frequency converter of series fc72 - sieb & meyer · lcd liquid crystal display led light...

�

FC72 Frequency Converter - 1 -

Frequency Converter of Series FC72

SIEB & MEYER AG

Auf dem Schmaarkamp 21 � D-21339 Lüneburg � GermanyTelephone: ++4131/203-0 � Telefax: ++4131/203-2000

Email: [email protected]: www.sieb-meyer.de

http://www.sieb-meyer.de

�

- 2 - Frequency Converter FC72

Copyright

Copyright © 2015 SIEB & MEYER AG. All rights reserved.

This manual or extracts therof may only be copied with the explicit authorization bySIEB & MEYER AG.

Trademarks

All product, font and company names mentioned in this manual may be trademarksor registered trademarks of their respective companies.

Identification Key

021-sfu-tec-2172/R011-SM-EN-rg/ac/she/uhOctober 07, 2015

� Contents


1 Used Symbols and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.1 Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 Product Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Safety Instruction and Application Advice . . . . . . . . . . . . . . . . . . . . . . . . . . 92.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.2 Appropriate Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.2.1 First Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.2.2 Second Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.2.3 PDS (Power Drive System) of Category C1 . . . . . . . . . . . . . . . . . . . . . . . . . . 102.2.4 PDS of Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.2.5 PDS of Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.3 Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.5 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.8 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Specific Safety Instruction for FC72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.1 Back-Magnetizing of Synchronous Motors (Field Weakening) . . . . . . . . . . . . 153.2 Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Unit Assembly Complying EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.1 Integration in Drive Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236.1 Electrical Output Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236.2 Electrical Input Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246.3 Applicable Mains Supply Modules of Other Manufacturers . . . . . . . . . . . . . . . 256.4 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266.4.1 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266.4.2 View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276.4.3 Mounting Holes of the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286.5 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296.5.1 3D View of the Converter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337.1 Speed-Controlled Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347.2 Position-Controlled Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347.2.1 Position-Controlled Operation with Higher-Ranking Controller . . . . . . . . . . . . 347.2.2 Position-Controlled Operation via Internal Positioning Functions . . . . . . . . . . 347.3 Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357.3.1 Overload of the Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357.3.2 Overload of the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377.4 Connections at the Frequency Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.4.1 View of the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.4.2 Connector Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407.4.2.1 Serial Interface (Connector X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417.4.2.2 Outputs (Connector X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417.4.2.2.1 Messages without Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417.4.2.2.2 Messages with Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457.4.2.2.3 Logic Operations of Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467.4.2.3 Inputs (Connector X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477.4.2.4 Speed Pulses (Connector X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527.4.2.5 Analog Values (Connector X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527.4.2.6 Motor Sensors (Connector X7, X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537.4.2.6.1 PTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547.4.2.6.2 PT 100 and KTY 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

�Contents


7.4.2.7 24 V-Input/GND (Connector X9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557.4.2.8 Ground (GND) and Analog Ground (AGND) . . . . . . . . . . . . . . . . . . . . . . . . . . 557.4.2.9 Input for Message "Power OK" (Connector X10) . . . . . . . . . . . . . . . . . . . . . . 557.4.2.10 Safety Contact (SC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567.4.2.11 Motor Phases (Terminals U, V, W) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567.4.2.12 Power Supply (Terminals +600, -600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8 Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598.1 Tips for a Trouble-Free Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598.2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9 Terminal and Connector Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619.1 Connector X2, Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619.2 Connector X3, Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629.2.1 Schematic Diagram of the Relay Outputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . 639.3 Connector X4, Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 649.4 Connector X5, Speed Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659.5 Connector X6, Analog Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679.5.1 Examples for Analog Reference Value Presetting . . . . . . . . . . . . . . . . . . . . . 679.6 Connector X7, Motor Sensors IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699.6.1.1 Sense Control Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709.7 Connector X8, Motor Sensors OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719.8 Connector X9, 24 V-Input/GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729.9 Connector X10, "Power o.k." . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729.9.1 Schematic Diagram of the Inputs at Connector X10 . . . . . . . . . . . . . . . . . . . . 739.9.2 Wiring Examples for Connector X10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749.10 Connection SC (Safety Contact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759.11 U, V, W - Motor Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759.12 +600, -600 - Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 769.13 Earth Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

10 Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7910.1 Status Messages ON, INE and OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7910.2 Status Messages FC0 to FC3 and FCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8010.3 Check of Internal Fuses after Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

11 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8711.1 Bus Connections (Profibus-DP; other types on demand) . . . . . . . . . . . . . . . . 8711.1.1 Profibus-DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8711.2 Connecting Cables for Sensors (Motor/Converter) . . . . . . . . . . . . . . . . . . . . . 89

12 Appendix: Wiring example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

13 Appendix: Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

� Used Symbols and Abbreviations


1 Used Symbols and Abbreviations

1.1 Units of Measurement

Apart from the commonly used units for dimensions, SIEB & MEYER uses theunits HU and WU, which are explained in the following:

Abbreviation Meaning

HU technical unit for the height 1HU � 44.45 mm / 1.75 inches

WU technical unit for the width 1WU � 5.08 mm / 0.2 inches

1.2 Symbols

The following table explains the symbols used in this manual for describing purpo-ses. Technical symbols and signs are supposed to be known and therefore notexplained.

Symbol Meaning

* Points to further information concerning the subject.

� Warning: indicates dangers which may cause damages to the product or personal inju-ries.

� Indicates dangerous contacts.

� Indicates currents and voltages.

� Indicates general notes, to which special attention should be paid to.

� Indicates measures or steps to be taken by the user.

�

LEDs indicating the module status

LED on

� LED off

� LED flashes

Protective earth conductor

Neutral / common

�Used Symbols and Abbreviations


1.3 Abbreviations

General abbreviations

BGV Regulations of the German professional association concerning the preven-tion of accidents (German Berufsgenossenschaftliche Verordnung)

-labelling (Communauté Européenne = European Community); confirmsthe conformity of products with the relevant EU standards and guidelines

CC SIEB & MEYER communication controllerDIN Deutsches Institut für Normung = German Institute for StandardsDZ differential measuring system for Z axisEC European CommunityEEC European Economic CommunityEMC Electromagnetic compatibilityEN European standardEnDat Encoder DataFC SIEB & MEYER frequency converterGB GigabyteGHz GigahertzHDLC high level data link controlHSSB high-speed serial busHz HertzIEC International Electrotechnical CommissionIPC industrial PCKB KilobyteLCD liquid crystal displayLED light emitting diodeLSB lowest significant bitMB MegabyteMC SIEB & MEYER motion controllerMD SIEB & MEYER motion driveMHz MegahertzMSB most significant bitNMI not maskable interruptNTC NTC-resistor (negative temperature coefficient)PDS Power Drive Systems (product standard EN 61 800-3)POF plastic optic fiberPS SIEB & MEYER power supplyPTC PTC-resistor (positive temperature coefficient)SFU static frequency converter (German statischer Frequenzumrichter)TFT thin flat tubeUL Underwriters Laboratories; international conformity assessment provider for

productsUSB universal serial busVAC alternating current voltageVCO voltage controlled oscillatorVDC direct current voltageVDE Association of German Electricians (German Verband Deutscher Elektro-

techniker)

� Used Symbols and Abbreviations


Physical connections

Physical connections are designed according to the type of wiring with the followingabbreviations:I inputO outputn.c. not connectedn/o normally open contactn/c normally closed contact

1.4 Product Designations

Product names mentioned in this documentation are trademarks or registered tra-demarks of their respective companies.

The appropriate name of the company is characterized by CAPITAL LETTERS.

Examples:

� SIEB & MEYER frequency converters of series FCXXSIEB & MEYER CNC 84.00

� PHOENIX terminal� measuring system by HEIDENHAIN

�Used Symbols and Abbreviations


�


2 Safety Instruction and Application Advice

According to Low-Voltage Guideline 73/23/EECMachine Guideline 98/37/ECElectromagnetic Compatibility 89/336/EEC

2.1 General Information

�Trained staffIn principle, the complete installation, the initial operation and themaintenance must only be carried out by trained staff.Trained staff, according to this fundamental safety instruction, arepersons, familiar with the installation, mounting, initial and perma-nent operation of the product and, are qualified appropriately forthe work. The standards DIN VDE 0100 and DIN VDE 0110 andalso the legal national rules for prevention of accidents must bepaid attention to.

�Energized and hot surfacesDuring the operation the units can have energized and hot surfa-ces according to their protection system.

�Damages / InjuriesSubjects can be damaged and persons be injured

� when covers are removed illegally,

� during any improper use,

� when either the installation or the operation is incorrect.

�ModificationsConsult SIEB & MEYER before carrying out any modificationswithin the unit.

2.2 Appropriate Use

Definition of the concepts acc. to IEC / EN 61800-3

2.2.1 First EnvironmentEnvironment with residential districts; this environment contains also establish-ments which are directly connected without intermediate transformer to the low-vol-tage power supply network, which supplies buildings used for domestic purposes(households).

Annotation: Examples for establishments within the first environment are houses,apartments, stores or offices in residential buildings.

2.2.2 Second EnvironmentEnvironment with all remaining establishments (e.g. industrial establishments)which are not directly connected to a low-voltage power supply network, whichsupplies buildings used for domestic purposes.

Annotation: Examples for establishments within the second environment are indu-strial areas and technical areas of buildings which are supplied by a transformer.

�


2.2.3 PDS (Power Drive System) of Category C1PDS with a rated voltage lower than 1,000 V, which is to be used within the firstenvironment.

2.2.4 PDS of Category C2PDS with a rated voltage lower than 1,000 V, which is neither a device with connec-tor nor a movable device and which must be installed and operated for the first timeby an expert, if it is used within the first environment.

Annotation: An expert is a person or an organisation which has the necessary expe-rience for the installation and/or initial operation of drive systems including its EMCaspects.

2.2.5 PDS of Category C3PDS with a rated voltage lower than 1,000 V, which is to be used within the secondenvironment and not within the first environment.

According to EN 61800-3, the electronic power drive systems (PDS) developed bySIEB & MEYER must be used in industrial establishments which are not directlyconnected to a low-voltage power supply network, which supplies buildings in re-sidential districts (also called second environment , category C3). Products of thiskind are only partly available.Since all products by SIEB & MEYER are electronic equipment used for the opera-tion of motors, electric loads and provided for the installation into machines or partsof a stationary installation, the safety-relevant aspects of the Machine Guidelines(98/37/EWG) must be taken into account.

�If the mechanics or the electronics of the device i s modified,the conformity with the EC/EEC guidelines and thus the label will expire.

Before initial operation, make sure that the machine will not expose danger (e.g.runaway moves). The conformity according to the safety standard EN 60204-1 andEN 61800-5-1 must have been proven.

The manufacturer of the system or the machine has to meet the requirements ofthe legal values regarding the Electromagnetic Compatibility (EMC). SIEB & MEY-ER�s units can be operated in industrial areas, provided the attached EMC informa-tion has been taken into consideration.

SIEB & MEYER takes care in its own EMC laboratory over their products to meetthe respective standards, when they are installed properly.

Deviations of the construction and the installation, described in the documentationand in the manual “Unit Assembly Complying EMC” require new measurements ofthe system or machine by the machine manufacturer to meet the statutory require-ments.Appropriate proceedings according to the EMC Product Standard (PDS) DIN/EN 61800-3 ensure the use in industrial areas.

� Products, not equipped with an AC supply line filter must be operated with a seriesconnected mains filter! Detailed information can be found in the chapter "Unit As-sembly Complying EMC".

�


If using the drive systems in residential areas, in business and commercial areas aswell as in small trade, the user has to take additional and larger filter measure-ments.

SIEB & MEYER products meet the requirements of the Low-Voltage Guideline73/23/EEC. The coordinated standards of the series IEC / EN 50178 and IEC / EN60 204-1 in combination with IEC / EN 60 947 and IEC / EN 61800-5-1 are strictlyused for the products.

Technical data and the connection specification can be found in the respective pro-duct documents.

2.3 Transport and Storage

Make sure, that the unit is correctly used. The following points must especially betaken into consideration:� Protection against mechanical damage (transport, handling, etc.)!� Protection against dirt and humidity!� Dry and well-ventilated storage area!� No storage in the open!� Storage temperature between �25�C to +55�C (�13�F to +131�F)! Shortly it may

be +70�C (+158�F).� Protection against contact with electronic components (electrostatic discharge)!� No modification of insulating distances!

2.4 Installation

The drive components are designed for fulfilling the degree of pollution 2 accordingto IEC 61800-1 / DIN EN 50178.� The units can be loaded to their maximum up to a height of 1,000 m M.S.L

(3,281 ft M.S.L.)� For an operation in areas higher than 1,000 m M.S.L. (3,281 ft M.S.L.) the capacity

must be reduced by 15 % per 1,000 m (3,281 ft.)� The ambient air must not contain aggressive, electrically conductive or flammable

substances and must not contain any amount of dust.� The maximum relative humidity is approx. 95 % (no condensation).� The admissible ambient temperature during the operation is between +5�C and

+40�C (+41�F and +104�F).� Make sure that the fans installed in the units have sufficient space to take in and

exhaust the cooling air!� Do not touch electronic components.

�SIEB & MEYER products contain electrostatically sen sitivecomponents that may easily be damaged by improper h and-ling.

�


2.5 Electrical Connection

�The valid rules for prevention of accidents (e.g. VBG 1 andVBG 4) should be paid attention to, when working atcurrent-carrying units.

The electrical installation must be carried out according to the relevant electricalcodes (e.g. appropriate wire gauges, fuse protection and connections of groundconductors must be considered).

Recommendations for the installation according to the EMC (e.g. shields, connecti-on to earth and line installations) can be found in the technical documents of theunit (only for machine manufacturers). The manufacturer of the system or machinehas to meet the requirements of the legislation regarding the EMC.

� All work at and within the units must only be carried out, when they are turned offand when the AC line is cut!

� The mains supply must be protected via an overload release with restricted gui-dance for each mains phase.

� The mains line should only be connected, when the work is completed!� Before turning on the unit the first time, make sure that the connected machine will

not have runaway axes!� After turning off the unit hazardous voltages may still exist for up to 3 minutes in

the power supply (due to capacitors).� Capacitive loads must not be connected to the output phases of the servo am-

plifiers and frequency converters.� Prevent cable loops. Therefore, the units must only be connected to earth at the

provided PE connection for the mains supply line and the racks only at the provi-ded earth screw.

Basically, the operation can be made with residual current operated devices. Never-theless, like all clocked units of the power electronics, also SIEB & MEYER�s pro-ducts can lead leakage currents via the earth system. Depending on the sensitivityof the residual current operated device and the installation type, the operation alongwith the device may arise problems. The following points should be taken into con-sideration:� Use shortest motor leads possible.� Do not connect additional consumers to the same residual current operated devi-

ce.� Use a residual current operated device with high response threshold.

�


2.6 Operation

Systems, into which servo amplifiers and frequency converters are mounted, possi-bly must be equipped with additional protective devices according to the valid safetyinstructions (e.g. law about technical material, rules for prevention of accidents,etc.).

All doors and covers must be closed during the operation.

�In order to ensure a trouble-free operation of the installation, thescrews must always be tightened!

2.7 Maintenance

The unit, especially the fan, must be checked regularly for cleanness and functiondepending on the ambient pollution.

2.8 Guarantee

The guarantee is only granted when the points 2.1 to 2.7 are taken into considerati-on.

This Safety Instruction and Application Advice does not assure any features.

�A first programming carried out by SIEB & MEYER doe s notrelease the user from his duty to check programmed valuesfor their correctness!

SIEB & MEYER AGApril 12, 2006

Save these Safety Instructions!

�


� Specific Safety Instruction


3 Specific Safety Instruction for FC72

3.1 Back-Magnetizing of Synchronous Motors (Field We a-kening)

Concerning synchronous motors, back-magnetizing is frequently used. Back-magneti-zing can be compared to field weakening - similar to asynchronous motors. In contrast to asynchronous motors, the synchronous motor is a voltage source dueto its permanent magnets. Depending on the motor design and the desired speed,high voltages may occur at the terminals of the motor. If the back-magnetizing of a synchronous motor is used, a current vector must beimpressed via the converter which is capable to reduce the required voltage at theterminals of the motor.

Advantage: Characteristic curves with field weakening profile can be generated -similar to asynchronous motors.

Disadvantage: If the control of the converter fails (e.g. in case of an error), high vol-tages can occur at the motor terminals which may destroy the converter if no furthermeasures are taken.

�These high voltages must absolutely be prevented!

The following limiting values are applied:

If the motor is used without additional protective arrangements, the voltage at theterminals of the motor must never exceed U = 520 Vrms which corresponds to a peakvoltage of U = 735 Vpeak. The indicated voltage values are voltages which are measu-red by means of the motor phases.

The peak voltage is calculated as follows:

voltage [V] = max. speed of the motor [krpm] × voltage constant [V/krpm]

U = n × kE

Example 1: maximum speed = 27000 rpmkE (acc. to data sheet) = 29.91 V/krpm

U = 27 krpm × 29.21 V/krpmU = 789 V

This motor must be connected using additional protective arrange-ments.

Example 2: maximum speed = 22000 rpmkE (acc. to data sheet) = 23.5 V/krpm

U = 22 krpm × 23.5 V/krpmU = 517 V

This motor can be connected without using additional protective ar-rangements.

�Specific Safety Instruction


If motors are to be used which are not capable to reduce the voltage to these limitingvalues, additional components must be used. One of this additional components isthe VP module (Type: Dynamic) of SIEMENS. If the control of the converter fails, thismodule limits the voltage to a value which does not damage the frequency converter.But also these modules may work incorrectly. Therefore, the maximum voltage gene-rated at the terminals of the motor must never exceed U = 1400 Vrms. This value cor-responds to a peak voltage of U = 2000 Vpeak. Also these indicated voltage values arevoltages which are measured by means of the motor phases.

�Please contact SIEB & MEYER for a safe dimensioning of thedrive!

3.2 Wiring Example

Example: VP module; company: Siemens

The VP module must always be connected to the output terminals of the output sta-ge. The cable connecting the VP module to the converter must not be longer than1.5 m (specified by Siemens).

The signaling contact of the VP module must be connected to the "Safety Contact" ofthe converter. This makes sure that the converter stops supplying energy as soon asthe VP module is activated.

� Unit Assembly Complying EMC


4 Unit Assembly Complying EMC

�The EC guidelines for the electromagnetic compatibi lity(EMC) must be taken into consideration for the init ial operati-on of all SIEB & MEYER units!

The manual "Unit Assembly Complying EMC" is available in German and English andcomprises

� the EMC guidelines� Information regarding the professional earth and wiring� Safety-relevant aspects� Extracts from the EMC product standard

Availability:

� Hard copy version directly from SIEB & MEYER� PDF file in the Internet under www.sieb-meyer.de

http://www.sieb-meyer.de/

�Unit Assembly Complying EMC


� General Information


5 General Information

The frequency converters of series FC72 in modular design have especially beendeveloped for high-speed asynchronous and synchronous motors.

The control circuit used in this series offers high advantage for applications. Leastmotor losses are especially required in fields of high-speed cutting.

So far the use of frequency converters caused the generation of considerable addi-tional losses in the motor spindles. Often the operation of frequency converters wasimpossible even in idle run due to high motor temperatures. Thus, the motor capacityhad to be reduced considerably. Even for applications requiring a high surface qualityof the workpiece (e. g. molding) least thermal expansion is very important.

The widely used pulse width modulation (PWM) is especially unsuitable for high-speed spindles, since high-frequency currents (up to 30 kHz) flow in the motor due tothe high switching frequency. These currents do not support the required rotatingfield, but only additionally heat the motor. A particular disadvantage is that theadditional losses are mainly generated in the rotor, in which a cooling can hardly berealized. Therefore, SIEB & MEYER has been using different control circuits for thefrequency converters.

The new converters of the series FC72 permit to minimize the converter-dependentlosses with regard to the application. This means that in most of the applications anadditional choke is not required.

Further advantages:

� Due to the fact that additional motor inductors are not necessary, considera-ble savings in costs and size can be obtained.

� Vector-controlled motor drive with motor frequencies of up to 2,000 Hz(120,000 RPM).

� No power reduction in higher speed ranges.

� Combinable with power supply modules of other manufacturers.

� Easy to mount and to service due to modular structure.

� Large power range of 20 to 170 kVA.

� Storage and selection possibilities of four different motor parameters

� Possibility of switching from wye to delta run

�General Information


5.1 Integration in Drive Systems

An operational drive combination consists of the following components:

� Frequency converter FC72XXX. The frequency converters are equipped with fastfuses for semiconductor protection.

� Mains supply unit of other manufacturers (e. g. Siemens) for the supply with540VDC to 680VDC. The mains supply unit must be equipped with a braking elec-tronics with ballast resistor, or a possibility to feed back energy.

� External 24VDC voltage supply to supply the electronics with the required auxiliaryvoltages. Current input approximately 2.0 A to 3.0 A. Usually each switch cabinetprovides a sufficient voltage supply of 24VDC.

� Speed evaluation via sine/cosine encoder or incremental encoder. (sensorlessvector control for asynchronous motors in preparation)

� Cooling system for water-cooling of the output stage heat sink (starting from powerrange 100 kVA). The cooling system of the motor spindle can be used additionally.

� Control system (CNC, PLC, PC or remote control) to control the requiredfunctions. Different interfaces are available: Profibus-DP; Interbus-S or Can-Bus(on demand) or the data transmission is realized in a conventional way via analogreference value and 24 V inputs and outputs.

� Accessories, for example motor chokes, motor filters or periphery for water-coo-ling, can be conceived by Sieb & Meyer considering the special requirements ofthe customer, and delivered on demand.

Arrangement example (XXX stands for power measured in kVA):

� General Information


�General Information


� Technical Data


6 Technical Data

6.1 Electrical Output Data

Type ofFrequencyConverter

Motor Apparent

Power

S [kVA]

(1)

Motor Phase

Current

I [A]

Motor Shaft Power

P [kW] / [ HP]

(2) OutputFrequency

f [Hz]

AmbientTemperature

T [�C]S1

(3)

S6

(4)

Peak

(5)

S1

(3)

S6

(4)

Peak

(5)

S1

(3)

S6

(4)

Peak

(5)

FC72020 20 25 34 29 36 50 14/18 18/24 25/33

0 to 2,000 max. 40

FC72030 30 38 48 44 55 70 22/29 27/36 35/46

FC72040 40 50 69 58 73 100 29/39 36/48 50/66

FC72055 55 69 83 80 100 120 40/53 50/67 60/80

FC72070 70 86 97 101 125 140 50/67 62/83 70/93

FC72100 100 125 138 145 181 200 72/96 90/120 100/133

FC72125 125 150 159 181 217 230 90/120 108/144 115/153

FC72150 150 159 170 217 230 245 108/144 115/153 123/164

-1 The apparent power S of the motor was calculated for an output voltage of 400Vms and a supply voltage of 600 VDC.

-2 The shaft power P of the motor was calculated assuming a power factor of cos� = 0.85 and a motor efficiency of � = 0.85.

-3 S1: Continuous load with S1 values.

-4 S6: Operation for 72 s with S6 values (load) alternating with 48 s with 40 % ofthe S6 values (idle run).

-5 The peak values are admissible for a maximum of 10 s.

�Technical Data


6.2 Electrical Input Data

Type of

FrequencyConverter

Direct Current

IDC [A]

(1)

Fuse for

SemiconductorProtection

(5)

Capacity of

IntermediateCircuit

[�F]

Cooling

Efficiency

� [%]

Direct Voltage

UDC [V]

(6)S1

(2)

S6

(3)

Peak(4)

FC72020 28 36 50 63 495

Air

Approx. 98 540 to 680

FC72030 44 54 70 80 660

FC72040 58 72 100 125 990

FC72055 80 100 120 160 1320

FC72070 100 124 140 200 1485

FC72100 144 180 200 250 2475

WaterFC72125 180 217 230 315 3630

FC72150 217 230 246 315 3630

-1 The consumed direct current IDC was calculated assuming the following:

� efficiency of the motor � = 0.85

� efficiency of the module � = 0.98

� mean value of the supply voltage UDC = 600VDC

-2 S1: Continuous load with S1 values.

-3 S6: Operation for 72 s with S6 values (load) alternating with 48 s with approxi-mately 10 % of the S6 values (idle run). The current consumption (IDC) duringidle run depends on the idle losses of the motor.

-4 The power supply module is loaded with the given peak values for a maximumof 10 s.

-5 The fuses for the semiconductor protection are installed in the converter modu-les as standard and have not to be provided by the customer.

-6 To the mean value of the connected d. c. voltage UDC applies:

� 0 V < U < +400 V measured from positive pole (+600) to earth

� 0 V > U > -400 V measured from minus pole (-600) to earth

To the peak value of the connected d. c. voltage UDC applies:

� 0 V < U < +800 V measured from positive pole (+600) to earth

� 0 V > U > -800 V measured from minus pole (-600) to earth

� Technical Data


6.3 Applicable Mains Supply Modules of Other Manufac turers

The mains supply modules listed in the following table are to be considered as sug-gestions and not as binding conditions for uninterrupted operation.

Type of FrequencyConverter

Mains Supply Modules

by SIEMENS

Series Simodrive 611

(1)

FC72020 E/R16/21

FC72030 E/R36/47

FC72040 E/R36/47

FC72055 E/R55/71

FC72070 E/R55/71 or E/R80/104

FC72100 E/R80/104 or E/R120/156

FC72125 E/R120/156

FC72150 E/R120/156

E/R = module with generative and regenerative supply

-1 For selecting the corresponding mains fuses, commutation chokes, transfor-mers, filters and main switches see Siemens Planning Guide for series SIMO-DRIVE 611.

�Due to the mode of operation of the mains supply modules amains filter is necessary to ensure an operation complying withthe EMC guidelines.

�Technical Data


6.4 Dimensions and Weights

6.4.1 Modules

Type of Fre-quency Con-

verter

Weight

[kg]

Width Height Depth

A B C C1 (1) D D1 (1)

[mm /In] [mm /In] [mm /In] [mm /In] [mm /In] [mm /In]

FC72020 15200/7.87

440/17.32 480/18.90 approx.550/21.65 260/10.24 approx.

330/13.00

FC72030 16

FC72040 31

350/13.78

FC72055 32

FC72070 33

FC72100 24

FC72125 26

FC72150 27

-1 module dimensions including connectors, terminals and cables

�In order to obtain an optimum cooling of the modules make surethat a space of approximately 150 mm (5.91 inches) is provided inthe area of the inlet and outlet of the cooling air.

� Technical Data


6.4.2 View

�Technical Data


6.4.3 Mounting Holes of the Modules

All mounting holes are suitable for M5 and M6 screws.

Module width

AB C D E F

[mm /In] [mm /In] [mm /In] [mm /In] [mm /In] [mm /In]

200/7.87 466/18.35 25/0.98 – – 175/6.89

350/13.78 466/18.35 25/0.98 – – 325/12.80

� Technical Data


6.5 Cooling

The converter modules up to a rated power of 70 kVA are ventilated. As already des-cribed, it must be ensured that enough space is provided for the fans to take in andblow out the cooling air (see also page 26). Additionally, a regular check of the fansconcerning their function and cleanness must be carried out (see Safety Instructions,page 9).

The frequency converters with a rated power of up to 100 kVA are equipped withaluminum bodies containing liquid coolants. When using liquid coolants, the followingmust be taken into consideration:

� The inlet temperature of the coolant must not exceed 35 �C.

� The coolant must be based on water and contain a corrosion preventive.

� Antifungal additives prevent the cooling channels from clogging.

� The coolant must be purified.

� Solids must not be carried.

� The following functions must be monitored:

– temperature

– maximum pressure

– pressure loss (leak in system)

– flux quantity

� The coolant must react chemically neutral.

� The operating pressure must not exceed a maximum of 4 bar.

� Bedewing of the heatsink and the connected coolant connections must beavoided! (Bedewing is caused by high humidity in combination with high tem-peratures, especially if the coolant temperature is low.).

� The Safety Instructions starting on page 9 must be observed.

Two couplings are mounted at the bottom of the output stage module for forward andreverse feed. The flow direction must absolutely be considered (see page 30).

�Technical Data


6.5.1 3D View of the Converter Module

� Technical Data


SIEB & MEYER uses couplings made by RECTUS of the series 21 KB (article no.21KB KS08 MPX). These connections are used for a double shut-off coupling in orderto ensure that water cannot leak.

Two plugs for plastic tubes with a diameter of 8 mm are delivered along with the con-verter (article no. 21KB KO08 MPX). Other plugs can directly be ordered at RECTUS(www.rectus.de).

Before the delivery the cooling system is checked by SIEB & MEYER in a pressuretest with 6 bar over a time period of 8 hours.

�Before works are carried out at the cooling system, the electricalequipment in the danger area must be isolated (e. g. switch cabi-net). Possible discharge times of the electrical equipment have tobe considered.

�Before electrical equipment in the danger area (e. g. switch cabi-net) is connected to the electrical mains supply, the cooling sys-tem must be checked for leaks.

The following table applies to coolant throughput and refrigerating capacity:

Converter ModuleMin. Coolant Throughput

[l/min]

Refrigerating Capacity

[kW]

FC72100 2.5 2.0

FC72125 3.0 2.5

FC72150 3.5 3.0

Optionally, the converter modules can be equipped with an efficient "2-chamber sys-tem" for protection against coolant leakage in the area of electronics. For detailedinformation please contact SIEB & MEYER.

http://www.rectus.de

�Technical Data


� Functional Description


7 Functional Description

With the "usual" mains supply with fixed voltage and frequency, three-phase motorscan only be driven with definite speed graduation according to the number of motorpoles. The maximum achievable speed is 3,000 RPM (3,600 RPM) for a 2-polemotor. When starting, the motor however loads the installation mains up to the 5-foldof the rated motor value, thus causing problems especially for bigger machines.

The use of frequency converters eliminates these limitations. The frequency con-verter changes the inflexible mains supply into a rotary field, continuously adjustablein voltage and frequency. As advantages, the speeds can be changed infinitely andthe starting currents can be reduced considerably.

In addition, suitable electronics can compensate parasitic characteristics of the motor,or high-dynamic control cycles can be initiated.

For the operation of three-phase motors, the following connections have to be madeat the vector-controlled frequency converters of the series FC72:

� Supply of d.c. voltage (540 VDC to 680 VDC)

� Connection of motor phases

� Motor sensor connection (speed sensors, PTC, etc.)

� Supply of +24 VDC/2.0 A to 3.0 A

� Instruction and reference value presetting

Instructions and reference values can be preset via various sources, as for exampleCNC controls or PCs with serial interface.

In order to start the motor the following conditions must be met:

� The feeding power supply module indicates "OK"

� The internal operating voltages are provided.

� The operating software must have finished its boot cycle.

� Status messages, interrupting the operation have not occurred (LEDs FC0 toFC3 are off).

� The inverter has been activated.

� The safety contact (SC) has been closed.

� The motor sensors are connected (PTC or temperature sensor and speedencoder).

�Functional Description


7.1 Speed-Controlled Operation

If the conditions mentioned in the previous section are met, all three green LEDs (ON,INE, OK) are on. If the function "Start/ " (pulse enable) has been selected, theStopmotor can be accelerated using a preset reference value. The acceleration time de-pends on the programmed values.

The frequency converter provides the signal "Speed OK" after reaching the referencefrequency. The desired job can be started.

During the operation overloads or malfunctions of either the motor or the convertermay occur. Then either the electronic protection or the current limitation functions willbe activated.

It is not required to drive the motor to "Speed Zero", if another reference value is to bepreset. Another reference value can be processed anytime, but the signal "SpeedOK" is cleared during the adaptation (time until reaching the new reference speed).

When selecting the function "Stop" or withholding the reference value, the motor isdecelerated with the programmed deceleration time.

7.2 Position-Controlled Operation

7.2.1 Position-Controlled Operation with Higher-Rank ing Con-troller

The converter permits to transmit the speed signals received by the motor sensors toa higher-ranking controller. The signals transmitted by the motor sensors are outputimpedance-converted on connector X8 (see page 54), thus permitting a higher-ran-king position control (e. g. for positioning jobs). In this operational mode the completeposition control is implemented in the higher-ranking controller.

7.2.2 Position-Controlled Operation via Internal Pos itioningFunctions

Manifold possibilities to position the rotor have already been implemented in the stan-dard software "Vector 7x" of the converter series FC72. In order to use thesefunctions the following supplementary conditions are required:

� The speed sensors of the motor must be equipped with a reference track.



For an absolute positioning, the reference track must only have one zero pul-se per rotation of the rotor.

� The function "positioning" must be assigned to one of the programmable in-puts.

� The function "calibration" must be assigned to one of the programmable in-puts.

� The function "position reached" must be assigned to one of the programma-ble outputs.

� Corresponding to the application, the software parameters for the speed andposition controller must have "useful" values. These parameters can be alte-red in the converter with the software "Vector 7x" and the included parametereditor.

After turning on the converter a calibration cycle has to be activated. While calibra-ting, the rotor rotates up to a maximum of 360� and searches for the zero pulse onthe reference track of the motor sensors. After the calibration the drive is ready for thedesired operations.

It is possible to preset an offset referring to the zero pulse.

Detailed information concerning the offset input (position) can be found in the opera-ting manual "Vector7x".

7.3 Overload

The converter contains two different evaluation functions for the behavior in case ofoverload. One function evaluates the load of the converter, the other function protectsthe connected motor. The function with the lower response threshold determines thebehavior of the combination of converter and motor.

7.3.1 Overload of the Converter

As you can see in the electrical output data (page 23), the converter can be loadedwith S1, S6 and peak values.

S1

Even at the maximum ambient temperature of 40 �C there will be no limitation, if theconverter is loaded up to S1 values.

S1 to S6



When loading the converter with values from S1 to S6 there will be limitations, only ifthe heatsink temperature gets too high. Countermeasures can be taken, for example,by evaluating the advance warning message "heatsink temperature".

If the heatsink temperature exceeds the maximum value, the motor is deceleratedwithin the preset deceleration time to speed 0. As soon as speed 0 is reached, theoutput stage will be deactivated and the error "heatsink temperature" will be display-ed.

S6 to Peak Value

For the range of S6 to peak values the existing load is evaluated by a so-calledI2t computer. The peak value is available for about 10 s. If the load is just above theS6 value, it is available for much longer since the current is evaluated as square va-lue.

The result of the I2t evaluation is saved to a "memory" which is faster filled than emp-tied. The memory will only be emptied, if the load has fallen below the correspondingS6 value. If the memory is not completely emptied when exceeding the S6 value, thepeak value is available for a correspondingly shorter period. If the memory is full, theconverter is turned off immediately without any warning. The error message"I2t converter" is displayed.



7.3.2 Overload of the Motor

The rated values and the maximum values of the motor are usually defined by themanufacturer of the motor or the spindle and integrated into the software togetherwith the motor parameters. These values can be altered. However, the alterationrequires a corresponding user level.

Rated Value

If the motor is loaded by the converter up to the rated value, there will be no limitation.

Peak Value

If the motor is loaded with values between the rated value and the peak value, theexisting load is evaluated by a so-called I2t computer. The peak value is available fora maximum of 10 s. If the load is just above the rated value, the peak value is availa-ble for much longer since the current is evaluated as square value.

The result of the I2t evaluation is saved to a "memory" which is faster filled than emp-tied. The memory will only be emptied, if the load has fallen below the correspondingrated value. If the memory is not completely emptied when exceeding the rated value,the peak value is available for a correspondingly shorter period. If the memory is full,the converter is turned off immediately without any warning. The error message"I2t motor" is displayed.



7.4 Connections at the Frequency Converter

�The following functional descriptions refer to the presetting at thestandard interface with analog speed reference value and 24Vinputs and outputs. The functions described also apply to the op-tional field bus systems (e.g. Profibus -DP).

7.4.1 View of the Module



Designation Function

+600, -600 Power supply, see page 57

U, V, W Motor phases, see page 56



7.4.2 Connector Assignment

LEDs Status indications, see page 80

X2 Serial interface, see page 41

X3 Outputs, see page 41

X4 Inputs, see page 41

X5 Speed pulses, see page 52

X6 Analog values, see page 41

X7 Motor sensors IN, see page 53

X8 Motor sensors OUT, see page 54

SC Safety contact, see page 56

X9 24 V supply, see page 55

X10 "Power OK", see page 72



7.4.2.1 Serial Interface (Connector X2)

This 9-pole Submin D connection permits the connection of PCs or notebooks andthe operation or programming of the frequency converter by means of the software"Vector 7x".

The pin assignment and further information can be found in the section "Terminal andConnector Assignment" (page 61 ff.).

7.4.2.2 Outputs (Connector X3)

All outputs described in the following are equipped with relay. These outputs are n/ocontacts, which are connected to the same reference point by means of a single-en-ded connection. This reference point (RP) is potential-free and provided as terminalon connector X3. These outputs are updated every 8 ms, i. e. the maximum delaytimes of the outputs are approximately tv � 8 ms.

All eight available outputs can be programmed individually concerning the selectionof the pertaining message. The assignment is realized by means of the software Vec-tor7x

Three types of messages can be distinguished:

� Messages without parameter� Messages with parameter� Logic operations of messages (similar to PLC)

7.4.2.2.1 Messages without Parameter

Ready for operation (Controller on)

In order to ensure that the converter can signal the message "Ready for Operation",the following conditions must be met:

� The 24 V supply is provided (the LED ON is on).� The feeding power supply module signals "OK"� The operating software must have finished its boot cycle.� The inverter is activated (controller enable).� The safety contact (SC) has been closed.� The motor sensors are connected (temperature sensor and speed sensor).� A status message interrupting the operation has not occurred (LEDs FC0 to FC3

are off).



Converter OK

If an error message is not provided, the message "Converter OK" is set. This messa-ge does not necessarily mean that the converter is "ready for operation".

Example:

An error message is provided, but the inverter has not been enabled.

Current limitation (Controller limit)

If the preset maximum current value for motor and/or converter is reached, this mes-sage is set. The response time (time between the occurrence of the current limitationand the activation of the relay output) takes a maximum of 8 ms. Since this signal isreacting very fast to load variations, especially in combination with a “hard” adjustedspeed controller, an “unsteady” signal output can be expected.

Calibrated

An absolute positioning of the rotor first requires a calibration. If a calibration is re-quested and executed successfully, this message is set.

Temperature Warning Converter

The function "Temperature Warning Converter" enables the user to initiate appropria-te measures without interrupting the process, before the system is turned off due toexcessive temperatures. Appropriate measures might be, for example, the reductionof the process feeds, and thus the relief of the converter.

If the warning threshold for the converter temperature is reached, this message willbe set. The predetermined warning threshold is at 85�C and cannot be varied. Theconverter is finally turned off at a temperature of 90�C.

Temperature Warning Motor

The function "Temperature Warning Motor" enables the user to initiate appropriatemeasures without interrupting the process, before the system is turned off due toexcessive temperatures. Appropriate measures can be, for example, the reduction ofthe process feeds, and thus the relief of the motor.

Premisses are:

� With the parameterization of the software the corresponding values, at which awarning is to be initiated, have been preset.

� The motor comprises a temperature sensor (PT 100 or KTY 84 ).



�If a PTC or a NTC is used, a temperature warning for the motor isnot possible.

The temperature value, at which the message "Temperature Warning Motor" is set,must be defined in the motor parameters.

Motor Overload

If the motor is loaded with values exceeding the rated current, this message is set. Anassignment to an output does only make sense, if a peak current has been defined inthe motor parameters.

Converter Overload

If the converter is loaded with values exceeding the rated current, this message is set.An assignment to an output does only make sense, if the connected motor uses theS6 range or the peak current range of the converter.

Motor (Bit 0)

This message is set, if the input "Motor (Bit 0)" has been selected with high signal(24 V), and if it has been switched to the corresponding motor parameters. I. e., themessage corresponds to an acknowledgment meaning “command received and exe-cuted”.

Motor (Bit 1)

This message is set, if the input "Motor (Bit 1)" has been selected with high signal(24 V), and if it has been switched to the corresponding motor parameters. I. e., themessage corresponds to an acknowledgment meaning “command received and exe-cuted”.

Speed Limitation (Bit 0)

This message is set if the input "Speed Limitation (Bit 0)" has been selected with highsignal (24 V) and if it has been switched to the corresponding motor parameters. I. e.,the message corresponds to an acknowledgment meaning “command received andexecuted”.

Speed Limitation (Bit 1)

This message is set if the input "Speed Limitation (Bit 1)" has been selected with highsignal (24 V) and if it has been switched to the corresponding motor parameters. I. e.,



the message corresponds to an acknowledgment meaning “command received andexecuted”.

Main Contactor

If a switching from wye to delta is executed with running motor, first the inverter mustbe deactivated (controller enable off). By means of the message "Main Contactor", itis now possible to turn off a main contactor (between converter and motor), if provi-ded. Afterwards the branches of all motor phases can be activated using the output"Wye/delta".

The basic procedure is as follows:

� inverter deactivated � main contactor off� switching from wye to delta run� main contactor on � inverter activated

After selecting the input "Wye/delta" the procedure mentioned above is executed bythe converter automatically with a preset timing. This message is activated, if themain contactor is to be turned on. See also output "Wye/delta", page 34. (Wiring ex-ample see appendix)

Wye/Delta

If a switching from wye to delta is executed with running motor, first the inverter mustbe deactivated (controller enable off) and a main contactor, if provided, between con-verter and motor must be switched off. Then the message "Wye/delta" can be usedto initiate a change-over of the branches of all motor phases.

The chronological procedure is as follows:

� inverter deactivated � main contactor off � switching from wye to delta run� main contactor on � inverter activated

After selecting the input "Wye/delta" the procedure mentioned above is executed bythe converter automatically with a preset timing. This output is active, if the wye para-meters have been selected, it is not active, if the delta parameters are used. See alsooutput "main contactor", page 34. (Wiring example see appendix)



7.4.2.2.2 Messages with Parameter

If "Messages with Parameter" are assigned to the outputs, the corresponding para-meters can be edited using the software Vector7x.

Actual current �

If the motor current is lower or equal to a preset reference current (reference value),this message is set. The reference value is entered as value in percent and corre-sponds to the pertaining parameter. A reference value of 100 % corresponds to thepeak current of the motor. If a peak current has not been preset, the rated current ofthe motor is the reference value.

Actual current >

If the motor current is higher than a preset reference current (reference value), thismessage is set. The reference value is entered as value in percent and correspondsto the pertaining parameter. A reference value of 100 % corresponds to the peakcurrent of the motor. If a peak current has not been preset, the rated current of themotor is the reference value.

Actual speed �

If the motor speed is lower or equal to a preset reference speed (reference value),this message is set. The reference value is entered as value in percent and corre-sponds to the pertaining parameter. A reference value of 100 % corresponds to themaximum speed.

Actual speed >

If the motor speed is higher than a preset reference speed (reference value), thismessage is set. The reference value is entered as value in percent and correspondsto the pertaining parameter. A reference value of 100 % corresponds to the maximumspeed.

Speed zero

The message "Speed zero" is set, if a preset reference value is not reached. Thereference value is entered in UPM and corresponds to the pertaining parameter.



Speed OK

The message "Speed OK" is set, if the preset reference speed value has been rea-ched. In order to prevent the output from switching already at very low speed devia-tions, a hysteresis (window) is set as reference value. If the actual speed value iswithin this “window”, the message "Speed OK" is set. The reference value refers tothe current reference value and is entered in %. Thus, the “window” corresponds tothe pertaining parameter.

Warning I²t motor

As already described in chapter 6.3.2 "Overload of the Motor" (page 37), a peak cur-rent can be determined for the motor. As soon as motor and converter are active(regulator on), a so-called I²t function runs in the background. If the counter readingreaches 100 %, the converter is turned off immediately, and a corresponding errormessage is displayed. In order to prevent the converter from turning off suddenly(machine standstill), this message can be used as advance warning. If the counterreading is bigger than a preset reference value, this message is set. The referencevalue corresponds to the parameter and can be entered as value from 0.0 % to 100.0%. The evaluation of current amplitude and time is preset by the settings in the motorparameters and cannot be changed when programming the outputs.

Load message

This message is set, if the current generating the torque exceeds a preset limit. Thepertaining parameter is entered in % and refers to the maximum value currently pos-sible. The maximum possible value is permanently calculated by the converter andthus permanently adapted for the comparison. The current generating the torque isproportional to the consumed active load of the motor and therefore - as a first ap-proximation - also proportional to the torque delivered at the motor shaft.

7.4.2.2.3 Logic Operations of Messages

The outputs can be combined pair-wise with basic logic functions - similar to PLCfunctions. In addition, the function of each individual output can be negated. This as-signment is realized by means of the software Vector7x.

Among other things, the following logic operations are possible:

Exchange a = b or b = aNegation a = !a or b = !bAND a = a & b or b = a & bNAND a = !(a & b) or b = !(a & b)OR a = a # b or b = a # bNOR a = !(a # b) or b = !(a # b)XOR (exclusive-OR) a = a $ b or b = a $ b



XNOR (exclusive-NOR) a = !(a $ b ) or b = !(a $ b)

The following pairs (input variable a and b) can be combined:

� Output 1 and 2� Output 3 and 4� Output 5 and 6� Output 7 and 8

Default Setting of the Outputs

The default setting set by SIEB & MEYER is as follows:

Output Pin X3 Message Parameter

1 1 Ready for operation (Controller on) -

2 2 Speed OK 5.0 %

3 3 Speed zero 100 RPM

4 4 Load message 90.0 %

5 5 Current limitation (Controller limit) -

6 6 Temperature Warning Converter -

7 7 Converter OK -

8 8 Warning I²t motor 80.0 %

�Pin 9 of the connector X3 is assigned with the shared referencepoint (RP) of the relay outputs.

7.4.2.3 Inputs (Connector X4)

The inputs described in the following are designed as 24 V inputs. Outputs are equip-ped with a relay. It is a high level logic, i. e. the required function is selected with 24 Vand deselected with 0 V. All eight inputs can be programmed individually concerningthe selection of the pertaining function. The assignment is realized by means of thesoftware Vector7x. The inputs are interrogated every 16 ms. This means, reactionson modifications at the inputs are initiated with a maximum delay time of approxima-tely tv � 16 ms.

�When you have selected the command source Profibus, someinputs are disabled.



Controller (Controller enable)

Using this function the output stages of the converter and the internal control circuitsare activated. If the selection has been successful, the converter signals "Ready forOperation" and the LED INE on the front panel is on.

Start/ (Pulse enable)Stop

Using the function input "Start/ " the converter can be started (24 V) or stopped.Stop(0 V).

Calibrate

The function "Calibrate" is required to realize an absolute positioning. It must be exe-cuted at least once after turning on the converter.

Positioning

Using the function "Positioning" the rotor can be set to one or more defined positions.When requesting the function "Positioning" an internal higher-ranking position control-ler is placed over the speed controller. Then the converter attempts to position themotor into the demanded position. If the positioning process has been successful, theconverter displays the message "Position OK". For this function the following pre-misses are required:

� The motor sensors must have a reference track.� The parameters of position controller and speed controller must be optimized. � Priority questions concerning start, speed reference value and request of the

function "Positioning" must be clearly defined.

� The motor must be calibrated.

Position bit 0, 1, 2

Each motor parameter set comprises an individually programmable position. Addi-tionally, four freely available positions are provided, which are assigned to the con-verter. This means, at a maximum five positions can be selected for a motor via theinputs "Position bit 0, 1, 2".

Position bit 2 Position bit 1 Position bit 0 Position

0 0 0 Motor 1

0 0 1 Converter 1

0 1 0 Converter 2

0 1 1 Converter 3

1 0 0 Converter 4

1 corresponds to 24 V




A modified selection of the inputs is only obtained by first deselecting and then againselecting the function "Positioning". It is possible to directly decelerate into the reques-ted position from any speed or position (spot braking). If higher safety standards arerequired for the positioning, it is recommended to calibrate anew before positioning.

Teach Position

A selection of this function is only executed in the following modes of operation:

� The converter signals "ready for operation", operates in the position-controlledmode, and the demanded position is reached.

or

� The function "Controller on" is deselected (not ready for operation). The deman-ded position must be adjusted manually.

�The accident prevention regulations must be observed!

The currently “taught” position is accepted by the transition from "Low" (0 V) to "High"(24 V) of the function "Teach Position". The position is saved to the memory of thecurrently selected motor parameter record.

�2

Don’t start the operating software Vector7x when the signal issent. Otherwise, the software of the frequency converter can bedestroyed because of data collision.

Motor Bit 0, 1

Four different, individually programmable motor parameter sets are provided. Theselection of the different parameters can be made via the inputs by means of thefunction "Motor Bit 0, 1".

Motor-Bit 0 Motor-Bit 1 Parameter record

0 0 1

0 1 2

1 0 3

1 1 4



A modified selection of the inputs is only obtained by deselecting first and then selec-ting again the function "Controller on" (Controller enable).



Speed Limitation Bit 0, 1

Four different, individually programmable groups of speed limitation for the analogreference value are provided. The different groups can be selected via the inputs bymeans of the function "Speed Limitation Bit 0, 1".

Speed limitation

Bit 0

Speed limitation

Bit 1

Group of speed

0 0 1

0 1 2

1 0 3

1 1 4



A modified selection of the inputs is only obtained by deselecting first and then selec-ting again the function "Controller on" (Controller enable).

Reset

With a transition from "Low" (0 V) to "High" (24 V) the reset is executed for possibleerrors. A reset will only be successful, if the cause for the error message is removed.The minimum pulse time for a reset should not take less than t = 16 ms.

Reversion of rotational direction

By selecting this function the current rotational direction of the motor is reversed. Avalue of 0 V will not cause a change of the rotational direction preset by the referencevalue. A value of 24 V will invert the current rotational direction. This function appliesto the speed-controlled mode.

Start enable

If this function is assigned to an input, the input must be selected with 24 V, otherwisea start is not possible. If this input is set to 0 V during operation, a sudden stop with apreset delay time will be initiated. This function can be interpreted as additional loc-king of the "Start/ " input. This function applies to the speed-controlled mode.Stop



Emergency stop

If this function is assigned to an input, the input mus be applied to 24 V, otherwise themotor is decelerated - with the preset delay time for emergency stop. The delay timefor the emergency stop is programmed in the motor parameters. This function appliesto any mode of operation.

Trigger Oscar

The software Vector7x comprises oscilloscope functions (Oscar). The moment, atwhich the oscilloscope starts with recording is called trigger moment. For this functiondifferent trigger possibilities are provided referring to internal measured quantities. Inorder to preset external events as trigger moment the function "Trigger Oscar" can beassigned to an input. The trigger is executed with a transition from "Low" (0 V) to"High" (24 V). It has to be considered that a trigger signal must be initiated approxi-mately 16 ms before the recording of the event starts.

No Function

If no function is to be assigned to an input, the assignment "No Function" must bechosen.

Default Setting of the Inputs

The default setting made be SIEB & MEYER is as follows:

Input Pin X4 Message

1 1 Start/Stop

2 2 Reset

3 3 Controller on (Controller enable)

4 4 No function.

5 5 No function.

6 6 No function.

7 7 No function.

8 8 No function.

�Pin 9 of connector X4 is connected to the reference ground(GND).



7.4.2.4 Speed Pulses (Connector X5)

This 9-pole Submin D plug-in connection permits to connect a speed sensor. Theoutput is opto-coupled, i.e. the output pulses – 6 per revolution – are provided withisolated potentials. The factor 6 already takes the unit "minute" into consideration.Thus a simple frequency counter can be used for displaying the motor speed.

1 kHz corresponds to 10,000 RPM

For pin assignment and further information see section "Terminal and ConnectorAssignment" (starting on page 61).

If no external 24 V supply is provided for the optocoupler and/or the inputs and out-puts, an internal 24 V supply can be applied to this connector. There are two possibili-ties:

� An external +24 V supply is not provided.

In this case an internal unstabilized voltage (internal +24 V) can be used at thestandard interface.

� The load current must not exceed 100 mA.

� An external +24 V supply is provided and is to be u sed.

In this case the internal 24 V supply must not be connected with the external 24 Vsupply.

� Beware of compensating currents!

7.4.2.5 Analog Values (Connector X6)

Reference Value Input (+, –)

The converter processes preset reference values with the programmed accelerationand deceleration times. Thus, the motor is always brought guided to the new referen-ce value and is never loaded with frequency variations. The speed reference value ispreset as analog voltage value at the standard interface.

An A/D converter digitizes the reference value and leads it to the processor. In orderto generate external reference values, a reference voltage of +10 V is provided at thestandard interface.



Positive reference values are used for the generation of clockwise rotating fields,negative values for counterclockwise rotating fields. The input is designed as differen-ce amplifier, for which the maximum input voltage is ± 10 V.

If the reference voltage (+10 V) is used for the generation of the reference value,lowest deviations will result.

Analog Outputs 1, 2

There are two analog outputs. Depending on the programmed assignment and sca-ling, voltages of �10 V to +10 V can be provided.

Resolution: ±9 bit (±511 increments)

Internal resistance: 1 k�

Actualization rate: approx. 2 ms

The following functions are provided at present:

� Load current

� Actual speed

� Power

� Torque

� Motor temperature

� Cooling

Functions and assignment of the functions can be altered by means of the software"Vector7x".

7.4.2.6 Motor Sensors (Connector X7, X8)

At the front panel two connections are provided (connectors X7 and X8). Thefunctions of both connections are described in the following.

"Gear wheel sensor systems" have proven successful for vector-controlled drives inhigh-speed technology. These sensor systems are excited by a gear wheel profile ona rotor, and their output signals are sine, cosine, or incremental values shifted by 90�.If an absolute positioning is required, a reference track (zero track) must be provided.The gear profiles are usually equipped with 32, 64, 128, 256, or 512 teeth). Any othernumber of teeth (e. g. 100) is also possible.

Motor Sensors IN (Connector X7)

Connector X7 (15-pole male Submin D connector, pin assignment on page 69) isprovided for the connection between motor and converter. The positioning signalstransmitted by the spindle sensors are processed and passed on to the converter formonitoring and controlling purposes.



Additionally, the converter can be adjusted to different sensors for monitoring themotor temperature. As a standard, the evaluating functions for PTC, PT 100 and KTY84 can be programmed. With the sensor types PT 100 and KTY 84, a temperaturewarning can additionally be assigned to one of the programmed outputs. The connec-tion with the converter is established via the connector X7.

Motor Sensors OUT (Connector X8)

Connector X8 (15-pole female Submin D connector, pin assignment on page 71) isprovided for the connection between the converter and a higher-ranking CNC. Theload signals are transmitted with transformed impedance from the motor sensors tothe connector and permit a higher-ranking position control (e.g. for positioning tasks).

7.4.2.6.1 PTCIf a PTC is integrated into the motor as temperature sensor and the converter hasbeen programmed correspondingly, the converter triggers automatically an higher-ranking stop when the rated PTC temperature is exceeded. The motor is deceleratedto speed = 0 within the programmed deceleration time. The corresponding error mes-sage is indicated and the converter signals "not ready for operation". This error canonly be reset after the motor has been cooled down sufficiently. The response thres-hold is 3.6 k�. That means, if the wiring at the motor protection inputs reaches thevalue of 3.6 k�, the higher-ranking stop is triggered.

7.4.2.6.2 PT 100 and KTY 84For the temperature sensors PT 100 and KTY 84 linearization functions have beenprogrammed in the converter. With these functions, the current temperature of themotor can be determined. This measurement permits to transmit, for example, war-nings to the operator or to a higher-ranking control. The following requirements mustbe met:

� The corresponding temperature sensor has to be programmed.

� The warning function has been assigned to one of the programmable out-puts.

If the temperature exceeds the warning threshold, it might reach the cut-off tempera-ture. The temperatures for warning and cut-off are defined by the manufacturer of themotor and are loaded together with the motor data into the converter. Therefore theycan only be altered in the motor parameters. If the cut-off temperature is reached, ahigher-ranking stop will be triggered as described under "PTC".



7.4.2.7 24 V-Input/GND (Connector X9)

This 2-pole Combicon plug-in/screwed connection must only be used for the external24 VDC supply (24 V-Input/GND).

For pin assignment and further information see section "Terminal and Connector As-signment" (starting on page 61).

7.4.2.8 Ground (GND) and Analog Ground (AGND)

The connector pins labeled with ground (GND) are provided as reference ground forthe digital inputs and outputs.

The connector pins labeled with analog ground (AGND) are provided as referenceground for the analog reference value and the analog outputs.

Both grounds (GND and AGND) are connected within the converter. Therefore thereis no potential isolation between the two connections.

7.4.2.9 Input for Message "Power OK" (Connector X10)

This 4-pole Mini Combicon plug-in connection permits to connect the signal "PowerOK". In case of an error, the output possibly provided by the power module can beconnected to connector 9. The logic evaluates the information correspondingly, thuspreventing the power module from a requested activation.

The input is opto-coupled, i.e. the signal has an isolated potential and thus offers ma-ximum protection against interferences.




7.4.2.10 Safety Contact (SC)

At the front panel of the converter there are two terminals labeled SC (Safety Con-tact). These terminals can be used as safety contact. If there is no connection to theseterminals, the activation of the output stage transistors is interrupted. This safetyfunction is exclusively hardware-dependent.

If in case of an emergency stop this safety contact is wired via a relay with a delayedcut-off contact, a guided stop (software) of the motor spindle can be performed beforethe power module is disconnected. Advantage: The motor is already at standstill whendisconnected and does not "spin" to stop (see wiring example).

The input meets the requirements of category 1 according to EN-954-1 and is similarto SIL1 according to IEC 61508. In order to reach a higher category, you must use asafety relay combination for emergency stop devices, interlocking devices and the likeaccording to IEC/EN 60204-1 (e.g. SRB-NA-R-C.19 by SCHMERSAL).

�Potentials (e. g. 24 V or ground) must not be applied to these ter-minals.

Wiring example:

� The relay is not delivered along with the converter.

7.4.2.11 Motor Phases (Terminals U, V, W)

These power terminals are used for the connection of the motor phases.



� The phases must not be interchanged.

The pin assignment and further information can be found in the chapter "Terminal andConnector Assignment" (starting on page 61).

7.4.2.12 Power Supply (Terminals +600, -600)

These terminals are provided for connecting the external power supply with 600 VDC

(540 VDC to 680 VDC).

� Make sure that the polarity is correct!


� Initial Operation


8 Initial Operation

For the initial operation of the converter pay attention to the chapters "Safety In-struction and Application Advice" (starting on page 9) and "Unit Assembly ComplyingEMC" (page 17).

8.1 Tips for a Trouble-Free Operation

� All lines to be connected should be as short as possible. The line cross-sectionsmust be adapted to the rated current and the wiring.

� Use shielded cables for the motor lines and for the supply lines of the standardinterface.

� The supply line for the reference value should be a separate shielded cable. If ne-cessary, the reference value should be grounded directly at the controller, not atthe frequency converter.

�Particularly in extremely electromagnetically interfered environ-ments (e.g. control cabinets with different power electronic devi-ces) a grounding of the ground potentials is favourable or evennecessary!

� All shielded cables should be connected at both ends. Shielding with largest surfa-ce and wiring without any "pig tails" is especially recommended.

� The ground of the separate switch cabinet components should be arranged radiallyto a star point (ground bus).

� Power lines and sensor or logic lines should be separated in different cable con-duits.

8.2 Connection

Before starting the connection, the module should be installed firmly according to itsapplication. In order to wire and connect the separate connecting facilities proceed asfollows:

� Set the main switch (if existing) to "0" and make sure that no dangerous contactvoltages are applied to the plug-in connections and terminal connections.

� Connect the cooling system to the output stage module (only output stages �100 kVA, page 29).

�Initial Operation


� Check the cooling system for leaks.

� Assign the standard interface correspondingly. If there is no standard interfaceavailable, proceed as described under "Bus Connections" starting on page 87.

� Assign the motor sensors (connector X7, page 53) correspondingly.

� If demanded, a connection from a higher-ranking position controller to the con-troller can be established (connector X8, page 54).

� Wire the safety contact (SC) as desired (page 56).

� Connect the external 24 VDC (2.0 A to 3.0 A) to the connector X9 (24 V In-put/GND), page 72.

� If existing, connect the PC to the connector 2 (page 41).

� Connect the motor as described in "U, V, W - Motor Phases", page 75.

� Ground the modules using the connection possibilities provided at the modules.

� Connect the external power supply to the terminals +600, –600 of the convertermodule, page 76.

�The polarity (+/–) must be correct! The supply lines must be dead!

� After the careful installation of all connections activate the supply line.

�

Is "Controller on" selected, and is the converter

"ready for operation"?

(LEDs ON, INE, OK are on) Yes No

�Enter a low speed reference value. �Check all connections again andobserve the section "Trouble Shoo-ting", starting on page 79.Are the direction of rotation and the speed of the motor

correct? Yes No

OK � A reversion of the rotational direction might beselected at the standard interface

� The preset polarity of the reference valuemight be wrong (only with analog referencevalue presetting)

� The motor phases or the sensor signals mightbe interchanged.

� Correct the reference value or the speed.

� Check the programming.

� Terminal and Connector Assignment


9 Terminal and Connector Assignment

9.1 Connector X2, Serial Interface

9-pole female Submin D connector

This plug-in connection permits to connect a PC or notebook. If the SIEB & MEYERsoftware "Vector7x" is installed on the PC, all operating and programming functionscan be used via this connection.

The table shows the pin assignment for the connection cable:

PC9-pole male submin D

Converter9-pole female submin D

Pin 2 RX �––� TX Pin 2

Pin 3 TX �––� RX Pin 3

Pin 5 GND �––� GND Pin 5

�Pins not mentioned in the table must not to be wired. Otherwisethis might cause damage to the converter and to the operatingdevice.

�Some manufacturers of PCs or notebooks connect GND (pin 5)and shielding (ground) within the device. In order to avoid possibledamage of the PC, converter, or the CNC, a shielded cable shouldbe used, which is connected with the shield only at the converterside. Please take into consideration that this single-ended shiel-ding is only an exception made necessary by the common PCtechnology.

�Terminal and Connector Assignment


9.2 Connector X3, Outputs

9-pole Submin D connector

Pin I/O Designation Function

1 O

Output 1

Default:

Ready for operation

(Regulator on)

Relay output:

Function fulfilled:RR

Function not fulfilled: RR

2 O

Output 2

Default:

Speed OK

Relay output:



3 O

Output 3

Default:

Speed zero

Relay output:



4 O

Output 4

Default:

Load message

Relay output:



5 O

Output 5

Default:

Current limitation

(Controller limit)

Relay output:



6 O

Output 6

Default:

Temperature war-ning converter

Relay output:






7 O

Output 7

Default:

Converter OK

Relay output:



8 O

Output 8

Default:

Warning I²t motor

Relay output:



9 O Reference pointrelay (RR)

Common reference point for all relay outputs (RR), free selection ofpotential.

�Conductive shells should be used for Submin D connectors. Thecable shield then must be connected with the largest surface areato the cable entry in the connector shell.

The following applies to relay contacts: 1 ADC/24 VDC.

9.2.1 Schematic Diagram of the Relay Outputs:



9.3 Connector X4, Inputs



1 IDefault: Start/ Stop

(Pulse enable)

+24 V: Converter starts

Ground or Pin not wired: Converter stops

2 I Default: Reset Reset input to acknowledge error messages. Reset is ma-de with a pulse of +24 V. Minimum pulse time 16 ms.

3 IDefault: Inverter enable

(controller enable)

+24 V: converter active

Ground or pin not wired: converter not active

4 I Default: No function. Wiring with 24 V requests the assigned function



7 I Default: No function. Wiring with 24 V requests the assigned function.

8 I Default: No function. Wiring with 24 V requests the assigned function.

9 I/O Ground (GND) Reference ground




9.4 Connector X5, Speed Pulses

9-pole male Submin D connector


1 O +24 V (internal) +24 V, unstabilized, max. 100 mA

2 - - -

3 - - -

4 - - -

5 - - -

6 O DZ pulsesOptocoupler output. Collector terminal. This output is low-ohmic six times per rotation. The remaining time it is high-ohmic.

7 - -

8 O DZ pulses Optocoupler output. Emitter terminal. This output is low-ohmic six times per rotation. The remaining time it is high-ohmic.

9 I/O Ground (GND)

Data of the optocoupler: max. 30 VDC, max. 5 mA




Wiring Example for Connector X5:



9.5 Connector X6, Analog Connections



1 O Reference voltage +10 V + 10 V reference voltage for the generation of the referencevalue, max. 50 mA

2 I Reference value input (+) Differential amplifier input, max. +/- 10 V,

Reference point for pin 3, Ri = 33 k�

3 I Reference value input (-)Differential amplifier input, max. +/- 10 V,

Reference point for pin 2, Ri = 33 k�

4 I/O Analog ground (AGND) Reference ground for all analog signals



7 O Analog output 1 0–10 V analog output, Ri = 1 k�, resolution = 511 bit

8 O Analog output 2 0–10 V analog output, Ri = 1 k�, resolution = 511 bit



9.5.1 Examples for Analog Reference Value Presetting

�Shielded lines are presupposed to be used for the examples be-low. Use the largest and shortest shield surface area of both lineends to put them to the earth potential.



Example 1:

Analog reference value presetting (0 to 10 V) via external potentiome-ter

Example 2:

Analog reference value presetting (0 to 10 V) via higher-ranking con-troller with differential output

Example 3:

Analog reference value presetting (0 to 10 V) via higher-ranking con-troller without differential output



9.6 Connector X7, Motor Sensors IN


The motor sensors, i.e. position and temperature sensors, are connected to the con-verter via this connector.


1 O +5 V Supply voltage (for the sensor)

2 I/O Analog ground(AGND) Reference ground for the listed analog signals

3 I Sine (+) 1 VPP measured to sine (–) / 500 mVPP measured to ground

4 I Sine (–) 1 VPP measured to sine (+) / 500 mVPP measured to ground

5 I/O Ground Reference ground

6 I Cosine (+) 1 VPP measured to cosine (–) / 500 mVPP measured to ground

7 I Cosine (–) 1 VPP measured to cosine (+) / 500 mVPP measured to ground

8 – not assigned –

9 I 5 V sense Measuring lead for the operating voltage supply.

10 I Reference (+) 1 VPP measured to reference (–) / 500 mVPP measured to ground

11 I/O 0 V sense Measuring lead for the operating voltage supply.

12 I Reference (–) 1 VPP measured to reference (+) / 500 mVPP measured to ground





14 I Motor protection(+)

Motor protection input. The function of this input depends on theconnected temperature sensor and the function of the evaluationelectronics to be programmed.

15 I Motor protection(–)

Motor protection input. The function of this input depends on theconnected temperature sensor and the function of the evaluationelectronics to be programmed.

�Conductive shells should be used for submin D connectors. Thecable shield then must be connected with the largest surface areato the cable entry in the connector shell.



9.6.1.1 Sense Control Examples

Sensor with 2 sense terminals

Sensor with 5 V sense terminal

Sensor without sense terminal

If only one cable is available which does not allow sense connection, the following pinsat the connector and the sensor must be connected:

� 5 V sense with +5V and

� 0 V sense with ground

Cable without sense conductors

�If the sense connections are not connected, the supply voltage(+5 V) can rise to approx. +6.9 V.



9.7 Connector X8, Motor Sensors OUT

15-pole male Submin D connector

The connector provides the impedance-converted position values (sine, cosine, refe-rence). The values can, for example, be used for a higher-ranking position controller.



2 I/O Analog ground(AGND) Reference ground for the analog signals, listed in this table

3 O Sine (+)1 VPP measured to sine (�) / 500 mVPP measured to ground

loadable with max. 10 mA

4 O Sine (�)1 VPP measured to sine (+) / 500 mVPP measured to ground



6 O Cosine (+)1 VPP measured to cosine (�) / 500 mVPP measured to ground


7 O Cosine (�)1 VPP measured to cosine (+) / 500 mVPP measured to ground




10 OReference (+) 1 VPP measured to reference (�) / 500 mVPP measured to ground



12 O Reference (�)1 VPP measured to reference (+) / 500 mVPP measured to ground








9.8 Connector X9, 24 V-Input/GND

2-pole Combicon

The plug/screw connection is only provided for the connection of the external 24 VDC

supply voltage (24 V-Input/GND).

Designation Function

24 V GND External voltage supply ground, reference point for pin 4

24 V Input External voltage supply +24 V, current consumption max. 4.0 A

The terminals are suited for finely stranded cables up to 2.5 mm2.

9.9 Connector X10, "Power o.k."

4-pole Mini Combicon

Plug-in connection for connecting the signal "Power OK". In case of an error, the out-put possibly provided by the power module can be connected to connector X10. Theconverter logic evaluates the information correspondingly and prevents the powermodule from a possibly requested activation.

The input is opto-coupled, i.e. the signal has an isolated potential and thus offers ma-ximum protection against interferences.


1 O +24 V (internal) +24 V, max. 100 mA

2 I Power OK (+)Anode connection of opto-coupler diode,

Imax = 11 mA for 24 V

3 I Power OK (–)Cathode connection of opto-coupler diode,

Imax = 11 mA for 24 V

4 I/O Ground (GND) Reference ground




9.9.1 Schematic Diagram of the Inputs at Connector X 10



9.9.2 Wiring Examples for Connector X10



9.10 Connection SC (Safety Contact)

2-pole Combicon

The plug-in connection is provided for the connection of possibly required safetyfunctions (e.g. emergency stop). A detailed description can be found in the section"Safety Contact" on page 56.

�Potentials (e. g. 24 V or ground) must not be applied to these ter-minals.

If the possibilities of this safety contact are not to be used, both pins must be connec-ted by a strap.


1 I SCSafety contact. If there is no contact to pin 2 of this connector,the output stages are deactivated, and thus the power supply tothe motor is disconnected.

2 I SCSafety contact. If there is no contact to pin 1 of this connector,the output stages are deactivated, and thus the power supply tothe motor is disconnected.


9.11 U, V, W - Motor Phases

These power terminals serve for connecting the motor phases. The terminals areconnected to the terminals with the same designation at the motor.

� The phases must not be interchanged!

Designation I/O Function

U O Connection to motor phase U

V O Connection to motor phase V

W O Connection to motor phase W



The following table lists the wire cross sections suited for the terminals:

Converter Mo-dule

Wire Cross Section [mm 2]

stiff flexible

FC72020 0.5 to 16 0.5 to 10

FC72030 0.5 to 25 0.5 to 16

FC72040 0.5 to 25 0.5 to 16

FC72055 6 to 35 10 to 25

FC72070 6 to 35 10 to 25

FC72100 25 to 95 35 to 95

FC72125 25 to 95 35 to 95

FC72150 25 to 95 35 to 95

9.12 +600, -600 - Power Supply

The power terminals are provided for connecting the external power supply with600 VDC (540 VDC to 680 VDC).

Depending on the construction and on the mains connection of the applied externalpower supply module, different voltage potentials to earth can arise:

The following applies to the mean value of the connected d.c. voltage:

0 V < U < +400 V measured from positive pole (+600) to earth

0 V > U > –400 V measured from negative pole (–600) to earth

The following applies to the peak value of the connected d.c. voltage:

0 V < U < +800 V measured from positive pole (+600) to earth

0 V > U > –800 V measured from negative pole (–600) to earth

� Make sure that the polarity is correct!

� The supply lines must be dead!



Designation I/O Function

+600 I Connection for positive pole of the external power supply with 600 VDC

–600 I Connection for negative pole of the external power supply with 600 VDC

The following table lists the wire cross sections suited for the terminals:

Convertermodule

Wire Cross Section [mm 2]

stiff flexible

FC72020 0.5 to 16 0.5 to 10

FC72030 0.5 to 25 0.5 to 16

FC72040 0.5 to 25 0.5 to 16

FC72055 6 to 35 10 to 25

FC72070 6 to 35 10 to 25

FC72100 25 to 95 35 to 95

FC72125 25 to 95 35 to 95

FC72150 25 to 95 35 to 95

9.13 Earth Connection

Every converter module permits a connection to earth. For this purpose a copper-pla-ted threaded bolt (M8) is provided at the lower part of the module.

� Trouble-Shooting


10 Trouble-Shooting

Possible malfunctions during the operation can be found and remedied by means ofvarious service facilities. Especially the modules of series FC72 provide multiplefunctions, thus easing the operation and maintenance. The following sections givedetailed information about the possibilities.

10.1 Status Messages ON, INE and OK

The following table provides further information:

LED Description

ON� The converter is turned on.

� The converter is turned off (24 V supply at converter module is missing).

INE� The processor module has activated the inverter.

� The processor module has deactivated the inverter.

OK� The processor module identifies the converter as ready for operation.

� The processor module does not identify the converter as ready for operation.

� LED is off

� LED is green

�Trouble-Shooting


10.2 Status Messages FC0 to FC3 and FCL

The messages FC0 to FC3 and FCL are status messages generated by the processormodule. No LED will be on, if the converter is ready for operation.

In case of errors, when selecting protection functions or loading software updates,various LEDs go on in combinations.

The following table can be used as reference for displayed error numbers.

� A status message is not necessarily an error message.

� LED is green

� LED is red

� LED is off

LEDs Function

Code

Meaning Possible Causes

FCL

FC0 FC1

FC2 FC3

�

��

��

129 Hardware error

The software identifies an error

in the equipment of the hardwa-

re.

� The hardware combination in the logic mo-

dule does not function correctly.

FCL

FC0 FC1

FC2 FC3

�

��

��

130 Logic voltages

One or more internal supply vol-

tages are missing. The logic mo-

dule signals "not ready for ope-

ration".

� Internal supply voltage of +14V is missing.

� Internal supply voltage of -14V is missing.

� Internal supply voltage of +24V is missing.

FCL

FC0 FC1

FC2 FC3

�

��

��

132 Overload

At least for a short time an over-

load or short circuit occurred.

The motor is immediately deacti-

vated. The logic module signals

"not ready for operation".

� Motor overload

� Short circuit of the output wiring (motor li-

nes/motor).

� Incorrect parameterizing of the con-

verter/motor.

� Disturbed evaluation of the motor sensor

pulses.

� The power unit is defective.

FCL

FC0 FC1

FC2 FC3

�

��

��

134 Power Error

The input signal Power OK sig-

nals an error.

� The signal Power OK is not connected.

� The power supply unit is defective.

� The power supply unit is not activated.


LEDs Function

Code



FCL

FC0 FC1

FC2 FC3

�

��

��

135 Error speed sensor

The sensor signals have been

beyond the defined tolerance.




� Severe disturbances of the sensor signals.

� Faulty speed sensors.

� Faulty connection between sensor and con-

verter.

� Faulty evaluation in the logic module.

FCL

FC0 FC1

FC2 FC3

�

��

��

136 Motor temperature

The motor got too hot. The mo-

tor is decelerated to n=0 within

the preset deceleration time and

then deactivated. The logic mo-


ration".

� Motor overload.

� The motor is insufficiently or incorrectly coo-

led.

� The temperature sensor is defective.

� Faulty sensor cable between motor and con-

verter.


FCL

FC0 FC1

FC2 FC3

�

��

��

137 Heatsink temperature

The heatsink of the converter

module got too hot. The motor is

decelerated to n=0 within the

preset deceleration time and

then deactivated. The logic mo-


ration".

� Insufficient supply of coolant.

� The ambient temperature is higher than

40�C.

� Internal fan(s) is (are) faulty.

� Overloaded power unit.

FCL

FC0 FC1

FC2 FC3

�

��

��

138 I2t motor

The motor has been loaded abo-

ve the rated power for too long.

� The motor was overloaded.

� The motor is possibly blocked (e.g. dama-

ged bearing).

� The motor is not suited for this application.

� Input of incorrect motor parameters.

� The motor is electrically damaged.


pulses.

FCL

FC0 FC1

FC2 FC3

�

��

��

140 Emergency Stop

The emergency stop function

has been assigned to one of the

inputs and has been selected.

�Trouble-Shooting

LEDs Function

Code



FCL

FC0 FC1

FC2 FC3

�

��

��

143 Undervoltage

At least for a short time the

supply voltage (+/–600) of the

power supply module was lower

than 500 VDC. The motor is im-

mediately deactivated. The logic

module signals "not ready for

operation".

� The connected power supply module

– does not signal "Power OK".

– is disconnected from the mains

voltage.

– is not suited for supplying an inter-

mediate circuit voltage of at least

500 VDC.

– is adjusted incorrectly and therefo-

re supplies an insufficient interme-

diate circuit voltage (too low).

– is dimensioned too small and the-

refore not able to keep the inter-

mediate circuit voltage stable

when under load.

– is faulty.

� Malfunction in the mains supply for the po-

wer supply module.

� A controller (CNC, PLC) possibly connected

to the power supply module prevents the

power supply module from activation.

� The fuse integrated in the power unit has

blown.

FCL

FC0 FC1

FC2 FC3

�

��

��

161 Max. speed exceeded

The evaluation of the motor sen-

sors has detected a speed ex-

cess > 110 % of the max. speed.



"not ready for operation"

� Severe disturbance of the sensor signal.



verter.

� Incorrect parameterizing of motor/sensor.

� Incorrect parameterizing of the speed sen-

sor.


FCL

FC0 FC1

FC2 FC3

�

��

��

164 Error delta-inc. supervision

The evaluation of the sensor

pulses of the motor detected a

physically impossible accelerati-

on or deceleration. The motor is

immediately deactivated. The

logic module signals "not ready

for operation".

� Severe disturbances of the sensor signals.



verter.


FCL

FC0 FC1

FC2 FC3

�

��

��

165 Synchronizing error

The connected synchronous mo-

tor could not be synchronized

after turn-on.

� The motor is blocked mechanically.

� The motor is damaged electrically.

� The evaluation of the motor sensor pulses is

disturbed.


LEDs Function

Code



FCL

FC0 FC1

FC2 FC3

�

��

��

167 Safety Contact (SC)

The safety contact (SC) was in-

terrupted. The motor is imme-

diately deactivated.

� The contact was opened by an external cir-

cuit.

� If the contact is not used, it must be bridged.

FCL

FC0 FC1

FC2 FC3

�

��

��

168 Communication timeout

If the converter is controlled via

the bus system or the PC the he-

artbeat bit has not been operated

on time.

� Defective communication line.

� The control panel has been failed.

FCL

FC0 FC1

FC2 FC3

�

��

��

169 I2t converter

The converter has been loaded

above the S6 values for too

long.

� The converter was overloaded.

� The motor is possibly blocked (e.g. dama-

ged bearing).

� The converter is not suited for this applicati-

on (too weak).

� Input of incorrect motor parameters.

� The motor is electrically damaged.


pulses.

FCL

FC0 FC1

FC2 FC3

�

��

��

171 Overvoltage

At least for a short time an over-

voltage of U > 820 VDC occurred.




� The connected power supply module

– is adjusted incorrectly and therefo-

re provides a too high intermedi-

ate circuit voltage.

– is not dimensioned for limiting the

intermediate circuit voltage to

max. 820 VDC.

– is faulty.

� A ballast circuit possibly connected in the

power supply module cannot consume the

regenerative energy completely.

� At least for a short time an overvoltage oc-

curred in the mains supply of the power

supply module.

FCL

FC0 FC1

FC2 FC3

�

��

��

172 Data error

The converter misses data from

the motor or the thermal sen-

sors.

� Motor data and converter are not compatible

(Upl-file is loaded into a converter which is

not compatible).

FCL

FC0 FC1

FC2 FC3

�

��

��

— Current limit

The converter supplies the max.

current possible.

� Overload.

� The motor phases are interchanged.

� Faulty or disturbed motor sensors.

� Faulty motor.

�Trouble-Shooting


10.3 Check of Internal Fuses after Overload

The modular system FC72 provides multiple protective measures for the electronics:

� The output stages are short-circuit proof and temperature monitored.

� Limitation of the output stage current in case of overload.

� Electronic protection of internal auxiliary voltages.

� Identification of internal overvoltages and undervoltages of the external supplyvoltage (+/– 600 V).

� Protection of the external supply voltages (+/– 600 V and 24 VDC) via fuses.

The fuses for the external supply voltages (+/– 600 V and 24 VDC) are located in thepower unit of the converter.

A common fuse (IEC 127) with 6.3 A / semi time-lag is used on the internal PCB forprotecting the external 24 VDC.

For checking or replacing the fuses the front panel of the converter module must beremoved.

�Before opening the front panel, the supply voltage (+/– 600 V)must be disconnected from the modules.

Even after turning off the supply voltage, hazardou s voltagesmay exist for up to 3 minutes in the module.

The smaller fuse with 6.3 A is located in a clamp on the lower part of the internal PCB.

The larger fuse for protecting the supply voltage (+/– 600 V) is connected via threadedbolts with the terminals and the internal PCB. This fuse must only be replaced by fu-ses for semiconductor protection having the same rated values.

The following fuses are included in the different converter modules:

ConverterModule

Siemens Sitor

Rated Value Type

FC72020 63 A 3NE8 718

FC72030 80 A 3NE8 720

FC72040 100 A 3NE8 721

FC72055 160 A 3NE8 724

FC72070 200 A 3NE8 725

FC72100 250 A 3NE8 727


ConverterModule

Siemens Sitor

Rated Value Type


FC72125 315 A 3NE8 731

FC72150 315 A 3NE8 731

�Trouble-Shooting


� Options


11 Options

11.1 Bus Connections (Profibus-DP; other types on de mand)

Currently, it is possible to connect the converter to a higher-ranking control viaProfibus-DP. For this, the Bus protocol DNC 61.00 by SIEB & MEYER is used. Detai-led information concerning the protocol can be found in the operating manual for thesoftware "Vector7x".

The connection via Profibus-DP is optional and must be ordered separately.

11.1.1 Profibus-DP

Connector X1, 9-pole female Submin D connector

Pin Designation

1 2M

2 not assigned

3 PRO_B

4 PRO_RTS

5 not assigned

6 2P5

7 not assigned

8 PRO_A

9 not assigned


�Options


�If the converter is to be used as final device in a Profibus com-pound, terminating resistors must be connected to the data lines.There are two possibilities:

� A bus cable containing these resistors is used;

� On the PCB 21.72.0005 three hook switches are provided.These hook switches must be closed, if the converter isconnected as final device, and if there are no terminatingresistors in the cable. In order to actuate the hook swit-ches the module has to be opened.

� Options


11.2 Connecting Cables for Sensors (Motor/Converter)

SIEB & MEYER can supply ready-made connecting cables for the connection of themotor sensors and the frequency converter. The cable is suitable for trailing chainsand resistant against mineral oils (PUR sheath).

Since the mechanical design and pin assignment of the various plug-in connectors atthe motor often differs, SIEB & MEYER should be consulted before the delivery.

The following cable can be supplied as a standard:

Spindle Connector Cable S&M Connector

15 11 0 V sense

green +5 V, sense 16 9 5 V sense

red +5 V 10 1 +5 V

blue 0 V 7 2 ground

signal 1

�white UA+ 1 3 sine (+)

brown UA– 2 4 sine (–)

signal 2

�pink UB+ 11 6 cosine (+)

black UB– 12 7 cosine (–)

zero signal

�grey UN+ 3 10 reference (+)

yellow UN– 13 12 reference (–)

internal shield 17 5 ground

green/black +TEMP(PTC+) 8 14 motor protection (+)

green/red –TEMP(PTC–) 9 15 motor protection (–)

housing housing

Spindle Connector: (Circular Connector)

17-pole

e.g.: Interconnection

SPNA 17B FSAN (solder connection)

SPNA 17B FRKN (crimp connection)

EVG

UC-17S1N1280DU (solder connection)

(protection system IP67)

Cable:

3 ×(2×0.14D) + 2×0.5 + 4×0.14

e.g. 6F×2 008-1BD41 Siemens

S&M Connector

15-pole male Submin D

Order number:

K217001xxx xxx stands for cable length in dm

Example:

Cable length = 14.3 m Order number: K217001143

�Options


� Appendix


12 Appendix: Wiring example

K1 main contactor

K2 delta contactor

K3 wye contactor

K1H auxiliary contactor

K2H auxiliary contactor

�Appendix


� Appendix: Revisions


13 Appendix: Revisions

The appendix describes alterations made in comparison to the version with theidentification number "021-sfu-tec-2172/R002-SM-EN-rg/ac/she" of May 20, 2003.


021-sfu-tec-2172/R003-SM-EN-rg/ac/she of January 14 , 2004

A warning was added in the chapter "Tips for Trouble-Free Operation".


021-sfu-tec-2172/R004-SM-EN-rg/ac/she of August 30, 2004

Completely revised.


021-sfu-tec-2172/R005-SM-EN-rg/ac/she of December 1 0, 2004

The status message 168 has been added.


021-sfu-tec-2172/R006-SM-EN-rg/ac/she of February 7 , 2005

Examples concerning the sense control have been added. The table in the chapter"Connecting Cables for Sensors (Motor/Converter)" has been modified. A warning hasbeen added to the chapter "Inputs (Connector X4)".


021-sfu-tec-2172/R007-SM-EN-rg/ac/she of March 29, 2006

The chapter "Specific Safety Instruction for FC72" has been added.


021-sfu-tec-2172/R008-SM-EN-rg/ac/she/uh of April 2 1, 2008

Upgrade of the chapter "Specific Safety Instruction for FC72".

�



021-sfu-tec-2172/R009-SM-EN-rg/ac/she/uh of April 30, 2009

Status message 167 added. Update of chapters “Safety Contact (SC)” and “Ground (GND) and Analog Ground (AGND)”.


021-sfu-tec-2172/R010-SM-EN-rg/ac/she/uh of February 18, 2015

Update of chapter “Ground (GND) and Analog Ground (AGND)” (due to technical changes of the device).


021-sfu-tec-2172/R011-SM-EN-rg/ac/she/uh of October 07, 2015

Error code 171: Voltage corrected. Analog outputs: Voltage and resolution corrected. Cable without sense conductors: Voltage corrected.

frequency converter of series fc72 - sieb & meyer · lcd liquid crystal display led light...

Documents