
9.2.1.2Factory Setting #12: Open Loop Hoist Macro

The factory setting for open-loop hoist allows operation of a hoist without tachometer. The selected control mode is open loop vector, no feedback encoder is required. Possible functions are express speed (eld-weakening) pushbutton mode plug-mode slowdown speed initiation by switches (i.e. binary inputs) Note: This factory setting can only be used in single drive applications (without follower)
9-7
Revised 6/26/01
9.2.1.3 Factory Setting #13: Bridge / Trolley Macro

The factory setting bridge / trolley congures the drive in V/f-mode without tachometer. This mode allows simple operation of two or more drives in parallel without any additional wiring of torque-signals This mode may only be used for traverse motions. The following functions are possible: pushbutton mode plug-mode slowdown speed initiation by switches (i.e. binary inputs) A two-drive application is congured simply by using the same speed reference as shown below. The load is balanced by the inherent slip of the induction motors.
Figure 9-3: Bridge/trolley operation conguration of the analog signal
For high performance applications a different control mode should be considered. These are: open loop vector for single drives open loop vector with droop function for multiple drives closed loop vector (when tachometer installed) These choices are possible but require additional system engineering.
9-8
9.2.1.4 Factory Setting #14: Bucket Crane Macro

The bucket crane conguration consists of two drives, one for the holding line and one for the closing line. These two drives can work independently with the 4-quadrant master-switch in speed control mode or, if the button on the master-switch is depressed, In speed-matched torque or speed-follower modes, the holding line becomes the follower (slave) of the closing line. Two different follower-modes have to be considered.
Figure 9-4: Bucket Crane

master closing line slave holding line
Figure 9-5: Bucket crane masterswitch
The master-switch auto-button activates these two different follower modes: Binary Input #2 (slave) is normally activated (while lowering in auto-mode) In this case the slave will be a speed-follower, the reference will be the actual speed from the master Analog Output #1 into slave AI#2 Binary Input #1 (slave) is normally activated (while raising in auto-mode) The slave will be a speed follower with a 20% higher setpoint than the master, until the torque of the slave is higher than the torque of the master. Once this threshold is reached, the slave will work as a torque follower. Figure 9-6: Bucket crane conguration of the analog signals
active in normal mode
master
speed ref #1 active in auto-mode speed ref #1 AI#1 speed ref #2 AI#2 torque ref AI#3
slave
CUVC EB2
masterswitch
9-9
Revised 6/26/01 Table: 9-5 Bucket crane binary input functions selection
Binary input states of the bucket crane follower drive (X = Dont Care)
BI 1 Speed-Matched Torque Follower Input BI 2 Speed Follower Input BI 5 Lower Input BI 6 Raise Input
0 0 0 1
0 0 1 0 (1) lower
X X 1 1 fault F055
0 1 X X (2)
1 0 X X (3)
1 1 X X fault F148
Follower drives control mode as a result of (1) raise above binary input
Mode: (1) (1)
normal, unipolar speed reference from Analog Input 1 direction will be selected by Binary Inputs 5 and 6
Mode: (2)
(2)
auto, (button pressed while master is lowering) speed follower bipolar speed reference from Analog Input 2
direction commands will be ignored
Mode: (3)
(3)
auto, (button pressed while master is raising) speed-limited torque match bipolar speed reference from AI2 + 20% bipolar positive torque limit from AI3 direction commands will be ignored
NOTICE
The drive will magnetize the motor and release the holding brake, when any Binary Input #1, #2, #3,or #4 is HIGH.
9-10
9.2.1.5 Analog Speed Reference Mode (Masterswitch-Operation)

Note : This function uses standard free function blocks and is available all factory settings The operation with a master-switch is the standard operation mode for all the four factory settings. The master-switch is connected to an interface board, which generates a 0-10V analog signal. This is evaluated in the drive as the absolute value of the speed reference. Additionally two binary signals are connected from the drive to the interface card, which select the direction. Only one of these signals may be HIGH at the same time. Figure 9-7: Induction master joystick control
A HIGH level at one of these both signals runs the drive with the analog reference, a LOW level at both signas causes the drive to ramp down to zero speed and switch off normally Figure 9-8: Speed vs. time, masterswitch control
9-11
Revised 6/26/01
9.2.1.62-Button Innite Adjustable Mode (Pushbutton-Operation)

This function uses standard free function blocks and is available in factory setting #11, #12, or #13.
The 2-button innitely-adjustable mode is a control mode that operates the drive by using two 2-step pushbuttons. After enabling this function, the analog input speed reference will no longer be functional. Figure 9-9: 2-button speed control
B1 # 6 raise B1 #3 accelerate
HOT
B1 #5 lower
Pressing one button in the first step starts the motor at minimum speed. The second step accelerates the motor until it is released again to the first step, where the speed remains constant. Releasing the button ramps down to zero or until the button is pressed again where the speed will be maintained. RAISE and LOWER may not be pressed at the same time as a fault will result.
2-button innite adjustable mode can be enabled by setting

P915 = 1 speed reference from 2-button mode The ramp times can be selected as normal by P462.1&2 and P464.1&2. Figure 9-10: speed vs. time, 2-button control function
9-12
9.2.2 BUL 425 Setup For a Closed-Loop Hoist Control

P358.1 =??? P060 = 2 P366 = 11 Set Access Key Parameter P358.1 given to you by MMH to unlock parameter access to commissioning level Select Fixed Settings menu to get access to MORRIS Crane and Hoist Macros Select the factory setting for closed-loop hoist control Set P366=11
! CAUTION DANGER
Caution_ Setting P970 = 0 will delete all parameter settings and set them to the chosen macro default values. Default factory settings below are shown in BOLD print. P970 = 0 Load the selected factory macro setting into memory. The display on the PMU will now count up all parameters and will display 008 or 009 when nished.
NOTICE
Note: BUL 425 will be looking for the encoder control track (+15VDC) signal (Fault F052 will occur during this step if not present on X402, terminal 11, of the DTI board). P358.1 =??? Set Access Key Parameter P358.1 given to you by MMH to unlock parameter access to commissioning level P060 = 5 P068 = ? Select Drive Setting menu Set P60=5 and enter machine data Tuned output lter 0 = with/ without output reactor 1 = with tuned sinusoidal output lter 2 = with tuned dv/dt output lter
P071 = ?
Nominal input unit line voltage [Volts] ( i.e. This setting varies, depending of the type of converter 230, 380, 460, 575 ) 460 VAC Set motor type 10: IEC Induction Motor (International) 11: NEMA Induction Motor (USA) 4: closed loop vector 5: torque control (follower) From motor nameplate From motor nameplate Set % If known, If not set to 0 and the value will be calculated automatically From motor nameplate
P095.1 = ?
P100.1 = ?
Set control type
P101.1 = ? P102.1 = ? P103.1 = ?
Rated motor voltage [Volts] Rated motor current [Amperes] Motor magnetizing current [%]
P104.1 = ? P105.1 = ?
IEC-motors only Cos Phi
NEMA-motors only Rated output power From motor nameplate

[Hp]
P106.1 = ?
NEMA-motors only efciency [%]
From motor nameplate
9-13
Revised 6/26/01
P107.1 = ? P108.1 = ? P115 = 1
Motor frequency [Hz] Motor rated speed [RPM] (slip speed) Start function Automatic Parameterization Maximum output current Select encoder type Enter encoder pulse number Automatic slowdown speed (optional) Maximum speed [Motor Positive RPM] (raise direction) Maximum speed [Motor Negative RPM] (lower direction) Minimum speed [% Motor Rated RPM] Overload limit function
From motor nameplate From motor nameplate Calculates and loads the required motor modeling data for the vector control algorithm * T h i s va l u e i s p r e s e t b y t h e a u t o m a t i c parameterization step above 12: motor encoder with control track 1024 20% 0000 RPM - 0000 RPM 0.5% This value must be set to 0 if the drive is working as a follower 100% The amount of torque without friction (0% disabled)
P128.1 = * P130.1 = ? P151.1 = ? P400 = ? P452.1 = ? P453.1 = ? P457.1 = ? P811 = ? P915 = ? P916 = ?
Pushbutton-mode speed control function 0 = disabled 1 = enabled Field-weakening function
0 = disabled 1 = enabled NOTE: the crane must be mechanically designed for running at express speeds. Optimize Drive Go to section 9.3 for Drive Optimization DANGER: The Optimization step must be completed before operation
9-14
9.2.3 BUL 425 Setup For an Open-Loop Hoist Control
! WARNING DANGER
Open -loop control entirely relies on correct input of information for the vector algorithm to properly calculate the velocity, the torque, slip, and other properties required in providing high-performance and safe operation. Accurate loading of motor data and other information is less forgiving than on closed-loop control. l
P358.1 =??? P060 = 2 P366 = 12
Set Access Key Parameter P358.1 given to you by MMH to unlock parameter access to commissioning level Select Fixed Settings menu to get access to MORRIS Crane and Hoist Macros Select the factory setting for open-loop hoist control Set P366=12
! CAUTION DANGER
P358.1 =??? Set Access Key Parameter P358.1 given to you by MMH to unlock parameter access to commissioning level P060 = 5 P068 = ? Select Drive Setting menu Set P60=5 and enter machine data Tuned output lter 0 = with/ without output reactor 1 = with tuned sinusoidal output lter 2 = with tuned dv/dt output lter This setting varies, depending of the type of converter 460 VAC 10: IEC Induction Motor (International) 11: NEMA Induction Motor (USA) 3: open loop vector From motor nameplate From motor nameplate Set % If known, If not set to 0 and the value will be calculated automatically From motor nameplate
P071 = ?
Input unit line voltage in [Volts]
P095.1 = ?
Set motor type
P100.1 = ? P101.1 = ? P102.1 = ? P103.1 = ?
Control type Rated motor voltage in [Volts] Rated motor current in [Amperes] Motor magnetizing current [%]
P104.1 = ? P105.1 = ?
IEC-motors only Cos Phi
NEMA-motors only Rated output power From motor nameplate

[Hp]
9-15
Revised 6/26/01
P106.1 = ? P107.1 = ? P108.1 = ? P115 = 1

Motor frequency [Hz] Motor rated speed [RPM] (slip speed) Start function Automatic Parameterization Maximum output current current boost (torque static)
From motor nameplate From motor nameplate From motor nameplate Calculates and loads the required motor modeling data for the vector control algorithm * T h i s va l u e i s p r e s e t b y t h e a u t o m a t i c parameterization step above 125% This value has to be 10%-20% higher than the required amount of torque under maximum load condition 20% This amount of current is added, when the drive is accelerating 20% 0000 RPM - 0000 RPM 2%
P128.1 = * P278.1 = ?
P279.1 = ? P400 = ? P452.1 = ? P453.1 = ? P457.1 = ? P915 = ? P916 = ?
current boost (torque dynamic) Automatic slowdown speed (optional) Maximum speed [Motor Positive RPM] (raise direction) Maximum speed [Motor Negative RPM] (lower direction) Minimum speed [% Motor Rated RPM]
Pushbutton-mode speed control function 0 = disabled 1 = enabled Field-weakening function
0 = disabled 1 = enabled NOTE: the crane must be mechanically designed for running at express speeds. Optimize Drive Go to section 9.3 for Drive Optimization DANGER: The Optimization step must be completed before operation Parameters that effect the open-loop performance at speeds below 10%... P278 is equal to the amount of torque (boost) current in this speed range. This current is not controlled by the speed controller. Note that even under no loadconditions, this current will be present. When the hoist is operating at low speeds for longer time periods, there will be a risk of overheating the machine. P279 is the amount of additional torque-current (boost) that is added to parameter P278, when the drive is accelerating or decelerating P467 is a multiplier to the actual selected ramp-time in the speed range up to 10% to avoid too dynamic movement. a value of 1 means normal performance, but no additional security, 4 means maximum security, but slower performance.
9-16
9.2.4 BUL 425 Setup for a Bridge / Trolley Control

P358.1 =??? P060 = 2 P366 = 13 Set Access Key Parameter P358.1 given to you by MMH to unlock parameter access to commissioning level Select Fixed Settings menu to get access to MORRIS Crane and Hoist Macros Select the factory setting for a bridge / trolley control Set P366=13
! CAUTION DANGER
P358.1 =??? Set Access Key Parameter P358.1 given to you by MMH to unlock parameter access to commissioning level P060 = 5 P068 = ? Select Drive Setting menu Set P60=5 and enter machine data Tuned output lter 0 = with/ without output reactor 1 = with tuned sinusoidal output lter 2 = with tuned dv/dt output lter This setting varies, depending of the type of converter 460 VAC 10: IEC Induction Motor (International) 11: NEMA Induction Motor (USA) 1: V/f control 3: open loop vector for single drive application From motor nameplate From motor nameplate(s) group drives: total of all motor-current Set % If known, If not set to 0 and the value will be calculated automatically From motor nameplate From motor nameplate
P071 = ?
P095.1 = ?
Set motor type
P100.1 = ?
Control type
P101.1 = ? P102.1 = ? P103.1 = ? P104.1 = ? P105.1 = ?
Rated motor voltage in [Volts] Rated motor current in [Amperes] Motor magnetizing current [%]
IEC-motors only Cos Phi NEMA-motors only

Rated output power [Hp]
P106.1 = ? P107.1 = ?

Motor frequency [Hz]
From motor nameplate From motor nameplate
9-17
Revised 6/26/01
P108.1 = ? P115 = 1 P128.1 = * P325.1 = *
Motor rated speed [RPM] (slip speed) Start function Automatic Parameterization Maximum output current (current limit)
From motor nameplate Calculates and loads the required motor modeling data * T h i s va l u e i s p r e s e t b y t h e a u t o m a t i c parameterization step above * T h i s va l u e i s p r e s e t b y t h e a u t o m a t i c parameterization step avobe (voltage boost from zero speed to value in P326) * T h i s va l u e i s p r e s e t b y t h e a u t o m a t i c parameterization step above 110% This value has to be 10%-20% higher than the required amount of torque under maximum load condition 20% This amount of torque is added, when the drive is accelerating 20% 0000 RPM - 0000 RPM 0.5%
V/f control voltage boost
P326.1 = * P278.1 = ?
V/f control boost end frequency open loop vector only current boost (torque static)
open loop vector only current boost (torque dynamic) Automatic slowdown speed Maximum speed [Motor Positive RPM] (forward direction) Maximum speed [Motor Negative RPM] (reverse direction)
P279.1 = ?
P400 = ? P452.1 = ? P453.1 = ?
P457.1 = 0.5 Minimum speed [% Motor Rated RPM] P915 = ? Optimize Drive
Pushbutton-mode speed control function 0 = disabled 1 = enabled Go to section 9.3 for Drive Optimization DANGER: The Optimization step must be completed before operation
9-18
9.2.5 BUL 425 Setup For a Bucket Crane Control

P358.1 =??? P060 = 2 P366 = 14 Set Access Key Parameter P358.1 given to you by MMH to unlock parameter access to commissioning level Select Fixed Settings menu to get access to MORRIS Crane and Hoist Macros Select the factory setting for a bucket crane control Set P366=14
! CAUTION DANGER
Caution_ Setting P970 = 0 will delete all parameter settings and set them to the chosen macro default values. Default factory settings below are shown in BOLD print. P970 = 0 Load the selected factory macro setting into memory. The display on the PMU will now count up all parameters and will display 008 or 009 when nished. Note: BUL 425 will be looking for the encoder control track (+15VDC) signal (Fault F052 will occur during this step if not present on X402, terminal 11, of DTI board). P358.1 =??? Set Access Key Parameter P358.1 given to you by MMH to unlock parameter access to commissioning level P060 = 5 P068 = ? Select Drive Setting menu Set P60=5 and enter machine data Tuned output lter 0 = with/ without output reactor 1 = with tuned sinusoidal output lter 2 = with tuned dv/dt output lter This setting varies, depending of the type of converter 460 VAC 10: IEC Induction Motor (International) 11: NEMA Induction Motor (USA) 4: closed loop vector From motor nameplate From motor nameplate Set % If known, If not set to 0 and the value will be calculated automatically From motor nameplate From motor nameplate
P071 = ?
P095.1 = ?
Set motor type
P100.1 = ? P101.1 = ? P102.1 = ? P103.1 = ?
Control type Rated motor voltage [Volts] Rated motor current [Amperes] Motor magnetizing current [%]
P104.1 = ? P105.1 = ?
IEC-motors only Cos Phi NEMA-motors only

Rated output power [Hp]
P106.1 = ? P107.1 = ?

Motor frequency [Hz]
From motor nameplate From motor nameplate
9-19
Revised 6/26/01
P108.1 = ? P115 = 1
Motor rated speed [RPM] (slip speed) Start function Automatic Parameterization Maximum output current
From motor nameplate Calculates and loads the required motor modeling data for the vector control algorithm * T h i s va l u e i s p r e s e t b y t h e a u t o m a t i c parameterization step above 12: motor encoder with control track 1024 PPR 0000 RPM - 0000 RPM 0.5%
P128.1 = *
P130.1 = 12 select encoder type P151.1 = ? P452.1 = ? P453.1 = ? P457.1 = ? Optimize Drive Enter encoder pulse number [PPR] Maximum speed [Motor Positive RPM] (raise direction) Maximum speed [Motor Negative RPM] (lower direction) Minimum speed [% Motor Rated RPM]
Go to section 9.3 for Drive Optimization DANGER: The Optimization step must be completed before operation
9-20
9.3 Drive Optimization (Tuning) of BUL 425 inverter drive
! WARNING DANGER
During the dynamic optimization the inverter pulses are released to the motor, the holding brake is released, and the motor rotates at several speeds! For reasons of safety, dynamic optimizations should rst be carried out, if possible, without coupling of the load. After the factory settings for the required crane or hoist motion has been loaded into memory along with the motor and machine data, as per one of the owcharts in Section 9.2, BUL 425 is now ready for optimization. This step has signicant importance in assuring trouble-free performance and safe operation, and must be performed. The drive optimization procedure includes three automatic tuning and measurement sequences. Each sequence is performed one at a time, and in the order as it appears below: Motor identication at standstill (Static Motor ID). During this measurement, the motor remains at rest with the holding brake set. Dynamic No-load Optimization. This measurement releases the brake and rotates the motor at several speeds, automatically adjusting the regulator and speed controller. Dynamic Controller Optimization - This measurement releases the brake and rotates the motor at several speeds, automatically adjusting the regulator and speed controller. Manual tuning and adjustments for optimizing the crane or hoist functions and performance.
9-21
Revised 6/26/01
9.3.1 Drive Optimization (Tuning) of BUL 425 Inverter

STATIC MOTOR IDENTIFICATION STEP 1.
P060 = 5 P115 = 2
Select Drive Settings menu set P60 = 5 (Commissioning parameter access level is required) Skip this step ONLY if using a tuned sinusoidal output lter ( P068 = 1). If P068 = 1 continue at Step 6 when possible or Most Importantly Step 10 below for all vector modes with P100 > 2. Select User Settings menu to allow activation (run command) in step 4.
2.
3.
P060= 0
! DANGER
4.
The drive must be started within 60 seconds of activating P115. Current ows through the motor, the brake will not open. The drive must be switched to off, when the display shows the status 008. Static ID Optimization is complete, For non-vector V/Hz modes (bridge & trolley drives with P 100 = 1), skip to step 13, Vector modes (P 100 = 3 or 4) must continue to step 5 and/or step 9.
NO LOAD MEASUREMENT (DYNAMIC) Ideally, Motor should be uncoupled for this portion of Tuning Procedure
STEP 5.
P060 = 5 P115 = 4 P060 = 0
Select Drive Settings menu set P60 = 5 (Commissioning parameter access level is required) If P100 > 2 ( Vector Modes Only ) Select No-Load Measurement Set P 115 = 4. Select User Settings menu Set P060 = 0 to allow activation (run command) in step 8 to be performed.
6.
7.
! DANGER
The drive must be started within 60 seconds of activating P115. Current ows through the motor, the brake will open, and the motor will rotate. The drive must be switched to off, when the display shows the status 008. No-Load Measurement is complete, vector modes (P100=3 or 4) must continue to step 9.
8.
Note: BUL 425 will be looking for a 15VDC encoder control track signal on factory settings of P366=11 or 14 as well as a brake answer-back signal, on all settings, check wiring of brake signal or change P605 (from 2 to 1) if answer-back is not present. Failure to have the required signals will result in the faulting of the drive during the autotuning procedures. (NOTE: P605 MUST BE RETURNED TO 2 WHEN AUTOTUNE IS COMPLETE
Optimization Continued on Next Page
9-22
Morris Material Handling Drive Optimization (Tuning) of BUL 425 Inverter Continued:
SPEED CONTROLLER OPTIMIZATION (DYNAMIC) NOTE: This portion can be done with motor uncoupled. If motor is then coupled and speed/current deviations occur (F152, F153, F156) this portion of the optimization should be redone with the motor coupled and empty hook (or Grapple) suspended. STEP 9.
P060 = 5 P115 = 5 P060= 0
Select Drive Settings menu set P60 = 5 (Commissioning parameter access level is required) If P100 > 2 ( Vector Modes Only ) Select Speed Controller Optimization Set P115 = 5 Select User Settings menu Set P060 = 0 to allow activation (run command) in step 12 to be performed.
10. 11.
! DANGER
The drive must be started within 60 seconds of activating P115. Current ows through the motor, the brake will open, the motor will rotate. The drive must be switched off, when the display shows the status 008. Speed Controller Optimization is complete. Go to step 13.
12.
Note: BUL 425 will be looking for a 15VDC encoder control track signal on factory settings of P366=11 or 14 as well as a brake answer-back signal, on all settings, check wiring of brake signal or change P605 (from 2 to 1) if answer-back is not present. Failure to have the required signals will result in the faulting of the drive during the autotuning procedures. (NOTE: P605 MUST BE RETURNED TO 2 WHEN AUTOTUNE IS COMPLETE)
13
Automatic Drive Optimization is now complete and drive is ready for operation. See Section 9.3.2 for typical manual adjustments that are possible to improve the crane or hoist performance.
9.3.2 Manual adjustments to improve BUL 425 performance

The factory settings combined with the prescribed drive optimization procedures of the previous section, are designed to provide total setup and adjustment for most crane applications. In some cases further adjustment may be required. Manual adjustments are possible to further improve the performance of your BUL 425 inverter on your crane application. Commissioning Level parameter access as a minimum will be required. A few recommendations are listed below, and in most cases, will improve the performance of your application to acceptable levels. If performance issues still persist contact Morris Material Handling technical services department.
Improve Speed Controller Performance
If Speed Deviation faults (F-152 & F-153) occur after optimization If speed control is sluggish with overshoot and undershoot in speed when loaded Try the following steps in the order in which they appear:
9-23
Revised 6/26/01 1. 2. Redo the speed-controller optimization under loaded conditions Section 9.3.1 steps 9-12. Increase the speed-controller proportional gain, P 235. Increase in 100% increments and retry. (Note: do not increase P235 more than 3 times its original value after optimization) Reduce the speed-controller integral reset time, P240. Reduce by 20% increments and retry. (Note: Do not reduce P240 below a value of 100 milliseconds. (Note: If load is coupled to motor during dynamic stepped speed controller optimiztion (i.d. step 6 on R46890) and speed deviation (F152 - F153 occur, reduce P240 to 100mS and repeat steps 9-12 in section 9.3.1.
3.
Reduce Hoist Roll-back
To reduce Roll-back during release of the holding brake: Try the following steps in the order in which they appear: 1. Increase the speed controller proportional gain, P 235. This will tighten up speed regulator which affect P901.2 Instantaneous Speed Dev. Increase in 100% increments and retry. (Note: do not increase P235 more than 3 times its original value after optimization) 2. Activate the start-pulse by increasing U842. Increase in (0.5 to 1.0%) increments to about 3% then try at no-load. If rollback is worse reduce U842 till improved at loaded and unloaded cases. 3. Reduce the speed-controller integral reset time, P240. Reduce by 20% increments and retry. (Note: Do not reduce P240 below a value of 100 milliseconds.
To reduce Roll-back during the setting of the holding brake:
Try the following steps in the order in which they appear: 1. Increase the brake set time P607. This parameter defaults at 0.5 seconds and can be increased to 1.5 or 2.0 seconds without problems. If sagging is eliminated reduce P607 in 0.1 second increments till sagging reappears then increase 0.1 seconds and leave.
9-24
9.3.3 Notes regarding Automatic Parameterization

The parameters listed the Compendium, includes changeable parameters as well as read-only (visualization) parameters of available induction motors, as well as all possible open-loop and closed-loop control modes (e.g. V/Hz characteristic, speed control and torque control). Unless otherwise specied, all percentage values refer to the reference quantities in P350 to P354. If reference quantities are changed, this will also change the signicance of the parameters with percentage normalization (e.g. P352 = Maximum frequency). Numerous parameters are calculated or set to xed values during automatic parameterization performed in section 9.2.2 thru 9.2.5 (P115 = 1) Most of the important ones are listed in the Table 9-6 below: Table: 9-6 : Parameters adjusted during Automatic Parameterization P068 P095 P100 P116 P117 P120 P121 P122 P127 P128 P130 P151 P161 P215 P216 P217 P223 P235 P236 P240 P258 P259 P273 P274 P278 P279 P283 P284 P287 P291 P293 P295 P303 P306 P313 P315 P316 P319 P322 P325 P326 P334 P335 P336 P337 P339 P340 P344 P347 P348 P357 P383 P388 P392 P396 P400 P452 P453 P457 P467 P471 P525 P536 P602 P603 P605 P606 P607 P611 P616 P617 P618 P804 P811 P901 P905 P915 P916
Automatic parameterization is also carried out by the standstill measurement (P115 = 2) During the standstill measurement (P115 = 2), the following parameters are measured or calculated: P103, P120, P121, P122, P127, P347, & P349. The controller settings resulting from these values are in: P283, P284, P315, & P316.
During the rotating measurement (P115 = 4), P103 and P120 are adjusted. During the n/f (speed or frequency) controller optimization P115 = 5, the parameters P116, P223, P235, P236, P240, & P471 are determined.
9-25
Revised 6/26/01
NOTICE
In principle, the automatic parameterization performed in one of the Sections 9.2.1 thru 9.2.4 (P115 = 1) and/or motor identication Section 9.3.1 (P115 = 2) should be redone as soon as one of the following parameters are adjusted in the converter "Drive setting" menu (P060 = 5): P068 = Output lter P095 = Motor type P097 = Motor number P100 = Control type P101...P109 = Motor rating plate data P339 = Release of modulation system P340 = Pulse frequency P357 = Sampling time Exceptions where this is not necessary are described below: If P068 is only adjusted between 0 and 2 (dv/dt lter). If P340 is adjusted in integer increments, e.g. from 2.5 kHz to 5.0 kHz...etc. If P339 is not set to over-modulated space vector modulation. If P339 = 4 the modulation depth P342 must be additionally set to approximately 90%. If changeover is made between speed and torque control (P100 = 4, 5).
9-26
10
10.1
GENERAL
BUL 425 control and status words

Description of the control word bits
There are two Control Words in BUL 425 inverters. These words each consist of 16 ON-Off state binary bits that control the inverter many aspects of the inverter they include start, stop, enable, etc. See pages 10-9 and 10-10 of this section for a complete listing of these. Statuses or drive condition can be viewed on the display. The operating statuses can be read in visualization parameter r001: e.g. READY TO POWERUP: r001 = 009. The function sequences are described for each bit to follow in the sequence that they actually occur the drive. Statuses are shown in ( ). Function diagram #180 on page 10-9 and #190 on page 10-10 refer to further function diagrams that may be required for information beyond the scope of this manual. The individual bits are further described on the following pages. The state of these bits can be viewed in display parameters r550 & r551
NOTICE
Bit 0: ON/OFF 1 command ( "ON") / (L "OFF1") Condition Result Positive edge change from Low to High (L H) in the READY TO POWER-UP condition (009). PRECHARGING (010) Main contactor or bypass contactor, if available, are switched-in (closed). The DC link is pre-charged. READY (011) If the drive was last powered-down with "OFF2", the next condition is only selected after the de-energization time (P603) has expired since the last shutdown GROUND FAULT TEST (012), only when the ground fault test has been selected (P375). RESTART ON THE FLY (013), if restart on the fly (control word bit 23 via P583) has been enabled. RUN (014). LOW signal and P100 = 3, 4 (closed-loop frequency/speed control) OFF1 (015), if the drive is in a status where the inverter is enabled. For P100 = 3, 4 and slave drive, the system waits until the higher-level open-loop/closed-loop control shuts down the drive. For P100 = 3, 4 and master drive, the setpoint at the ramp-function generator input is inhibited (setpoint = 0), so that the drive decelerates along the parameterized down ramp (P464) to the OFF shutdown frequency (P800). After the OFF delay time (P801) has expired, the inverter pulses are halted, and the main contactor or bypass contactor), if available, are opened. If the OFF1 command is withdrawn again when the drive is ramping-down, (e.g. as the result of an ON command), ramp-down is interrupted, and the drive goes back into the RUN (014) condition.
Condition Result
10-1
Rev 10/20/00
Condition Result
For PRECHARGING (010), READY (011), RESTART-ON-THE-FLY (013) or MOT-ID-STANDSTILL (018), the inverter pulses are inhibited, and the main contactor (option)/bypass contactor, if available, is opened. SWITCH-ON INHIBIT (008); compare status word 1, bit 6 READY-TO-POWER-UP (009), if "OFF2" or "OFF3" are not present. Low signal and P100 = 5 (closed-loop torque control) An OFF2 command (electrical) is executed.
Bit 1: OFF2 command (L "OFF2") electrical Condition Result LOW signal The inverter pulses are inhibited, and the main contactor (option)/bypass contactor, if available, are opened. POWER-ON INHIBIT (008), until the command is removed. The OFF2 command is simultaneously connected from three sources (P555, P556 and P557)!
Note
Bit 2: OFF3 command (L "OFF3") (fast stop) Condition Result LOW signal This command has two possible effects: DC braking is enabled (P395 = 1): DC BRAKING (017) The drive decelerates along the parameterized downramp for OFF3 (P466) until the frequency for the start of DC braking is reached (P398). The inverter pulses are then inhibited for the duration of the deenergization time (P603). After this, the drive DC brakes with an adjustable braking current (P396) for a braking time, which can be, parameterized (P397). The inverter pulses are then inhibited and the main contactor (option)/bypass contactor, if available, is opened. DC braking is not enabled (P395 = 0): The setpoint is inhibited at the ramp-function generator input (setpoint = 0), so that the drive decelerates along the parameterized downramp for OFF3 (P466) to the OFF shutdown frequency (P800). The inverter pulses are inhibited after the OFF delay time (P801) has expired, and the main/bypass contactor, if used, is opened. If the OFF3 command is withdrawn while the drive is decelerating, the drive still continues to accelerate.
10-2
For PRE-CHARGING (010), READY (011), RESTART-ON-THE-FLY (013) or MOT-ID STANDSTILL (018), the inverter pulses are inhibited, and the main/bypass contactor, if used, is opened. If the drive operates as slave drive, when an OFF3 command is issued, it automatically switches-over to the master drive. POWER-ON inhibit (008), until the command is withdrawn. NOTE The OFF3 command is simultaneously effective from three sources (P558, P559 and P560)! Priority of the OFF commands: OFF2 > OFF3 > OFF1 Bit 3: Inverter enable command (H "inverter enable")/(L "inverter inhibit") Condition Result HIGH signal, READY (011) and the de-energization time (P603) has expired since the last time that the drive was shutdown. RUN (014) The inverter pulses are enabled and the setpoint is approached via the ramp-function generator. LOW signal For RESTART-ON-THE-FLY (013), RUN (014), KINETIC BUFFERING with pulse enable, OPTIMIZATION OF THE SPEED CONTROLLER CIRCUIT (019) or SYNCHRONIZATION (020): The drive changes over into the READY (011), condition, and the inverter pulses are inhibited. If OFF1 is active (015), the inverter pulses are inhibited, the main/bypass contactor, if used, is opened, and the drive goes into the POWER-ON INHIBIT (008) condition. If OFF3 is active (016 / fast stop), the inverter inhibit command is ignored, fast stop is continued and, after shutdown (P800, P801), the inverter pulses are inhibited.
Condition Result
Bit 4: Ramp-function generator inhibit command (L "RFG inhibit") Condition Result LOW signal in the RUN (014) condition. The ramp-function generator output is set to setpoint = 0.
Bit 5: Ramp-function generator hold command (L "RFG hold") Condition Result LOW signal in the RUN (014) condition. The actual setpoint is "frozen at the ramp-function generator output".
10-3
Rev 10/20/00
Bit 6: Setpoint enable command (H "setpoint enable") Condition Result HIGH signal and the de-energization time have expired (P602). The setpoint at the ramp-function generator input is enabled.
Bit 7: Acknowledge command ( "Acknowledge") Condition Result Rising (positive) edge change from L to H (L H) in the FAULT condition (007). All of the current faults are deleted after they have been previously transferred into the diagnostics memory. POWER-ON INHIBIT (008), if no actual faults are present. FAULT (007), if there are no faults. The Acknowledge command is simultaneously effective from the three sources (P565, P566 and P567) and always from the PMU!
NOTE
Bit 8: Inching 1 ON command ( "Inching 1 ON") / (L "Inching 1 OFF") Condition Result Positive (rising) edge change from L to H (L H) in the READY TO POWERUP (009) condition. An ON command is automatically executed (refer to control word bit 0), and inching frequency 1 (P448) is enabled in the setpoint channel. The ON/OFF1 command (bit 0) is ignored for active inching operation! The system must wait until the de-energization time (P603) has expired LOW signal An OFF1 command is automatically executed (refer to control word bit 0).
Condition Result
Bit 9: Inching 2 ON command ( "Inching 2 ON") / (L "Inching 2 OFF") Condition Result Rising (positive) edge change from L to H (L H) in the READY TO POWERUP (009) condition. An ON command is automatically executed (refer to control board bit 0), and inching frequency 2 (P449) is enabled in the setpoint channel. The ON/OFF1 command (bit 0) is ignored if inching is active. The system must wait until the de-energization time (P603) has expired. LOW signal An OFF1 command is automatically executed (refer to control word bit 0).
Condition Result
10-4
Bit 10: Control from the PLC command (H "control from the PLC") Condition HIGH signal; the process data PZD (control word, setpoints) are only evaluated if the command has been accepted; this data is sent via the SST1 interface of the CU, the CB/TB interface (option) and the SST/SCB interface (option). If several interfaces are used, only the process data of the interfaces are evaluated, which send an H signal. For an L signal, the last values are received in the appropriate dual port RAM of the interface. An H signal appears in the visualization parameter r550 "control word 1", if one of the interfaces sends an H signal!
Result
NOTE
Bit 11: Clockwise rotating field command (H "clockwise rotating field") Condition Result HIGH signal The setpoint is influenced in conjunction with bit 12 counter-clockwise rotating field.
Bit 12: Counter-clockwise rotating field command (H "counter-clockwise rotating field") Condition Result NOTE HIGH signal The setpoint is influenced in conjunction with bit 11 "clockwise-rotating field". The counter-clockwise rotating field and the clockwise rotating field command have no influence on supplementary setpoint 2, which is added after the ramp-function generator (RFG)!
Bit 13: Command to raise the motorized potentiometer (H "raise motorized potentiometer") Condition Result HIGH signal The motorized potentiometer in the setpoint channel is driven in conjunction with bit 14 "motorized potentiometer, lower".
Bit 14: Command to lower the motorized potentiometer (H "lower motorized potentiometer") Condition Result HIGH signal
The motorized potentiometer in the setpoint channel is driven in conjunction with bit 13 "raise motorized potentiometer". Bit 15: Command external fault 1 (L "External fault 1") Condition Result LOW signal FAULT (007) and fault message (F035). The inverter pulses are inhibited, the main contactor/bypass contactor, if used, is opened.
10-5
Rev 10/20/00
Bit 16: Function data set FDS bit 0 command Result In conjunction with bit 17 "FDS BIT 1" one of the four possible function data sets is energized.
Bit 17: Function data set FDS bit 1 command Result In conjunction with bit 16 "FDS BIT 0" one of the four possible function data sets is energized.
Bit 18: Motor data set, MDS bit 0 command Condition Result READY TO POWER-UP (009), PRE-CHARGING (010) or READY (011) One of the four possible motor data sets is energized in conjunction with bit 19 "MDS BIT 1".
Bit 19: Motor data set, MDS bit 1 command Condition Result READY TO POWER-UP (009), PRE-CHARGING (010) or READY (011) One of the four possible motor data sets is energized in conjunction with bit 18 "MDS BIT 0".
Bit 20: Fixed setpoint FSW bit 0 (LSB) command Result In conjunction with bit 21 "FSW BIT 1", one of the four possible fixed setpoints is energized to input as percentage fixed setpoints, referred to the reference frequency P352 or reference speed P353.
Bit 21: Fixed setpoint FSW bit 1 (MSB) command Result In conjunction with bit 20 "FSW BIT 0" one of the four possible fixed setpoints is energized for input as percentage fixed setpoints, referred to the reference frequency P352 or the reference speed P353.
Bit 22: Synchronizing enable command (H "synchronizing enable") Condition Result For converter synchronization (P534 = 1): HIGH signal, TSY (option) available and P100 = 2 (V/f characteristic for textile applications). For line synchronization (P534 = 2): HIGH signal, TSY (option) P100 = 1, 2 or 3
The command enables the synchronizing function.
10-6
Bit 23: Restart-on-the-fly enable command (H "restart-on-the-fly enable") Condition Result HIGH signal The command enables the restart-on-the-fly function.
Bit 24: Droop/technology controller enable command (H "droop/technology controller enable") Condition Result HIGH signal The command enables the droop function, if P100 (open-loop/closed-loop control type) is assigned 3 (closed-loop frequency control) or 4 (closed-loop speed control), parameter P246 <> 0 and the inverted pulses of the drive converter are enabled. The speed/frequency controller output, fed back as negative signal to the speed/frequency setpoint, can be set via parameter P245 (source steadystate) and P246 (scaling steady-state)
Bit 25: Controller enable command (H "controller enable") Condition Result HIGH signal and the drive converter inverter pulses are enabled. The speed controller output is enabled for the appropriate control type (P100 = 0,4,5).
Bit 26: Command, external fault 2 (L "External fault 2") LOW signal; it is only activated from the READY (011) condition onwards and after an additional time delay of 200 ms. Result FAULT (007) and fault message (F036). The inverter pulses are inhibited, the main contactor, if available, is opened. Bit 27: Slave/master drive command (H "Slave drive")/(L "Master drive") Condition Condition Result HIGH signal, P100 (open-loop/closed-loop control type) = 3, 4 (closed-loop frequency/speed control), and the drive inverter pulses are enabled. Slave drive: The closed-loop control acts as closed-loop torque control (M closed-loop control). With f closed-loop control, precise torque control is not possible until from about 10 % of motor rated speed onwards. LOW signal, P100 (open-loop/closed-loop control type) = 3, 4 (closed-loop frequency/speed control), and the drive converter inverter pulses are enabled. Master drive: The closed-loop control operates as closed-loop speed or frequency control (closed-loop frequency/speed control).
Condition Result
10-7
Rev 10/20/00
Bit 28: Command, external alarm 1 (L "External alarm 1") Condition Result LOW signal The operating status is maintained. An alarm message is issued (A015).
Bit 29: Command, external alarm 2 (L "External alarm 2") Condition Result LOW signal The operating status is maintained. An alarm message is issued (A016).
Bit 30: Select, BICO data sets (H "data set 2") / (L "data set 1") Condition Result Condition Result HIGH signal The parameter settings of data set 2 for all binector and connector commands and signals are activated. LOW signal The parameter settings of data set 1 for all binector and connector commands and signals are activated.
Bit 31: Main contactor checkback signal command (H "main contactor checkback signal") Condition Result HIGH signal, corresponding to the wiring and parameterization of the main contactor (option). The checkback time can be set in P600. Checkback signal, "main contactor energized" (closed).
10-8
n959.25 = 4
15 8 14 13 12 11 10 9
Display of r550 on PMU
Bit No. Src ON/OFF1 Bit 0 0=OFF1, Shutdown via ramp-function generator, followed by pulse disable, 1=ON, operating condition (edge-controlled) 0=OFF2, pulse disable, motor coasts down 1=Operating condition 0=OFF3, quick stop 1=Operating condition 1=Inverter enable, pulse enable 0=Pulse disable 1=Ramp-function generator enable 0=Set ramp-function generator to 0 1=Start ramp-function generator 0=Stop ramp-function generator 1=Setpoint enable 0=Setpoint disable 0 =>1 Edge fault acknowledgement to sequence control 1) to braking control [470.1] to setpoint processing [300.5] P554.B (5/22) B
Meaning
Control word 1 r550 Control word 1 K0030

7 6 5 4
3 2
Src1 OFF2(coast)
P555.B (1/20) B Bit 1
Src2 OFF2(coast)
P556.B (1/1) B
Src3 OFF2(coast) Bit 2 Src InvRelease Bit 3
P557.B (1/1) B P561.B (1/1) B P562.B (1/1) B Bit 4
&
Src RampGen Rel
to sequence control 1) to braking control [470.1] to sequence control 1) to braking control [470.1] to setpoint processing [318.3], [328.3] to sequence control 1)
"Safe OFF" checkback
Src1 OFF3(QStop) P558.B (1/1) B
to setpoint processing [317.6], [327.6] to setpoint processing [317.6], [327.6]
&
Bit 5 Src Setp Release Bit 6 P564.B (1/1) B Bit 7 Src Inching Bit0 Bit 8 1=Inching bit0 P568.B (0/0) B P569.B (0/0) B Bit 9 1=Inching bit1
Src RampGen Stop P563.B (1/1) B
to setpoint processing [317.1], [327.1]
Src1 Fault Reset
P565.B(2107) B
to sequence control 1) to sequence control 1) to setpoint processing [316.1], [318.2], [326.1], [328.2]
Src2 Fault Reset Src Inching Bit1
P566.B (0/0) B
Src3 Fault Reset
P567.B (0/18) B Bit 10 Src FWD Speed Bit 11 P571.B (1/1) B P572.B (1/1) B Bit 12 P573.B (8/0) B P574.B (9/0) B P575.B (1/1) B 1=Control requested 0=No control requested
from PMU [50.7]
1=Clockwise phase sequence enable 0=Clockwise phase sequence disable 1=Counter-clockwise phase sequence enable 0=Counter-clockwise phase sequence disable
to sequence control 1) to setpoint processing [316.1], [318.2], [326.1], [328.2] Note: This bit must be set in the first PZD word of the telegram received from serial interfaces, so that the converter will accept the process data as being valid (compare USS, PROFIBUS, etc.) to setpoint processing [316.4], [326.4]
Src REV Speed Src MOP UP
to setpoint processing [316.4], [326.4]
1) The sequence control is the internal control (software) for realizing the drive status (r001) Src MOP DOWN
Bit 13 1=Raise mot. potentiometer
to setpoint processing [300.1]
Bit 14 1=Lower mot. potentiometer
to setpoint processing [300.1]
Pre-assignment of the BICO parameters: 1. Binector valid for BICO data set 1 2. Binector valid for BICO data set 2 Src No ExtFault1
Bit 15
0=External fault 1 1=No external fault
to sequence control 1) to fault processing
1 Control word 1
8 - 180 -
7 Function diagram MASTERDRIVES VC
10-9
10-10
n959.26 = 4 Bit No. Display of r551 on the PMU
31 30 29 28 27 26 25 24
Rev 10/20/00
Meaning
Control word 2 r551 Control word 2 K0031
Src FuncDSetBit0 Bit 16 Select fixed setpoint bit 0 to data sets [540.4]
P576.B (0/0) B
Src FuncDSetBit1 Bit 17

23 22 21 20 19
P577.B (0/0) B Select fixed setpoint bit 1 to data sets [540.4]
18 17
16
Src MotDSet Bit0 Bit 18 Select motor data set bit 0 to data sets [540.4]
P578.B (0/0) B
Src MotDSet Bit1 Bit 19 Select motor data set bit 1 to data sets [540.4]
P579.B (0/0) B
Src FixSetp Bit0 Bit 20 Select fixed setpoint bit 0 to fixed setpoints [290.6]
P580.B (0/16) B
Src FixSetp Bit1 Bit 21 Select fixed setpoint bit 1 to fixed setpoints [290.6]
P581.B (0/0) B
Src Sync Release Bit 22 1= Enable synchronizing 0=Synchronizing disabled to synchronization [X02] 1=Enable flying restart 0=Flying restart disabled to sequence control 1) 1=Enable droop, speed controller 0=Droop, speed controller disabled 1=Enable speed controller 0=Speed controller disabled 0=External fault 2 1=No external fault 2 0=Master drive (speed control) 1=Slave drive (torque control) 0=External alarm 1 1=No external alarm 1 0=External alarm 2 1=No external alarm 2 0=Select BICO data set 1 1=Select BIC data set 2 0=No checkback, waiting time P600 active 1=Checkback main contactor
P582.B(5002) B
Src Fly Release Bit 23
P583.B (0/0) B
Src Droop Rel Bit 24
P584.B (0/0) B
to speed control [365.7], [367.4]
Src n-Reg Rel Bit 25
P585.B (1/1) B
1
to speed control [360.5], [361.5]
No.n-Reg Rel B0099
Src No ExtFault2 Bit 26
P586.B (1/1) B
to sequence control 1) to fault processing to speed control to fixed setpoints to sequence control 1) to alarm processing to sequence control 1) to alarm processing to data sets [540.4] Separate function diagrams are available for master and slave drive control! 1) The sequence control is the internal control (software) for realizing the drive status (r001).
Src Master/Slave Bit 27
P587.B (0/0) B
Src No Ext Warn1 Bit 28
P588.B (1/1) B
Src No Ext Warn2 Bit 29
P589.B (1/1) B
Src BICO DSet Bit 30
P590.B (14) B
Pre-assignment of the BICO parameters: 1. Binector valid for BICO data set 1 2. Binector valid for BICO data set 2
Src ContactorMsg Bit 31
P591.B (0/0) B
to sequence control 1)
1 Control word 2
8 - 190 -
10.2
GENERAL
Description of the status word bits

There are two Status Words in BUL 425 inverters. These words each consist of 16 ON-Off state binary bits that display the status of many aspects of the inverter they include fault, alarm, contactor energized, pre-charging bus, ready for run, etc. See pages 10-17 and 10-18 of this section for a complete listing of these. The drive uses these statuses to know what state it is in and what it can do etc. Likewise they can be useful to servicing personnel in diagnosing problems with the drive. The operating statuses can be read in visualization parameter r001: e.g. READY TO POWER-UP: r001 = 009. The function sequences are described for each bit to follow in the sequence that they actually occur the drive. Statuses are shown in ( ). Function diagram #200 on page 10-17 and #220 on page 10-18 refer to further function diagrams that may be required for information beyond the scope of this manual. The individual bits are further described on the following pages. The state of these bits can be viewed in display parameters r552 & r553
NOTICE
Bit 0: Message, "Ready to power-up" (H) HIGH signal Significance POWER-ON INHIBIT (008) or READY TO POWER-UP (009) status The power supply, the open- and closed-loop control is operational. The inverter pulses are inhibited. If an external power supply and a main contactor (option)/bypass contactor are available, it is possible to bring the DC link into a no-voltage condition, when the drive converter is in this status!
Bit 1: Message, "Ready" (H) HIGH signal Significance PRE-CHARGING (010) or READY (011) status The power supply, the open-loop and the closed-loop control are operational. The unit is powered-up. Pre-charging has been completed. The DC link has been ramped-up to the full voltage. The inverter pulses are still inhibited.
Bit 2: Message, "Run" (H) HIGH signal Significance RESTART-ON-THE-FLY (013), RUN (014), OFF1 (015) or OFF3 (016) The unit is functioning. The inverter pulses are enabled. The output terminals are live.
10-11
Rev 10/20/00
Bit 3: Message "Fault" (H) HIGH signal Significance Fault (007) status A fault has occurred.
Bit 4: Message "OFF2" (L) LOW signal Significance OFF2 command available The OFF2 command was output (control word bit 1).
Bit 5: Message "OFF3" (L) LOW signal Significance OFF3 (016) status, and/or OFF3 command available The OFF3 command was output (control word bit 2).
Bit 6: Message "Power-on inhibit" (H) HIGH signal Significance POWER-ON INHIBIT (008) status The power supply, open-loop and closed-loop control are operational. If an external power supply and a main contactor (option)/bypass contactor are available, it is possible to bring the DC link voltage in this drive converter status into a no-voltage condition! The message is available as long as an OFF2 command is present via control word bit 1 or an OFF3 command is available via control word bit 2 after the setpoint has been ramped-down, or an ON command is available via control word bit 0 (edge evaluation).
Bit 7: Message, "Alarm" (H) HIGH signal Significance Alarm (Axxx) An alarm has been issued. The signal is present until the cause has been resolved.
Bit 8: Message "Setpoint-actual value deviation" (L) LOW signal Significance Alarm, Setpoint-actual value deviation (A034) The frequency actual value deviates from the frequency setpoint (reference value, by a value, which exceeds P794 (setpoint-actual value deviation, frequency), for a time, which is longer than P792 (setpoint-actual value deviation time). The bit is again set as H signal, if the deviation is less than parameter value P792.
Bit 9: Message "PZD control requested" (H) HIGH signal Still present.
10-12
Bit 10: Message, "Comparison frequency reached" (H) HIGH signal Significance The parameterized comparison frequency has been reached. The absolute frequency actual value is greater than or equal to the parameterized comparison frequency (P796). The bit is again set to L signal, as soon as the absolute value of the comparison frequency (P796), minus the parameterized comparison frequency hysteresis (P797 as %, referred to the comparison frequency (P796)) is fallen below.
Bit 11: Message "Fault, undervoltage" (H) HIGH signal Significance "Undervoltage in the DC link" fault (F008) The DC link voltage has fallen below the permissible limit value. Refer to the Section "Fault- and alarm messages"
Bit 12: Message "Main contactor energized" (H) HIGH signal Significance The main contactor (AC unit)/precharging contactor (DC unit) (option) is operated. The main contactor/precharging contactor (option) can be driven with the appropriate wiring and parameterization.
Bit 13: Message "RFG active" (H) HIGH signal Significance Ramp-function generator active The ramp-function generator output (r480 / KK0073) is not equal to the rampfunction generator input (r460 / KK0072). A hysteresis, which can be parameterized (P476 as %, referred to the rated system frequency P352), can only be taken into account for an analog setpoint input. When the synchronizing function is selected, alarm A069 is initiated, as long as the ramp-function generator is active in the setpoint channel of the synchronizing converter. The synchronizing operation is not started as long as the ramp-function generator is active.
Bit 14: Message, "Clockwise rotating field" (H)/ "Counter-clockwise rotating field" (L) HIGH signal Significance LOW signal Significance Clockwise rotating field The frequency setpoint for the closed-loop control (speed/frequency setpoint, r482 / KK0075) is greater than or equal to 0. Counter-clockwise rotating field The frequency setpoint for the closed-loop control (speed/frequency setpoint, r482 / KK0075) is less than 0.
10-13
Rev 10/20/00
Bit 15: Message "KIP/FLN active" (H) HIGH signal Significance The kinetic buffering (KIP) function or flexible response (FLN) is active. KIP: A brief power failure is bypassed using the kinetic energy of the connected load. FLN: The converter can be operated up to a minimum DC link voltage of 50% of the rated value.
Bit 16: Message "Restart-on-the-fly active" (H) HIGH signal Significance The restart-on-the-fly function is active, or the excitation time (P602) is running. The drive converter is switched to a motor that is still rotating. Overcurrent is prevented as a result of the restart-on-the-fly function. The excitation time (magnetization time) is active.
Bit 17: Message "Synchronism has been reached" (H) HIGH signal Significance Prerequisite Synchronism has been reached. Synchronism has been reached. TSY (option) available and P100 (open-loop/closed-loop control type) = 2 (V/f characteristic for textile applications) or P100 = 1, 2, 3 at line synchronism (P534 = 2).
Bit 18: Message "Overspeed" (L) LOW signal Significance Alarm "Overspeed" (A033) The frequency actual value is either: greater than the maximum frequency for the clockwise rotating field (P452) plus a hysteresis (P804 as %, referred to P452) or less than the maximum frequency for the counter-clockwise rotating field (P453) plus a hysteresis (P804 as %, referred to P453). The bit is again set to an H signal as soon as the absolute value of the frequency actual value is less than or equal to the absolute value of the appropriate maximum frequency.
Bit 19: Message External fault 1 (H) HIGH signal Significance "External fault 1" A "External fault 1" is present in control word, bit 15.
Output at the terminal strip (PEU, CUVC, TSY, SCI1/2, EB1, EB2) with L signal.
Bit 20: Message "External fault 2" (H) HIGH signal Significance "External fault 2" A "External fault 2" is present in control word bit 26.
10-14
Bit 21: Message "External alarm" (H) HIGH signal Significance "External alarm" An "external alarm 1" is present in control word bit 28, or, "external alarm 2" in control word bit 29.
Bit 22: Message "Alarm i2t drive converter" (H) HIGH signal Significance Alarm "i2t alarm, inverter" (A025) If the instantaneous load status is maintained, then the drive converter will be thermally overloaded.
Bit 23: Message "Fault, converter overtemperature" (H) HIGH signal Significance "Inverter temperature too high" fault (F023) The limiting inverter temperature has been exceeded.
Bit 24: Message "Alarm, converter overtemperature" (H) HIGH signal Significance Alarm, "inverter temperature too high" (A022) The inverter temperature threshold to release an alarm has been exceeded.
Bit 25: Message "Alarm, motor overtemperature" (H) HIGH signal Significance Alarm Motor overtemperature it involves an I2t alarm, motor (A029) or an overtemperature alarm from the KTY (P380 > 1) or PTC thermistor (P380 = 1). The alarms initiated either by calculating the motor load (r008 / K0244) or from the KTY84 sensor (r009 / K0245). Parameters involved in the calculation: P380 (mot. temp. alarm), P382 (motor cooling), P383 (mot. temp.T1), P384 (mot. load limit).
10-15
Rev 10/20/00
Bit 26: Message "Fault, motor overtemperature" (H) HIGH signal Significance Fault, "Motor overtemperature" It involves an "I2t fault, motor" (F021) or an overtemperature fault, from KTY (P381 > 1) or PTC thermistor (P381 = 1).
Bit 27: Reserve
Bit 28: Message, "Fault, motor stalled/locked" (H) HIGH signal Significance Precondition Fault, Motor stalled or blocked (F015) The drive has either stalled or is locked. Blocking recognition at P100 = 3, 4 f/n control: setpoint/actual value deviation has occurred (bit 8), torque limit (B0234) reached, speed < 2 % and time in P805 expired In the case of M control (P100 = 5) or slave drive (P587), blocking is not recognized.
Bit 29: Message "Bypass contactor energized" (H) HIGH signal Significance The bypass contactor is energized after precharging has ended (applies only to AC units equipped with bypass contactor). A bypass contactor (option) can be energized with the appropriate wiring and parameterization.
Bit 30: Message "Alarm sync. error" (H) HIGH signal Significance Prerequisite Alarm, "Synchronizing error" (A070) After successful synchronization, the phase deviation is greater than the parameterized tolerance range (P531). TSY (option) available and P100 (open-loop/closed-loop control type) = 2 (V/f characteristic for textile applications) or P100 = 1, 2, 3 at line synchronism (P534 = 2).
Bit 31: Message "Pre-charging active" (H) HIGH signal Significance PRE-CHARGING (010) condition Pre-charging is realized after an ON command.
10-16
n959.27 = 4
Display of r552 on the PMU

15 14 13 12 11 10 9 8
Bit No.
Meaning
Status word 1 r552 Status word 1 K0032
from sequence control 1) B0100 Rdy for ON
Bit 0
1=Ready to switch on 0=Not ready to switch on B0101

7 6 5 4
1
Not Rdy for ON
3
from sequence control 1) B0102 Rdy for Oper
Bit 1
1=Ready for operation (DC link loaded, pulses disabled) 0=Not ready for operation
1
B0103 NotRdy for Oper
2 1
from sequence control 1) B0104 Operation
Bit 2
1=Run (voltage at output terminals) 0=Pulses disabled
1
B0105 Not operating
1) The sequence control is the internal control (software) for realizing the drive status (r001).
from sequence control 1) B0106 Fault
Bit 3
1=Fault active (pulses disabled) 0=No fault
1
B0107 No fault
from sequence control 1) B0108 No OFF2
Bit 4
0=OFF2 active 1=No OFF2
1
B0109 OFF2
from sequence control 1) B0110 No OFF3
Bit 5
0=OFF3 active 1=No OFF3
1
B0111 OFF3
from sequence control 1) B0112 Blocked
Bit 6
1=Switch-on inhibit 0=No switch-on inhibit (possible to switch on)
1
B0113
Not blocked
from alarm processing B0114 Alarm
Bit 7
1=Warning active 0=No warning
1
B0115
No alarm
from messages [480.7] B0116 No Deviation
Bit 8
1=No setpoint/actual value deviation detected 0=Setpoint/actual value deviation
B0117
Deviation
from sequence control 1)
Bit 9
1=PZD control requested (always 1)
from messages [480.7] B0120
Bit 10
1=Comparison value reached 0=Comparison value not reached 1=Low voltage fault 0=No low voltge fault 1=Request to energize main contactor 0=No request to energize main contactor 1=Ramp-function generator active 0=Ramp-function generator not active 1=Positive speed setpoint 0=Negative speed setpoint 1=Kinetic buffering/flexible response active 0=Kinetic buffering/flexible response inactive
1
CompV OK
B0121
CompV not OK
from fault processing
Bit 11
1
B0122 Low Voltage
B0123
No Low Voltage
Bit 12
1
B0124 Energize MCon
B0125
N.Energ.MCon
from setpoint processing [317.8], [327.8] Bit 13 Bit 14
1
B0126
B0127 RampGen active
RampGen n.act.
from messages [480.7]
1
B0128
B0129 Speed Setp FWD
Speed Setp REV
From KIB/FLR control [600.8], [605.8] Bit 15
1
B0130 KIB/FLR active
B0131
KIB/FLR n.active
1 Status word 1
8 - 200 -
10-17
10-18
n959.28 = 4 Display of r553 on the PMU
31 30 29 28 27 26 25 24
Rev 10/20/00
Bit No.
Meaning
Status word 2 r553 Status word 2 K0033
from sequence control 1) B0132 Fly/Exc active
Bit 16
1=Flying restart or excitation active 0=Flying restart not active or excitation finished B0133
23 22 21 20 19
Fly/Exc n.act. 2)
18 17 16
from synchronization [X01.6] B0134 Sync reached
Bit 17
1=Synchronism achieved 0=Synchronism not achieved
1
B0135 Sync n.reached
from messages [480.7] B0136 Overspeed
Bit 18
0=Overspeed 1=No overspeed
1
B0137 No Overspeed
1) The sequence control is the internal control (software) for realizing the drive status (r001).
from sequence control 1) B0138 Ext Fault 1
Bit 19
1=External fault 1 active 0=No external fault 1
1
B0139 No Ext Fault 1
from sequence control 1) B0140 Ext Fault 2
1=External fault 2 active Bit 20 0=No external fault 2
1
B0141 No Ext Fault 2
2) in addition ExcitationEnd B0255
from sequence control 1) B0142 Ext Warning
1=External warning active Bit 21 0=No external warning
1
B0143
No Ext Warning
from alarm processing B0144 Ovld Warn Drive
Bit 22
1=Converter overload warning active 0=No converter overload warning
1
B0145
No OvldWarn Drv
from fault processing B0146 Tmp Flt Drive
Bit 23
1=Converter overtemperature fault active 0=No converter overtemperature fault
1 1
B0148 TmpWarn Drive
B0147
No Tmp Flt Drv
from alarm processing
Bit 24
1=Converter overtemperature warning active 0=No converter overtemperature warning 1=Motor overtemperature warning active 0=No motor overtemperature warning
B0149
No TmpWarn Drv
from alarm processing B0150
Bit 25
1
TmpWarnMotor
B0151
No TmpWarnMotor
from fault processing B0152
Bit 26
1=Motor overtemperature fault active O=No motor overtemperature fault
1
TmpFltMotor
B0153
No TmpFltMotor
Bit 27 Reserve
from block/pullout diagnosis [485.8] Bit 28 Bit 29 1=Bypass contactor energized (only AC units) 0=Bypass contactor not energized 1=Fault during synchronization 0=No fault during synchronization 1=Pre-charging active 0=Pre-charging not active
1=Motor pulled out/blocked fault active 0=No motor pulled out/blocked fault
1
B0156 Motor PullOut
B0157
No MotorPullOut
1
B0158 ChrgRelay close
B0159
ChrgRelay open
from synchronization [X01.6]
Bit 30
1
B0160 Sync Fault
B0161
No Sync Fault
Bit 31
1
B0162 Prechrg active
B0163
Prechrg n.act.
1 Status word 2
8 - 210 -
11
WARNING
Maintenance
BUL 425 inverter drives are operated at high voltages. All work carried out on or with the equipment must conform to all national and local electrical codes. Qualified personnel should only do maintenance and service work. Only spare parts authorized by the manufacturer should be used. The prescribed maintenance intervals and also the instructions for repair and replacement must be complied with. Hazardous voltages are still present in the drive units up to 5 minutes after the converter has been powered down due to the DC link capacitors. Thus, the unit or the DC link terminals must not be worked on until at least after this delay time. The power terminals and control terminals can still be at hazardous voltage levels even when the motor is stationary. If it is absolutely necessary that the drive converter be worked on when powered-up: Never touch any live parts. Always stand on an ungrounded, isolated, and ESD-compatible pad. If these warnings are not observed, this can result in death, severe bodily injury or significant material damage.
BUL 425 should be periodically inspected as follows 1. 2. Disconnect, lock out, and tag the power source that feeds the equipment being serviced. Wait until the charge lamp is out before proceeding. After removing power, allow at least five minutes to pass and verify that the dc bus capacitors have discharged to a safe level (below 50Vdc) before contacting internal components. Connect a dc voltmeter across the dc bus+ and - terminals. Start with the meter on the highest scale and progressively switch to a lower scale as the indicated voltage falls below the maximum value of the scale used. Whenever possible, never work on "live" equipment alone. Assure that all external terminals, connectors, and fasteners are secure. Compressed air can cause debris to float in the air, and can cause injury to the face or eye. Be sure that you are wearing appropriate face and eye protection. Using dry compressed air (not exceeding 85 psi), remove buildup of dust and dirt from the cooling fins and power elements. Printed circuit cards use surface-mounted components. Check printed circuit boards, capacitors, and other electrical components for discoloration that may indicate impending failure. Check the cooling fans for foreign matter, undue noise, or abnormal vibration. As a guide, it is recommended that fans be replaced every 20,000 hours. Inspect and change/wash any air filter in a detergent solution every 3 to 6 months, or whenever half the effective area is clogged. Clean electrical components (thyristors, resistors, diodes, transistors, etc.) using a suction-type device. Compressed air aimed at components on PC boards can dislodge components. Avoid aiming compressed air at PC boards and wear face and eye protection or serious injury to the eyes or face could result from flying particles.
3.
4. 5. 6. 7. 8.
WARNING
11-1
Rev 10/20/00
11.1
Replacing the fan

BUL 25 units include cooling fans that are designed for an L 10 operating time 35 000 hours at an ambient temperature of Tu = 40 C. These fans should be replaced in good time to avoid costly downtime of the unit.
Fan assemblies for frame sizes A, B, and C only
The units have a fan which operates as soon as the unit is connected to the voltage supply. The fan is located on the bottom of the unit. Replace the fan as follows: Undo the two M4x49 Torx screws Pull out the protective cover together with the fan from underneath Withdraw fan connector X20 Install the fan in reverse sequence.
X20
M4 x 49 Torx T20 and spring washer
Protective cover M4 x 49 / Torx T20 and spring washer Figure 11-1
Fan E1
Cover and fan for housing size A to C
Fan assembly for frame size D
The fan is screwed onto a bracket and is located at the bottom section of the unit. Replace the fan as follows: Withdraw fan connector X20. Unscrew the two M5x16 Torx screws at the bottom of the unit. Pull the bracket out of the unit from underneath. Unscrew the M4 fan screws. Install the fan in reverse sequence.
11-2
Fan
M4 screw (Torx T20)
Captive washer
Bracket Washer Spring washer M5x16 Torx T25 Washer Spring washer M5x16 Torx T25
Figure 11-2
Fan with bracket for housing size D
Replacing the fan fuse frame size D
The fuses are located in the upper section of the unit in a fuse holder. You have to open the fuse holder to replace the fuses.
Fuse link
Fuse holder closed Figure 11-3
Fuse holder open Fuse holder for housing size D
Fan assemblies for The fan assembly consists of: frame sizes E, F, & G the fan housing a fan The fan assembly is installed between the capacitor battery and the motor connection. Withdraw connector X20. Remove the cable fastening. Undo the two M6x12 Torx screws. Pull out the fan assembly towards the front. Install the new fan assembly in reverse sequence.
Replacement
11-3
Rev 10/20/00
Prior to start-up, check that the fan can run freely and check for correct direction of airflow. The air must be blown upwards out of the unit.
Torx M6x12 Torx M6x12
Fan
Figure 11-4
Fan housing
Fan assembly
Fan assembly for frame size K
The fan assembly consists of: the fan housing the fan The fan assembly is installed at the top of the chassis. Withdraw connector X20. Undo the two M8 screws of the fan assembly. Pull out the fan assembly towards the front (if necessary, tilt it slightly downwards at the front) and lay it down safely.
CAUTION
The fan assembly weighs up to 80 lbs. depending on its design.
11-4
Undo the cable fastenings and fan connections. Take the fan support plate out of the fan assembly and remove the fan from the support plate. Install the new fan assembly in the reverse sequence. Prior to start-up, check that the fan can run freely and check for correct direction of airflow. The air must be blown upwards out of the unit. The direction of rotation is counter-clockwise when seen from above.
Figure 11-5
Fan assembly -E1, fan transformer primary fuse, starting capacitor -C110
11.2
Replacing the fan fuse frame size K

The fuses are located in a fuse-holder, which is mounted on a DIN rail in the bottom of the unit. The fuse holder has to be opened to replace the fuses.
11-5
Rev 10/20/00
11.3
Replacing the fan transformer fuses F3 & F4 (frame size K)

The fan fuses F-3 & F-4 are in a fuse holder located below the fan in front of the air baffle plate. To replace the fuses, the fuse holder has to be opened.
Figure 11-6
Fan transformer (-T10), fan transformer fuses (-F3, -F4)
11.4
Replacing the fan transformer
Frame sizes E, F & G The fan transformer is screwed on behind the motor connection. Frame size K Mark the connecting cables on the transformer and disconnect them. Undo the screw connections at the bottom on the transformer plate and remove the transformer. (In frame size K secure the transformer against falling down!) Install the new transformer in the reverse sequence.
11-6
11.5
Replacing the starting capacitor

The starting capacitor is situated: next to the fan connection (frames E, F, & G) located inside the fan housing (frame K, -C110). To replace: Withdraw the plug connections on the starting capacitor. Unscrew the starting capacitor. Install the new starting capacitor in reverse sequence.
11.6
Replacing the capacitor battery

The capacitor battery is an assembly that consists several DC link capacitors, the capacitor support, and the DC bus link module. To remove:
Frame sizes E and F
Disconnect the electrical connection to the inverter bus module. Undo the mechanical interlock. Swing the capacitor battery out towards the front and lift the unit out towards the top. Remove the connection for the balancing resistor (cable lug M6). Detach the mechanical fastening. Swing the capacitor battery out towards the front and lift the unit at an angle of 45 out of the converter. The capacitor battery consists of three modules. Each module has a capacitor support and a DC link bus module. Withdraw the plug connections. Detach the mechanical fastening (four screws: two on the left, two on the right). Swing the capacitor battery out as far as it will go, slightly raise the unit and pull it forwards out of the converter.
Frame size G
Frame size K
CAUTION
The capacitor battery weighs up to 15 kg, depending on the converter output!
11-7
Rev 10/20/00
11.7
Replacing the SML and the SMU

SML: Snubber Module Lower SMU: Snubber Module Upper Remove the capacitor battery. Undo the fixing screws (4 x M8, 6 - 8 ft-lbs. or 4 x M6, 2 - 4 ft-lbs., 1 x M4, max 1.25 ft-lbs.). Remove the modules. Install the new modules in the reverse sequence.
11.8
Removal
Removing and installing the module busbars (frame size G)

Remove the capacitor battery. Undo the screws of the module busbars. M8 power connections M6 fastening on spacers M4 circuit. Take out the insulation of the SMU / SML. Lift out the module busbars. The spacing between the plus busbar and the minus busbar must be at least 4 mm. In order to install the module busbars, you must therefore use a template, e.g. a 4 mm thick piece of plastic. Place the module busbars and SMU/SML insulation on spacer bolts and fix in place (M6). Place the template instead of the DC link bus module in the module busbars. Locate the SMU and SML and tighten the modular connections (M8, 6 8 ftlbs., M6, 2 - 4 ft-lbs.). Screw the nuts tight on the spacer bolts (5 ft-lbs.). Connect the circuit resistors (M4, 1.25 ft-lbs.) Tighten the power connections (M8, 10 ft-lbs.) Remove the template from the module busbars.
Template 4 mm
Installation NOTE
Module screw connection +
Module screw connection
4
Figure 11-7 Installing the module busbars
11-8
11.9
Replacing the balancing resistor

The balancing resistor is situated in the rear installation level on the heat sink between the inverter modules, i.e. behind the capacitor battery and the module busbars. Remove the capacitor battery. Remove the module busbars and the IGD module. Undo the fixing screws and take out the balancing resistor. Install the new component in reverse sequence. The balancing resistor is tightened with 1. Ft-lbs. Coat the base plate evenly and thinly with a thermo-lubricant, paying attention to correct contact assignment.
11.10
Replacing the PCU (frame sizes E, F, & G)

To replace the Pre-Charge Unit or PCU: Withdraw connector X39. Remove the screws at the bus connection U1/L1, V1/L2, W1/L3, C, D, and PE1. Unlock the spacers and take out the PCU. Install the new PCU in the reverse sequence. Take out the PCC unit. Withdraw connector X39. Remove the screws at the bus connection U1/L1, V1/L2, W1/L3, C, D, and PE1. Unlock the spacers and take out the PCU. Install the new PCU in the reverse sequence.
Frame sizes E and F
Frame size G
11.11
Replacing the PCC (Frame sizes E, F, & G)

To replace the Precharge Control Circuit or PCC: Take out the PCU (frame sizes E and F). Withdraw connector X11, X12, X13 and X246 on the PCC. Disconnect the NUD cable. Remove the fixing screws of the PCC unit.
Unlock the spacers and take out the PCC. Install the new PCC in the reverse sequence.
11-9
Rev 10/20/00
11.12
Replacing the rectifier module

Remove the PCC and the PCU. Dismantle the input bus module and the rectifier bus module. Undo the screws of the faulty module and remove it. Remove the PCC together with the support plate Remove the PCU, PSU and the electronics box. Dismantle the input bus module and the rectifier bus module. Install the new PCU in the reverse sequence. Coat the contact surfaces of the heat sink thinly and evenly with a thermolubricant.
Removal Frame sizes E and F Frame size G
Installation
Tighten the fixing screws of the rectifier module with 3 ft-lbs. Re-install the remaining components in the reverse sequence.
11.13
Replacing the IVI

To replace the Inverter-Value Interface IVI: (interface board for the power section). The IVI board is screwed on at the rear of the electronics box.
Frame sizes E, F & G Withdraw the connections X205, X206, X208, X31 and X33 from the IVI board. Remove the capacitor battery (frame sizes E and F). Disconnect the fiber-optic cables (frame size G with rated input voltage of 3 phase AC 660 - 690 V or DC 890 - 930 V). Remove the PSU together with its insulation (frame size G) Take all the units out of the electronics box and place them on a suitable surface that is not statically charged. Undo the two fixing screws of the electronics box. Push the electronics box out of its interlock and remove it towards the front. Pull out the ABO adaption board. Unscrew the IVI board and take it out. Install the new IVI in reverse sequence.
11-10
Frame size K
Unscrew the two screws of the electronics slide-in unit and pull it out to its end-stops. Disconnect the ground cable of the electronics slide-in unit. Remove all boards from the electronics box and place them on a suitable surface that cannot be statically charged. Unscrew the two fixing screws of the electronics box. Push the electronics box out of its interlock and take it out towards the front. Pull out the ABO Adaption Board. Disconnect the fiber-optic cables.
Unscrew the IVI board and take it out. Install the new IVI in the reverse sequence.
11.14
Replacing the VDU and the VDU resistor

To replace the Voltage-Dividing Unit or VDU: The VDU and the VDU resistor are only found on converters with higher supply voltages. The VDU bracket is an integral component of the electronics slide-in unit. Detach the plug-in connections. Undo the fixing screw Take out the VDU. Install the new VDU in the reverse sequence. Unscrew the cable fasteners. Detach the plug-in connections. Take out the VDU resistor.
VDU
VDU resistor
Install the new VDU resistor in the reverse sequence.
11-11
Rev 10/20/00
11.15
Replacing the PSU
To replace the Power Supply Unit or PSU: Frame sizes E, F & G Withdraw connectors X18, X258 and X70. Remove the Torx screw with ground connection from the side panel. Push the PSU out of its locking pins and take it out sideways and towards the front of the unit, under the input bus. Install the new PSU in the reverse sequence. Remove the VDU and the VDU resistor (if present). Remove the VDU retainer plate. Detach the plug-in connections on the PSU. Undo the screws (six Torx M4 screws) on the PSU. Take out the PSU. Install the new PSU in the reverse sequence.
Frame size K
11.16
Replacing the IGD

To replace the IGBT Gate Driver or IGD: The IGD board is mounted directly on the IGBT modules. Take out the capacitor battery. Remove the electronics box with IVI board for frame size E. Mark the output wiring U2/T1, V2/T2 and W2/T3 and disconnect it. Remove the inverter bus module after unscrewing the twelve M6 screws. Withdraw connector X295.
Frame sizes E and F
Frame size G
Undo the fixing screws and remove the IGD board. The IGD board is mounted directly on the IGBT modules. Take out the capacitor battery. Remove the SML and SMU modules. Remove the module busbars. Remove the fiber-optic cables or connector X295. Withdraw connectors X290 and X291. Undo the fixing screws and remove the IGD board.
NOTE
The spacing between the plus busbar and the minus busbar must be at least 4 mm. In order to install the module busbars, you must therefore use a template, e.g. a 4 mm thick piece of plastic.
11-12
Frame size K
The IGD board is situated behind the module busbars. Take out the capacitor battery. Take out the SML and SMU modules. Remove the module busbars. Remove the nine fiber-optic cables at the top of the IGD. Withdraw the P15 feeder cable.
Undo the fixing screws and remove the IGD board. Install the new IGD in the reverse sequence. Make sure when doing so that you push in the fiber-optic cables up to the endstop.
11.17
Replacing the TDB (frame size K)

To replace the Thyristor Driver Board TDB: The TDB is arranged in front of the thyristor modules. These are situated in the rectifier section between the fan assembly and the inverter. Remove the cover (undo screws, then first of all detach the right-hand snap hook, and then the left-hand snap hook) Withdraw connectors X246, X11, X12 and X13. Disconnect the PUD and NUD connections of the pre-charging resistors R1 nd R2 (M4, Torx). Disconnect the connections to phases U, V, W. Disconnect the NUD1, NUD2, and NUD3 connections. Remove the TDB board. Install the new TDB in the reverse sequence. See figure under section "Replacing the thyristor modules"
11-13
Rev 10/20/00
11.18
Replacing the IGBT module

It is possible to check the power transistors in circuit. Each transistor has a back-diode in parallel across its collector emitter circuit. Since these diodes usually fail with the power transistor device itself, a good diode usually means a good transistor. Using a diode junction tester with (-probe) on term C and (+probe) to : T1, T2, and T3 (terminals to motor) should read 0.3V forward conduction voltage to all three terminals. Using a diode junction tester with (+probe) on term D and (-probe) to : T1, T2, and T3 (terminals to motor) should read 0.3V forward conduction voltage to all three terminals. Replacement is carried out as in the case of the IGD board, with the following additions: Remove the fixing screws of the faulty IGBT module and take it out. Install a new IGBT module, paying attention to the following: Coat the contact surfaces thinly and evenly with a thermo-lubricant. Tighten the fixing screws of the IGBT module to 4 ft-lbs., observing the sequence of tightening in Figure 11-8 below. Modules with the same type designation e.g. FZxxxxRYYKF4 must be installed in every phase (frame size K).
3 C E 6
In Circuit testing of IGBTs
Replacing IGBT modules
Screw on IGBT module: 1. Hand-tighten (~ 0.5 Nm) Sequence 1 - 2 - 3 - 4 - 5 - 6 2. Tighten with 5 Nm (Order No. 6SE7031-8EF60: 2.5 - 3.5 Nm) Sequence 1 - 2 - 3 - 4 - 5 - 6 Figure 11-8 Screwing on the IGBT module
11-14
11.19
Replacing the thyristor modules (V1 to V3, frame size K)

Replacement as in the case of the TDB, with the following additions: Disconnect the supply cables C+ D of the option terminals Disconnect the connection of the C and D bars between the rectifier and the inverter. Disconnect the connections U, V, W of the modules. Disconnect the connections between modules and C(+) bar. Remove the connecting bar C(+). Disconnect the connections between modules and D() bar. Remove the connecting bar D(). Undo the module fixing screws (M6, Torx). Remove the module (weight approx. 1.1 lbs). Clean the contact surface. Coat the new modules thinly and evenly with a thermo-lubricant and mount them. Tightening torque of the fixing screws: 4 ft-lbs. 15 %. Further installation is performed in the reverse sequence. Tightening torque of the electrical connections (C and D): 9 ft-lbs. (+ 5 %, 10 %).
Figure 11-9
TDB board, pre-charging resistors and thyristor modules V1, V2, V3
11-15
Rev 10/20/00
11.20
Replacing the PMU

To replace the Paramterizing Metering unit or PMU: Turn the snaps on the front cover by 90 Open up the front cover Withdraw connector X108 on the CU (Control Unit) Remove ribbon cable from the guide hooks Carefully press the snap catches upwards on the inner side of the front cover using a screwdriver Tilt the PMU and remove it Install new PMU in reverse sequence.
Frame sizes A, B, C &D
Rear side of the front cover
Snap catches PMU-board
Figure 11-10
Replacing the PMU on Frame sizes A, B , C , & D
Frame sizes E, F, G, &K
To replace the PMU on frames E, F ,G , & K Remove the ground cable on the side panel. Carefully press the snap catches on the adapter section together, remove the PMU with adapter section from the electronics box. Withdraw connector X108 on the CUx board. Carefully lift forward the PMU out of the adapter section using a screwdriver. Install the new PMU in the reverse sequence.
11-16
Adapter section PMU Snap catches
E-box
Figure 11-11
PMU with adapter section on frames E, F, G, & K
11-17
Rev 10/20/00
11.21
Replacing the pre-charging resistors (R1 - R4, Frame K)

These are situated on the right next to the TDB board in the rectifier section. Remove the cover (undo screws, then detach first the right-hand snap catch and then the left-hand snap catch). Disconnect the PUD and the NUD connections of the pre-charging resistors R1 - R4 (M4, Torx). Detach the pre-charging resistors and take them out. Install the new pre-charging resistor with torque of 15 ft-lbs. 10 %.
CAUTION
Do NOT tilt the pre-charging resistor!
Mount the fastenings and the connections in the reverse sequence. See figure under section "Replacing the thyristor modules"
11.22
Frame size K
Replacing the circuit resistor

Take out the capacitor battery. Take out the SML and SMU modules. Remove the module busbars. Undo the fixing screws (2 x M5, torque: max. 1.8 Nm) and take out the circuit resistor. The new resistor must be thinly and uniformly rolled in a thermo-lubricant. Max. torque of the electrical connections: 1.8 Nm. Install the new circuit in the reverse sequence.
11-18
12
Forming
If the BUL 425 inverter has been non-operational for more than one year, the DC link capacitors have to be newly formed. If this is not carried out, the unit can be damaged when the line voltage is powered up. If the BUL 425 inverter was started-up within one year after having been manufactured, the DC link capacitors do not have to be re-formed. The date of manufacture of the unit can be read from the serial number. (Example: A-L60147512345)
Digit 1 and 2 3 Example AL M N O 4 1 to 9 O N D 5 to 14 Meaning Place of manufacture 1999 2000 2001 2002 January to September October November December Not relevant for forming
How the serial number is made up to determine date of manufacture.
The following applies for the above example: Manufacture took place in June 1999. During forming, the DC link of the unit is connected up via a rectifier, a smoothing capacitor and a resistor. As a result, the DC link capacitors receive a defined voltage and a limited current, and the internal conditions necessary for the function of the DC link capacitors are restored.
3AC
A
Forming
C / L+ Disconnect
U1/L1 V1/L2 W1/L3
D / L-
Motorconnection
U2/T1 V2/T2 W2/T3
Pre-charging
DC link
PE1
Inverter
PE2
Rectifier
Figure 12-1
Forming circuit
12-1
Rev 10/20/00
Components for the forming circuit (suggestion)
Forming Frame Sizes A, B, C, & D:

Rated Voltage 3AC 220 V to 230 V 3AC 380 V to 480 V 3AC 500 V to 600 V A SKD 50 / 12 SKD 62 / 16 SKD 62 / 18 R C 220 / 100 W 22 nF / 1600 V 470 / 100 W 22 nF / 1600 V 680 / 100 W 22 nF / 1600 V
Forming Frame Sizes E, F, & G:

Rated Voltage 3AC 200 V to 230 V 3AC 380 V to 480 V 3AC 500 V to 600 V 3AC 660 V to 690 V A SKD 50 / 12 SKD 62 / 16 3 x SKKD 81 / 22 3 x SKKD 81 / 22 R C 220 / 100 W 20 nF / 1600 V 330 / 150 W 22 nF / 1600 V 470 / 200 W 22 nF / 1600 V 470 / 100 W 22 nF / 1600 V
Forming Frame Size K:

Rated Voltage 3AC 380 V to 480 V 3AC 500 V to 600 V 3AC 660 V to 690 V
Table 12-1
R SKD 62 / 16 3 x SKKD 81 / 22 3 x SKKD 81 / 22
100 / 500 W 22 nF / 1600 V 150 / 500 W 22 nF / 1600 V 150 / 500 W 22 nF / 1600 V
Components for bus capacitor forming circuits
Forming Procedure
Before you form the unit, all mains connections must be disconnected. The converter incoming supply must be switched off. Connect the required components in accordance with the circuit example. Energize the forming circuit. The duration of forming depends on the idle time of the converter.
6 5 4 3 2 1
Forming time in hours
Off-circuit idle time in years

1 2 3 4 5
Figure 12-2
Forming time as a function of converter idle time about 1 Hour / Year
12-2
13 Commissioning Parameter List For BUL 425

Parameter list Vector Control
Parameter
r001 Drive Status 1
Description
Visualization parameter for the current status of the converter or inverter. The converter status is, for example, determined by the control commands for the internal sequence control (see control words 1 and 2, r550, and r551) and by menu selection P060.
Data
Dec.Plc.: 0 Unit: Indices: Type: O2
Read/write
Menus: - Parameter menu + General parameters + Motor/encoder + Encoder data + Control/gating unit + Position control + Diagnostics + Trace + Technology + Synchronism + Positioning - Fixed settings - Quick parameterization - Board configuration - Drive setting - Download - Upread/free access - Power section definition
0 = Power section definition 1 = Initialization of converter or inverter 2 = Hardware initialization 3 = Drive system initialization 4 = Board configuration 5 = Drive setting 6 = Selection of several drive test functions 7 = Fault 8 = Start inhibit 9 = Ready for ON 10 = Precharging of Dc link bus 11 =Ready for operation 12 = Ground fault test 13 = "Flying restart" is active 14 = Operation 15 = OFF1 is active 16 = OFF3 is active 17 = "DC braking" is active 18 = Motor data identification at standstill is active 19 = Optimization of speed controller 20 = "Synchronization" active 21 = Download
r002 Rot Freq 2
Visualization parameter for the speed actual value in Hz (multiplied by the pole pair number P109 of the drive) Display quantity for the PMU parameterizing unit and the OP (see P049). In function diagram: 350.7, 351.7, 352.7
Dec.Plc.: 3 Unit: Hz Indices: Type: I4
Menus: - Parameter menu + General parameters - Upread/free access
r003 Output Volts 3
Visualization parameter for the output voltage of the converter or inverter (fundamental rms) In function plan 285.3, 286.3
Dec.Plc.: 1 Unit: V Indices: Type: I2
r004 Output Amps 4
Visualization parameter for the output current of the converter or inverter (fundamental rms) In function diagram 285.7, 286.7
Dec.Plc.: 1 Unit: A Indices: Type: I4
13-1
Rev 10/20/00
Parameter
r005 Output Power 5
Description Data
Read/write
Dec.Plc.: 1 Unit: % Indices: Type: I2 Menus: - Parameter menu + General parameters - Upread/free access
Visualization parameter for the output active power. The display value is normalized to the reference power which is derived from the product of reference frequency P352 and reference torque P354. In function diagram: 285.7, 286.7
r006 DC Bus Volts 6
Visualization parameter for DC link voltage. Displayed quantity for the PMU parameterizing unit and the OP (r049). In function diagram: 285.3, 286.7
Dec.Plc.: 0 Unit: V Indices: Type: I2
r011 act. MotDataSet 11
Visualization parameter for the currently active motor data sets. 1 = Data set 1 2 = Data set 2 3 = Data set 3 4 = Data set 4 A motor data set is selected with control word bits 18 and 19. The relevant BICO parameters for linking the control word bits are P578 and P579. In function diagram: 20.5
Menus: - Parameter menu + General parameters - Drive setting - Upread/free access
r012 Active BICO DSet 12
Visualization parameter for the currently active BICO data set. 1 = Data set 1 2 = Data set 2 A BICO data set is selected with control word bit 30. The relevant BICO parameter for linking the control word bit is P590. In function diagram: 20.5
r013 Active FuncDSet 13
Visualization parameter for the currently active function data set. 1 =Data set 1 2 = Data set 2 3 = Data set 3 4 = Data set 4 A function data set is selected with control word bits 16 and 17. The relevant BICO parameters for linking the control word bits are P576 and P577. In function diagram: 20.5
Parameter
r014 Setp Speed
Description
Visualization parameter for the speed setpoint at the speed controller input or at the frequency input
Data
Dec.Plc.: 1 Unit: 1/min
Read/write
Menus: - Parameter menu
13-2
of the v/f control. 14 In function diagram: 360.4, 361.4, 362.4, 363.4 Indices: Type: I4
+ General parameters - Upread/free access
r015 n(act) 15
Visualization parameter for the speed actual value. In function diagram: 350.7, 351.7, 352.7
Dec.Plc.: 1 Unit: 1/min Indices: Type: I4
P030* Src Disp Binec 30
BICO parameter for selecting binectors which are to be shown in visualization parameter r031. The binector numbers entered in the respective index are displayed in the same index of parameter r031. In function diagram: 30.1
index1: 0 Unit: Indices: 5 Type: L2 ,B
Menus: - Parameter menu + General parameters - Upread/free access Changeable in: - Drive setting - Ready
r031 Display Binector 31
Visualization parameter for displaying the binectors given in P030. The binectors displayed in the respective index have been selected in the same index of parameter P030. In function diagram: 30.2
Dec.Plc.: 0 Unit: Indices: 5 Type: O2
P032* Src Disp Conn 32
BICO parameter for selecting connectors which are to be displayed in visualization parameter r033 in [%]. The connector numbers shown in the respective index are displayed in the same index of parameter r033. In function diagram: 30.1
index1: 0 Menus: Unit: - Parameter menu Indices: 5 + General parameters Type: L2, K, K - Upread/free access Changeable in: - Drive setting - Ready
r033 Display Conn 33
Visualization parameter for displaying the connectors given in P032. The connectors displayed in the respective index have been selected in the same index of parameter P032. A connector value of 4000 H or 4000 0000 H is shown at 100 %. In function diagram: 30.2
Dec.Plc.: 3 Unit: % Indices: 5 Type: I4
P048* PMU OperDisp 48
Function parameter for selecting parameter whose value is to be indicated in the operating display of the PMU.
Init: 2 Min: 0 Max: 3999 Unit: Indices: Type: O2
Menus: - Parameter menu + General parameters - Upread/free access Changeable in: - Drive setting - Ready
13-3
Rev 10/20/00
Parameter
P053* Parameter Access 53
Description
Function parameter for releasing interfaces for parameterization. 0 Hex = None 1 Hex = Cbx communication board 2 Hex = PMU operator control panel 4 Hex = Serial interface (SCom/SCom1), also OP1S and PC 8 Hex = SCB serial input/output modules 10 Hex = Txxx technology board 20 Hex = Serial interface 2 (SCom2) 40 Hex = Second CB board Each interface has a code number. When the number or the sum of different numbers assigned to the interfaces is/are entered, the interface(s) is/are released for use as a parameterizing interface. Example: The factory-setting value 6 is the sum of 2 and 4. This means that parameterization is allowed via the PMU and serial interface 1 and thus for the OP1S as well. The parameter can always be written from any interface. This also applies if this interface has not been released for parameterization purposes.
Data
Init: 6 Min: 0 Max: 65535 Unit: Indices: Type: V2
Read/write
Menus: All menus Changeable in: All states
P060* Menu Select 60
Function parameter for selecting the current menu. 0 = User parameter (selection of the visible parameters in P360) 1 = Parameter menu 2 = Fixed settings (for factory settings) 3 = Quick parameterization (changes to "Drive Setting" state) 4 = Board configuration (changes to "Board Configuration" state) 5 = Drive setting (changes to "Drive Setting" state) 6 = Download (changes to "Download" state) 7 = Upread/Free access 8 = Power section definition (changes to "Power section definition" state) If it is not possible to change to another state due to the currently valid state, the corresponding menu cannot be selected either. Example: "Operating" state, change to "Download" not possible. "Ready for switching on" state, change to "Download" not possible. With parameters P358 Key and P359 Lock, menus can be locked with the exception of the menus "User parameters" and "Fixed settings".
Menus: All menus Changeable in: All states
13-4
Parameter
P068* Output Filter 68
Description
Function parameter for entering the output filter. Parameter values 0 = without output filter 1 = with sinusoidal output filter 2 = with dv/dt output filter The parameter value 1 limits the implementable depth of modulation to the range of space vector modulation (see also P342 and r345, maximum depth of modulation). The pulse frequency P340 is adapted to the envisaged sinusoidal filter after exiting the drive setting (see P060 = 5). Notes: For n/f/Torque control and for temperature adaption (P386 > 0), the sinusoidal filter envisaged for the converter is taken into account. . The parameter value 2 limits the adjustable pulse frequency P340 to 3 kHz. In function diagram: 430.3, 390.7, 405.6
Data
Read/write
Menus: - Parameter menu + General parameters - Drive setting - Upread/free access Changeable in: - Drive setting
r069 SW Version 69
Visualization parameter for displaying the software versions of the basic board as well as the optional boards in slots A to G Index 1: Software version of basic board Index 2: Software version of optional board Slot A Index 3: Software version of optional board Slot B Index 4: Software version of optional board Slot C Index 5: Software version of optional board Slot D Index 6: Software version of optional board Slot E Index 7: Software version of optional board Slot F Index 8: Software version of optional board Slot G The slots D-G are not available in type COMPACT PLUS. For optional boards which contain no software, (e.g. SBR, SLB), the parameter value in the respective index is always 0.0.
Menus: - Parameter menu + General parameters - Fixed settings - Quick parameterization - Board configuration - Drive setting - Download - Upread/free access - Power section definition
P070* Order No. 6SE70. 70
Function parameter for entering the order numbers of converter or inverter modules. These numbers tell the control board which power section it works with.
For parameter values, see annex "Compendium".
Menus: - Parameter menu + General parameters - Upread/free access - Power section definition Changeable in: - Power section definition
13-5
Rev 10/20/00
Parameter
P071 Line Volts 71
Description
Function parameter for entering the line voltage of the converter or inverter. Converter (AC/AC): rms value of the line AC voltage Inverter (DC/AC): input direct voltage The value is for calculating the rated DC link voltage as a basis for the voltage limits of the Vd(max) and Vd(min) [KIB) controller (e.g. undervoltage failure limit).
Data
Init: ~ Min: 90 Max: 1320 Unit: V Indices: Type: O2
Read/write
Menus: - Parameter menu + General parameters - Quick parameterization - Drive setting - Upread/free access Changeable in: - Drive setting
P072 Rtd Drive Amps 72
Parameter for displaying the rated current of the converter or inverter. The rated current is the current which can be output continuously. It must be identical to the current indicated on the rating plate of the converter. Note: This parameter must not be changed in the case of multi-parallel units as the converter rated current is determined in this case dynamically upon energizing the electronics power supply from the number of active slaves and the maximum converter rated current (in the EEPROM). If the parameter is changed this may overwrite the EEPROM value.
Init: ~ Min: 4,5 Max: 6540,0 Unit: A Indices: Type: O4
Menus: - Parameter menu + General parameters - Drive setting - Upread/free access - Power section definition Changeable in: - Power section definition
P073 Rtd Drive Power 73
Parameter for displaying the rated power of the converter or inverter.
Init: ~ Min: 0,3 Max: 6400,0 Unit: kW Indices: Type: O2
Menus: - Parameter menu + General parameters - Upread/free access - Power section definition Changeable in: - Power section definition
13-6
Parameter
P095* Type of Motor 95
Description
Function parameter for changing between international (IEC) and US (NEMA) motor data parameterization. If NEMA is selected, the efficiency and the rated motor output instead of the power factor cos(PHI) are displayed during motor parameterization. Parameter values: 10: IEC induction motor 11: NEMA induction motor 12: Synchronous motor (externally excited) 13 Synchronous perm. Note: Selection of a synchronous motor (12, 13) is only considered for certain special applications. P95 can also be at "0" (factory settging) during operation of permanently-excited synchronous motors. In both cases, the following functions are disabled: Synchronizing (P582), Flying restart (P583, P525, P526), Automatic restart (P373), DC braking (P395), Motor identification (P115=2,3,4,6), Control mode (P100=0,1,2,3 for P95=12), Control mode (P100=0,2,4,5 for P095=13). Synchronizing (P582) is used for P095=12 for resetting to the initial position if P172 is not connected.
Data
index1: 10 Min: 0 Max: 13 Unit: Indices: 4 Type: O2
Read/write
Menus: - Parameter menu + Motor/encoder + Motor data - Quick parameterization - Drive setting - Upread/free access Changeable in: - Drive setting
P100* Control Mode 100
Function parameter for selecting the open/closed loop control mode Parameter values: 0: v/f control with superposed speed control (only for P095 = 10, 11) 1: v/f control (only for P095 = 10, 11, 13) 2: v/f control for textile applications; allows no frequency corrections (e.g. by the current limitation controller) (only for P095 = 10, 11) 3: Frequency control (without tachometer) (only for P095 = 10, 11, 13) 4: Speed control (only for P095 = 10, 11, 12) 5: Torque control (only for P095 = 10, 11, 12) In function diagram: 14
13-7
Rev 10/20/00
Parameter
P101* Mot Rtd Volts 101
Description
Function parameter for entering the rated motor voltage. The rating plate value of the voltage for the current kind of connection (star/delta) and for line duty has to be entered. Note: Input for Siemosyn motors is the rated voltage at rated motor frequency. For P95=13 (motor type =sync.perm.), the motor rated voltage is only used as a normalization quantity for the rated motor impedance to which all resistances and reactances are referred (e.g. P075). in function diagram: 405.3
Data
index1: ~ Min: 100 Max: 2000 Unit: V Indices: 4 Type: O2
Read/write
P102* Motor Rtd Amps 102
Function parameter for entering the rated motor current for the connected synchronous or induction motor. The rating plate value for the current kind of connection (star/delta) has to be entered. Permissible values: 0.125 * P072 <= P102 < 1.36 * P072
index1: ~ Min: 0,6 Max: 6553,5 Unit: A Indices: 4 Type: O4
Menus: - Parameter menu + Motor/encoder + Motor data - Quick parameterization - Drive setting - Upread/free access Changeable in: - Drive setting Menus: - Parameter menu + Motor/encoder + Motor data - Drive setting - Upread/free access Changeable in: - Drive setting - Drive setting
P103* Motor Magn Amps 103
Function parameter for entering the motor magnetizing current referred to the rated motor current. The correct input improves the calculation of motor parameters in automatic parameterization (P115=1). The value is determined during motor data identification (P115=2,3) and during the no-load test (P115=4). Synchronous motor (P95=12): Reactive current component at the motor rating point. Note: The value always has to be set to 0.0% so that the rated motor current is contributed completely to torque generation. Precondition: P095 = 10,11,12 (Motor type = Induction IEC, Induction NEMA, Synchronous motor)
index1: ~ Min: 0,0 Max: 95,0 Unit: % Indices: 4 Type: O2
P104* MotPwrFactor 104
Function parameter for entering the power factor for the connected induction motor. The rating plate value has to be entered. Precondition: P95 = 10,12 (motor type: induction IEC, synchronous motor)
index1: ~ Min: 0,500 Max: 1,000 Unit: Indices: 4 Type: O2
13-8
Parameter
P105* Motor Rtd Power 105
Description
Function parameter for entering the rated motor power in Hp (rating plate value). Precondition: P095 = 11 (motor type: NEMA induction motor)
Data
index1: ~ Min: 0,1 Max: 2000,0 Unit: hp Indices: 4 Type: O2
Read/write
P106* Motor Rtd Effic. 106
Function parameter for entering the rated motor efficiency (rating plate value). Precondition: P095 = 11 (motor type: NEMA induction motor)
P107* Motor Rtd Freq 107
Function parameter for entering the rated motor frequency (rating plate value). P100 = 0, 1, 3, 4, 5: maximum value 200 Hz P100 = 2: maximum value 600 Hz The pole pair number (P109) is automatically recalculated if parameters are changed.. For induction motors, a slip (r110) must exist to P108*P109/60 to enable the slip compensation to correctly operate. Note: Changing this parameter may also change the pulse frequency (P340). In function diagram: 405.4
index1: 50,00 Min: 8,00 Max: 500,00 Unit: Hz Indices: 4 Type: O2
P108* Motor Rtd Speed 108
Function parameter for entering the rated motor speed (rating plate value). Note: P100 = 0, 4, 5 (v/f control with speed controller, - Quick parameterization speed/torque control) is only available with this information. The pole pair number (P109) is automatically recalculated if parameters are changed. For induction motors, a slip (r100) must exist to P107/P109*60 to enable slip compensation to correctly operate.
index1: 0,0 Min: 0,0 Max: 36000,0 Unit: 1/min Indices: 4 Type: I4
Menus: - Parameter menu + Motor/encoder + Motor data
- Drive setting - Upread/free access Changeable in: - Drive setting
13-9
Rev 10/20/00
Parameter
P109* Motor #PolePairs 109
Description
Function parameter for entering the motor pole pair number for the connected synchronous/induction motor. The parameter is automatically calculated if the rated frequency (P107) and the rated speed (P108) are changed, and it can be checked and corrected if necessary. Note: - For applications with pulse encoder (130=11,12,15,16), a maximum pole pair number of P109=15 is possible. - P109 must be written into when downloading (P060=6). - For machines with rated data for regenerative duty, the automatically calculated pole pair number must be increased by 1. In function diagrams: 360.2, 361.2, 362.2, 363.2, 364.2
Data
Read/write
r110 Motor Rtd Slip 110
Visualization parameter for the rated motor slip, referred to rated motor frequency (P107). Precondition: P095 = 10, 11 (motor type = induc. IEC; induc. NEMA) In function diagrams: 395.3
Dec.Plc.: 2 Unit: % Indices: Type: O2
Menus: - Parameter menu + Motor/encoder + Motor data - Drive setting - Upread/free acces
P113* Mot Rtd Torque 113
Function parameter for entering the rated motor torque. The parameter is for normalizing torque quantities of the process data signals and visualization parameters and has no influence on the accuracy of the control system. If P113 and P354 (reference torque) are set identically, a signal is displayed to the amount of the rated motor torque as 100% (=4000 Hex). In function diagram: 20.6
index1: ~ Min: 0,01 Max: 900000,00 Unit: Nm Indices: 4 Type: O4
Menus: - Parameter menu + Motor/encoder + Motor data - Drive setting - Upread/free access Changeable in: - Drive setting
13-10
Parameter
P114 Technol. Cond. 114
Description
Function parameter for selecting various technology boundary conditions for starting up the control system. Depending on what is selected, the parameter influences some of the following parameters during automatic parameterization mode (P115=1) or during motor data identification (P115=2,3): P216,P217,P223,P235,P236,P240,P273,P279,P287, P291,P295,P303,P315,P339,P344,P536. 0 = standard drive (e.g. pumps, fans) normal default setting 1 = torsion, gear play and large moment of inertia (e.g. paper machines) 2 = acceleration drives with constant inertia (e.g. shears) 3 = high load impact requirements (with f control only possible after approx. 20%fmot,n) 4 = high smooth running characteristics at low speeds (at n control with high number of encoder pulses) 5 = efficiency optimization during partial load by reducing the flux (dynamically simple drives) 6 = high starting torque (heavy-duty starting) 7 = Torque dynamics in the field weakening area (e.g. motor test beds) The parameter settings are only to be regarded qualitatively and only serve to show the influence on the respective application. A start-up always refers to a concrete application and cannot be replaced by this support. The supplementary notes in the Operating Instructions or in the Compendium should be observed. CAUTION. Damage may arise as a result of incorrect settings!
Data
Read/write
Menus: - Parameter menu + Motor/encoder + Motor data + Functions - Quick parameterization - Drive setting - Upread/free access Changeable in: - Drive setting
13-11
Rev 10/20/00
Parameter
P115* Calc MotModel 115
Description
Function parameter for selecting various start-up sections and special functions. Parameter values: 1 = Automatic parameterization Calculation of parameters for the v/f open-loop control and closed-loop control from the rating plate data of the motor and the gating unit configuration (e.g. P340 Pulse frequency) 2 = Motor data identification at standstill: Parameterization of closed-loop control from the measured motor data (without setting the n/f controller); contains the ground fault test and function 1. (only for P095 = 10, 11 induction motor) 3 = Complete motor data identification: (contains the functions 1, 2, 4, 5, 7) (only for P100 = 3, 4, 5 vector control types). (only for P095 = 10, 11 induction motor)
Data
Read/write
Menus: - Parameter menu + Motor/encoder + Motor data + Functions - Drive setting - Upread/free access Changeable in: - Drive setting - Drive setting
Note: After alarm A078, the unit must be switched on and the measurement at standstill commences. After the measurement at standstill has been completed, the alarm message A080 appears and the unit has to be powered up again. Then the no-load measurement and the speed controller optimization begin. 4 = No-load measurement (only for P100 = 3, 4, 5 vector control types), (only for P095 = 10, 11 induction motor). 5 = n/f controller optimization (only for P100 = 3, 4, 5 vector control types) 6 = Self-test: (corresponds to the functions of 2, but no parameters are changed (only for P095 = 10, 11 induction motor) 7 = Tachometer test: (only for P100 = 3, 4, 5 vector control types) Note: If functions 1 to 3 are selected in the "Drive setting" converter status, the reference parameters P350 to P354 are pre-assigned to the rated motor data!
P116 Start-up Time 116
Function parameter for setting the start-up time of the drive. The start-up time is the time from standstill to rated motor speed at acceleration with rated motor torque. The parameter value thus corresponds to the moment of inertia and is allowed for in the calculation of the n/f controller pre-control (P471). Pre-assignment for automatic parameterization (P115=1,2) with 1.00 s or for n/f controller optimization (P115=3,5) with the measured value. Precondition: P100=3,4 (n/f control) Function diagrams: 317.7
index1: 1,00 Min: 0,10 Max: 327,67 Unit: s Indices: 4 Type: O2
Menus: - Parameter menu + Motor/encoder + Motor data - Upread/free access Changeable in: - Drive setting - Ready
13-12
Parameter
P128 Imax 128
Description
Function parameter for setting the maximum current (fundamental rms) This parameter sets the setpoint for current limitation to protect the motor and the drive (Imax controller for v/f control modes or current controller for vector control modes).
Data
index1: ~ Min: 0,1 Max: 6553,5 Unit: A Indices: 4 Type: O4
Read/write
Menus: - Parameter menu + Control/gating unit + Speed control + Current control + V/f open-loop control - Upread/free access Changeable in: - Drive setting - Ready
Setting range: 0.125 to 4,00 * Imot,n , but maximum 1.36 or 1.6 * Iconv,n (P72). depending on the type of converter. During automatic parameterization (P115 = 1) and motor data identification (P115 = 2, 3), the value is pre-set to 1.5 times the rated motor current (P102). Reaction (derating) may result from the pulse frequency parameter change (P340). Function diagrams: 370.2, 371.2, 372.2, 373.2 r129 Imax(set) 129 v/f control modes (P100 = 0, 1, 2): Setpoint of the current limitation controller Vector control modes (P100 = 3, 4, 5): Limitation for the setpoints of the current controller Function diagrams: 370.2, 371.2, 372.2, 373.2 P130* Select MotEncod 130 Function parameter for setting the kind and place of connection of the used tachometer 10 = without tachometer 11 =pulse encoder 12 = pulse encoder with control track 13 = analog tachometer via analog input 1 14 = analog tachometer via analog input 2 15 = pulse encoder with zero pulse 16 = pulse encoder with zero pulse and control track index1: 10 Min: 0 Max: 16 Unit: Indices: 4 Type: O2 Visualization parameter of the realized maximum current for current limitation (see P128). It allows for the influence of the It calculation. Dec.Plc.: 1 Unit: A Indices: Type: I4
Menus: - Parameter menu + Control/gating unit + Speed control + Current control + V/f open-loop control - Upread/free access
Menus: - Parameter menu + Motor/encoder + Encoder data + Control/gating unit + Position control - Drive setting - Upread/free access Changeable in: - Drive setting
Notes: P130 = 11, 12, 15, 16 (pulse encoder) Only pulse encoders with a phase shift of 90 between the 2 tracks can be used. At setting 12 or 16, a low level signal or disconnecting the terminal for the control track will cause the fault message F052. This is for reporting a broken wire in the tachometer cable. P151 (pulse number of pulse encoder) Please refer to the relevant operating instructions for precise instructions on how to start up the tachometer you are using. P130 = 13, 14 (analog tachometer) P138 (Analog tachometer scaling) The ATI board is necessary for tachometer voltages > 10 V P095 = 12 (synchronous motor): P130 = 15 or 16 is necessary (due to zero pulse for position monitoring) Function diagrams: 250.6
13-13
Rev 10/20/00
Parameter
P139* ConfSetpEnc 139
Description
Function parameter for configuration of the setpoint encoder on an SBP. The setpoint encoder can either process one digital setpoint from two independent rectangular-shaped frequency signals or, alternatively, form one setpoint from an external pulse encoder signal and a rectangular-shaped frequency signal. xxx0 = channel 1 / encoder input HTL unipolar xxx1 = channel 1 / encoder input TTL unipolar xxx2 = channel 1 / encoder input HTL differential input xxx3 = channel 1 / encoder input TTL/RS422 differential input xx0x = channel 2 HTL unipolar xx1x = channel 2 TTL unipolar xx2x = channel 2 HTL differential input xx3x = channel 2 TTL/RS422 differential input x0xx = encoder with 5 V voltage supply x1xx = encoder with 15 V voltage supply 0xxx = setpoint encoder deactivated 1xxx = Frequency counter mode (frequency evaluation) 2xxx = Encoder signal evaluation mode
Data
Init: 0 Unit: Indices: Type: L2
Read/write
Menus: - Parameter menu + Motor/encoder + Encoder data - Board configuration - Drive setting - Upread/free access Changeable in: - Quick parameterization
P140* SetpEnc Pulse# 140
Function parameter for the pulse number of the setpoint encoder. The parameter has to be set to the number of pulses of the setpoint encoder connected to an SBP board. If the first frequency channel of the setpoint encoder is in the "encoder signal evaluation" mode (P139=2xxx), the parameter value is used for normalizing the setpoint generation (together with the motor ref. frequency).
Menus: - Parameter menu + Motor/encoder + Encoder data - Drive setting - Upread/free access Changeable in: - Drive setting - Drive setting
P141* SetpEncFreq 141
Function parameter for the reference frequency of the setpoint encoder. The parameter value determines which input frequency results in an output of 100% on the setpoint encoder. If the setpoint encoder is the "frequency counter" mode (P139=1xxx), the parameter values are used to normalize the output values.
index1: Menus: 10000 - Parameter menu Min: 500 + Motor/encoder Max: 1000000 + Encoder data - Drive setting Unit: Hz - Upread/free access Indices: 2 Changeable in: Type: O4 - Drive setting
P151* Encoder Pulse # 151
Function parameter for entering the number of pulses of the pulse encoder. Setting instructions The product "pulse number * motor frequency" (P107) should not exceed 400000, as otherwise the speed computation will be inaccurate. Precondition: P130 = 11,12,15,16 (Pulse encoder) Function diagrams: 250.3
Menus: - Parameter menu + Motor/encoder + Encoder data + Control/gating unit + Position control - Drive setting - Upread/free access Changeable in: - Drive setting
Parameter
Description
Data
Read/write
13-14
P235 n/f-Reg Gain 1 235
Function parameter for entering the n/f controller gain. The value is pre-set during automatic parameterization (P115 = 1, 2) or is calculated from the measured during n/f controller optimization (P114 = 3, 5). Precondition: P100 = 0, 3, 4, 5 (v/f control with n control, vector control types) Function diagrams: 360.4, 361.4, 362.4, 363.4
Menus: - Parameter menu + Control/gating unit + Speed control - Upread/free access Changeable in: - Drive setting - Ready
P236 n/f-Reg. Gain2 236
Function parameter for entering the speed controller gain above the corner point P234 of the gain adaption. At speeds between P233 and P234, the gain is interpolated linearly from P235 to P236. Precondition: P100 = 0,3,4,5 (v/f control with n control, vector control types) Function diagrams: 360.4, 361.4, 362.4, 363.4
r237 n/f RegGain(act) 237
Visualization parameter for the currently effective gain of the speed controller. Precondition: P100 = 0, 3, 4, 5 (v/f control with n control, vector control types) Function diagrams: 360.6, 361.6, 362.6, 363.
Menus: - Parameter menu + Control/gating unit + Speed control - Upread/free access
P240* n/f Reg Time 240
Function parameter for entering the integral time of the speed controller. The value is pre-set during automatic parameterization (P115 = 1, 2) or is taken from the measurement during n/f controller optimization (P115 = 3, 5). Note: With value 32001 ms, the I component is turned off (the speed controller operates as a P controller). Precondition: P100 = 0, 3, 4, 5 (v/f control with n control, vector control types) Function diagrams: 360.7, 361.7, 362.7, 363.7
index1: ~ Min: 25 Max: 32001 Unit: ms Indices: 4 Type: O2
13-15
Rev 10/20/00
Parameter
P278 Torque (static) 278
Description
Function parameter for the maximum required steady-state torque during encoder-less speed control (frequency control) in the lower speed range. At frequency control (P100=3) and non-active EMF model (B0253 = 0), a constant current is impressed to the motor. Torque(static) represents the maximum torque occurring during constant setpoint frequency. For safety reasons, the parameter should allow for at least 10 % more than the expected load. Parameter values: 0%= Rated magnetizing current is injected (r119) Setting instructions: During acceleration, the transition to the counter EMF model (B0253 = 1) is significantly influenced by the setting of this parameter and by the protective mode of the ramp function generator (P467). The value is assigned during automatic parameterization (P115=1). Precondition: P100 = 3 (frequency control)
Data
index1: ~ Min: 0,0 Max: 200,0 Unit: % Indices: 4 Type: I2
Read/write
P279 Torque (dynamic) 279
Function parameter for the maximum additional dynamic torque during encoder-less speed control (frequency control) in the lower speed range. An additional acceleration torque (P279) is added to the steady state torque (P278) during frequency acceleration and deceleration. The total current during acceleration is calculated from the settings of P278 and P279.During steady state operation only the current for P278 is impressed. Setting instructions: For the sole purpose of acceleration torque, the speed control precontrol (P471) can be used. The value is assigned during automatic parameterization (P115=1). Precondition: P100 = 3 (frequency control) In function diagram: 382.2
index1: ~ Min: 0,0 Max: 200,0 Unit: % Indices: 4 Type: I2
P325 Boost Volts 325
Function parameter for the voltage boost at f = 0 Hz. The value is calculated during automatic parameterization (P115 = 1, 2). Precondition: P100 = 0, 1, 2 (v/f control modes) P318 = 1 (voltage boost) In function diagram: 405.1
index1: ~ Min: 0,0 Max: 500,0 Unit: V Indices: 4 Type: O2
Menus: - Parameter menu + Control/gating unit + V/f open-loop control - Upread/free access Changeable in: - Drive setting - Ready
13-16
Parameter
P326 Boost End Freq 326
Description
Function parameter for the end frequency of the voltage boost. In the range from 0 Hz to end frequency, the voltage boost is reduced to 0. Special case: The input value 0 Hz causes the output voltage to stay constant until crossing the normal v/f curve ("horizontal" boost). The value is pre-set during automatic parameterization (P115 = 1) or during motor data identification (P115 = 2, 3). Precondition: P100 = 0,1,2 (v/f control modes) In function diagram: 405.3
Data
index1: ~ Min: 0,00 Max: 300,00 Unit: Hz Indices: 4 Type: O2
Read/write
P330 V/Hz Mode 330
Function parameter for the v/f mode. Parameter values: 0: linear characteristic (for constant-torque drives) 1: parabolic characteristic (for pumps, fans, etc.)
Precondition: P100 = 0, 1, 2 (v/f control modes) In function diagram: 405.2
Menus: - Parameter menu + Control/gating unit + V/f open-loop control - Drive setting - Upread/free access Changeable in: - Drive setting
P336 Slip Comp Gain 336
Function parameter for the proportional gain of slip compensation (also taking the rotor temperature into account). The value is pre-set during automatic parameterization (P115 = 1, 2,3). Setting instructions: 0.0 %: Slip compensation off 50 % - 70 %: Full slip compensation at cold motor (partial load) 100 %: Full slip compensation at warm motor (full load) Note: Rating plate data for rated current (P102), rated speed (P108) and rated frequency (P107) must be entered correctly and fully. Precondition: P100 = 1 (v/f control)
13-17
Rev 10/20/00
Parameter
Parameter P339 ModSystemRelease 339
Description
Description Function parameter for release of the edge modulation systems Parameter values: 0: all systems 1: edge modulation systems above 60 Hz 2: edge modulation systems above 100 Hz 3: no edge modulation systems 4: overmodulated space vector modulation 5: overmodulated space vector modulation without pulse frequency switchover Note: During operation with overmodulated space vector modulation, the harmonic contents in the output current are increased. The drive can then be heated up more strongly. With P342, the modulation depth factor can be limited gradually again (result in r345). In function diagram: 390.8, 405.8
Data
Data index1: 0 Min: 0 Max: 5 Unit: Indices: 4 Type: O2
Read/write
Read/write Menus: - Parameter menu + Gating unit - Drive setting - Upread/free access Changeable in: - Drive setting
P340* Pulse Frequency 340
Function parameter for entering the pulse frequency for asynchronous space vector modulation. Note: The setting range of the pulse frequency depends on the type of unit and on the settings of the open/closed loop control. (e.g. by selecting an output filter (see P068)). If noise damping is active (P535>0), the pulse frequency is limited to a minimum value of 45*motor rated frequency (P107), otherwise to a minimum value of 30*P107 and at P107=83.3...104Hz to a minimum value of 2.5kHz. Caution: If the pulse frequency is increased, P128 (maximum current) can be reduced (derating). If the pulse frequency is then reduced again, the changed value in P128 remains! In function diagram: 390.6, 420.5, 405.5
index1: 2,5 Min: 1,5 Max: 16,0 Unit: kHz Indices: 4 Type: O2
Menus: - Parameter menu + Gating unit - Drive setting - Upread/free access Changeable in: - Drive setting
P350* Ref Amps 350
Function parameter for entering the reference current. The value entered is for normalizing all current quantities and corresponds to a connector value of 4000 H (100 %). The closed-loop control system can process up to twice the value entered. In function diagram: 20.5
Init: ~ Min: 0,1 Max: 6553,5 Unit: A Indices: Type: O2
Menus: - Parameter menu + Functions - Drive setting - Upread/free access Changeable in: - Drive setting
13-18
Parameter
P351* Ref Volts 351
Description
Function parameter for entering the reference voltage. The value entered is for normalizing all voltage quantities and corresponds to a connector value of 4000 H (100 %). The closed-loop control system can process up to twice the value entered. In function diagram: 20.5
Data
Init: ~ Min: 100 Max: 2000 Unit: V Indices: Type: O2
Read/write
P352* Ref Frequency 352
Function parameter for entering the reference frequency. The value entered is for normalizing all frequency quantities and corresponds to a connector value of 4000 0000 H (100 %). The closed-loop control system can process up to twice the value entered. Note: If the parameter is changed, P353 is automatically adjusted. Caution: By changing the parameter, the frequency limitations are changed as well. In function diagram: 20.5
Init: ~ Min: 4,00 Max: 600,00 Unit: Hz Indices: Type: O2
P353* Ref Speed 353
Function parameter for entering the reference speed. The value entered is for normalizing all the speed quantities and corresponds to a connector value of 4000 0000H (100 %). The closed-loop control system can process up to twice the value entered. Note: If the parameter is changed, P352 is automatically adjusted. Caution: By changing the parameter, the speed limitations are changed as well. In function diagram: 20.5
Init: ~ Min: 1 Max: 36000 Unit: 1/min Indices: Type: O2
P354* Ref Torque 354
Function parameter for entering the reference torque. The value entered is for normalizing all torque quantities and corresponds to a connector value of 4000 H (100 %). The closed-loop control system can process up to twice the value entered. Note: The reference power is the product of reference frequency and reference torque. Caution: By changing the parameter, the torque limitations are changed as well. In function diagram: 20.5
Init: ~ Min: 0,10 Max: 900000,00 Unit: Nm Indices: Type: O4
13-19
Rev 10/20/00
Parameter
P357 Sampling Time 357
Description
Function parameter for the base sampling time T0 of the n/f/T control and the v/f control. Setting instructions: - Before reducing the sampling time, the calculation time headroom should be checked (parameter r829) in the "Operating" state. A minimum headroom of 5 % should always be ensured to prevent the operation from programming a slow reaction. - If fault message F042 "Calculation time" occurs, the sampling time must be increased. In function diagram: 15.7
Data
Init: 1,2 Min: 0,8 Max: 4,0 Unit: ms Indices: Type: O2
Read/write
P358* Key 358
Function parameter for entering the key. If the values in both indices tally with the values entered in Lock parameter P359, other menus can also be selected in P060 as well as the menu "User Parameters" and the menu "Fixed settings".
index1: 0 Unit: Indices: 2 Type: L2
Menus: - User parametersParameter menu + Functions - Upread/free access Changeable in: - Drive setting
P380* Mot Tmp Warning 380
Function parameter for entering the temperature threshold at which the alarm message "Motor overtemperature" (A023) is tripped. Example: For isolation class B: <= 110 C (60 K-value is at 1FK6/1FT6) For isolation class F: <= 145 C (100 K-value is at 1FK6/1FT6) Description for setting: a parameter value > 0 activates this function
index1: 0 Min: 0 Max: 200 Unit: C Indices: 4 Type: I2
Menus: - Parameter menu + Diagnostics + Faults/warnings + Functions - Drive setting - Upread/free access Changeable in: - Drive setting - Drive setting - Ready
P381* Mot Tmp Fault 381
Function parameter for entering the temperature threshold at which the fault message "Motor overtemperature" (F020) is tripped. Example: For isolation class B: <= 120 C (60 K-value is at 1FK6/1FT6) For isolation class F: <= 155 C (100 K-value is at 1FK6/1FT6) Setting instructions: The PTC evaluation is activated by setting P381=1. The PTC thermistor evaluation identifies an overtemperature condition, if the PTC thermistor resistance is > 1.5KOhm. The temperature sensing using a KTY84 sensor is activated for a setting value P381>1.
index1: 0 Min: 0 Max: 200 Unit: C Indices: 4 Type: I2
Menus: - Parameter menu + Diagnostics + Faults/warnings + Functions - Drive setting - Upread/free access Changeable in: - Drive setting - Drive setting - Ready
13-20
Parameter
P382* Motor Cooling 382
Description
The type of motor cooling has an influence on the calculation of the permissible load cycle during the I2t monitoring for the motor. The parameter value 1 (= factory setting) has to be selected for all 1FT6 and 1FK6 motors. Parameter values: 0: self-cooled 1: force-cooled
Data
Read/write
Menus: - Parameter menu + Diagnostics + Faults/warnings + Functions - Quick parameterization - Drive setting - Upread/free access Changeable in: - Drive setting - Drive setting - Ready Menus: - Parameter menu + Diagnostics + Faults/warnings + Functions - Quick parameterization - Drive setting - Upread/free access Changeable in: - Drive setting - Ready
P383 Mot ThermT-Const 383
Thermal time constant of motor Setting instructions: The it calculation is activated by a parameter value >= 100 seconds. Example: for a 2-pole 1LA5063 motor, the value should be set to 8 min (from the table) *60s/min =480s . If the utilization limit parameterized in P384 is exceeded, the diagnostic signal F021 is set. Precondition: P95 >=10 or P97=0
index1: 100 Min: 0 Max: 16000 Unit: s Indices: 4 Type: O2
P452* n/f(max, FWD Spd 452
Maximum setpoint for clockwise rotating field. Limitation by: - 5 times the rated motor frequency - pulse frequency (P761) This parameter is to be set in rpm, max rpm 2700
index1: Min: 0, Max: 2700 Unit: RPM Indices: 4 Type: I4 index1: -110,0 Min: -200,0 Max: 0,0 Unit: % Indices: 4 Type: I4
Menus: - Parameter menu + Setpoint channel - Drive setting - Upread/free access Changeable in: - Drive setting Menus: - Parameter menu + Setpoint channel - Drive setting - Upread/free access Changeable in: - Drive setting
P453* n/f(max,REV Spd) 453
Maximum setpoint for counter-clockwise rotating field. Limitation by: - 5 times the rated motor frequency - pulse frequency (P761) This parameter is to be set in rpm, min rpm -2700
P457* Min Setp 457
Minimum speed of the motor
index1: Min: -200,0 Max: 200,0 Unit: % Indices: 4 ,MDS Type: I4 index1: 10,0 Min: 0,0 Max: 999,9 Unit: Indices: 4 ,FDS Type: O2
This parameter is now in the motor data set
Menus: - Parameter menu + Setpoint channel - Upread/free access Changeable in: - Drive setting - Ready
P462 Accel. Time 462
Acceleration time of the ramp-function generator for acceleration from 0 to 100%. Unit: as defined in P463 (acceleration time unit) Note: The value is only increased during motor identification (P115 = 3.5) if the set acceleration time is too low and the unit (P463, P465) for acceleration and deceleration times is in seconds. (The drive cannot realize the set acceleration time as the torque limit was reached earlier).
13-21
Rev 10/20/00
Parameter
P464 Decel. Time 464
Description
Deceleration time of the ramp-function generator for deceleration from 100% to 0% Unit: as defined in P465 (unit of deceleration time) Note: The value is only increased during motor identification (P115 = 3.5) if the set time is too small and the unit (P463, P465) for acceleration and deceleration is indicated in seconds. (The drive cannot realize the set deceleration time as the torque limit was reached earlier).
Data
index1: 10,0 Min: 0,0 Max: 999,9 Unit: Indices: 4 ,FDS Type: O2
Read/write
P467 ProtRampGen Gain 467
Factor by which the acceleration time (P462) is index1: 1,0 extended (protective ramp-function generator) Min: 1,0 Notes Max: 100,0 V/f open-loop control types (P100 = 0, 1, 2): Unit: Protective ramp-function generator is active up Indices: 4 to a frequency of 15 % of the rated motor frequency ,FDS (P107). See Section "Ramp-function generator Type: O2 RFG" in operating instructions, part 2 f-control (P100 = 3): The protective ramp-function generator is active up to 1.1 times the changeover frequency to EMF model (P284). Acceleration is also influenced by the current settings (P202, P203, P204) with inactive EMF model (P284 = 0). During control of permanently excited synchronous motors (P100=3), the protective ramp-function generator (>=5) has to be set such that the drive does not stall during acceleration. Also at least 20% has to be input in P202. n/Torque control (P100 = 4, 5) The protective ramp-function generator is ineffective. The protective ramp-function generator is only active if the acceleration time (P463) is selected in seconds. During motor identification (P052 = 8, 10), the value is only increased if the set acceleration time is too low and the unit (P463, P465) for both acceleration and deceleration times is in seconds. Setting instruction: The parameter value 1.0 turns the protective ramp-function generator OFF. Precondition: P100 = 0, 1, 2, 3 (v/f open-loop control, f regulation.
P471 Scale Torq(PRE) 471
Function parameter for the gain of the n/f controller precontrol. The acceleration torque is calculated from the speed setpoint changes at the ramp-function generator output (r478) taking into consideration the moment of inertia (see P116). Accelerations due to additional setpoint 2 in the setpoint channel are not accounted for in the calculation. The value is pre-assigned with 0.0% during automatic parameterization (P115 = 1, 2) and with 100.0% during n/f controller optimization (P115 = 3, 5). Setting instructions: 0.00%: Precontrol inactive 100.0%: Precontrol of the n/f controller with rated motor torque at the time indicated in P116 Precondition: P100 = 3, 4 (n/f control) in function diagram: 317.7
13-22
Parameter
P536 n/f RegDyn(set) 536
Description
Function parameter for setting the dynamic response of the speed control circuit. It is used as an optimization criterion for dimensioning the n/f controller (P115 = 3, 5). Note: A change will only become active if the n/f controller optimization is subsequently carried out (P115 = 3, 5) Setting instructions: - For drives with gear play and/or shafts with strong torsion, optimization should be commenced with low dynamic response values (from 10%). - For drives with high requirements on synchronism and dynamic response, 200% should be selected. - In the case of encoder-free speed control (f-control), maximum values of approx. 100% are to be selected. Precondition: P100 = 3,4,5 (Vector control modes);
Data
index1: 50 Min: 10 Max: 200 Unit: % Indices: 4 Type: O2
Read/write
Menus: - Parameter menu + Functions - Upread/free access Changeable in: - Drive setting - Ready
r550 Control Word 1 550
Visualization parameter for displaying control word 1. Bits 0 to 15 are displayed.
Dec.Plc.: 0 Unit: Indices: Type: V2
Menus: - Parameter menu + Control and status words - Upread/free access
r551 Control Word 2 551
Visualization parameter for displaying control word 2. Bits 16 to 31 are displayed.
r552 Status Word 1 552
Visualization parameter for displaying status word 1. Bits 0 to 15 are displayed.
r553 Status Word 2 553
Visualization parameter for displaying status word 2 Bits 16 to 31 are displayed.
P605 BrakeCtrl 605
Function parameter for selecting a brake control unit. 0 = Without brake 1 = Brake without check-back message 2 = Brake with check-back message
Menus: - Parameter menu + Sequence control - Upread/free access Changeable in: - Drive setting
13-23
Rev 10/20/00
Parameter
P606 BrakeOpenTime 606
Description
Function parameter for entering the brake opening time. If there is a brake present (P605), the setpoint release is delayed by the set time. The brake can thus open safely before starting of the motor.
Data
Init: 0,20 Min: 0,00 Max: 10,00 Unit: s Indices: Type: O2
Read/write
Menus: - Parameter menu + Sequence control + Diagnostics + Messages/displays - Upread/free access Changeable in: - Drive setting
P607 BrakeCloseTime 607
Function parameter for entering the brake closing time. If there is a brake present (P605), blocking of the firing pulses is additionally delayed by the set time after an OFF command. The brake can thus safely close before the motor is de-energized. In addition, the turn-off time set in P0801 must be greater than the sum of the set times in P617 and P607.
Menus: - Parameter menu + Sequence control + Diagnostics + Messages/displays - Upread/free access Changeable in: - Drive setting
P611 Brake Thresh 611
Function parameter for entering brake threshold 1, whereby, if this threshold is exceeded, the brake is to open.
Init: 0,0 Min: 0,0 Max: 200,0 Unit: % Indices: Type: O2
Menus: - Parameter menu + Sequence control - Upread/free access Changeable in: - Drive setting - Ready
P616 BrakeThresh2 616
Function parameter for entering brake threshold 2. If the actual value falls below this threshold after an OFF command, the brake is closed and a firing-pulse block is initiated by the brake control unit (B278). The value entered here should not be smaller than the turn-off value parameterized in P800.
Menus: - Parameter menu + Sequence control - Upread/free access Changeable in: - Drive setting - Ready
P617 BrakeThresh2Time 617
Function parameter for entering the time by which closing of the brakes is to be delayed after an OFF command. If the threshold value falls below brake threshold 2 after an OFF command, closing of the brake is delayed by the time entered.
Menus: - Parameter menu + Sequence control + Diagnostics + Messages/displays - Upread/free access Changeable in: - Drive setting - Ready
P618 AnaIn Offset
Off delay time for inverter enable (Flux off delay)
index1: Min: 0.00
618
Max:600.00 Unit: sec Indices:
Menus: - Parameter menu - Drive setting + Terminals - Upread/free access Changeable in: - Drive setting
13-24
Parameter
r637 Analn Setp 637
Description
Visualization parameter for displaying the setpoint provided by the analog input. i001 = CU-1: Setpoint of the analog input 1 i002 = CU-2: Setpoint of the analog input 2
Data
Read/write
Menus: - Parameter menu + Terminals - Upread/free access
r646 Status DigIn 646
Visualization parameter for displaying the signal level at the digital inputs and outputs of the terminal strip for the basic unit.
r673 EB2 Termin Disp 673
Visualization parameter for displaying the signal level of the digital inputs and outputs of EB2 Index 1: First inserted EB2 Index 2: Second inserted EB2
Dec.Plc.: 0 Unit: Indices: 2 Type: V2
r682 EB2 AnaIn Setp 682
Visualization parameter for displaying the setpoint which is provided by the analog input of EB2. Index 1: First inserted EB2 Index 2: Second inserted EB2
P781* Fault Delay 781
Function parameter for setting a delay time for various faults. Special case: Value 101.0 means that the fault is never triggered. Index 1: Ext. fault 1 Index 2: Ext. fault 2 Index 3: delay time after A035 (w/ both directions selected) trips on Fault F055 P781.3 < 101 delay time P781.3 = 101 not active Index 4: Index 5: Index 6: Index 7: Index 8: Index 9: Index 10: Index 11: SCom1 telegram failure Index 12: SCom2 telegram failure Index 13: CB/TB telegram failure Index 14: 2nd CB telegram failure Index 15: SCB telegram failure Index 16: SLB telegram failure Index 17: Index 18: Index 19: Index 20:
index1: 0,0 Min: 0,0 Max: 101,0 Unit: s Indices: 20 Type: O2
Menus: - Parameter menu + Diagnostics + Faults/warnings - Upread/free access Changeable in: - Drive setting - Ready
13-25
Rev 10/20/00
Parameter
P804 Overspeed Hyst 804
Description
Function parameter for entering the hysteresis for the "Overspeed" message. An overspeed message is indicated in status word 2, bit 18.
Data
Read/write
Menus: - Parameter menu + Diagnostics + Messages/displays - Upread/free access Changeable in: - Drive setting - Ready
P807 Off 3 atfr alrm 807
Off 3 after alarm on / off
Dec.Plc.: 0 Min: 0 Max: 1 Type:
Menus: - Parameter menu + Diagnostics - Design Level
P811 Max torq stpt
Maximum allowable torque measurement Overload Function 0 % deactivates detection .
811
Unit: % Min: 0.0 Max: 200.0 Indices:
Menus: - Parameter menu + Diagnostics - Fixed settings - Drive setting - Upread/free access Menus: - Parameter menu + Diagnostics - Fixed settings - Drive setting - Upread/free access
r812 Overload data 811
Visualization parameter for displaying data during Overload Function r812.1 displays % speed during overload detection r812.2 displays % torque during overload detection
Unit: % Min: 0.0 Max: 200.0 Indices:2
r827 Generat. Date 827
Visualization parameter for displaying the date on which the firmware of the basic unit was generated. Index 1: Year Index 2: Month Index 3: Day
Menus: - Parameter menu + Diagnostics + Messages/displays - Drive setting - Upread/free access - Power section definition
r828 SW ID 828
Visualization parameter for displaying the software codes. With the help of these codes, the compatibility of the individual software versions can be checked. Index 1: Basic board Index 2: Optional board in slot A Index 3: Optional board in slot B Index 4: Optional board in slot C Index 5: Optional board in slot D Index 6: Optional board in slot E Index 7: Optional board in slot F Index 8: Optional board in slot G For boards without software (e.g. SBR, SLB), 0.0 is always shown in the corresponding index.
Menus: - Parameter menu + Diagnostics + Messages/displays - Fixed settings - Quick parameterization - Board configuration - Drive setting - Download - Upread/free access - Power section definition
13-26
Parameter
Description
Note: The parameter may only be used for test purposes. Precondition: parallel connected unit
Data
Read/write
P900 Smoothing Const 900
Smoothing function for constant speed deviation detection for fault
Min: 0 Max: 100 Unit: - msec Indices: 2
Menus: - Parameter menu - Upread/free access Changeable in: - Drive Setting Menus:
P901 Deviation stpt
Setpoint for allowable speed deviation detection for fault P901.1 permissible setpoint for F152 P901.2 permissible setpoint for F153 Min: 0 Max: 100 Unit: - msec Indices: 2
- Parameter menu
- Upread/free access Changeable in: - Drive Setting
901
P902 Delay time F152 902 P903 Fault enable F152 & F153 903
Sets delay time before activating Speed Deviation Fault F152
Min: 0.00 Max: 1.00 Unit: - sec Indices: 1 Min: 0 Max: 1 Unit: Indices:2
Menus: - Parameter menu - Upread/free access Changeable in: - Drive Setting Menus: - Parameter menu - Upread/free access Changeable in: - Design Level
Enables fault detection for F152 & F153 faults Both indices required for activation P903.1 enable F152 & F153 P903.2 enable F152 & F153
P904 Smoothing Zero Spd 904
Sets smoothing filtering to Zero Speed Detector For Fault detection F154
Min: 0 Max: 100 Unit: -msec Indices:2
Menus: - Parameter menu - Upread/free access Changeable in: - Design Level
P905 Maximum Zero Spd 904
Sets maximum level for Zero Speed Detector For Fault detection F154
Min: 0.00 Max: 1.00 Unit: - % Indices:1
Menus: - Parameter menu - Upread/free access Changeable in: - Design Level Menus: - Parameter menu - Upread/free access Changeable in: - Design Level Menus: - Parameter menu - Upread/free access Changeable in: - Design Level
P906 Fault enable F154 906
Enables fault detection for F154 Zero-speed Fault both signals are Anded P906.1 enable F154 on release of braking control P906.2 enable F154 fixed high (used to activate)
Min: 0 Max: 1 Unit: Indices:2
P907 Delay time F154 907
Sets delay time before activating Zero Speed Fault F154
Min: 0.00 Max: 0.50 Unit: - sec Indices: 1
13-27
Rev 10/20/00
Parameter
P915 Enable PBmode 915
Description
Enables infinitely-adjustable 2-Button speed control mode 1= Active
Data
Read/write
P916 Enable Field Weakening 916
Enables field weakening for above base speed operation (Note reduction in max torque when active 1 = Active
r947 Fault Memory 947
Visualization parameter for displaying the last 8 fault trips. For each fault trip, up to 8 faults occurring at the same time can be stored. Only those faults are stored to which a fault number is assigned.
Menus: - Parameter menu + Diagnostics + Faults/warnings - Drive setting - Upread/free access
Index 1 to 8: 1st (last) fault trip, faults 1 to 8 Index 9 to 16: 2nd fault trip, faults 1 to 8 Index 17 to 24: 3rd fault trip, faults 1 to 8 Index 25 to 32: 4th fault trip, faults 1 to 8 Index 33 to 40: 5th fault trip, faults 1 to 8 Index 41 to 48: 6th fault trip, faults 1 to 8 Index 49 to 56: 7th fault trip, faults 1 to 8 Index 57 to 64: 8th (oldest) fault trip, faults 1 to 8 The value 0 in index 1 means that no fault is active at the present time. Further information for describing fault trips is contained in r782, r949, P952. The fault memory is deleted with the help of P952.
r949 Fault Value 949
Visualization parameter for displaying fault values. Fault values contain additional information on the faults which have occurred and allow more exact diagnosis. The fault values are assigned to the faults and are stored in the same indices as the associated fault numbers in r947. Indices 1 to 8: 1st (last) fault trip, fault values 1 to 8 Indices 9 to 16: 2nd fault trip, fault values 1 to 8 Indices 17 to 24: 3rd fault trip, fault values 1 to 8 Indices 25 to 32: 4th fault trip, fault values 1 to 8 Indices 33 to 40: 5th fault trip, fault values 1 to 8 Indices 41 to 48: 6th fault trip, fault values 1 to 8 Indices 49 to 56: 7th fault trip, fault values 1 to 8 Indices 57 to 64: 8th (oldest) fault trip, fault values 1 to 8 Further information on describing fault trips are contained in in r782, r947, P952. The fault memory is deleted with the help of P952.
Menus: - Parameter menu + Diagnostics + Faults/warnings - Drive setting - Upread/free access
r951 FaultTextList 951
List of fault texts. Each fault text is stored under the index corresponding to its fault.
Menus: - Parameter menu + Diagnostics + Faults/warnings - Upread/free access
13-28
Parameter
Description
Data
Read/write
P952* # of Faults 952
Function parameters for displaying the stored fault trips and for deletion of the fault memory. If 0 is entered, the whole fault memory consisting of r782, r947, r949 is deleted.
Menus: - Parameter menu + Diagnostics + Faults/warnings - Upread/free access Changeable in: - Drive setting
r953 Warning Param 1 953
Visualization parameter for displaying which of warnings 1 to 16 are active.
Visualization parameter for displaying which of warnings 81 to 96 are active. Warnings 81 to 96 are tripped by a built-in communication board (CBx).
Visualization parameter for displaying which of warnings 97 to 112 are active. Warnings 97 to 112 are tripped by a built-in technology board.
Visualization parameter for displaying which of warnings 113 to 128 are active. Warnings 113 to 128 are tripped by a built-in technology board.
13-29
Rev 10/20/00
r964 Drive ID 964
Function parameter for unit data identification. The parameter contains a string of characters of the "text" type. The first 2 characters contain the ID number for identifying the unit on PROFIBUS. A further 24 characters contain the contain the drive type name for display in visualization systems. A further 24 characters contain the software version and the date the software was generated. Example of the contains of the string: 2 Byte: ID number: 8022Hex 24 Byte: model name: MASTERDRIVES VC 24 Byte: Software version and date generated V3.0 Day Month Year
Dec.Plc.: 0 Unit: Indices: Type: VS
Menus: - Parameter menu - Upread/free access
U842* Start Pulse 2842
Setting value for the start pulse (gearbox pulse) in %. The start pulse is added to the speed setpoint after the ramp-function generator. This brief additional setpoint is injected into the speed controller. This thus prevents the load briefly sagging (dropping). The nominal system speed (P2801) is the reference quantity. Correlation: P2843 (Smooth Start Pulse) P2844 (Source Start Pulse) Precondition: P2800 = 1
index1: 0,0 Min: -100,0 Max: 100,0 Unit: % Indices: 4 Type: I2
Menus: - Parameter menu - Upread/free access Changeable in: - Drive setting - Ready
n911 Board ID 2911
Visualization parameter for displaying the board ID. This ID enables various hardware statuses of the installed electronic boards to be determined. Index 1: Basic board Index 2: Optional board on slot A Index 3: Optional board on slot B Index 4: Optional board on slot C Index 5: Optional board on slot D Index 6: Optional board on slot E Index 7: Optional board on slot F Index 8: Optional board on slot G
Menus: - Parameter menu - Fixed settings - Quick parameterization - Board configuration - Drive setting - Download - Upread/free access - Power section definition
n912 VCS SW Inform 2912
Information on the software version of the gating unit processor Index 1: Software version Index 2: Software ID Index 3: Generation date year Index 4: Generation date month Index 5: Generation date day
Menus: - Parameter menu - Fixed settings - Quick parameterization - Board configuration - Drive setting - Download - Upread/free access - Power section definition
13-30
Section 14
14.1 Faults
BUL 425 Faults and Alarms

General information regarding faults For each fault, the following information is available: Parameter r947 Fault number r949 Fault value r951 Fault list P952 Number of faults r782 Fault time If a fault message is not reset before the electronic supply voltage is switched off, then the fault message will be present again when the electronic supply is switched on again. The unit cannot be operated without resetting the fault message. (Exception: Automatic restart has been selected, see P373). Table: 14-1 Fault numbers, causes and their counter-measures
Number / Fault
F001 Main contactor checkback
Cause
If a main contactor checkback is congured, no checkback occurs within the time set in P600 after the powerup command. In the case of externally excited synchronous motors (P095 = 12), there is no checkback for the excitation current unit.
Counter-measure
P591 Source Contactor Message Parameter value must be in conformance with the connection of the main contactor checkback. Check the checkback loop of the main contactor (or the checkback of the excitation current unit in the case of synchronous motors).
F002 Pre-charging
When pre-charging, the minimum DC link voltage (P071 Line Volts x 1.34) of 80 % has not been reached. The maximum pre-charging time of 3 seconds has been exceeded.
Check the supply voltage, Compare with P071 Line Volts (Compare P071 with the DC link voltage on DC units). Check the rectier/regenerative unit on DC units. The rectier/regenerative unit must be switched on before the inverter is switched on. Check the supply voltage or input DC voltage. Converter is operating in regenerative mode without feedback possibility. If the converter supply voltage is at the upper tolerance limit and it is operating at full load, F006 can also be caused by a line phase failure. Possibly
F006 DC link overvoltage
Shutdown has occurred due to excessive DC link voltage. Line voltageI DC voltage range I Shutdown value -----------------------------------------------------------200 V - 230 V I 270 V - 310 V I appr. 410 V 380 V - 480 V I 510 V - 650 V I appr. 820 V 500 V - 600 V I 675 V - 810 V I appr. 1020 V 660 V - 690 V I 890 V - 930 V I appr. 1220 V For parallel-connected converters (BF L) r949 = 1: Overvoltage in the DC link of the master r949 = 2: Overvoltage in the DC link of the slave.
- Increase P464 Decel Time, - Activate P515 DC Bus Volts Reg. (check P071 beforehand) - Reduce P526 Fly Search Speed. - Reduce P259 Max Regen Power (only for P100 = 3, 4 or 5)
14-1
Revised 6/26/01
F008 DC link undervoltage
The lower limit value of 76% of the DC link voltage (P071 Line Volts), or of 61% when kinetic buffering has been enabled, has been fallen short of. Undervoltage in the DC link in 'normal' operation (i.e. no SIMULATION). Undervoltage in the DC link with active kinetic buffering and speed less than 10 % of the rated motor speed. It was a 'brief power failure' which was not detected until system recovery (auto restart ag).
Check - Input DC voltage - DC link
F010 DC link overvoltage
Due to excessive DC link voltage, shutdown has taken place: Line voltage DC link range Shutdown value 380 V - 480 V 510 V - 650 V 740 V Note: Only at U800 = 1 and f(Pulse) > f(derating) Lower threshold value than F006 !
Check the supply voltage Check the braking resistor Converter operates in regenerative mode without a feedback possibility. Braking unit must be set to the lower response threshold (673 V)
F011 Overcurrent
Overcurrent shutdown has occurred. The shutdown threshold has been exceeded. The phase in which an overcurrent has occurred is indicated in a bit-coded manner in the fault value (see P949). Phase U --> Bit 0 = 1--> fault value = 1 Phase V --> Bit 1 = 1--> fault value = 2 Phase W--> Bit 2 = 1--> fault value = 4 If an overcurrent occurs simultaneously in several phases, the total of the fault values of the phases concerned is the resulting fault value.
- Check the converter output for short-circuit or earth fault - Check the load for an overload condition - Check whether motor and converter are correctly matched - Check whether the dynamic requirements are too high
F012 I too low
During excitation of the induction motor, the current did not rise above 12.5% of the setpoint magnetizing current for no-load operation.
Only for closed loop n/f/T control (P100 = 3, 4, or 5) If no motor is connected, go into the simulation mode P372. Check current detection, check power section.
F014 I too low
During excitation of the motor, the current component is less than 25% of the motor no-load current. Note: Only for U800 = 1 Irrespective of the type of control (Difference to F012)
Check the output contactor Check the motor cable
14-2
F015 Motor stall
Motor has stalled or is locked: - if the static load is too high - if the acceleration or deceleration time is too fast, or if load change is too fast and too great, - due to incorrect parameterization of the pulse encoder pulse number P151 or of the analog tachometer scaling P138 - due to disturbed speed signals (tachometer shield not connected) The fault is only generated after the time set in P805. The binector B0156 is set in the status word 2 r553 Bit 28. To detect whether the drive is blocked, see P792 (Perm Deviation) and P794. With n/f control, this fault is tripped if the torque limits have been reached (B0234). With speed control (P100 = 4) and master drive (see P587), the fault can also point to an interruption in the encoder cable. This case has the same signicance as if the drive is locked. With v/f control, the I(max) controller has to be activated (P331). The monitor does not operate with v/f textile applications (P100 = 2). Motor has stalled or is locked: In the case of synchronous motors (P095 = 12, 13): by reaching the maximum frequency In the case of externally excited synchronous motors (P095 = 12): as a result of missing or excessively high excitation current (ux is too small or too great). When the maximum frequency (including control reserves) (B0254) has been reached on synchronous motors, the fault is generated immediately. If the deviations in the rotor ux are too great, rst of all, the converter current is switched to zero, the excitation current is reduced and, after some time, the fault message is tripped at the level of the double damping time constant (2*r124.1). During this wait time, the status word bit B0156 (r553.28) is set already.
- Reduce load - Release brake - Increase current limits Increase P905 PullOut/BlckTime - Increase P792 response threshold for set/actual deviation Only for f/n/T control (P100 = 3, 4, 5) - Increase torque limits or torque setpoint Only n/T control or v/f control with speed controller: (P100 = 0, 4, 5) - Check tachometer cable break - Check pulse encoder pulse number -Check analog tachometer scaling - Connect shield of tachometer cable on motor side and converter side - Reduce smoothing of speed pre-control P216 (only n/ T control) only frequency control:(P100 = 3) - Slow down acceleration time (see also P467 ProtRampGen Gain). Increase current in the lower frequency range (P278, P279, P280) - Switch in speed controller pre-control (P471>0). Set EMF controller more dynamically (315) to max. approx. 2 - Increase changeover frequency for the EMF model (P313). Replace by speed control with pulse encoder in the case of overmodulated n/f controller - Track speed setpoint with the speed actual value so that the set/actual deviation is always less than that set in P792. Only for synchronous motor: (P095 = 12) - Check current limits of the excitation unit. - Check excitation current setpoint and actual value (incl. wiring) - Check voltage limits of the excitation unit during dynamic current changes. - Check drive system for resonance oscillations.
F018 F set y
The found set frequency could not be implemented. Reasons: - Additional setpoint 2 too high - Speed actual-value at standstill negative (signal ripple) and negative direction of rotation locked.
- Check additional setpoint 2 - Release negative directions of rotation with low maximum speed.
14-3
Revised 6/26/01
F019 Motor not found F020 Motor temperature
Motor has not been found (during ying restart without tachometer).
Power up after coasting. Possibly increase P525 Fly Search Amps.
The motor temperature limit value has been exceeded. r949 = 1 limit value of motor temperature exceeded r949 = 2 short-circuit in the cable to the motor temperature sensor or sensor defective r949 = 4 wire break in the cable to the motor temperature sensor or sensor defective r949 = 5 wire break and limit value exceeded
Check the motor (load, ventilation, etc.). The actual motor temperature can be read in r009 Motor Temperature. Check P381 Mot Temperature Fault - check the KTY84 input at connector X103:29,30 for short-circuit.
F021 Motor I2t F023 Inverter temperature
Parameterized limit value of the I2t monitoring for the motor has been exceeded.
Check: P383 Mot Temperature T1
The limit value of the inverter temperature has been exceeded. r949 = 1: Limit value of inverter temperature has been exceeded. r949 = 2: Sensor 1: wire break of sensor cable or sensor defective r949 = 18: Sensor 2: wire break of sensor cable or sensor defective r949 = 34: Sensor 3: wire break of sensor cable or sensor defective r949 = 50: Sensor 4: wire break of sensor cable or sensor defective.
Measure the air intake and ambient temperature. Please observe the reduction curves at >40 C. Check: - Whether the fan -E1 is connected and is rotating in the correct direction - that the air entry and discharge openings are not restricted - Temperature sensor at -X30.
F025 UCE Ph. L1
There has been an UCE shutdown in phase L1
Check: - phase L1 for short-circuit or ground fault (-X2:U2 - including motor) - that CU is correctly inserted - That the switch for "SAFE OFF" (X9/5-6) is open (only for units with order No. ...-11,...-21,...-31, ...-61).
F026 UCE Ph. L2
There has been an UCE shutdown in phase L2.
Check: - phase L2 for short-circuit or ground fault (-X2:V2 - including motor) - that CU is correctly inserted - that the switch for 'SAFE OFF' (X9/5-6) is open (only for units with order Nos....-11, ...-21,...-31, ...-61)
F027 UCE Ph. L3
There has been an UCE shutdown in phase L3.
Check: - phase L3 for short-circuit or ground fault (-X2:W2 - including motor) - that CU is correctly inserted - that the switch for 'SAFE OFF' (X9/5-6) is open (only for units with order Nos....-11, ...-21,...-31, ...-61)
14-4
F028 Supply phase F029 Meas. value sensing
The frequency and the amplitude of the DC link ripple indicate a single-phase power failure.
Check the supply voltage.
A fault has occurred in the measured value sensing system: - (r949 = 1) Offset adjustment in phase L1 not possible
Fault in measured value sensing Fault in power section (valve cannot block) Fault on CU
- (r949 = 2) Offset adjustment in phase L3 not possible. - (r949 = 3) Offset adjustment in phases L1 and L3 not possible. - (r949=65) Automatic Adjustment of the analog inputs is not possible F035 Ext. Fault 1 Parameterizable external fault input 1 has been activated Check: - whether there is an external fault - whether the cable to the appropriate digital input has been interrupted - P575 Source No ExtFault1 F036 Ext. Fault 2 Parameterizable external fault input 2 has been activated Check: - whether there is an external fault - whether the cable to the appropriate digital input has been interrupted - P585 Source No ExtFault2 F037 Analog input An analog input is taking place in operating mode 4..20mA and a wire break has occurred. The number of the analog input concerned is shown in fault value (r949). Check the connection to - Analog input 1 -X102: 15, 16. - Analog input 2 -X102: 17, 18. Check parameters - P632 CU AanIn Conf - P634 CU AnaIn Smooth - P631 CU AnaIn Offset F038 Voltage OFF during parameter storage F040 AS internal F041 EEPROM fault F042 Calculating time Calculating time problems Reduce the calculating time load: - Increase P357 Sampling Time - Calculate individual blocks in a slower sampling time Observe r829 CalcTimeHdroom. A fault has occurred when storing the values in the EEPROM. Replace CU (-A10) Incorrect operating status Replace CU (-A10) During a parameter task, a voltage failure has occurred on the board. Re-enter the parameter. The number of the parameter concerned can be seen in fault value r949.
14-5
Revised 6/26/01
F044 BICO manager fault
A fault has occurred during the softwiring of binectors and connectors.
Strwert r949: >1000 : Fault during softwiring of connectors >2000 : Fault during softwiring of binectors - Voltage OFF and ON - Factory setting and new parameterization - Replace the board
F045 Opt. Board HW
A hardware fault has occurred when accessing an optional board
Replace CU. Check connection of the board subrack to the optional boards and replace if necessary.
F046 Par. Task F047 Gating Calc Time
A fault has occurred during the transfer of parameters to the gating unit processor.
Power the unit down and up again. Replace CU (-A10)
The calculating time in the gating unit computer is not sufcient
Replace CU (-A10). In case of synchronous motors (P095 = 12): Pulse frequency set too high (P340>2kHz).
F048 Gating Pulse Freq F049 SW version F050 TSY Init. F051 Speed encoder
The pulse frequency set in P340 is not permissible.
Change P340 Pulse Frequency.
The rmware versions on the CU have different rmware release.
Use uniform rmware
Error when initializing the TSY board
Check: - Whether the TSY is correctly inserted
Digital tachometer or analog tachometer sensing are faulty
Check the parameters: - P130 Source SpdActV - P151 Pulse # - P138 AnalogTachScale - P109 Motor #PolePairs The product of P109 and P138 must be smaller than 19200. Check or replace tachometer. Check connection to tachometer. Replace CU
F052 n-Cntr.Input
The fault input on the TSY has been active
Cancel tachometer with control track P130 Source Spd ActV Replace TSY Check the tachometer connection at the TSY. Several versions are possible, depending on the type of tachometer.
14-6
F053 Tachometer dn/dt
The permissible change value of the speed encoder signal P215 dn(act,perm) has been doubly exceeded.
Check tachometer cables for interruptions. Check earthing of tachometer shield. - The shield must be connected both at the motor and the converter side. - The encoder cable must not be interrupted. - The encoder cable must not be laid together with the power cables. - Only recommended encoders should be used. - In the case of a signal fault, the DT1 board may have to be used. If necessary, change P215 - With P806 (observe parameter description) it is possible during operation to switch over to encoder-free operation.
F054 Sensor board initialization fault
A fault has occurred during initialization of the encoder board.
Fault value r949 1: Board code incorrect 2: TSY not compatible 3: SBP not compatible 7: Board double 20: TSY board double 60: Internal error
F055 Wrong external input signals 1 F056 SIMOLINK telegram failure
A fault has occurred because of release in both directions (forward & reverse) occurred at the same time. Note: this fault is only available when the drive is not in the follower mode Communication on the SIMOLINK ring is disturbed.
Check input directional run commands and source for shorted input.
- Check the ber-optic cable ring - Check whether an SLB in the ring is without voltage - Check whether an SLB in the ring is faulty - Check P741 (SLB TlgOFF)
F057 Brake does not open
The brake has not opened, the output current of the converter has exceeded the parameterized current threshold (U840) for longer than one second (with the rotor locked) Note: Only with U800 = 1
Check brake Check I(max) brake (U840). The set threshold must be at least 10% above the maximum possible acceleration current.
F058 Parameter fault Parameter task F059 Parameter fault after factory setting/init. F060 MLFB is missing
A fault has occurred during the processing of a parameter task.
No remedy
A fault has occurred in the initialization phase during the calculation of a parameter.
The number of the inconsistent parameter is indicated in fault value r949. Correct this parameter (ALL indices) and switch voltage off and on again. Several parameters may be affected, i.e. repeat process. After acknowledgement, in INITIALIZATION enter a suitable MLFB in parameter P070 MLFB (6SE70..). (Only possible with the corresponding access stages to both access parameters). Acknowledge the fault and change the corresponding parameter value. The missing parameter is indicated in r949 as a fault value.
This is set if the MLFB = 0 after exiting INITIALIZATION (0.0 kW). MLFB = order number.
F061 Incorrect parameterization
A parameter entered during drive setting (e.g. P107 Mot Rtd Freq, P108 Mot Rtd Speed, P340 Pulse Frequency) is not in a permissible range (depending on control type)
14-7
Revised 6/26/01
F062 Multi-parallel circuit
Fault in connection with the multi-parallel circuit or board ImP1 has been detected.
r949 = 10: Communications card does not reply. When writing the control word, BUSY is not active if CSOUT is inactive. Communications card is probably not inserted. r949 = 11,12: Timeout during BUSY during initialization. BUSY does not become active within 1 sec. r949 = 15: Timeout during BUSY during normal communication. BUSY does not become active within 1 sec. r949 = 18: Timeout when reading out the fault information from the ImPIs. Within one second after activation of FAULT no fault cause can be supplied by the IMP1. r949 = 20+i: HW conict. This is set if bit HWCONF is set in status word of slave i. (Fault in the conguration of the multiparallel circuit) r949 = 30+i: HW version of ImPI is not compatible. The relevant slave number is contained in i. r949 = 40: Number of slaves does not tally with the setpoint number of slaves of the unit. r949 = 50+I Inconsistency in the number of slaves. The number of slaves notied by the ImPI is not in conformance with the number of status words or with the setpoint number of slaves of the MLFB. Counter-measure: - Check ImPI or communications card and replace, if necessary. - Check conguration of multi-parallel circuit. - Check parameterization. - Replace CU. - Replace ImPI.
F065 Scom Telegram
No telegram was received at an Scom interface (Scom/ USS protocol) within the telegram failure time.
Fault value r949: 1 = interface 1 (SCom1) 2 = interface 2 (SCom2) - Check the connection CU -X100:1 to 5 and check the connection PMU -X300. - Check "SCom/SCB TLG OFF" P704.01 (SCom1) and P704.02 (SCom2) - Replace CU (-A10).
14-8
F070 SCB initialization fault
A fault has occurred during initialization of the SCB board.
Fault value r949: 1: Board code incorrect 2: SCB board not compatible 5: Error in conguration data 6: Initialization timeout 7: SCB board double 10: Channel error
F072 EB initialization fault
A fault has occurred during initialization of the EB board.
Fault value r949: 2: 1st EB1 not compatible 3: 2nd EB1 not compatible 4: 1st EB2 not compatible 5: 2nd EB2 not compatible 21: Three EB1 boards 22: Three EB2 boards 110: Fault on 1st EB1 120: Fault on 2nd EB1 210: Fault on 1st EB2 220: Fault on 2nd EB2
F073 AnInp1SL1 F074 AnInp2 SL1 F075 AnInp3 SL1 F076 AnInp1 SL2 F077 AnInp2 SL2 F078 AnInp3 SL2 F079 SCB telegram failure
4 mA at analog input 1, slave 1 fallen short of
Check the connection of the signal source to the SCI1 (slave 1) -X428: 4, 5. Check the connection of the signal source to the SCI1 (slave 1) -X428: 7, 8. Check the connection of the signal source to the SCI1 (slave 1) -X428: 10, 11. Check the connection of the signal source to the SCI1 (slave 2) -X428: 4, 5. Check the connection of the signal source to the SCI1 (slave 2) -X428: 7, 8. Check the connection of the signal source to the SCI1 (slave 2) -X428: 10, 11. - Check the connections of the SCB1(2). - Check P704.03"SCom/SCB Tlg OFF" - Replce SCB1(2) - Replace CU (-A10)
No telegram has been received by the SCB (USS, peerto-peer, SCI) within the telegram failure time.
F080 TB/CB initialization fault
Fault during initialization of the board at the DPR interface
Fault value r949: 1: Board code incorrect 2: TB/CB board not compatible 3: CB board not compatible 5: Error in conguration data 6: Initialization timeout 7: TB/CB board double 10: Channel error Check the T300/CB board for correct contacting, check the PSU power supply, check the CU / CB / T boards and check the CB initialization parameters: - P918.01 CB Bus Address, - P711.01 to P721.01 CB parameters 1 to 11
14-9
Revised 6/26/01
F081 OptBrdHeartbeatCounter
Heartbeat-counter of the optional board is no longer being processed
Fault value r949: 0: TB/CB heatbeat-counter 1: SCB heartbeat-counter 2: Additional CB heartbeat-counter - Acknowledge the fault (whereby automatic reset is carried out) - If the fault re-occurs, replace the board concerned (see fault value) - Replace ADB - Check the connection between the subrack and the optional boards (LBA) and replace, if necessary
F082 TB/CB telegram failure
No new process data have been received by the TB or the CB within the telegram failure time.
Fault value r949: 1 = TB/CB 2 = additional CB - Check the connection to TB/CB - Check P722 (CB/TB TlgOFF) - Replace CB or TB
F085 Add. CB initialization fault
A fault has occurred during initialization of the CB board.
Fault value r949: 1: Board code incorrect 2: TB/CB board not compatible 3: CB board not compatible 5: Error in conguration data 6: Initialization timeout 7: TB/CB board double 10: Channel error Check the T300 / CB board for correct contacting and check the CB initialization parameters: - P918.02 CB Bus Address, - P711.02 to P721.02 CB Parameters 1 to 11
F087 SIMOLINK initialization fault F090 Mld Param. F091 Mld Time
A fault has occurred during initialization of the SLB board.
- Replace CU - Replace SLB
An error occurred when attempting to change a parameter from the standstill measurement or the rotating measurement (Mot ID). The rotating measurement takes longer than programmed in a measured status. Possible causes: Load torque too high Load torque not uniform Ramp-function generator disabled Due to entries for - Permissible phase sequence - Maximum frequency, - Minimum speed, - Changeover frequency between V and I model, - Start of eld-weakening frequency, - Frequency suppression bandwidth it was not possible to determine a permissible frequency range for the rotating measurement.
Power down and power up again. If it reoccurs, replace the CU.
Eliminate the cause and re-start the measurement (power up the converter again). If it re-occurs, replace the CU.
F095 Mld n(set)
There must be a 10% frequency range, which lies above 1.1 times the changeover frequency and below 0.9 times the start of eld-weakening frequency. Possible counter-measures - Permit both phase sequences - Increase maximum frequency - Reduce minimum speed, - Reduce changeover frequency between the V and I model. - Reduce or remove the frequency suppression bandwidth.
14-10
F096 Mld abort
The rotating measurement was aborted due to the inadmissible external intervention.
The fault value in r949 denes the type of intervention: 4 Setpoint inhibit 5 Changeover, setpoint channel 8 Unexpected change in the converter status 12 Motor data set changeover (for function selection "Complete Mot ID") 13 Changeover to slave drive 14 Motor data set changeover to data set with v/ f_charac 15 Controller inhibit is set 16 Ramp-function generator is disabled 17 Selection "Tacho test" for F controller 18 Ramp-function generator stopped Eliminate cause 22 Inverter inhibit: Check inverter release (P561)
F097 Mld measured value F098 Mld Tachof
The measured values for the nominal ramp-up time when optimizing the controller deviate too greatly. Cause: very unsteady load torque The rotating measurement has detected a fault in the speed actual value signal. The fault value denes the type of fault. The fault measurement may have been erroneously generated if the drive speed is externally forced (e.g. completely locked drive generates the "no signal" message)
If necessary, increase the torque limit values to 100 percent
The fault value in r949 denes the type of intervention 4 No speed signal present 5 Sign of the signal is incorrect 6 A track signal is missing 7 Incorrect gain 8 Incorrect pulse number Checking the measurement cables. Checking the parameters - P130 Source Speed ActV - P1151 Encoder Pulse #
F100 GRND Init
During the ground fault test, a current not equal to zero has been measured, or an UCE or overcurrent monitoring has responded, although no value has yet been triggered.
The cause of the fault can be read out from r376 "Ground FaultTest Result". Check the converter output for short-circuit or ground fault (-X2:U2, V2, W2 - including motor). Check that the CU is inserted correctly. Sizes 1 and 2: - Check the transistor modules on the PEU board -A23 for short-circuit. Size 3 and 4: - Check the transistor modules -A100, -A200, -A300 for short-circuit
14-11
Revised 6/26/01
F101 GRND UCE
During the ground fault test, the UCE monitoring has responded in a phase in which no valve has been triggered.
Check valves in the power section for short-circuit, and on converters with ber-optic gating, check the gating unit wiring and the UCE checkbacks for correct assignment. R376 can be interrogated to indicate which UCE monitoring has responded.
F102 GRND Phase
During the ground fault test, a current ows in a phase in which no valve has been triggered or the UCE monitoring has responded in the phase in which the valve has been triggered.
The fault value can be read out from r949. The digit of the xth position indicates the valve where the fault occurred at power-up. X O O O x = 1 = V+ x = 4 = Ux = 2 = V- x = 3 = U+ x = 5 = W+ x = 6 = W-
The gure of the xth digit indicates the phase in which I is 0 and thus a valve must be defective (always conductive). O O O X x = 1 = Phase 1 (U) x = 3 = Phase 3 (W) x = 4 = Phase 1 (U) or 3 (W) Examine phase for defective valves (always conductive). F103 Ground fault There is a ground fault or a fault in the power section. During the ground fault test, a current ows from the phase in which a valve has been triggered, the overcurrent comparitor has responded, or a UCE monitoring has responded in a phase in which a valve has been triggered. Read out fault value from r949. The digit of the xth position indicates the valve where the fault occurred at power-up. XOOO XOOO x = 1 = V+ x = 2 = V- x = 3 =U+ x = 4 = U- x = 5 = W+ x = 6 = W-
Check the motor including the feeder cable for shortcircuit. If no ground fault is present, check the power section for defective valves (always conductive). The digit of the xth position indicates the phase in which I is 0 and therefore a valve must be defective (always conductive). OOOX 1 = Current in phase 1 (U) 2 = UCE in phase 2 (V) 3 = Current in phase 3 (W) 4 = Only overcurrent occurred
The speed of the motor shaft during the ground-fault test should be less than 10 % of the rated speed! 1) In phase V there is a ground fault or a defective valve (always conductive) or the "SAFE OFF" switch (X9/5-6) is open (only for units with Order No. ...-11, ...-21, ...31).
14-12
F107 MLd = 0
A fault has occurred during the test pulse measurement
Read out fault value from r949. The gures of the grey shaded areas indicate which fault has occurred. OOXX xx = 01: Both current actual values remain 0 xx = 02: Motor-converter cable phase U interrupted xx = 03: Motor converter phase V interrupted xx = 04: Motor-converter phase W interrupted xx = 05: Current actual value I1 remains 0 xx = 06: Current actual value I3 remains 0 xx = 07: Valve U+ does not trigger xx = 08: Valve U- does not trigger xx = 09: Valve V+ does not trigger xx = 10: Valve V- does not trigger xx = 11: Valve W+ does not trigger xx = 12: Valve W- does not trigger xx = 13: Sign I1 incorrect xx = 14: Sign I3 incorrect xx = 15: Sign I1 and I3 incorrect xx = 16: Sign I1 confused with I3 xx = 17: I1 confused with I3 and both currents have an incorrect sign The digit of the xth digit indicates where the fault has occurred. XOOO x = 0 = Single converter x = 1 = Inverter 1 x = 2 = Inverter 2 x = 3 = Inverters 1 and 2 Check that all 3 motor feeder cables and the motor windings do not have any interruption. Check the connection between the current converter and the electronics and check the current converter itself. Check the correct input of the rating plate data for the motor data set valid during the measurement.
F108 Mld Unsymetrical
During the DC measurement, the measurement results for the individual phases differ signicantly. The fault value indicates which quantity(ies) is (are) concerned and in which phase the greatest deviation occurred.
Read out fault value from r949. The digit of the xth position indicates; O O O X Transverse voltage too high x = 1 = phase R x = 2 = phase S x = 3 = phase T OOXO OXOO XOOO Dev. stator resistance (1, 2, 3 as above) Dev. Rotor resistance (1, 2, 3 as above) Dev. Dead-time compensation (1, 2, 3 as above)
X O O O O Dev. Valve voltage (1, 2, 3 as above) The motor, power section or actual-value sensing are signicantly non-symmetrical.
14-13
Revised 6/26/01
F109 Mld R(L) F110 Mld di/dt
The rotor resistance determined during DC measurement deviates too signicantly from the value, which was calculated by the automatic parameterization from the rated slip. During test pulse measurement, the current has increased signicantly faster than was expected. Thus for the 1st test pulse, an overcurrent condition occurred within the rst half of the minimum switch-on time
- Incorrect input of rated speed or rated frequency - Pole pair number incorrect - There may be a short-circuit between two converter outputs. - The motor rating plate data have not been correctly parameterized. - The motor leakage is too low.
F111 Fault e_Func F112 Unsymmetrical I_sigma F114 MId OFF
A fault has occurred while calculating the equalization function.
The individual leakage test results deviate too signicantly.
The converter has automatically stopped the automatic measurement due to the time limit up to power-up having been exceeded or due to an OFF command during the measurement, and has reset the function selection in P115.
Re-start with P115 function selection = 2 "Motor identication at standstill".The ON command must be given within 20 sec. after the alarm message A078 = standstill measurement has appeared. Cancel the OFF command and re-start measurement.
F115 KF internal F116 Technology board fault F117 Technology board fault F118 Technology board fault F119 Technology board fault F120 Technology board fault F121 Technology board fault F122 Technology board fault F123 Technology board fault F124 Technology board fault F125 Technology board fault F126 Technology board fault F127 Technology board fault
A fault has occurred during calculations in the context of the MotID.
Power-down the converter and electronics and power-up again.
See separate TB documentation, consult factory
14-14

F128 Technology board fault F129 Technology board fault F130 Technology board fault F131 Technology board fault F132 Technology board fault F133 Technology board fault F134 Technology board fault F135 Technology board fault F136 Technology board fault F137 Technology board fault F138 Technology board fault F139 Technology board fault F140 Technology board fault F141 Technology board fault F142 Technology board fault F143 Technology board fault F144 Technology board fault F145 Technology board fault F146 Technology board fault F147 Technology board fault F148
Wrong external signals #2
A fault occurred because drive received Binary Inputs #1 and # 2 at the same time. This fault is only available in factory setting #14 Bucket Crane control (P130=14)
Check binary inputs for miswiring or shorts Check connections on X-101 & X-901& X900 Connectors
14-15
Revised 6/26/01
F149 Fault 2 Function blocks F150 Fault 3 Function blocks F151 Fault 4 Function blocks F 152 Speed deviation (timed)
An active signal is present at binector U062 (1).
Examine cause of fault, see function diagram 710
An active signal (1) is present at binector U063.
This fault is available in vector control modes when the speed is greater than 13% At timed speed deviation fault occurs when the difference between the actual and reference speeds exceeds P901.1 (13%) for a time longer than P902 (0.50 sec). This fault is not available in follower (slave) modes.
F 153 Speed deviation (immediate)
This fault is available in vector control modes when the speed is greater than 15% An immediate speed deviation fault occurs when the difference between the actual and reference speeds exceeds P901.2 (15%) This fault is not available in follower (slave) modes.
F 154 Zerospeed
A zero-speed fault trip occurs when the actual speed value is less than P905 (0.05%) for longer than P907 (0.20 sec) The fault can be disabled by P906. This fault is only available in closed-loop vector modes P366 = 11 or 14 that are not used as a follower (slave). An Overspeed trip occurs if the speed is higher than P452 + P804 or lower than P453 P804. This fault is available in all modes.
F 155 Overspeed (immediate) F 156 Current deviation
This fault is available in vector control modes when the speed is less than 50% A current deviation fault occurs when the difference between the actual and reference current exceeds P912 (20%) for a time longer than P913 (Oms).
F243 Link int. F244 ParaLink int.
Fault in internal linking. One of the two linked partners does not reply.
Replace CU (-A10).
Fault in the internal parameter linking
Release comparison of gating unit software and operating software regarding the transfer parameters. Replace CU (-A10)
F255 Fault in EEPROM
A fault has occurred in the EEPROM.
Switch off the unit and switch it on again. If the fault re-occurs, replace the CU.
14-16
14.2
BUL 425 Alarms

The alarm message is periodically displayed on the PMU by A = alarm/ alarm message and a 3-digit number. An alarm cannot be acknowledged. It is automatically deleted once the cause has been eliminated. Several alarms can be present. The alarms are then displayed one after the other. When the converter is operated with the OP1S operator control panel, the alarm is indicated in the lowest operating display line. The red LED additionally ashes (refer to the OP1S operating instructions). Table: 14-2 : Alarm numbers, causes and their counter-measures
Number / Alarm
A001 Calculating time A002 SIMOLINK start alarm A014 Simulation active alarm
Cause
The calculating time utilization of the CU board is too high
Counter-measure
- Observe r829 CalcTimeHdroom - Increase P357 Sampling Time or - Reduce P340 Pulse Frequency
Start of the SIMOLINK ring is not functioning.
- Check the ber-optic cable ring for interruptions - Check whether there is an SLB without voltage in the ring - Check whether there is a faulty SLB in the ring
The DC link voltage is not equal to 0 when the simulation mode is selected (P372 = 1).
- Set P372 to 0. - Reduce DC link voltage (disconnect the converter from the supply)
A015 External alarm 1
Parameterizable external alarm input 1 has been activated.
Check - whether the cable to the corresponding digital input has been interrupted. - parameter P588 Source No External Warn1
A016 External alarm 2
Parameterizable external alarm input 2 has been activated.
Check - whether the cable to the corresponding digital input has been interrupted. - parameter P588 Source No Et Warn2
A017 SAFE OFF alarm active A020 Overcurrent
The switch for blocking the inverter pulses (X9 terminal 5-6) has been opened (only for units with Order No. ...-11, ...-21, ...-31, ...61) An overcurrent condition has occurred.
Close switch X9 5-6 and thus release the inverter pulses.
Check the driven load for an overload condition. - Are the motor and the converter matched? - Have the dynamic performance requirements been exceeded.
A021 Overvoltage A022 Inverter temperature
An overvoltage condition has occurred.
Check the supply voltage. The converter regenerates without regeneration possibility.
The threshold for initiating an alarm has been exceeded.
Measure intake air or ambient temperature. Observe reduction curves at > 40C. Check - Whether the fan -E1 is connected and is rotating in the correct direction. -The air intake and discharge openings for blockage. - The temperature sensor at -X30. - r833 indicates the maximum converter temperature of all existing measuring points.
14-17
Revised 6/26/01
A023 Motor temperature
The parameterizable threshold for initiating an alarm has been exceeded.
Check the motor (load, ventilation, etc.). The current temperature can be read in r009 Motor Temperature Check the KTY84 (thermocouple) input at connector X103:29,30 for short-circuit.
A024 Motor movement A025 I2t Inverter
The motor has moved during motor data identication.
Lock the motor.
If the instantaneous load condition is maintained, then the inverter will be thermally overloaded.
Check: - P72 Rtd Drive Amps - MLFB P70 - P128 Imax - r010 Drive Utilization Motor load cycle is exceeded! Check the parameters: P382 Motor Cooling P383 Mot Temperature T1 P384 Mot Load Limits
A029 I2t motor
The parameterized limit value for the I2t monitoring of the motor has been exceeded.
A033 Overspeed
Bit 3 in r553 status word 2 of the setpoint channel. The speed actual value has exceeded the value of maximum speed plus the set hysteresis.
P804 Overspeed Hys plus P452 n/f(max, FWD Spd) or P453 n/f(max, REV Spd) has been exceeded Increase the parameter for the maximum frequencies or reduce the regenerative load.
A034 Setpoint/actual value deviation
Bit 8 in r552 status word 1 of the setpoint channel. The difference between frequency setpoint/actual value is greater than the parameterized value and the control monitoring time has elapsed.
Check the following: - whether an excessive torque requirement is present - whether the motor has been dimensioned too small. Increase values P792 Perm Deviation Frq/ set/actual DevSpeed and P794 Deviation Time Check whether cable(s) to the corresponding digital input(s)on connectors X-101 X-900, and X-901 are shorted or miswired.
A035 Direction Alarm A036 Brake checkback "Brake still closed" A037 Brake checkback "Brake still open" A038 Overload A041 Vdmax controller inhibit
The forward and reverse directions are enabled at the same time.
The brake checkback indicates the "Brake still closed" state.
Check brake checkback (see FD 470)
The brake checkback indicates the "Brake still open" state.
Check brake checkback (see FD 470)
This warning occurs at load current in excess of rated motor amps
Reduce load
The line voltage is too high or the drive line voltage (P071) is incorrectly parameterized. The Vdmax controller is disabled despite parameter access (P515), as otherwise the motor would accelerate immediately in operation to the maximum frequency. Motor is stalled or blocked. The alarm cannot be inuenced by P805 "PullOut/BlckTime", but by P794 "Deviation Time"
Check - the line voltage - P071 Line Volts Check - whether the drive is locked - whether the encoder cable is interrupted during speed control and whether the shield is connected. - Whether the drive has stalled - For synchronous motors (P095=12): excitation current injection
A042 Motor stall/lock
14-18
A043 n-act jump
The permissible change value of the speed encoder signal (P215) has been exceeded. Additionally for synchronous motors (P095=12): The motor rotates with more than 2% of the rated speed at the time of inverter release. The inverter status "Ready for operation" is not exited.
Check the tachometer cables for interruptions. Check the earthing of the tachometer shield. - The shield must be connected both on the motor and on the converter side. - The encoder cable must not be interrupted. The encoder cable must not be laid with the power cables. - Only the recommended encoders should be used. - If there is a signal fault, use the DTI board if necessary. If required, change P215. - Additionally for synchronous motors (P095=12): Do not grant inverter release until the motor is at standstill
A044 I too low
Only for synchronous motors (P095=12) in operation: The difference smoothed with P159 between excitation current setpoint and actual value (r160 - r156) deviates from zero by more than 25% of the rated magnetizing current.
Only for synchronous motors P095=12) Check: - whether the current limitation of the excitation current control is too small, - whether the dynamic performance of the excitation current injection is too low, - whether the excitation current injection function is operating, - whether the wiring of excitation current actual-value P155 is correct, - whether the wiring of excitation current setpoint r160 is correct, - whether there is a wire break between MASTERDRIVES and the excitation device, - whether the voltage limitation is too low for dynamic excitation current control, - whether the analog output for r160 takes place without isolating ampliers (despite cable length>4 m)
A045 DC braking activated A049 No slave
The DC braking function has been activated and the motor frequency is still above the frequency at which DC braking begins (P398). At serial I/O (SCB1 with SCI1/2), no slave is connected or ber-optic cable is interrupted or slaves are without voltage.
- Increase frequency at which DC braking begins
P690 SSCI AnaIn Conf - Check slave. - Check cable.
A050 Slave incorrect
At ser. I/O the slaves required according to a parameterized conguration are not present (slave number or slave type): Analog inputs or outputs or digital inputs or outputs have been parameterized which are not physically present. In a peer-to-peer connection a baud rate has been selected which is too high or too different.
Check parameter P693 (analog outputs), P698 (digital outputs). Check connectors K4101...K4103, K4201...K4203 (analog inputs) and binectors B4100...B4115, B4120...B4135, B4200...B4215, B4220...B4235 (digital inputs) for connecting. Adjust the baud rate in conjunction with the SCB boards P701 SCom/SCB Baud Rate
A051 Peer baud rate A052 Peer PcD L
In a peer-to-peer connection, a PcD length has been set which is too high (>5).
Reduce number of words P703 SCom/SCB PcD #
14-19
Revised 6/26/01
A053 Peer Lng f. A057 TB Parameter A061 Alarm 1 Function blocks A062 Alarm 2 Function blocks A063 Alarm 3 Function blocks A064 Alarm 4 Function blocks A065 Auto restart active
In a peer-to-peer connection, the pcD length of transmitter and receiver do not match.
Adjust the word length for transmitter and receiver P703 SCom/SCB PcD # Replace TB conguration (software)
Occurs when a TB is logged on and present, but parameter tasks from the PMU, SCom1 or SCom2 have not been answered by the TB within 6 seconds. An active signal is present at binector U065 (1).
Check cause of alarm (see FD 710)
The auto restart option (P373) restarts the drive. A possibly parameterized power-up delay time (P374) expires if ying restart is not selected. During precharging of the DC link, there is no time monitoring i.e. with an external electronics power supply, it is also switched-in again. The measured target frequency of the external converter (or supply) is greater than the parameterized maximum frequency of the synchronizing converter.
Caution! Personnel could be in danger when the drive automatically restarts. Check whether the auto restart function is really required! Check: - P452 n/f(max, FWD Spd)/ P453 n/f(max,REV Spd) are correct and - correct motor data set P578 Source MotDSet Bit0 are selected
A066 fsyn > fmax
A067 fsyn < fmin
The measured target frequency of the external converter (or supply) is less than the minimum frequency required for synchronizing.
Check: - r533 Sync Target Freq - Synchronizing cable.
A068 fsyn<>fsoll
The setpoint frequency of the synchronizing converter deviates too signicantly from the measured target frequency of the external converter (or supply). The permissible deviation can be set in P529. Synchronizing is not started as long as the rampfunction generator in the synchronizing converter setpoint channel is active. This alarm is only output if synchronizing is selected.
Adjust total setpoint (main and additional setpoints) to the target frequency displayed in visualization parameter r533.
A069 Regeneration active
Wait until acceleration has been completed. Check whether - P462 Accel Time - P463 Accel Time Unit has been correctly set.
A070 Sync error A071 tSY missing
This alarm is output if the phase difference goes outside the synchronizing window (P531) after successful synchronization. An attempt has been made to start synchronization with either the synchronizing board not inserted or not parameterized.
The alarm can only be deleted after synchronization has been exited.
Insert the TSY board in the subrack
14-20
A075 Ls, Rr Dev.
The measured values of the leakage measurement or of rotor resistance deviate signicantly.
Usually the leakage reactance P122 is the average value resulting from the measured values in r546.1...12, and the rotor resistance r126 from the values in r542.1..3. If individual measured values signicantly deviate from the average values, they are automatically not taken into account for the calculation (for RI) or the value of the automatic parameterization remains (for Ls). It is only necessary to check the results for their plausibility in the case of drives with high requirements on torque or speed accuracy.
A076 t-comp lim A077 r-g limit A078 Stands. Meas
The determined compensation time was limited to the value range of 0.5 s - 1.5 s.
Converter output and motor output are too different. Check motor data input P095 to P109.
The measured resistance has been limited to the maximum value of 49%.
Converter output and motor output are too different. Check motor data input P095 to P109.
The standstill measurement is executed when the converter is powered up. The motor can align itself s eve r a l t i m e s i n a c e r t a i n d i r e c t i o n w i t h t h i s measurement. The rotating measurement has been aborted or cannot commence because an inverter stop command is present.
If the standstill measurement can be executed without any danger: - Power up the converter. P561 Source InvRelese - Release the inverter If necessary, re-start the measurement by powering-up the converter. If the rotating measurement can be executed without any danger: - Power up the converter. New conguration necessary
A079 Mld Inv Stop
A080 MotId:Dr.M
When the conver ter is powered up, the rotating measurement automatically accelerates the drive. The drive can then only be externally controlled in a restricted fashion. The following description refers to the 1st CBP. For other CBs or the TB see operating instructions for CB board. The ID byte combinations which are being sent from the DP master in the conguration telegram are not in conformance with the permissible ID byte combinations. (See also Compendium, Chapter 8, Table 8.2-12). Consequence: No connection is made with the PROFIBUS master.
A081 CB alarm
A082 CB alarm
The following description refers to the CBP. For other CBs or the TB see the operating instructions for the CB board. No valid PPO type can be identied from the conguration telegram of the DP master. Consequence: No connection is made with the PROFIBUS master.
New conguration necessary.
A083 CB alarm
The following description refers to the 1st CBP. For other CBs or the TB see the operating instructions for the CB board. No net data or invalid net data (e.g. complete control word STW1=0) are being received from the DP master. Consequence: The process data are not passed on to the dual port RAM. If P722 (P695) is not equal to zero, this will cause the fault message F082 to be tripped.
14-21
Revised 6/26/01
A084 CB alarm
The following description refers to the 1st CBP. For other CBs or the TB see the operating instructions for the CB board. The telegram trafc between the DP master and the CBP has been interrupted (e.g. cable break, bus cable pulled out or DP master powered down). Consequence: If P722 (P695) is not equal to zero, this will cause the fault message F082 to be tripped.
A085 CB alarm
The following description refers to the 1st CBP. For other CBs or the TB see the operating instructions for the CB board. The CBP does not generate this alarm!
A086 CB alarm
The following description refers to the 1st CBP. For other CBs or the TB see the operating instructions for the CB board. Failure of the heart-beat counter on the basic unit. The heartbeat counter on the basic unit is no longer being incremented. The communication between the CBP and the basic board is disturbed.
A087 CB alarm
The following description refers to the 1st CBP. For other CBs or the TB see the operating instructions for the CB board. Fault in the DPS manager software of the CBP.
A088 CB alarm A089 CB alarm A090 CB alarm A091 CB alarm A092 CB alarm A093 CB alarm A094 CB alarm A095 CB alarm A096 CB alarm A097 TB alarm 1 A098 TB alarm 1 A099 TB alarm 1
See user manual for CB board
See user manual for CB board Alarm of the 2nd CB board corresponds to A81 of the 1st CB board See user manual for CB board Alarm of the 2nd CB board corresponds to A82 of the 1st CB board See user manual for CB board Alarm of the 2nd CB board corresponds to A83 of the 1st CB board See user manual for CB board Alarm of the 2nd CB board corresponds to A84 of the 1st CB board See user manual for CB board Alarm of the 2nd CB board corresponds to A85 of the 1st CB board See user manual for CB board Alarm of the 2nd CB board corresponds to A86 of the 1st CB board Alarm of the 2nd CB board. Corresponds to A87 of the 1st CB board See user manual for CB board See user manual for CB board Alarm of the 2nd CB board corresponds to A88 of the 1st CB board See separate TB documentation, consult factory
14-22
A100 TB alarm 1 A101 TB alarm 1 A102 TB alarm 1 A103 TB alarm 1 A104 TB alarm 1 A105 TB alarm 1 A106 TB alarm 1 A107 TB alarm 1 A108 TB alarm 1 A109 TB alarm 1 A110 TB alarm 1 A111 TB alarm 1 A112 TB alarm 1 A113 TB alarm 2 A114 TB alarm 2 A115 TB alarm 2 A116 TB alarm 2 A117 TB alarm 2 A118 TB alarm 2 A119 TB alarm 2
14-23
Revised 6/26/01
A120 TB alarm 2 A121 TB alarm 2 A122 TB alarm 2 A123 TB alarm 2 A124 TB alarm 2 A125 TB alarm 2 A126 TB alarm 2 A127 TB alarm 2 A128 TB alarm 2
14-24
14.3 Fatal errors (FF)

Fatal errors are serious hardware or software errors, which no longer permit normal operation of the unit. They only appear on the PMU in the form "FF<No>". The software is re-booted by actuating any key on the PMU. Table: 14-3 : Fatal Error
Number / Fault FF01 Time slot overow - Replace the CU FF03 Access fault Optional board Serious faults have occurred while making access to external optional boards (CB, TB, SCB, TSY ..). - Replace the CU - Replace the LBA - Replace the optional board FF06 Stack overow - Replace the CU FF13 Wrong rmware version A version conict between the rmware and the hardware has occurred. - Replace rmware - Replace CU Stack has overowed For VC: Increase sampling time (P357) For MC: Reduce pulse frequency (P340)
Cause
A time slot overow which cannot be corrected has been detected in the higher-priority time slots.
Counter-measure
- Increase sampling time (P357 or reduce pulse frequency (P340)
14-25
Revised 6/26/01
14-26
15
15.1
BUL 425 inverter spare parts lists

230 VAC Inverters
For Parts Call: MMH @ 1(800)-727-8774
R46333D3-2-10 ( 3HP @ 230VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
CUVC Main Control Board
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A30 PMU Parameterizing Unit For Frame Sizes A, B, AND E To M Cooling Fan DC 24V For Frame Size A Terminal Block Plug Set For CUVC Frame Sizes A To D
R46889D5
-E1
R46889D3
EXTRAS
R46333D5-2-16 ( 5HP @ 230VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A30 PMU Parameterizing Unit For Frame Sizes A, B, & E TO M Cooling Fan DC 24V For Frame Sizes B & C Terminal Block Plug Set CUVC For Frames A To D
R46889D6
-E1
R46889D3
EXTRAS
Technical contents subject to change without notice.
15-1
Rev 10/20/00
R46333D10-2-29 ( 7.5/10HP @ 230VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A30 PMU Parameterizing Unit For Frame Sizes A, B, & E TO M
R46889D6
-E1
Cooling Fan DC 24V For Frame Sizes B & C Terminal Block Plug Set CUVC For Frames A To D
R46889D3
EXTRAS
15-2
R46333D15-2-49 ( 15HP @ 230VAC )
Quantity
1 1 1 1 1 3
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D129
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100s,-A200s,-A300s IGBT Transistor Module CM 150DY-12H, 2 X 150A, 600V Pre-Charging Unit PCU For Units 69A AND 81A 3 AC 208-230V PMU Parameterizing Unit For Frame Sizes C AND D DC Link Capacitors Complete Complete With Holder 6600UF, 400V MKP Capacitor For Cooling Fan 2UF, 400V RADIAL COOLING FAN R2E190-AE77-B3, AC 230V FOR ENCLOSURE SIZE D Fuse Switch Disconnect ST10 CSA B081145 Fuse Link FNQ-R-2, 2A, 600V Transformer For Cooling Fan 3 AC 200-230V - AC 230V Current Transformer ES 100-9594, 100A Bridge Rectifier SKD 110/08, 110A, 800V Terminal Block Plug Set For CUVC Frames A TO D
R46889D85
-A24
R46889D2
-A30
R46889D35
-C...
R46889D14
-C110
R46889D7
-E1
R46889D75
-F101#,-F102#
R46889D76
-F101,-F102
R46889D19
-T10
R46889D54
-T4,-T5
R46889D58
-V1
R46889D3
EXTRAS
15-3
Rev 10/20/00
R46333D20-2-63 ( 20HP @ 230VAC )
Quantity
1 1 1 1 1 3 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D129 R46889D85
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100s,-A200s,-A300s -A24 IGBT Transistor Module CM 150DY-12H, 2 X 150A, 600V Pre-Charging Unit PCU For Units 69A AND 81A 3 AC 208-230V PMU Parameterizing Unit For Frame Sizes C AND D DC Link Capacitors Complete Complete With Holder 6600UF, 400V MKP Capacitor For Cooling Fan 2UF, 400V RADIAL COOLING FAN R2E190-AE77-B3, AC 230V FOR ENCLOSURE SIZE D Fuse Switch Disconnect ST10 CSA B081145 Fuse Link FNQ-R-2, 2A, 600V Transformer For Cooling Fan 3 AC 200-230V - AC 230V Current Transformer ES 100-9594, 100A Bridge Rectifier SKD 110/08, 110A, 800V Terminal Block Plug Set For CUVC Frames A TO D
R46889D2
-A30
R46889D35
-C...
R46889D14
-C110
R46889D7
-E1
R46889D75
-F101#,-F102#
R46889D76
-F101,-F102
R46889D19
-T10
R46889D54
-T4,-T5
R46889D58
-V1
R46889D3
EXTRAS
15-4
R46333D25-2-74 ( 25HP @ 230VAC )
Quantity
1 1 1 1 1 3
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D130
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100s,-A200s,-A300s IGBT Transistor Module CM 200DY-12H, 2 X 200A, 600V Pre-Charging Unit PCU For Units 69A AND 81A 3 AC 208-230V PMU Parameterizing Unit For Frame Sizes C AND D DC Link Capacitors Complete Complete With Holder 8800UF, 400V MKP Capacitor For Cooling Fan 2UF, 400V RADIAL COOLING FAN R2E190-AE77-B3, AC 230V FOR ENCLOSURE SIZE D Fuse Switch Disconnect ST10 CSA B081145 Fuse Link FNQ-R-2, 2A, 600V Transformer For Cooling Fan 3 AC 200-230V - AC 230V Current Transformer ES 100-9594, 100A Bridge Rectifier SKD 160/08, 160A, 800V Terminal Block Plug Set For CUVC Frames A TO D
R46889D85
-A24
R46889D2
-A30
R46889D36
-C...
R46889D14
-C110
R46889D7
-E1
R46889D75
-F101#,-F102#
R46889D76
-F101,-F102
R46889D19
-T10
R46889D54
-T4,-T5
R46889D59
-V1
R46889D3
EXTRAS
15-5
Rev 10/20/00
15.2
460 VAC Inverters
R46333D3-4-6 ( 3HP @ 460VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A30 PMU Parameterizing Unit For Frame Sizes A, B, AND E To M Cooling Fan DC 24V For Frame Size A Terminal Block Plug Set For CUVC Frame Sizes A To D
R46889D5
-E1
R46889D3
EXTRAS
R46333D5-4-9 ( 5HP @ 460VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A30 PMU Parameterizing Unit For Frame Sizes A, B, & E TO M Cooling Fan DC 24V For Frame Size A Terminal Block Plug Set CUVC For Frames A To D
R46889D5
-E1
R46889D3
EXTRAS
Technical contents subject to change without notice
15-6
R46333D7-4-12 ( 7.5HP @ 460VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A30 PMU Parameterizing Unit For Frame Sizes A, B, AND E To M Cooling Fan DC 24V For Frame Sizes B & C Terminal Block Plug Set For CUVC Frame Sizes A To D
1 1
R46889D6 R46889D3
-E1 EXTRAS
R46333D10-4-16 ( 10HP @ 460VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
R46889D6
-E1
R46889D3
EXTRAS
15-7
Rev 10/20/00
R46333D15-4-23 ( 15HP @ 460VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D2
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A30 PMU Parameterizing Unit For Frame Sizes C & D Cooling Fan DC 24V For Frame Sizes B & C Bridge Rectifier SKD 62/16, 60A, 1600V Terminal Block Plug Set CUVC For Frames A To D
R46889D6
-E1
R46889D60
-V1
R46889D3
EXTRAS
R46333D20-4-31 ( 20HP @ 460VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D2
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A30 PMU Parameterizing Unit For Frame Sizes C & D Cooling Fan DC 24V For Frame Sizes B & C Bridge Rectifier SKD 62/16, 60A, 1600V Terminal Block Plug Set CUVC For Frames A To D
R46889D6
-E1
R46889D60
-V1
R46889D3
EXTRAS
15-8
R46333D25-4-34 ( 25HP @ 460VAC )
Quantity
1 1 1 1 1 3
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D131
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100s,-A200s,-A300s IGBT Transistor Module BSM100GB120DN2, 100A, 1200V Pre-Charging Unit PCU F.UN.47 U. 72A 3 AC 380-460V 46.5A 3 AC 500-575 PMU Parameterizing Unit For Frame Sizes C AND D DC Link Capacitors Complete Complete With Holder 2200UF, 800V MKP Capacitor For Cooling Fan 2UF, 400V RADIAL COOLING FAN R2E190-AE77-B3, AC 230V FOR ENCLOSURE SIZE D Fuse Switch Disconnect ST10 CSA B081145 Fuse Link FNQ-R-6/10, 0.6A, 600V Transformer For Cooling Fan 3 AC 380-500V - AC 230V Current Transformer ES 100-9594, 100A Bridge Rectifier SKD 82/16, 80A, 1600V Terminal Block Plug Set For CUVC Frames A TO D
R46889D86
-A24
R46889D2
-A30
R46889D37
-C...
R46889D14
-C110
R46889D7
-E1
R46889D75
-F101#,-F102#
R46889D77
-F101,-F102
R46889D20
-T10
R46889D54
-T4,-T5
R46889D61
-V1
R46889D3
EXTRAS
15-9
Rev 10/20/00
R46333D30-4-43 ( 30HP @ 460VAC )
Quantity
1 1 1 1 1 3
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D131
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100s,-A200s,-A300s IGBT Transistor Module BSM 100GB120DN2, 100A, 1200V Pre-Charging Unit PCU F.UN.47 U. 72A 3 AC 380-460V 46.5A 3 AC 500-575 PMU Parameterizing Unit For Frame Sizes C AND D DC Link Capacitors Complete Complete With Holder 2200UF, 800V MKP Capacitor For Cooling Fan 2UF, 400V RADIAL COOLING FAN R2E190-AE77-B3, AC 230V FOR ENCLOSURE SIZE D Fuse Switch Disconnect ST10 CSA B081145 Fuse Link FNQ-R-6/10, 0.6A, 600V Transformer For Cooling Fan 3 AC 380-500V - AC 230V Current Transformer ES 100-9594, 100A Bridge Rectifier SKD 82/16, 80A, 1600V Terminal Block Plug Set For CUVC Frames A TO D
R46889D86
-A24
R46889D2
-A30
R46889D37
-C...
R46889D14
-C110
R46889D7
-E1
R46889D75
-F101#,-F102#
R46889D77
-F101,-F102
R46889D20
-T10
R46889D54
-T4,-T5
R46889D61
-V1
R46889D3
EXTRAS
15-10
R46333D40-4-54 ( 40HP @ 460VAC )
Quantity
1 1 1 1 1 3
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D132
Designation
-A10
Description
R46889D86
-A24
R46889D2
-A30
R46889D38
-C...
R46889D14
-C110
R46889D7
-E1
R46889D75
-F101#,-F102#
R46889D77
-F101,-F102
R46889D20
-T10
R46889D54
-T4,-T5
R46889D62
-V1
R46889D3
EXTRAS
15-11
Rev 10/20/00
R46333D50-4-65 ( 50HP @ 460VAC )
Quantity
1 1 1 1 1 3
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D132
Designation
-A10
Description
R46889D86
-A24
R46889D2
-A30
R46889D38
-C...
R46889D14
-C110
R46889D7
-E1
R46889D75
-F101#,-F102#
R46889D77
-F101,-F102
R46889D20
-T10
R46889D54
-T4,-T5
R46889D62
-V1
R46889D3
EXTRAS
15-12
R6333D60-4-84 ( 60HP @ 460VAC )
Quantity
1 1 1 1 1 6
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D133
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100, -A110, -A200, -A210, -A300, -A310 -A20 -A24 -A26 -A27 IGBT Transistor Module BSM 150GB120DN2, 150A, 1200V Inverter Interface Unit IVI PCC Precharge Control Unit For Frame E To H ABO Standardizing Module For Units 3 AC, 380-460V 92A Pre-Charging Unit PCU For Frames E & F, 3 AC 380575V IGD1 Inverter Gating Module For units 3 AC 380-460 92A PMU Parameterizing Unit For Frame Sizes A, B & E To M DC Link Capacitors Complete Complete With Holder 5000UF, 800V MKP Capacitor For Cooling Fan 2UF, 400V Radial Cooling Fan Unit 190 For Enclosure Size E
PSU1 Power Supply Unit For
1 1 1 1
R46889D32 R46889D87 R46889D89 R46889D102
R46889D104
-A29
R46889D1
-A30
R46889D39
-C...
1 1
R46889D14 R46889D8
-C110 -E1
R46889D82
-G25
Frames E & H 3 AC 380-460 2 R46889D77 -G25-F,-G25-F2 Fuse Link FNQ-R-6/10, 0.6A, 600V Transformer For Cooling Fan 3 AC 380-500V - AC 230V
Line Side Thyristor Module TT93N16LOF,2 X 93A, 1600V
R46889D21
-T10
R46889D65
-V1,-V2,-V3
R46889D4
EXTRAS
Terminal Block Plug Set For CUVC Frames E To M
15-13
Rev 10/20/00
R46333D75-4-113 ( 75HP @ 460VAC )
Quantity
1 1 1 1 1 6
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D134
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100, -A110, -A200, -A210, -A300, -A310 -A20 -A24 -A26 IGBT Transistor Module BSM 300GA120DN2S, 300A, 1200V Inverter Interface Unit IVI PCC Precharge Control Unit For Frame E To H ABO Standardizing Module For Units 3 AC, 380-460V 146A Pre-Charging Unit PCU For Frames E & F, 3 AC 380575V IGD1 Inverter Gating Module For units 3 AC 380-460, 146A PMU Parameterizing Unit, For Frame Sizes A, B & E To M
1 1 1
R46889D32 R46889D87 R46889D90
R46889D102
-A27
1 1
R46889D105 R46889D1
-A29 -A30
R46889D40
-C...
DC Link Capacitors Complete Complete With Holder 7500UF, 800V MKP Capacitor For Cooling Fan 2.5 UF, 400V Radial Cooling Fan Unit 190 For Frame Size F
R46889D15
-C110
1 1 2 1
R46889D9 R46889D82 R46889D76 R46889D22
-E1 -G25 -G25-F1,-G25-F2 -T10
Frames E To H 3 AC 380-460 Fuse Link FNQ-R-2, 2A, 600V Transformer For Cooling Fan 3 AC 380-500V - AC 230V
Line Side Thyristor Module TT142N16KOF,2 X 142A, 1600V
R46889D66
-V1,-V2,-V3
R46889D4
EXTRAS
15-14
R46333D100-4-133 ( 100HP @ 460VAC )
Quantity
1 1 1 1 1 6
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D134
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100, -A110, -A200, -A210, -A300, -A310 -A20 IGBT Transistor Module BSM 300GA120DN2S, 300A, 1200V Inverter Interface Unit IVI
R46889D32
1 1
R46889D87 R46889D90
-A24 -A26
PCC Precharge Control Unit For Frame E To H ABO Standardizing Module For Units 3 AC, 380-460V 146A Pre-Charging Unit PCU For Frames E & F, 3 AC 380575V IGD1 Inverter Gating Module For units 3 AC 380-460, 146A PMU Parameterizing Unit, For Frame Sizes A, B & E To M DC Link Capacitors Complete Complete With Holder 7500UF, 800V MKP Capacitor For Cooling Fan 2.5 UF, 400V Radial Cooling Fan Unit 190 For Frame Size F
R46889D102
-A27
1 1 1
R46889D105 R46889D1 R46889D40
-A29 -A30 -C...
R46889D15
-C110
1 1
R46889D9 R46889D82
-E1 -G25
Frames E To H 3 AC 380-460 2 1 R46889D76 R46889D22 -G25-F1-G25-F2 -T10 Fuse Link FNQ-R-2, 2A, 600V Transformer For Cooling Fan 3 AC 380-500V - AC 230V
R46889D66
-V1,-V2,-V3
R46889D4
EXTRAS
15-15
Rev 10/20/00
R46333D125-4-169 ( 125HP @ 460VAC )
Quantity
1 1 1 1 1 6
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D135
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100, -A11, -A200, -A210,-A300, -A310 -A20 -A24 -A26 IGBT Transistor Module 1MB1 400GNA120, 400A, 1200V Inverter Interface Unit IVI PCC Precharge Control Unit For Frame E To H ABO Standardizing Module For Units 3 AC, 380-460V 186 A Pre-Charging Unit PCU For Frames G & H, 3 AC 380575V IGD1 Inverter Gating Module For units 3 AC 380-460, 186A PMU Parameterizing Unit, For Frame Sizes A, B & E To M DC Link Capacitors Complete Complete With Holder 10,000UF, 800V MKP Capacitor For Cooling Fan 2.5 UF, 400V Radial Cooling Fan Unit 225/B7 For Frame Size F
1 1 1
R46889D32 R46889D87 R46889D91
R46889D102
-A27
1 1 1
R46889D106 R46889D1 R46889D41
-A29 -A30 -C...
R46889D15
-C110
1 1
R46889D9 R46889D82
-E1 -G25
Frames E To H 3 AC 380-460 2 1 R46889D76 R46889D22 -G25-F1-G25-F2 -T10 Fuse Link FNQ-R-2, 2A, 600V Transformer For Cooling Fan 3 AC 380-500V - AC 230V
Line Side Thyristor Module TT162N16KOF,2 X162A, 1600V
R46889D67
-V1,-V2,-V3
R46889D4
EXTRAS
15-16
R46333D150-4-191 ( 150HP @ 460VAC )
Quantity
1 1 1 1 1 12
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D134
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100, -A101, -A110, -A111,-A200s, -A300s -A20 IGBT Transistor Module BSM 300GA120DN2S, 300A, 1200V Inverter Interface Unit IVI
R46889D32
1 1
R46889D87 R46889D92
-A24 -A26
PCC Precharge Control Unit For Frame E To H ABO Standardizing Module For Units 3 AC, 380-460V 315 A Pre-Charging Unit PCU For Frames G & H, 3 AC 380575V IGD1 Inverter Gating Module For units 3 AC 380-460, 260A PMU Parameterizing Unit, For Frame Sizes A, B & E To M DC Link Capacitors Complete Complete With Holder 12500UF, 800V MKP Capacitor For Cooling Fan 4 UF, 400V Radial Cooling Fan Unit 225/B7 For Frame Size G
R46889D103
-A27
1 1 1
R46889D107 R46889D1 R46889D42
-A29 -A30 -C...
R46889D16
-C110
1 1
R46889D10 R46889D82
-E1 -G25
Frames E To H 3 AC 380-460 2 1 R46889D80 R46889D23 -G25-F1-G25-F2 -T10 Fuse Link FNQ-R-2.5, 2.5A, 600V Transformer For Cooling Fan 3 AC 380-500V - AC 230V
R46889D68
-V1,-V2,-V3
R46889D4
EXTRAS
15-17
Rev 10/20/00
R46333D200-4-287 ( 200HP @ 460VAC )
Quantity
1 1 1 1 1 12
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D136
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100, -A101, -A110, -A111,-A200s, -A300s -A20 -A24 -A26 IGBT Transistor Module BSM 400GA120DN2S, 400A, 1200V Inverter Interface Unit IVI PCC Precharge Control Unit For Frame E To H ABO Standardizing Module For Units 3 AC, 380-460V 315 A Pre-Charging Unit PCU For Frames G & H, 3 AC 380575V IGD1 Inverter Gating Module For units 3 AC 380-460, 315A PMU Parameterizing Unit, For Frame Sizes A, B & E To M DC Link Capacitors Complete Complete With Holder 15000UF, 800V MKP Capacitor For Cooling Fan 5 UF, 400V Radial Cooling Fan Unit 250/B7 For Frame Size G
1 1 1
R46889D32 R46889D87 R46889D93
R46889D103
-A27
1 1 1
R46889D107 R46889D1 R46889D43
-A29 -A30 -C...
1 1 1 2 1
R46889D17 R46889D11 R46889D82 R46889D78 R46889D24
-C110 -E1 -G25 -G25-F1-G25-F2 -T10
Frames E To H 3 AC 380-460 Fuse Link FNQ-R-5, 5A, 600V Transformer For Cooling Fan 3 AC 380-500V - AC 230V
R46889D69
-V1,-V2,-V3
R46889D4
EXTRAS
Technical contents subject to change without notice .
15-18
R46333D250-4-337 ( 250HP @ 460VAC )
Quantity
1 1 1 1 1 6 3 3 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D137 R46889D123 R46889D126 R46889D32 R46889D87
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100,-A200,-A300, -A110,-A210,-A310 -A109,-A209,-A309 -A119,-A219,-A319 -A20 -A24 IGBT Transistor Module Z900R12KF5, 900A, 1200V Snubber Module Upper Unit SMU2 Snubber Module Lower Unit SML2 IVI Inverter Interface Unit PCC Pre-Charging Control Unit For Frames Sizes E To H Standardizing Module ABO For Units 3 AC 380-460V 370A PCU2 Pre-Charging Unit For Frame Sizes G & H 3 AC 380-575V, 50/60HZ Inverter Control Unit IGD4 FOR UNITS 3 AC 380-460V AND DC 510-620V, 370A Parameterizing Unit PMU For Frame Sizes A, B, AND E To M
R46889D94
-A26
R46889D103
-A27
R46889D108
-A29
R46889D1
-A30
R46889D44
-C...
DC Link Capacitors Complete With Holder 17500UF, 800V
R46889D17
-C110
MKP Capacitor For Cooling Fan 5UF, 400V
R46889D11
-E1
Radial Cooling Fan Unit 250/B7 For Frame Size G Power Supply Unit PSU1 For Frame Sizes E To H 3 AC 380-460, 50/60HZ
R46889D82
-G25
15-19
Rev 10/20/00
R46333D250-4-337 ( 250HP @ 460VAC ) Continued
Quantity
2
Order Number
R46889D78
Designation
-G25-F1,-G25-F2
Description
Fuse Link FNQ-R-5, 5A, 600V
R46889D114
-R1
Pre-Charging Resistor 2 X 12 OHM
R46889D118
-R10
Temperature Sensor NTC 10K
R46889D119
-R100
Symmetry Resistor 3 X 2K4 OHM 214W 5% Shading Resistor 2R0 OHM 20W 5% Transformer For Cooling Fan AC 380-460V - AC 230V 1.85A
R46889D122
-R109,-R209,-R309 ,-R119,-R219,-R319 -T10
R46889D25
R46889D55
-T4,-T5
Current Transformer ES1000-9662, 390A Line Side Thyristor Module TT285N16KOF, 2 X 285A, 1600V Terminal Block Plug Set For CUVC Frames E To M
R46889D70
-V1,-V2,-V3
R46889D4
EXTRAS
R46333D300-4-464 ( 300HP @ 460VAC )
15-20
Quantity
1 1 1 1 1 6
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D138
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100,-A101,-A200, -A201,-A300,-A301 IGBT Transistor Module Z1200R12KF5, 1200A, 1200V
R46889D124
-A109,-A209,-A309
Snubber Module Upper Unit SMU3
R46889D127
-A119,-A219,-A319
Snubber Module Lower Unit SML3 IVI Inverter Interface Unit Thyristor Driver Board TDB Standardizing Module ABO For Units 3 AC 380-460V 510A Inverter Gating Module IGD7 FOR UNITS 3 AC 380-460V AND DC 510-620V, 510A Parameterizing Unit PMU For Frame Sizes A, B, AND E To M DC Link Capacitors Complete With Holder 9000UF, 800V
1 1 1
R46889D33 R46889D88 R46889D95
-A20 -A24 -A26
R46889D110
-A29
R46889D1
-A30
R46889D45
-C...
R46889D18
-C110
R46889D12
-E1
Radial Cooling Fan Unit 250/B7 RH28M-2EK.3F.1R 230V Power Supply Unit PSU2 For Frame Sizes J To M 3 AC 380-460, 50/60HZ Inlet Jet For Radial Cooling Fan Unit
R46889D83
-G25
R46889D13
-E1#
15-21
Rev 10/20/00
Quantity
2
Order Number
R46889D75
Designation
-F101#, -F102#
Description
Fuse Switch Disconnect ST10 CSA B081145
R46889D78
-F101,-F102
R46889D75
-F3#, -F4#
R46889D79
-F3,-F4
Fuse Link ATDR4, 4A, 600V
R46889D117
-R1#, -R2#
Pre-Charging Resistor 15 OHM 35Watt 20%
R46889D116
-R1, -R2
Pre-Charging Resistor AB85301M00815 OHM 20%
R46889D118
-R10,-R20,-R30
R46889D121
-R100,-R200,-R300
Symmetry Resistor 3 X 4K7 OHM
R46889D122
-R109,-R209,-R309 ,-R119,-R219,-R319 -T10
Shading Resistor 2R0 OHM 20W 5% Transformer For Cooling Fan AC 380-460V - AC 230V Current Transformer ES1000C, 1000A Line Side Thyristor Module TT500N16KOF, 2 X 500A, 1600V Terminal Block Plug Set For CUVC Frames E To M
R46889D26
R46889D56
-T4,-T5,-T6
R46889D71
-V1,-V2,-V3
R46889D4
EXTRAS
R46333D400-4-537 ( 400HP @ 460VAC )
15-22
Quantity
1 1 1 1 1 6
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D138
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100,-A101,-A200, -A201,-A300,-A301 IGBT Transistor Module Z1200R12KF5, 1200A, 1200V
R46889D124
-A109,-A209,-A309
Snubber Module Upper Unit SMU3
R46889D127
-A119,-A219,-A319
Snubber Module Lower Unit SML3 IVI Inverter Interface Unit Thyristor Driver Board TDB Standardizing Module ABO For Units 3 AC 380-460V 590A Inverter Gating Module IGD7 FOR UNITS 3 AC 380-460V AND DC 510-620V, 510A Parameterizing Unit PMU For Frame Sizes A, B, AND E To M
1 1 1
R46889D33 R46889D88 R46889D96
-A20 -A24 -A26
R46889D110
-A29
R46889D1
-A30
R46889D46
-C...
DC Link Capacitors Complete With Holder 11250UF, 800V
R46889D18
-C110
R46889D12
-E1
Radial Cooling Fan Unit 250/B7 RH28M-2EK.3F.1R 230V Power Supply Unit PSU2 For Frame Sizes J To M 3 AC 380-460, 50/60HZ Inlet Jet For Radial Cooling Fan Unit
R46889D83
-G25
R46889D13
-E1#
15-23
Rev 10/20/00
Quantity
2
Order Number
R46889D75
Designation
-F101#, -F102#
Description
R46889D78
-F101,-F102
R46889D75
-F3#, -F4#
R46889D79
-F3,-F4
Fuse Link ATDR4, 4A, 600V
R46889D117
-R1#, -R2#
Pre-Charging Resistor 15 OHM 35Watt 20%
R46889D116
-R1, -R2
Pre-Charging Resistor AB85301M00815 OHM 20%
R46889D118
-R10,-R20,-R30
R46889D121
-R100,-R200,-R300
Symmetry Resistor 3 X 4K7 OHM Shading Resistor 2R0 OHM 20W 5% Transformer For Cooling Fan AC 380-460V - AC 230V Current Transformer ES1000C, 1000A Line Side Thyristor Module TT500N16KOF, 2 X 500A, 1600V Terminal Block Plug Set For CUVC Frames E To M
R46889D122
-R109,-R209,-R309 ,-R119,-R219,-R319 -T10
R46889D26
R46889D56
-T4,-T5,-T6
R46889D71
-V1,-V2,-V3
R46889D4
EXTRAS
15-24
15.3
575 VAC Inverters
R46333D3-5-4 ( 3HP @ 575VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A30 PMU Parameterizing Unit For Frame Sizes A, B, AND E To M Cooling Fan DC 24V For Frame Sizes B & C Terminal Block Plug Set For CUVC Frame Sizes A To D
R46889D6
-E1
R46889D3
EXTRAS
R46333D5-4-7 ( 5HP @ 575VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
R46889D6
-E1
R46889D3
EXTRAS
15-25
Rev 10/20/00
R46333D7-5-10 ( 7.5HP @ 575VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
R46889D6
-E1
R46889D3
EXTRAS
R46333D10-5-14 ( 10HP @ 575VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D1
Designation
-A10
Description
R46889D6
-E1
R46889D3
EXTRAS
15-26
R46333D15-5-20 ( 15HP @ 575VAC )
Quantity
1 1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D2
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A30 PMU Parameterizing Unit For Frame Sizes C & D
R46889D6
-E1
Cooling Fan DC 24V For Frame Sizes B & C Bridge Rectifier SKD 62/18, 60A, 18600V Terminal Block Plug Set CUVC For Frames A To D
R46889D63
-V1
R46889D3
EXTRAS
15-27
Rev 10/20/00
R46333D20-5-26 ( 20HP @ 575VAC )
Quantity
1 1 1 1 1
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly
R46889D139
-A100,-A200,-A300
IGBT Transistor Module BSM100GB170DN2, 100A, 1700V Pre-Charging Unit PCU F.UN.47 U. 72A 3 AC 380-460V 46.5A 3 AC 500-575 PMU Parameterizing Unit For Frame Sizes C AND D DC Link Capacitors Complete Complete With Holder 1500UF, 1000V
R46889D86
-A24
R46889D2
-A30
R46889D47
-C...
R46889D14
-C110
MKP Capacitor For Cooling Fan 2UF, 400V RADIAL COOLING FAN R2E190-AE77-B3, AC 230V For Enclosure Size D Fuse Switch Disconnect ST10 CSA B081145 Fuse Link FNQ-R-6/10, 0.6A, 600V
R46889D7
-E1
R46889D75
-F101#-F102#
R46889D77
-F101-F102
R46889D27
-T10
Transformer For Cooling Fan 3 AC 500-575V - AC 230V Current Transformer ES 100-9594, 100A Bridge Rectifier SKD 82/18, 60A, 1800V Terminal Block Plug Set For CUVC Frames A TO D
R46889D54
-T4,-T5
1 1
R46889D63 R46889D3
-V1 EXTRAS
15-28
R46333D25-5-31 ( 25HP @ 575VAC )
Quantity
1 1 1 1 1 3
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D139
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100,-A200,-A300 IGBT Transistor Module BSM100GB170DN2, 100A, 1700V Pre-Charging Unit PCU F.UN.47 U. 72A 3 AC 380-460V 46.5A 3 AC 500-575
R46889D86
-A24
R46889D2
-A30
PMU Parameterizing Unit For Frame Sizes C AND D DC Link Capacitors Complete Complete With Holder 1500UF, 1000V
R46889D47
-C...
R46889D14
-C110
R46889D7
-E1
R46889D75
-F101#,-F102#
R46889D77
-F101,-F102
R46889D27
-T10
R46889D54
-T4,-T5
1 1
R46889D63 R46889D3
-V1 EXTRAS
15-29
Rev 10/20/00
R46333D40-5-42 ( 30/40HP @ 575VAC )
Quantity
1 1 1 1 1 3
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D140
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100,-A200,-A300 IGBT Transistor Module BSM150GB170DN2, 150A, 1700V Pre-Charging Unit PCU F.UN.47 U. 72A 3 AC 380-460V 46.5A 3 AC 500-575
R46889D86
-A24
R46889D2
-A30
PMU Parameterizing Unit For Frame Sizes C AND D DC Link Capacitors Complete Complete With Holder 2250UF, 1000V
R46889D48
-C...
R46889D14
-C110
R46889D7
-E1
R46889D75
-F101#,-F102#
R46889D77
-F101,-F102
R46889D27
-T10
R46889D54
-T4,-T5
1 1
R46889D64 R46889D3
-V1 EXTRAS
15-30
R46333D50-5-55 ( 50HP @ 575VAC )
Quantity
1 1 1 1 1 6
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D141
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100, -A110, -A200, -A210, -A300, -A310 -A20 -A24 -A26 IGBT Transistor Module BSM 200GA170DN2S, 200A, 1700V Inverter Interface Unit IVI PCC Precharge Control Unit For Frame E To H ABO Standardizing Module For Units 3 AC, 500-575V 61A Pre-Charging Unit PCU For Frames E & F, 3 AC 380575V IGD1 Inverter Gating Module For units 3 AC 500-575 61A PMU Parameterizing Unit For Frame Sizes A, B & E To M DC Link Capacitors Complete Complete With Holder 3500UF, 1000V MKP Capacitor For Cooling Fan 2UF, 400V Radial Cooling Fan Unit 190 For Enclosure Size E
1 1 1
R46889D32 R46889D87 R46889D97
R46889D102
-A27
1 1 1
R46889D111 R46889D1 R46889D49
-A29 -A30 -C...
R46889D14
-C110
1 1
R46889D8 R46889D84
-E1 -G25
Frames E & H 3 AC 500-575V 2 1 R46889D77 R46889D28 -G25-F,-G25-F2 -T10 Fuse Link FNQ-R-6/10, 0.6A, 600V Transformer For Cooling Fan 3 AC 500-575V - AC 230V
R46889D72
-V1,-V2,-V3
R46889D4
EXTRAS
15-31
Rev 10/20/00
R46333D60-5-71 ( 60HP @ 575VAC )
Quantity
1 1 1 1 1 6
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D142
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100, -A110, -A200, -A210, -A300, -A310 -A20 -A24 -A26 IGBT Transistor Module BSM 300GA170DN2S, 300A, 1700V Inverter Interface Unit IVI PCC Precharge Control Unit For Frame E To H ABO Standardizing Module For Units 3 AC, 500-575V 79A Pre-Charging Unit PCU For Frames E & F, 3 AC 380575V IGD1 Inverter Gating Module For units 3 AC 500-575, 79A PMU Parameterizing Unit, For Frame Sizes A, B & E To M DC Link Capacitors Complete Complete With Holder 3800UF, 1000V MKP Capacitor For Cooling Fan 2.5 UF, 400V Radial Cooling Fan Unit 190 For Frame Size F
1 1 1
R46889D32 R46889D87 R46889D98
R46889D102
-A27
1 1 1
R46889D111 R46889D1 R46889D50
-A29 -A30 -C...
R46889D15
-C110
1 1
R46889D9 R46889D84
-E1 -G25
Frames E To H AC 500-575V 2 1 R46889D81 R46889D29 -G25-F1,-G25-F2 -T10 Fuse Link FNQ-R-1.5, 1.5A, 600V Transformer For Cooling Fan 3 AC 500-575V - AC 230V
R46889D72
-V1,-V2,-V3
R46889D4
EXTRAS
15-32
R46333D100-5-98 ( 75/100HP @ 575VAC )
Quantity
1 1 1 1 1
6
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D142
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100s, -A200s,-A300s IGBT Transistor Module BSM 300GA170DN2S, 300A, 1700V Inverter Interface Unit IVI PCC Precharge Control Unit For Frame E To F ABO Standardizing Module For Units 3 AC, 500-575V 128A
PreCharging Unit PCU1
1 1 1
R46889D32 R46889D87 R46889D99
-A20 -A24 -A26
R46889D102
-A27
For Frames E to F, 3 AC 380575V 1 1 1 R46889D111 R46889D1 R46889D51 -A29 -A30 -C... IGD1 Inverter Gating Module For units 3 AC 500-575, 79A PMU Parameterizing Unit, For Frame Sizes A, B & E To M DC Link Capacitors Complete Complete With Holder 5000UF, 1000V MKP Capacitor For Cooling Fan 2.5 UF, 400V Radial Cooling Fan Unit 220 For Frame Size F
R46889D15
-C110
1 1 2
R46889D9
-E1 -G25 -G25-F1-G25-F2
R46889D84
Frames E To H 3 AC 500-575
R46889D81
Fuse Link FNQ-R-1.5, 1.5A, 600V Transformer For Cooling Fan 3 AC 500-575V - AC 230V
Line Side Thyristor Module TT85N18KOF,2 X 85A,1800V
R46889D29
-T10
R46889D72
-V1,-V2,-V3
R46889D4
EXTRAS
15-33
Rev 10/20/00
R46333D150-5-142 ( 125HP/150 @ 575VAC )
Quantity
1 1 1 1 1 12
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D141
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100s, -A200s, -A300s, IGBT Transistor Module BSM 200GA170DN2S, 200A, 1700V Inverter Interface Unit IVI PCC Precharge Control Unit For Frame E To H ABO Standardizing Module For Units 3 AC, 500-575V 156 A Pre-Charging Unit PCU For Frames G & H, 3 AC 380575V IGD1 Inverter Gating Module For units 3 AC 500-575, 156A PMU Parameterizing Unit, For Frame Sizes A, B & E To M DC Link Capacitors Complete Complete With Holder 7500UF, 1000V MKP Capacitor For Cooling Fan 4 UF, 400V Radial Cooling Fan Unit 225/B7 For Frame Size G
1 1 1
R46889D32 R46889D87 R46889D100
-A20 -A24 -A26
R46889D103
-A27
1 1 1
R46889D112 R46889D1 R46889D52
-A29 -A30 -C...
R46889D16
-C110
1 1
R46889D10 R46889D84
-E1 -G25
Frames E To H 3 AC 500-575 V 2 1 R46889D80 R46889D30 -G25-F1-G25-F2 -T10 Fuse Link FNQ-R-2.5, 2.5A, 600V Transformer For Cooling Fan 3 AC 500-575V - AC 230V
R46889D73
-V1,-V2,-V3
R46889D4
EXTRAS
15-34
R46333D200-5-205 ( 200HP @ 575VAC )
Quantity
1 1 1 1 1 12
Order Number
R46888D1 R46892D1 R46887D1 R46885D2 R46885D3 R46889D142
Designation
-A10
Description
LBA Local Bus Adapter EB- 2 Expansion Board RB-2 120V Signal Converter RB-2 Cable Plug Assembly -A100s, -A200s, -A300s, IGBT Transistor Module BSM 300GA170DN2S, 300A,1700V
3 3 1 1
R46889D125 R46889D128 R46889D32 R46889D87
-A109,-A209,-A309 -A119,-A219,-A319 -A20 -A24
Snubber Module Upper Unit SMU1 Snubber Module Lower Unit SML1 IVI Inverter Interface Unit PCC Pre-Charging Control Unit For Frames Sizes E To H
R46889D101
-A26
Standardizing Module ABO For Units 3 AC 500-575V 225A PCU2 Pre-Charging Unit For Frame Sizes G & H 3 AC 380-575V, 50/60HZ
R46889D103
-A27
R46889D113
-A29
Inverter Control Unit IGD3 FOR UNITS 3 AC 500-575V 192 A Parameterizing Unit PMU For Frame Sizes A, B, AND E To M DC Link Capacitors Complete With Holder 10000UF, 1000V
R46889D1
-A30
R46889D53
-C...
R46889D17
-C110
1 1
R46889D11 R46889D84
-E1 -G25
Radial Cooling Fan Unit 250/B7 For Frame Size Power Supply Unit PSU1 For Frame Sizes E To H 3 AC 380-460, 50/60HZ
15-35
Rev 10/20/00
Quantity
2 1
Order Number
R46889D80 R46889D115
Designation
-G25-F1,-G25-F2 -R1
Description
Fuse Link FNQ-R-2.5, .5A, 600V Pre-Charging Resistor 2 X 15 OHM Temperature Sensor NTC 10K Symmetry Resistor 3 X 3K6 OHM 143W 5% Shading Resistor 2R0 OHM 20W 5% Transformer For Cooling Fan AC 500-575V - AC 230V 1.85A Current Transformer ES500-9661, 315A Line Side Thyristor Module TT210N18KOF, 2 X 210A, 1800V Terminal Block Plug Set For CUVC Frames E To M
1 1
R46889D118 R46889D120
-R10 -R100
R46889D122
-R109,-R209,-R309 ,-R119,-R219,-R319 -T10
R46889D31
R46889D57
-T4,-T5
R46889D74
-V1,-V2,-V3
R46889D4
EXTRAS
15-36
16
BUL 425 Crane & Hoist Control Diagrams

The following pages in this section show the standard congurations of Morris Material Handling crane and hoist controls using the BUL 425 inverter drive systems. These draiwngs intend to show, both the incoming power circuitry as well as the 115 VAC control circuitry of the standard stepless speed controls. Additional control information is provided ont he connection of the MMH standard holding brake, and dynamic braking resistor controls. The basic control congurations covered in this section include the following control diagrams: BUL 425 Standard Stepless Open-Loop Hoist Control BUL 425 Standard Stepless Closed-Loop Hoist Control BUL 425 Standard Stepless Traverse Motion Control
16-1
Rev. 10/20/00
16-2
16-3
Rev. 10/20/00
16-4
17-1
AC Contactor
Glossary of Terms
An alternating-current AC Contactor is designed for the specic purpose of establishing and interrupting an alternating-current power circuit. Actual Signals refer to real values that the BUL 425 inverter either measures or calculates, from the motor and its wiring, or the unit itself. This data can be displayed on the operator panel display (PMU - Parameterizing Metering Unit). The data is also available through programmable analog outputs on the, or the serial communications port X-300 connector, located on the PMU on the drive face, See section 7. Adjustable Speed is the concept of varying the speed of a motor, either manually or automatically. The desired operating speed (set speed) is relatively constant regardless of load. Ambient Temperature is the temperature of the medium such as air, water, or earth into which the heat of the equipment is dissipated. For self-ventilated equipment, the ambient temperature is the average temperature of the air in the immediate neighborhood of the equipment. For air-or gas-cooled equipment with forced ventilation, the ambient temperature is taken as that of the in going air or cooling gas. For self-ventilated enclosed (including oilimmersed) equipment considered as a complete unit, the ambient temperature is the average temperature of the air outside of the enclosure in the immediate neighborhood of the equipment. An Ammeter is an instrument used to measure current. It is calibrated in amperes of electrical current. Ampacity is the current carrying capacity of conductors or equipment expressed in amperes of current. An Ampere is the basic unit measuring the quantity of electricity. The Analog Inputs are one of BUL 425 control media. The most characteristic property of the analog signal is that the signal level varies between a minimum and a maximum. BUL 425 is equipped with two types of analog inputs: The standard for BUL 425 are programmed as voltage signal inputs: There is one bipolar differential voltage input for 0 ... 10 VDC signals on the EB-2 board and two bipolar non-differential inputs on the CUVC board. In addition there is a constant voltage source output on the CUVC board that can feed external potentiometers connected to these inputs. The current signal input: The above inputs can be programmed as current inputs with range and offset adjustments for 0 ... 20 mA signals inputs in lieu of voltage signals.
Actual Signals
Adjustable Speed
Ambient Temperature
Ammeter
Ampacity
Ampere Analog Input (AI)
These analog inputs can be programmed to control a number of drive functions. See Sections 7 for the standard conguration of the analog inputs. Analog Output (AO) The BUL 425 is equipped as standard with two programmable Analog Outputs that are Bipolar 0 ... 10 voltage outputs and can be congured as 0 ... 20mA current outputs. The default
17-1
Rev 11/7/00
signals are Motor speed and Output current. See Section 7 for information on the analog outputs. Application Macro The BUL 425 is supplied with Crane & Hoist Motion application macros. Macros are sets of pre-programmed operating instructions (i.e. parameters) in BUL 425 memory. BUL 425 is tted with four preprogrammed macros or factory default parameter sets that make crane conguration easy includes: Closed-Loop Hoist Vector Control using encoder feedback Open-Loop Hoist Vector Control (encoder-less) Scalar Volts/Hertz Traverse Control Closed-Loop 2-Motor Bucket Crane Vector Control
See Sections 8 & 9 for more information. Auxiliary contacts Auxiliary Contacts of a switching device are contacts in addition to the main-circuit contacts and function with the movement of the latter. The standard of measuring the diameter of wires in the united states; analogous to square millimeters of the cross sectional area of the conductor. The Base Speed of an adjustable speed motor is lowest rated speed obtained at rated load and rated voltage at the temperature rise specied in the rating. This rating usually appears on the motor nameplate. BCD is a system of numbers representing a decimal digit (0-9) with four binary (on/off) lines. BCD is a recognized industrial standard; BCD input (e.g., thumb-wheels) and output (e.g., numerical displays) are readily available. A Binary number system is a numerical system where the values are represented numerically using 1s and 0s (on/off). This system is commonly employed in modern electronic hardware since circuits can be economically designed for on/off status. A Bit is a single number whose value can be either a one or a zero. See Digital Inputs See Digital Outputs A Block Diagram is a simplied drawing of a system showing major items as blocks; normally used to show how the system works and the relationship between major items. During Regenerative Braking, the BUL 425 inverter excites the motor with ac power, and with an overhauling load, the motor acts as a generator, feeding power back to the inverter through the IGBT modules and into the DC Link or intermediate circuit where it is stored. The revolving ux is maintained, which enables continuous control of the motor.
AWG (American Wire Gauge) Base Speed
BCD (Binary Coded Decimal)
Binary
Bit Binary Inputs (BI) Binary Outputs (BO) Block diagram
Braking
17-2
BUL 425 Operaiton and Maintenance Manual
Regenerative
Regenerative braking is typically employed when motor speed must be reduced from its present speed rather than the calling for a complete stop. In normal operation, the generated power can be consumed by the BUL 425s intermediate circuit, as much as 15% of the units power rating can be used for energy absorption (or braking), in which case the inverters braking ability is very limited. Additional braking power is available through the use of external DC bus powered DC (choppers) Dynamic Braking Unit(s) and Braking Resistors. See Dynamic Braking Unit The Braking Resistor is an optional device that turns the excess power into heat. The Braking Unit detects any rise in the intermediate circuit voltage and applies the Braking Resistor accordingly. The Braking Resistor must be installed in a suitable cabinet to enable sufcient heat dissipation. Braking Torque is the torque applied to the load by the driven motor or brake while decelerating. Breakaway Torque is the required torque in starting a machine from standstill. It is always greater than the torque needed to maintain motion. The Breakdown Torque of an ac motor is the maximum torque that will develop with rated voltage applied at rated frequency. A full wave rectier that conducts current in only one direction of the applied input alternating current resulting in approximate DC at the output. A diode Bridge Rectier is a non-controlled full wave rectier that produces a constant rectied dc voltage. An SCR bridge rectier is a full-wave rectier with an output that can be controlled by switching on the gate control element A Brush is a conductor, usually composed of some element of carbon, serving to maintain an electrical connection between stationary and moving parts of a machine. The brush is mounted in a spring loaded holder and positioned tangent to the commutator segments against which it "brushes. The conductor(s) serving as a common connection for two or more circuits. Busbars are the conductive bars used as the main current supplying elements of panelboards or switchboards; also the conductive bars used within the enclosure of a busway. A Byte is an unsigned eight bit variable which can take on the values between 0 and 255 (i.e., A byte is an eight bit unit of data of any type). Bits within bytes are labeled from 0 to 7 with 0 being the least signicant bit. A Circuit is a closed path through which current ows from a source, through various components and back to the Source. A Circuit Breaker is an electromagnetic device that opens a circuit automatically when current exceeds a predetermined value. It can be reset by operating a lever or by other means.
Braking Resistor
Braking Torque
Breakaway Torque
Breakdown Torque
Bridge Rectier
Bridge Rectier (Diode, SCR)
Brush
Bus Busbars
Byte
Circuit
Circuit breaker
17-3
Rev 11/7/00
Closed-Loop Control
In its elementary form, a Closed-Loop Control consists of an actuator (motor), a comparitor, an amplier and a sensor (tachometer, encoder, etc.). Usually, a modern high performance drive system has several separate feedback loops, such as current, voltage, speed and position feedback. Advanced semiconductor memory that requires DC power to retain its content. However, the amount of DC power is very Iow in comparison to other memory techniques, allowing relatively small batteries to maintain this memory for one year without application of AC power. Short for the National Electric Code. A Coil is a wire or cable wrapped in a series of closed loops. A Comparitor is a device that compares one signal to another, usually the process signal compared to the set point or command signal. In a literal sense, Compendium is a brief summary of a larger work. The Compendium is technical document for the BUL 425 inverter that is weighted towards the conguration, support, and operation of the software functionality of a product. A Conductor is any substance that allows electrical energy to ow through it. Armature voltage controlled DC Drives are constant-torque drives. They are capable of providing rated torque at any speed between zero and the base (rated) speed of the motor. Horsepower varies in direct proportion to speed, and 100% rated horsepower is developed only at 100% rated motor speed with rated torque. Most of the crane and hoists applications are Constant Torque Applications. The range of motor operation where the drive's output is held constant as output frequency is varied. This speed range produces motor performance similar to a dc drive's constant horsepower range. The BUL 425 inverter uses this range of operation for express speeds. This relationship exits in ac drives where the output voltage is varied directly proportional to frequency to rated. This type of operation is required to allow the motor to produce constant rated torque as speed is varied and is commonly called the constant torque range of the motor. A Contact is a device designed for repetitive electrical connections. A Contactor is a two-state (on-off) device for repeatedly establishing and interrupting an electric power circuit. Interruption is obtained by introducing a gap or very large impedance. The Continuous Rating is the maximum constant load that can be carried continuously without exceeding established temperature-rise limitations under prescribed conditions of test and within the limitations of established standards. The control circuit of a control apparatus or system; is the circuit which carries the electric signals directing the performance of the controller but does not carry the main power circuit.
CMOS
CODE Coil Comparitor
Compendium
Conductor Constant Torque Applications
Constant Voltage Range
Constant Volts per Hertz (V/Hz)
Contact Contactor
Continuous rating
Control circuit
17-4
Control Circuit
A Control Circuit refers to BUL 425s Crane and Hoist 115VAC control signals as well as other electrical circuits that control the crane or hoist operation. A general term to dene the relative motion between motor shaft and the driven load, commonly called Gear-In Ratio. A control function that prevents a current from exceeding its prescribed limits. Note: Current-limit values are usually expressed as percent of rated-load value. A system of control in which acceleration is so governed that the motor armature current does not exceed an adjustable maximum value. A fuse that, when its element is melted by a current within its specied current-limiting range, abruptly introduces a high arc voltage to reduce the current magnitude and duration. The CUVC refers to the main microprocessor control board used by all of the BUL 425 inverted drives. Control - Unit - Vector - Control A Default Value is a factory set parameter value in the BUL 425 software. All parameters are assigned factory default values for the different crane and hoist application macros. At the time of this macro download, these preset values are loaded into the units memory. These values can be altered, as required, to match the needs of the application and required functions. See Sections 8 & 9 for more information on the application macros, the parameters, and their default values. The DC Link connects the rectier circuit to the inverter circuit in BUL 425. The DC Link is also called the intermediate circuit. The Digital Inputs are one of BUL 425 control media. The BUL 425 inverter is supplied as standard with an RB-2 115VAC interface board. This board takes 115 VAC external control signal inputs and converts them to isolated low-voltage control signal inputs that are directly sent to the main drive control board, the CUVC board. The most characteristic property of the digital signal is that the signal level can only be low (0 VDC) to represent "0" or high (+24 VDC) to represent "1". BUL 425 is equipped with seven digital inputs on the CUVC. These digital inputs can be programmed to control a number of ac drive functions. See Section 7 for information on the digital inputs. BUL 425 is equipped with three programmable Digital Outputs. Each digital output is equipped with a relay contact output from the RB-2 interface board capable of delivering 115VAC signal outputs (contact closures) to the crane or hoist control. Two of default output signals are Run and Fault the third is programmable. See Section 7 for information on the digital outputs. A Dimension Outline Drawing (base plan, oor plan, etc.) Is one which shows the physical space and mounting requirements of a piece of equipment. It may also indicate ventilation requirements and space provided for connections or the location to which connections are to be made.
Coupling ratio
Current Limit
Current limit acceleration Current-limiting fuse
CUVC
Default Value
DC Link
Digital Input (DI)
Digital Output (DO)
Dimension Outline Drawing
17-5
Rev 11/7/00
Diode
A Diode is an electronic device having two electrodes; one being the cathode, and the other the anode. A diode allows current to pass in only one direction from anode to cathode. A Disconnect is a device, or group of devices, or other means whereby the conductors of a circuit can be disconnected from their supply source. The Dynamic Braking Unit or DBU, is an optional device that controls the disposal of excess power that is generated in regenerative braking. The regenerated power will cause the DC Link or intermediate circuit voltage to rise. Unless this energy is disposed of the unit will fault on DC bus overvoltage. The DBU disposes of the excess power by introducing a resistor (Braking Resistor) across the intermediate circuit (DC bus) and controlling the current through the resistor, dissipating the excess energy in the form of heat. The EB-2 or I/O extension board is used as standard by all BUL 425 inverters. Its purpose is to increase the numbers of both analog and digital inputs and outputs. EEPROM chip is used in to store parameter values, fault codes, etc. When new parameter values are programmed, an electric signal is sent to the EEPROM to erase its previous value to make room for the new value. It only takes 20 milliseconds to erase the old value with the electric signal. An EEPROM is unaffected when power is removed from the chip, such as on loss of power. Efciency is the ratio of mechanical output to electrical input indicated by a percent. In motors, it is the effectiveness with which a motor converts electrical energy into mechanical energy. BUL 425 inverters as standard include an Electronic Box or three-position card rack to house the microprocessor and control interfaces. All units are supplied with this card rack to house and protect the control cards from electrical noise as well as physical harm. An Electromagnet is a device consisting of a ferromagnetic core and a coil that produces appreciable magnetic effects only when an electric current exists in the coil. See Pulse Encoder Electro-Static Discharge refers to the phenomenon in which an electrostatic charge discharges or transfers between two objects of unequal electrostatic potential. The integrated circuits inside BUL 425 are extremely sensitive to high voltage static electricity. This manual contains numerous warnings against electrostatic discharges in situations where such a phenomenon could cause permanent damage to the units sensitive circuits. See Default Value AC Induction motors are torque producing devices. They are able to produce a constant magnitude of torque, over the speed range from Zero RPM to Rated Nameplate RPM (slip speed at full load). This is known as the Constant Torque range of the motor. When connected to an inverter, induction motors can produce constant torque over this speed range (zero to rated speed) when the inverter produces a constant Volts/Hertz output. For a
Disconnect
Dynamic Braking Unit (DBU)
EB-2 Board
EEPROM (Electrically Erasable Programmable Read Only Memory
Efciency
Electronic Box
Electromagnet
Encoder ESD
Factory Default Field Weakening
17-6
460VAC, 60 Hertz motor this would be 460 / 60 or 7.67 V/Hz. Hence at 30 Hertz (half rated frequency) 230 volts would be required from the inverter to produce rated torque. Once rated frequency and voltage are reached the inverter can no longer increase the voltage with the frequency. At this point (called crossover) is the start of the Field Weakening speed range (called constant Horsepower range) of the motor. Most 60 hertz induction motors can run at 90 hertz, check with MMH before using eld weakening on your application. Since the voltage can no longer be increased with the frequency above rated speed, the torque capability continues to be reduced as Field Weakened speed continues to increase. The BUL 425 inverter has as standard, a software limit, set to protect mechanical equipment at 2700 RPM maximum motor shaft speed. Flux The magnetic ux is the magnetic eld between magnetic poles. In this manual the ux refers to the level of magnetization inside a squirrel cage induction motor. Space Vector Control is based on controlling this magnetizing ux and the relative motor shaft position to produce the desired motor torque and speed. Flux optimization or load adaption, improves motor efciency and reduces motor noise in applications that do not require high motor control precision. Running the motor at full ux enables instantaneous changes in motor load while maintaining constant motor speed, but it should be noted that excessive heat can be produced in the motor with over-magnetization. A Follower Drive or slave, is one in which the reference input and operation are direct functions of another drive, called the master drive or lead section. There are four combinations of forward and reverse rotation and forward and reverse torque of which a regenerative drive is capable. BUL 425 is capable of producing all of these combinations of torque. Braking units are required for excessive regeneration capability. The four combinations are: 1. Forward rotation/forward torque (motoring) 2. Forward rotation/reverse torque (regeneration) 3. Reverse rotation/reverse torque (motoring) 4. Reverse rotation/forward torque (regeneration) Frequency Frequency is the number of complete cycles an alternating current, sound wave, or vibrating object undergoes per second. Full-Load Current is the current of a motor operated at its full load torque as depicted on the motor nameplate. Full-Load Speed is the speed that the output shaft of the drive motor attains with rated load connected and with the drive controller adjusted to deliver rated output at rated speed. Full-Wave Rectication inverts the negative half-cycle of the input sinusoid so that the output contains two half-sine pulses for each input cycle.
Follower drive
Four-Quadrant Operation
Full Load current
Full-load speed (slip speed) Full-Wave Rectication
17-7
Rev 11/7/00
Fuse
A Fuse is a protecting device that opens a circuit when the fusible element is severed by heating, due to overcurrent passing through. Ratings on fuses include: voltage, rated current, maximum current, and time delay. The menu structure of BUL425 has designed clusters or groups of parameters into Menus. These menus limit access to only those parameters that are needed for certain specic functions or tasks at hand and reducing the possibilities of making unintentional changes to unrelated parameters, and allow quicker scrolling to related parameters using the PMU operator keypad. Parameter P060 has the following ve menu settings that can be used during commissioning: 0 = User operational menu 2 = Fixed factory settings menu (Crane/Hoist application macros) 4 = Option board conguration menu Not used by BUL 425 5 = Drive setting menu 8 = Power section denition
Group
Ground (PD)
An electrical Ground is a large conducting body (as the earth) used as a common return for an electric circuit and as an arbitrary zero of potential. A Heater Element is the part of a thermal overload relay that is intended to produce heat when conducting current. Heater elements are sometimes referred to as heaters, thermal units, current elements, or heating elements. Hertz is the unit of frequency - cycles per second Horsepower is a unit of power for doing work and equals 746 watts. Many parameters of the BUL 425 inverter are indexed which is a way of setting (or observing) multiple values under the same parameter number. Since indexing is used for several different reasons for different parameters, there is no general denition of index. Each parameter denition describes the reason for that parameters index. An Induction Motor is an alternating-current motor in which the primary winding on one member (usually the stator) is connected to the power source. A secondary winding on the other member (usually the rotor) carries the in-duced current. There is no physical electrical connection to the secondary winding, its current is induced. Inertia is a measure of a body's resistance to changes in velocity, whether the body is at rest or moving at a constant velocity. The velocity can be either linear or rotational. The moment of inertia (WK 2) is the product of weight on) of an object and the square of radius of gyration (K2). The radius of gyration is a measure of how the mass of the object is distributed about the axis of rotation. WK 2 is usually expressed in units of lb-ft 2 The Inner-Loop is the innermost feedback circuit in a closed loop control scheme that establishes the coarse control. It is also called a minor loop.
Heater element (thermal overload relay)
Hertz Horsepower Indexed Parameters
Induction Motor
Inertia
Inner-Loop
17-8
Insulation Insulation Check
Insulation is a nonconductor of electricity usually used to prevent conduction. Insulation Checks, called hi-potential tests, are performed to determine the circuit overvoltage properties before electrical cabling is commissioned. The checks are usually carried out by applying ac voltage considerably above the nominal for about one minute, while checking for electrical breakdown. If such checks are performed, BUL 425 must be disconnected from the circuits that are being checked. Insulation Resistance Tests, called hi-potential tests, are performed to determine the circuit resistance properties before electrical cabling is commissioned. The test involves applying a very high voltage between two conductors while measuring the current to determine the insulation resistance properties of the circuit. If such tests are performed, BUL 425 must be disconnected from the circuits that are being tested. An Integrated Circuit is a circuit in which different types of devices, such as resistors, capacitors, and transistors, are made from. A single piece of material and then connected to form a circuit. An Interconnection Diagram is one that shows only the external connections between controllers and associated machinery and equipment. The Intermediate Circuit is the link between the rectier circuit and the inverter circuit in BUL 425 main circuit. The intermediate circuit is also called the DC Link or DC Bus of the inverter. Inverter Circuit is the part of the BUL 425 inverters main circuit that converts the intermediate circuit dc voltage to an ac voltage of the desired frequency. IR Compensation is a function in the BUL 425 inverter, that provides motors with extra voltage at the output frequencies below the nominal in order to achieve necessary torque producing magnetic ux, and eliminating the effects of voltage losses in the power cabling and as well as the motor itself. The Space Vector Control modes compensate for these losses automatically. In Scalar V/Hz control modes IR Compensation is adjusted by a parameter. An Isolation Transformer is a device that electrically separates the drive from the ac power line. An isolation transformer provides the following advantages: In dc motor applications, it guards against inadvertent grounding of plant power lines through grounds in the dc motor armature circuit. Enhances protection of semiconductors from line voltage transients. Reduces disturbances from other solid state control equipment such as drives without isolation transformers, time clock systems, electronic counters, etc.
Insulation Resistance Test
Integrated Circuit
Interconnection Diagram Intermediate Circuit
Inverter Circuit
IR Compensation
Isolation Transformer
Kilowatt KVA Leakage
A Kilowatt is a unit of electrical power equal to 1000 watts. Kilovolts times amperes. Kilo Volt - Amperes Leakage is the undesirable ow of current.
17-9
Rev 11/7/00
Limit-Switch
A Limit-Switch control device that converts mechanical motion into an electrical control signal. For a speed control system Linearity is the maximum deviation between actual and set speed expressed as a percentage of set speed. Steady state current taken from the line with the rotor at standstill ( at rated voltage and frequency). This is current when starting the motor and load. The minimum torque that a motor will develop at rest for all angular position of the rotor (with rated voltage applied at rated frequency). A Lug is a device for terminating a conductor to facilitate the mechanical and electrical connection. Main circuit refers to the BUL 425 inverters high power electrical circuit. Themain circuit consists of the rectier circuit and the inverter circuit. There is a capacitive DC Link between the two that is called the intermediate circuit. A Master Drive is the controller that sets the reference input for one or more Follower drives. The MLFB number or order number for the BUL 425 inverter and is located on the units nameplate. This number appears in the form: 6SE70xx-xxxx and denes a number of things about the product including voltage and current. A Module is unit or set of circuit elements packaged so it can be readily A Motor is an apparatus used to convert from electrical to mechanical energy. A Motor Constant is the ratio of motor torque to motor input power. This is a system in which one control operates two or more motors simultaneously, maintaining a constant ratio between speeds of the motors. The Motor ID Run, called Static ID is the procedure for Optimization of the BUL 425 inverter. In this procedure the motor is introduced to the BUL 425 inverter, its windings are pulsed with electrical current, and a mathematical model of the motor is formed from the startup data. This model can be enhanced with the motor Dynamic Optimizations in demanding applications, as 100% motor control accuracy is usually only achieved with these Optimizations. See Section 9.3 for more information on Optimizing BUL 425 inverters. The National Electric Code is recommendations of the national re protection association and revised every three years. City or state regulations may differ from code regulations and take precedence over NEC rules. The National Electrical Manufacturers Association is non-prot organization organized and supported by manufactures of electrical equipment and supplies. Some of the standards NEMA species are: HP rating, speeds, frame sizes and dimensions, torque and enclosures.
Linearity
Locked-Rotor Current
Locked-Rotor Torque
Lug
Main Circuit
Master Drive MLFB
Module Motor Motor Constant Multi-Motor Operation
Motor ID Run
NEC
NEMA
17-10
Neutral
A Neutral is the element of a circuit from which other voltages are referenced. Measured with respect to magnitude and time displacement in steady-state conditions. The National Fire Protection Association is an organization to promote the science and improve the methods of re protection, which sponsors various codes, including the national electrical code. No-Load is the state of a machine rotating at normal speed under rated conditions, but with no output is connected. The No-Load Speed is the speed that the output shaft of the drive motor attains with no external load connected and with the drive controller adjusted to deliver rated output at rated speed. "Off-Delay" signies that the timing period of a time delay relay is initiated upon de-energization of its coil. An Ohm is the unit of electrical resistance or impedance. An instrument for measuring resistance in ohms. Ohms Law is a mathematical relationship between voltage, current, and resistance. Current( I ) = Voltage( E ) / Resistance ( R ).
NFPA
No-Load
No-Load Speed
Off-Delay
OHM Ohmmeter Ohms law
Oil-tight Control Circuit Devices
Oil-tight Control Circuit Devices are devices such as pushbutton switches, pilot lights and selector switches which are so designed that, when properly installed, they will prevent oil and coolant from entering around the operating or mounting means. "On-Delay" signies that the timing period of a time delay relay is initiated upon energization of its coil. An Open-Loop Control system is one that lacks feedback. BUL 425 inverters use algorithms and complex calculations to improve accuracy. Operating Overload is the overcurrent to which electric apparatus is subjected in the course of the normal operating conditions that it may encounter. For example, those currents in excess of running current, which occurs for a short time as a motor is started or jogged are considered normal operating overloads for control apparatus. Allows the operator to start and stop the drive controller by push buttons or switches, and set the motor speed by turning a potentiometer to the desired dial setting. Operator controls may be integrated into the controller or mounted remotely from the drive controller. Drive Optimization is a required procedure that is necessary on all BUL 425 inverter drives See Section 9.3. It includes the following autotuning features: Static Motor Identication (Static ID)
On-Delay
Open-Loop
Operating Overload
Operator Control Station
Optimization
17-11
Rev 11/7/00
Optional Devices
Dynamic No-Load Measurement\ Dynamic Speed controller Optimization
Option Boards, Modules, and other optional devices are optional accessories that can be employed to extend BUL 425 operations and functions. The same Option Boards can be tted with all available ratings of the BUL 425 inverter.Some t within the electronic box or card rack of the base unit such as Probus communications boards, and others can be mounted on standard installation hardware next to the unit i.e. DIN rail mounting such as the DTI (Digital Tachometer Interface) board and Power supply. Federal law 91-596 of 1970, charging all employers engaged in business affecting interstate commerce to be responsible for providing a safe working place; it is administered by the Department of Labor (DOL). The outmost feedback circuit in a closed-loop control scheme that establishes the vernier -trim for precise regulation of the controlled variable. An Overcurrent Relay is a relay that operates when the current through the relay during its operating period is equal to or greater than its trip setting. An Overload Relay is an overcurrent relay which functions at a predetermined value of overcurrent to cause disconnection of the load from the power supply. An overload relay is intended to protect the load (for example, motor armature) or its controller, and does not necessarily protect itself. Overshoot is the amount that a controlled variable exceeds desired value after a change of input. Overspeed is a condition common in control of dc motors caused by a change in eld strength due to a thermal increase as the motor reaches operating temperature. As eld strength is reduced due to decreasing eld current, output speed is increased with a constant armature terminal voltage. A loss of speed feedback will also produce over speed. Parameters are operating instructions for BUL 425. Parameters are organized into logical parameter groups. Parameter values can be altered individually or as a group through the use of the application related preprogrammed parameter sets, Application Macros. See Sections 8 & 9 for more information. The Pick-Up Voltage or Current of a magnetically operated device is the voltage or current applied, at which the device starts to operate. An assembly diagram showing detailed component layout with identifying nameplates or markings. Plugging is a control function, which provides breaking torque by reversing the AC motor line voltage polarity or phase sequence so that the AC motor develops a counter-torque exerting a retarding force. The PMU or Parameterizing-Metering-Unit is the operator interface or keypad used for selecting and changing parameters or reading out values within the regulator or software blocks.
OSHA (Occupational Safety and Health Act)
Outer-Loop
Overcurrent Relay
Overload Relay
Overshoot
Over-speed
Parameter
Pick-U Voltage or Current PIX
Plugging
PMU
17-12
Potentiometer
A Potentiometer is a three-terminal rheostat, or a resistor with one or more adjustable sliding contacts that functions as an adjustable voltage divider. Expressed by the formula: Watts = 1.732 x E line (rms) x I line (rms) x cos (power factor), represents the ratio of total watts input to total rms volt-amperes input. This considers the harmonic content of line input, as well as the fundamental wave of the line, and is always lower than the displacement power factor. The Power Factor Displacement is the ratio of the active power of the fundamental wave, to the apparent power of the fundamental wave in rms volt-amperes. Displacement power factor is the power factor for which electric power utility companies charge penalties for low power factor. It is the measure of how closely the voltage and current are in phase. A Preset Speed is a control function that establishes a desired operating speed of a drive before initiating the speed change and can be an Analog or Digital value. A Pulse is a signal of relatively short duration. A Pushbutton switch (pushbutton) is a switch having a manually operable plunger, rocker or button for actuating the switch(s). The Pulse Encoder is an external digital instrument for providing BUL 425 feedback of the motor speed in applications that require precision speed control, or long time operation at near zero speeds. The pulse encoder usually mounted to the motor or driven equipment and provides speed data to the DTI or digital tach interface board. See Section 7.2.4 for connection information. The PWE # is a parameter value P070 that denes the output power of the inverter to the CUVC motherboard controlling it. A PWM inverter is a type of AC adjustable frequency drive that accomplishes frequency and voltage control at the output section (inverter) of the drive. The drive's output voltage is always constant amplitude and by "chopping" (Pulse Width Modulating) the average voltage is controlled. A memory where individual bits are stored and accessed, in lieu of groups of bits as used for numerical storage. RAM loses its memory when it loses power. The RAM stores working bookkeeping values while it is running, (i.e., counter values, etc.). A Rating (of a controller) is an arbitrary designation of an operating limit. It is based on power governed, the duty, and service required. Note: A rating is arbitrary in the sense that it must necessarily be established by denite eld standards and cannot, therefore, indicate the safe operating limit under all conditions that may occur. A Rating of a device is the designated limit(s) of the rated operating characteristic(s). Note: Such operating characteristics as current, voltage, frequency, etc., may be given in the rating. The RB-2 interface is supplied as standard on BUL 425 inverters. This board allows 115VAC crane control inputs to the drive, isolates them, and converts them to the required low-voltage
Power Factor (calculated)
Power Factor, Displacement
Preset Speed
Pulse Pushbutton
Pulse Encoder
PWE
PWM
RAM (Random Access Memory)
Rating (of a Controller)
Rating (of a Device)
RB-2 (115VAC Interface Board)
17-13
Rev 11/7/00
signals required by the drive. This board also provides three relay outputs, used by the crane control. Bright LED status indicators ore provided. Reactance Reactance is a force that opposes changes in current or voltage. The inertia of electrons causes them to oppose sudden changes in current ow or voltage. The term rectication is used to designate the process by which electric energy is transferred from an alternating current circuit to a direct current circuit. A Rectier is a circuit element bounded by two circuit terminals that has the characteristic of conducting current substantially in one direction only. Note: The rectier may consist of more than one semiconductor cell, diode, or rectier stack connected in series or parallel or both, to operate as a unit. The Rectier Circuit is a part of BUL 425 main circuit that converts the incoming AC line (mains) power to a DC voltage feeding the intermediate circuit or DC Link. The rectier circuit consists, the rectier bridge and the DC lter capacitors. The motor speed change between minimum load and full-load torque, expressed as a percentage of the full-load motor speed. This change is measured after all transient disturbances, due to load change, have terminated. % Speed Reg. = (Min-Load Spd Full-Load Spd) x 100 (Motor Rated Spd)
Rectication
Rectier
Rectier Circuit
Regulation of Drive
Minimum load is normally expressed as 5% of rated load. Rated speed is the motor operating speed when developing full-load torque with 100% voltage and frequency applied. This is normally termed base speed. For drives operated in the eld weakened range, regulation is specied as a percentage of top speed. Speed regulation for standard drives is expressed as a percentage of base speed. Set speed regulation is expressed as a percentage of base speed. Set speed regulation is expressed as a percentage change in speed from an operating point (set speed) due to load changes. If a drive had 1% regulation of base speed, a 2% change of set speed could result at 1/2 motor speed. Formula (1) is more realistic than formula (2), since the friction in the driven machine normally loads the motor appreciably and the changing work load on the machine subjects the motor to a smaller speed change than from absolute no-load to full load torque. % regulation = (no-load speed - full-load speed) x 100 (motor rated speed) regulation, steady-state
The regulated value due to the following variation in operating parameters occurring independently or simultaneously. (load remaining constant for speed and voltage regulators.) Relay A Relay is an electric device that is designed to interpret input conditions in a prescribed manner and, after specied conditions are met, to respond to cause contact operation or similar abrupt changes in associated electric control circuits. Remote Control is a control function that provides for initiation or change of a control function from a remote point. To Reset is to restore a mechanism, storage, or device to a prescribed state.
Remote control
Reset
17-14
Resolution
The smallest distinguishable increment into which a quantity can be divided (e.g., Position or shaft speed). It is also the degree to which nearly equal values of a quantity can be discriminated. For encoders, it is the number of unique electrically identied positions occurring in 360 degrees of input shaft rotation. Response Time is the time required, following the initiation of a specied stimulus to a system, for an output going in the direction of necessary corrective action to rst reach a specied value. RMS Root-Mean-Squared - the effective value of sine wave power. Reversing is the changing the direction of rotation of the motor armature or rotor. A dc motor is reversed by changing the polarity of the eld or the armature, but not both. An ac motor is reversed by changing the connections of two legs on the three phase power line. The reversing function can be performed in one of the following ways: DC contactor reversing is done by changing the phase rotation of an AC motor or the polarity to a DC motor armature with switching contactors. The contactors are operated by momentary push buttons, and/or limit switches to stop the motor and change directions. A zero speed (anti-plugging) circuit is associated with this system to protect the motor and control. DC eld reversing is accomplished by changing the dc polarity to the motor shunt eld. This type of reversing can be accomplished with dc rated contactors or by means of an electronically controlled solid state eld supply. DC manual reversing is the act of reversing the dc polarity to the motor armature by changing the position of a single switch. The switch is usually detented to give a degree of mechanical anti-plugging protection. Limit switches and remote stations cannot be used with this system. Dynamic braking is recommended. AC or DC static reversing is the act of reversing the dc polarity of the dc motor armature of phase rotation of an ac motor with no mechanical switching. This is accomplished electronically with solid state devices. Solid state anti-plugging circuitry is generally a part of the design.
Response Time
RMS Reversing
ROTOR (Rotating Machinery)
A Rotor is the rotating member of a machine with a shaft. Note: In a direct-current machine with stationary eld poles, alternating-current series, and repulsion-type motors, it is commonly called the armature. Electronic Industries Association (EIA) standard for data communications. Denes the electrical characteristics of the interface between two data handling devices. A Schematic or elementary diagram is one which shows all circuits and device elements of an equipment and its associated apparatus or any clearly dened functional portion thereof. Such a diagram emphasizes the device elements of a circuit and their functions as distinguished from the physical arrangement of the conductors, devices or elements of a circuit system. The Service of a Controller is the specic application in which the controller is to be used, for example:
RS232 / RS422 / RS485 Ports Schematic Diagram
Service of a Controller
17-15
Rev 11/7/00
1. General Purpose. 2. Denite Purpose (a) crane and hoist (b) elevator (c) machine tool, etc. Service Factor Service Factor is a multiplier, which when applied to the drive rated horsepower, indicates a permissible maximum loading at which the drive can be operated continuously. To determine the horsepower required for greater than standard service factor, multiply the rated horsepower by the service factor. If the rating thus calculated is not standard, select a drive (same base speed motor) with the next higher rating. Standard drives have a 1.0 service factor. A Short Circuit is often an unintended low-resistance path through which current ows around, rather than through, a component or circuit. Simolink is an option feature available for BUL 425 inverters. It provides a Peer-To-Peer ber-optic high-speed serial connection for drive to drive communications. A detectable physical quantity or impulses (such as a voltage, current, or magnetic eld strength by which messages or information can be transmitted. An SCR is a bistable semiconductor device comprising three or more junctions that can be switched from the OFF state to the On state or vice versa, such switching occurring within at least one quadrant of the principal voltage-current characteristic. Single-Phasing is the abnormal operation of a three-phase machine. It occurs when a phase of the supply is lost by the disconnection of a conductor. Slaving is the method of connecting controls in cascade (series or parallel). A number of slave units can be utilized, each running a drive at a different speed. When the manually operated master control calls for a speed change, the slave units will respond in proportion, maintaining the speed ratios between them. Slip is the difference between synchronous speed and operating speed of an induction motor. Slip is load dependent, such that at no load the slip approaches zero rpm, and at full load the slip approaches a value of 3-5% of synchronous speed. Slip Compensation is a function of the inverter that provides induction motors with extra voltage and frequency at the inverter output to compensate for the motor shaft speed lost with increasing motor slip with load. This function is automatically compensated for in both ClosedLoop and Open-Loop Vector control modes since BUL 425 is speed/torque referenced. In Scalar V/Hz control mode, IR Compensation is set by parameter a setting. Solid State refers to a device, circuit, or system that does not depend on physical movement of solids, liquids, gases, or plasma. The Speed Range is all the speeds that can be obtained in a stable manner by action of the control equipment governing the performance of the motor. The speed range is generally expressed as the ratio of the maximum to the minimum operating speed.
Short Circuit
Simolinnk
Signal
Silicon Controlled Rectier (SCR)
Single-Phasing
Slaving
Slip
Slip Compensation
Solid State
Speed Range
17-16
Speed RegulationConstant Start-up Data
The slope of the motor speed-torque characteristic is referred to the Speed Regulation Constant. Start-up Data refers to the motor nameplate information and other application related data that is entered into BUL 425 during start-up. Or Static ID See Motor ID Run Starting Torque is the torque exerted by the motor during the starting period. (a function of speed or slip.) Surge is a transient wave of current, potential, or power in the electric circuit. Note: a transient has a high rate of change of voltage (current) in the system. A form of protection in which an abnormal condition causes disconnection or inhibits connection of the protected equipment in accordance with the rate of change of current, voltage, or power. A device operative in conformance with the rate of change of current, voltage, power, to prevent the rise of such quantity above a predetermined value. A Switch is a device for opening and closing or for changing the connections of a circuit. Note: a switch is understood to be manually-operated unless otherwise stated. Synchronous Speed is the speed of rotation of the magnetic ux of a motor, produced by or linking the primary winding. System Efciency is the ratio of the mechanical power supplied to load, to the total input power under specied operating conditions. The input power includes that for auxiliary functions such as motor eld, phase control, switching equipment, overload protection, and fans. See Pulse Encoder A Thermal Overload Relay is a relay that functions (trips) by means of a thermally responsive system to load current through it. A Thermal Protector is a protective device for assembly as an integral pert of a machine that protects the machine against dangerous overheating due to overload and, in a motor, failure to start. Notes: (1) It may consist of one or more temperature-sensing elements, integral with the machine and a control device external to the machine. (2) When a thermal protector is designed to perform its function by opening the circuit to the machine and then automatically closing the circuit after the machine cools to a satisfactory operating temperature, it is an automatic-reset thermal protector. (3) When a thermal protector is designed to perform its function by opening the circuit to the machine but must be reset manually to close the circuit, it is a manual-reset thermal protector.
Static Identication Starting torque
Surge
Surge protection
Surge suppressor
Switch
Synchronous Speed
System Efciency (for a drive system)
Tachometer Thermal Overload Relay Thermal Protector (rotating Machinery)
17-17
Rev 11/7/00
Torque
Torque refers to a turning force applied to a shaft, tending to cause rotation. Torque is normally measured in pound-feet and is equal to the force applied, times the radius through which it acts. A method of using current limit circuitry to regulate torque instead of speed. A Transistor is an active semiconductor device that has three or more electrodes. The three main electrodes used are the emitter, collector and base. Conduction is by electrons and carriers or holes. Germanium and silicon are the materials most often used as the semiconductor material. The Triggering or ring circuit determines at which point in the positive half-cycle of the AC line voltage, the SCR's will start to conduct. UEC is a term used to dene the fast-acting current measurement system used by the BUL 425 inverter. This system monitors input, output, and ground currents in fault determination. Microprocessor Evaluated - Current Undervoltage or low-voltage Protection is the effect of a device, operative on the reduction or failure of voltage, to cause and maintain the interruption of power, to the main circuit.
Torque control Transistor
Trigger (triggering circuit) UEC
Undervoltage protection (low voltage protection) Volt (E) Voltage Voltage Drop Wiring Diagram
The Volt is a unit of voltage Voltage is the electrical property that provides energy or electrical pressure for current ow. Voltage Drop is the difference in voltage between two points of a circuit. A Wiring or connection Diagram is one that locates and identies electrical devices, terminals, and interconnecting wiring in an assembly. Words are unsigned 16-bit variables that can take on the values between 0 and 65,535. Bits within words are labeled from 0 to 15 with 0 being the least signicant bit.
Word
17-18
2000, Morris Material Handling Technical Publications Oak Creek, WI 53154 1-800-727-8774 Catalog 425-1

CAT425

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BULLETIN 425

ADJUSTABLE FREQUENCY CONTROL

OPERATION and MAINTENANCE MANUAL CATALOG 425-1

CATALOG 425-1 PUBLICATIONS DEPARTMENT OAK CREEK, WI 53154 0701

Dangers, Warnings, Cautions, Notices

Morris Material Handling

INTRODUCTION TO THIS MANUAL

WHAT THIS MANUAL CONTAINS

MATERIAL SAFETY DATA SHEETS (MSDS)

LOCKOUT/ TAGOUT PROCEDURES

BUL 425 Operation and Maintenance Manual

GENERAL SAFETY INSTRUCTIONS

BUL 425 Operation and Maintenance Manual

Morris Material Handling

BUL 425 Operation and Maintenance Manual

Morris Material Handling

DEFINITIONS AND WARNINGS ............................................................................... 1-1

DESCRIPTION .......................................................................................................... 2-1

FIRST START-UP ..................................................................................................... 3-1

TRANSPORT, STORAGE, & UNPACKING ............................................................... 4-1

TECHNICAL DATA FOR BUL 425 INVERTERS ....................................................... 5-1

6 6.1 6.2 6.2.1 6.2.2 6.2.3 6.3

7 7.1 7.1.1 7.1.2 7.1.3 7.2 7.2.1 7.2.2 7.2.3 7.2.4

8 8.1 8.2 8.3

BUL 425 Operation and Maintenance Manual

Morris Material Handling

COMMISIONING PARAMETER LIST FOR BUL 425............................................... 13-1

14 14.1 14.2 14.3

15 15.1 15.2 15.3

BUL 425 CRANE AND HOIST CONTROL DIAGRAMS........................................... 16-1

GLOSSARY OF TERMS.......................................................................................... 17-1

BUL 425 Operation and Maintenance Manual

Morris Material Handling

Definitions and Warnings

BUL 425 Operation and Maintenance Manual

Morris Material Handling

Safety and Operating Instructions for Drive Converters

BUL 425 Operation and Maintenance Manual

Morris Material Handling

Terminal strip Control electronics Internal power supply

PMU Serial interface

U1/L1 V1/L2 W1/L3 PE Rectifier Pre-charging DC link Inverter

U2/T1 Motor connecW2/T3 tion V2/T2 PE2

Circuit principle of the frequency converter

200VAC 230VAC Constant Torque Inverter Drive Controller

Smartorque 200 - 230VAC Inverter Ratings & Input Fuse Selection

BUL 425 Operation and Maintenance Manual

Morris Material Handling

380 460VAC Constant Torque Inverter Drive Controller

Output Current (Amps) 5.6

500VAC 600VAC Constant Torque Inverter Drive Controller

60 75 / 100 125 / 150 200

R23969D12 (Qty. 3) Req. R23969D12 (Qty. 3) Req. R23969D13 (Qty. 3) Req.

Smartorque 500 600VAC Inverter Ratings & Input Fuse Selection

BUL 425 Operation and Maintenance Manual

Morris Material Handling

Unpack and check the units

Form the DC link capacitors, if necessary

See Section 7 "Connectingup"

Power up the external 24 V supply or the line voltage

See Sections 8 & 9 "Parameterization"

Connect remaining control and motorcables and prepair for optimization

Optimize the system performance