Lenze 8600 series Operating Instructions Manual
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Lenze 8600 series Operating Instructions Manual

Inverter drives variant dancer-position control with torque control
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EDB8600UE-V009
00392929
hze
Operating Instructions
Inverter Drives
8600 series
Varian f
Dancer-position control
with Torque control

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Summary of Contents for Lenze 8600 series

  • Page 2 These Operating Instructions are valid for the units with the following nameplate data: 8601 E.6x.6x.V009 8602 E.6x.6x.V009 8603 E.6x.6x.V009 8604 E.6x.6x.V009 8605 E.6x.6x.V009 8606 E.Gx.Gx.VOO9 8607 E.6x.6x.VO09 8608 E.6x.6x.V009 8609 E.6x.6x.V009 8610 E.6x.6x.V009 8611 E.6x.6x.VO09 8612 E.6x.6x.V009 8613 E.6x.6x.VO09 8614 E.6x.6x.VO09 8615 E.6x.6x.V009 Hardware Version + index Software version + index...
  • Page 3 use these Operating lnstructions... To locate information on specific topics, simply refer to the table of contents at the beginning and to the index at the end of the Operating Instructions. These Operating Instructions use a series of different Symbols to provide quick reference and to highlight important items.

  • Page 5: Table Of Contents

    5.2.4 Description of further inputs and Outputs 5.2.5 Digital inputs and Outputs 5.2.6 Description of the digital iunputs and Outputs 5.2.7 Frequency output 6, fd 5.3 Operation with DC-bus supply 5.3.1 Connection of several drives 5.3.2 DC-voltage supply 5.4 Screenings 5.5 Grounding of control electronics lenze...
  • Page 6 6 Accessories 6.1 Brake resistors 6.1 .l Selection of the brake resistor 6.1.2 Technical data of brake resistors 6.2 Mains Chokes 6.2.1 Selection of the mains Choke 6.2.2 Technical data of mains Chokes 6.3 Motorfilter 6.3.1 Technical data of motor filters 6.4 Sine filter 6.4.1 Technical data of sine filters 6.5 Gable protection...
  • Page 7 4 Closed-loop speed control 4.1 Analog act. value 4.2 Digital act. value 4.3 Frequency Pilot control 4.4 Adjustment of the act. value gain 4.4.1 Automatic adjustment 4.4.2 Manual adjustment 4.5 Setting of the controller Parameters 4.6 Additional functions 5 Programming of the freely assignable inputs and Outputs 5.1 Freely assignable digital inputs 5.2 Functions of the freely assignable digital inputs...
  • Page 8 9 Dancer-Position control 9.1 Application examples , ;> , . ’ , , . ,, . 9.1.3 Grinding and cutting-off wheel drives 9.2 Control structure of dancer-Position control with Pilot control for winding drives , , j , j , : . s 9.2.1 Diameter detection 9.2.2 Dancer-Position controller 9.3 Loop or dancer-Position control for line drives...
  • Page 9 12 Serial intetfaces 12.1 LECOMI interface X6 12.2 LECOM2 interface (Option) 12.3 LECOM Codes 12.3.1 Controller address 12.3.2 Operating state 12.3.3 Controller state 12.3.4 Pole pair number 12.3.5 Baud rate (LECOMl) 12.3.6 History of reset faults 12.3.7 Code bank (LECOMI) 12.3.8 Enable automation interface (LECOM2) 12.3.9 High resolution data 12.4 Attribute table...

  • Page 11: Planning

    Planning Features of the 8600 series variant dancer-Position control In addition to numerous Standard functions, this variant offers various functions which are required for a dancer-Position control used for winding applications. Another possibility is to activate a torque control. For more detailed information about the special functions see...
  • Page 12 Dancer-Position controller with speed and diameter Diameter detection via analog input of the dancer-Position controller via ramp function Soft insertion generator or multiplication with the main setpoint Sensor compensator for fault and diameter corrections Torque control with Speed limitation Approvals (types 8602 to 8611) VDE 0160, VDE reg.-no.

  • Page 13: Technical Data

    Technical data General data M a i n s v o l t a g e : 3 x 46OV AC, 45 to 65 Hz Permissible voltage range: 330...526 (as alternative: 470...740\1 DC supply) O u t p u t v o l t a g e : adjustable, mains-independent) When using a mains Choke,...

  • Page 14: Dimensions

    Dimensions v i e w The scope of delivery includes: frequency controller type 86XX-E Potentiometer accessory kit incl. protection covers and plug-in terminals Operating Instructions...

  • Page 15: Application As Directed

    The 8200 series consists of electrical devices which are designed for application in industrial power installations. The controllers are directed as components for the control of variable Speed drives with AC motors for the installation into control cabinets or control boxes as controllers for the installation of drive Systems The controllers comply with the protection requirements of the EC Low-Voltage Directive.

  • Page 16: Ce Conformity

    CE conformity What is the purpose of EC directives? EC directives are issued by the European Council and are intended for the determination of common technical requirements (harmonization) and cet-tification procedures within the European Community. At the moment, there are 21 EC directives of product the member states.

  • Page 17: Ec Low-Voltage Directive (73/23/Eec)

    EC Low-Voltage Directive (73/23/EEC) CE mark directive (93/68/EEC) amended by: The controllers of the 8600 series were developed, designed, and manufactured in compliance with the above-mentioned EC directive Lenze GmbH & Co KG, Postfach 101352, D-31763 Hameln The compliance with the protective requirements of the above mentioned EC directive was confirmed by the award of the VDE- EMC label of the accredited test laboratory VDE Prüf- und...

  • Page 18: Electromagnetit Compatibility (89/336/Eec)

    First amended directive (92/31/EEC) CE mark directive (93/68/EEC) The controllers of the 8600 series cannot be driven in stand-alone Operation for the purpose of the regulation about electromagnetic compatibility (EMVG of 09/11/92 and 1st EMVGÄndG - amended directive - of 30/08/95). The EMC tan only be checked when integrating the controller into a drive System.
  • Page 19 Considered basic Standards for the test of noise immunity: Hameln, 27/11/1995 (Tinebor) ngineer in Charge of CE...
  • Page 20 The controllers of the 820~ and 821~ types were developed, designed, and manufactured under the sole responsibility of Lenze GmbH & Co KG, Postfach 10 13 52, D-31763 Hameln The controllers are directed to be installed in a machine or to be assembled together with other components to form a machine or a System.

  • Page 21: Application-Specific Controller Selection

    Application-specific controller selection Applications with extreme overload, peak torque to 230% of the rated motor torque overload torque are necessary (e.g. presses, drilling machines). a maximum of 30s. With cyclic overload, the ratio between overload to cycle time must not exceed 0.2. using the Codes Cl 19 and Cl20 (see page 82) (factory setting) 50°C is permissible.

  • Page 22: Applications With High Overload, Peak Torque Up To 170 % Of The Rated Motor Torque

    Applications with high overload, peak torque up to 170 % of the rated motor torque overload behaviour of a controller (e.g. general mechanical engineering, hoists, travelling drives, a maximum of 30s. For cyclic overload, the ratio overload to cycle time must not exceed 0.1.

  • Page 23: Applications With Medium Overload, Peak Torque Up To 135 % Of The Rated Motor Torque

    Applications with medium overload, peak torque up to 135 % of the rated motor torque overload torque are necessary (e.g. Ventilators, a maximum of 30s. For cyclic overload, the ratio overload to cycle time must not exceed 0.1. using the Codes Cl 19 and Cl20 (see page 82 ) of 40°C is permissible.

  • Page 24: Handling

    Handling 4 . 1 Mechanical installation These frequency controllers must only be used as built-in units. bottom. controllers 8612 . . . 8615 this free space must also be allowed at both sides. Ensure unimpeded Ventilation of cooling air. If the cooling air contains pollutants (dust, flakes, grease,aggressive gases ), which may impair the controller separate air duct, installation of a fiter, regular cleaning, etc.

  • Page 25: Electrical Installation

    Electrical installation The Controllers contain sensitive electrostatic compontents. controller connections, the Personne1 must be free of electrostatic Charge. These persons tan discharge themselves by touching the PE fixing screw or another grounded metal part in the control cabinet. All control inputs and Outputs of the controller are mains- isolated.

  • Page 26: Motor Protection

    4.2.2 Installation in compliance with EMC Lenze has built up typical drives with these controllers and has verified the conformity. In the following this System is called “CE-typical drive system”.

  • Page 27: Ce-Typical Drive System

    (motor filter or sine filter). All cables from and to t3e controller must be screened. Lenze System cables meet these requirements. Ensure that the motor cable is laid separately from the other cables must not be connected to one terminal Strip.
  • Page 28 Installation Connect the Controller, mains fitter, and mains Choke to the grounded mounting plate. Zinc-coated mounting plates allow a permanent contact. If the mounting plates are painted, the paint must be removed in every case. When using several mounting plates they must be connected with as large surface as possible (e-g.

  • Page 29: Switching On The Motor Side

    Part of the CE-typical drive System on mounting plate P a i n t - f r e e b a r e m e t a l P a i n t - f r e e b a r e m e t a l , contact surfaces c o n n e c t i o n b e t w e e n...

  • Page 30: Wiring

    Wiring Power connections cabinet All power terminals remain live up to 3 minutes after mains disconnection!

  • Page 31: Tightening Torques Of The Power Terminals

    5.1.1 Tightening torques of the power terminals Tightening Ibfin) Ibfin) (13.3...16 Ibfin) (53,..70Ibfin) Ibfin) Control connections Layout: 44 45 KIlK14Al Control terminals Input of digital frequency/incremental encoder LECOM interface (RS232/485) 2nd input of digital frequency/incremental encoder (Option) Output of digital frequency (Option) Field bus connections (Option, e.g.

  • Page 32: Analog Inputs And Outputs

    52.1 Analog inputs and Outputs (unipolar setpoint) (bipolar setpoint) Monitor Outputs Feedback Setpoint 5.2.2 Further inputs and Outputs thermal contact incremental encoder temperatu re- relay output monitoring...

  • Page 33: Description Of The Analog Inputs And Outputs

    5.2.3 Description of the analog inputs and Outputs Analog inputs Switch setting Parameter (factory setting) setting see 7 5 , 6 8 75.68 Voltage supply for -1 OV/7mA P o t e n t i o m e t e r Analog Outputs (monitor Outputs) T e r m i n a l Switch setting...

  • Page 34: Digital Inputs And Outputs

    5.2.5 Digital inputs and Outputs The functions for the digital inputs and Outputs shown below are factory-set. To switch the Signal cables, only use relays with low- current contacts. Relays with gold-plated contacts have proven for this. All digital inputs and Outputs are PLC compatible and are - when operated with an external voltage supply (24 V) - isolated from the rest of the control Stage.
  • Page 35 Internal voltage supply (1 Inputs: Input voltage: 0 to 30 v LOW Signal: HIGH Signal: Input current: for 15 V 5 mA per input Outputs: Maximum voltage supply: 30 v Maximum output current: 50 mA per output external resistor at least 300 0 for 5 V, e.g.

  • Page 36: Description Of The Digital Iunputs And Outputs

    5.2.6 Description of the digital iunputs and Outputs Digital inputs Freely assignable input Digital Outputs...

  • Page 37: Frequency Output 6, Fd

    speed of the drive via a digital display device, you tan use the frequency output “6 times field frequency”. As factory setting, this digital Outputs,...

  • Page 38: Operation With Dc-Bus Supply

    Operation with DC-bus supply 5.3.1 Connection of several drives Drives which are supplied by a three-phase voltage tan also be linked via the terminals +UG and -UG for energy-sharing. This type of connection requires all controllers to be supplied simultaneously with the same mains voltage, with each controller being connected to the recommended mains Choke.

  • Page 39: Screenings

    5.4 Screenings Cable screenings increase the noise immunity of the drive System and reduce the interfering radiation. The power and control terminals of the controllers are noise immune without screened cables up to severity class 4 to IEC 801-4. Burst of 4kV on the power terminals and 2kV on the control terminals are permissible.

  • Page 40: Accessories

    Accessories Accessories are not included in the scope of supply. In the generator mode, e.g. when decelerating the drive, the inertias are braked and/or short deceleration times are set, the DC bus voltage may exceed its maximum permissible value. In the and indicates “overvoltage “.

  • Page 41: Selection Of The Brake Resistor

    6.1 .l Selection of the brake resistor The following combinations ensure The set continuous power of the controller is the reference for the combination. Operation at rated power (factory setting) 8 6 0 2 8 6 0 3 8 6 0 4 8 6 0 5 3 7 0 2 4 0...
  • Page 42 suitable brake resistor as follows: Determine the resistance: Resistance [Q] 2 required brake peak power Depending on the unit the resistances must not fall below the Depending on the unit the resistances must not fall below the following values: following values: Controller type Controller type Min.

  • Page 43: Technical Data Of Brake Resistors

    6.1.2 Technical data of brake resistors All listed brake resistors are equipped with an integrated temperature monitoring. The brake contact which is switched in the event of overtemperature is designed for: max. 250 V AC max. 0.5 A Grid-protected brake resistors...

  • Page 44: Mains Chokes

    Moulded module resistors on heatsink Brake resistor Dimensions Resistance Order number 3 7 0 2 2 5 2 4 0 3 2 5 Brake resistor Resistor values Resistance Order number P o w e r Peak brake power Heat capacitance 3 7 0 0 .

  • Page 45: Selection Of The Mains Choke

    6.2.1 Selection of the mains Choke the combination. Operation at rated power (factory setting) 8602 8 6 0 3 8 6 0 4 8605 3 x 2.5 3 x 2.5 3 x 1.6 12.0 12.0 8607 8 6 0 8 8609 8 6 1 0 15.0...

  • Page 46: Technical Data Of Mains Chokes

    6.2.2 Technical data of mains Chokes Mains Order no. Weight mm mm mm mm mm m m m m 2 5 A / 1.2mH 3 5 A / 0.88mH 1 6 1 4 5 A / 0.75mH 1 6 1 85A / 0.38mH 2 0 5 2 0 .

  • Page 47: Motorfilter

    6.3 Motor filter Advantages of using a motor filter: The motor filter reduces capacitive currents caused by parasitic cable capacitances. The slope of the motor voltage (dv/dt) is limited to 500 V/ps. Motorfilters are always required for: unscreened cables langer than 1 OOm. screened cables longer than 50m.

  • Page 48: Technical Data Of Motor Filters

    6.3.1 Technical data of motor filters Design A Design B With motor currents z 55 A please use motor filters which are connected in parallel.

  • Page 49: Sine Filter

    6.4 Sine filter Advantages of using a sine filter: Sinusoidal output voltages to supply electronie devices. Irrstall the sine filter as close as possibie to the controller. Select the control mode “V/f-characteristic control” not permissibie. The chopper frequency must be set to 8 kHz (CO1 8 = -4-). The controller is loaded additionally with approximately 10% of the rated current of the sine filter.

  • Page 50: Technical Data Of Sine Filters

    6.4.1 Technical data of sine filters Design A Design B factory.

  • Page 51: Gable Protection

    Cable protecting fuses for recommended 8601 - 03 Controller type Rated fuse current 2 0 A 3 5 A 5 0 A 16 mm2 Cable Cross-sectlon 4 mm2 6 6 1 2 6613 6 6 1 4 8 6 1 5 Controller type 6 3 A 125A...

  • Page 52: Rfi Filters

    RFI filters Advantage of using a RFI filter: Please note: Because of the generation of leakage currents, the RFI filters must be connected to earth. The RFI filter must always be connected to earth at first even if you only want to test the Otherwise, the System is not protected against shock.

  • Page 53: Technical Data Of Rfi Filters

    6.6.2 Technical data of RFI filters Design A Design B Order number Filter type Weight Design Rated 2 2 0 1 1 5 1 0 0 1 8 0 1 1 5 6 . 5 1 . 8 2 4 0 1 5 0 1 3 5 2 0 0...

  • Page 54: Accessories For Networking

    Connecting module 21 lOlB- Interßus-S Features: Additional module for the Lenze series 4900, 8600, 9200 Slave connection module for the communication System Can be integrated into the base controllers Can be combined with the automation modules 2211 PP,...

  • Page 55: Connecting Elements For Optical Fibre Cables-Lecom-Li

    Connecting elements for Optical fibre cables-LECOM-LI Lenze offer a series of specially designed connection accessories for the controllers, in Order to use the fibre optic communication bus. The accessories included adapters with Optical transmitter and cables, data transmission with a very high immunity to interferences is possible.

  • Page 56: Initial Switch-On

    Initial switch on After mains connection the controller is ready to operate after approx. 0.5 seconds. The frequency controllers are factory-set such that a four-pole Standard motor with 400V rated voltage and 50Hz according to the settings. In case of motor ratings according to section 3.2 or 3.3, page 17ff, it is necessary to increase the permanent output power accordingly.

  • Page 57: Parameter Setting

    Parameter setting Keypad P l a i n t e x t d i s p l a y D i s p l a y o f S t a t u s : F i e a d y f o r O p e r a t i o n ( L E D g r e e n ) Imax-limit reached (LED red) Pulse inhibit (LED yellow), released b y :...

  • Page 58: Basic Parameter Setting

    Basic Parameter setting Programming of the frequency controller enables the drive to be adapted to your application. The possible settings are arranged in letter “C”. Esch code provides one Parameter which tan be selected according to the application. Parameters tan be absolute or relative values of a physical unit (e.g.
  • Page 59 The arrow Position marks whether you are in the code or in the Parameter level. ‘0 ‘1 ‘5 ‘0 ‘0 ‘H ‘r ‘e ‘0 ‘e ‘n ‘c ‘0 ‘0 ‘r The maximum field frequency of 60Hz is now set and is accepted immediately.

  • Page 60: Parameter Setting By Two Codes

    2.1 .l Parameter setting by two Codes Some Parameters are set by two Codes. A preselection code is used to select the Parameter which is to be changed. The Parameter is then changed by another Code. For example, to set the JOG frequency JOG3, first set the preselection code CO38 to Save Parameters After the acceptance, new Parameters are saved in the RAM until...

  • Page 61: Basic Settings

    Basic settings Operating mode The controllers of the 8600 series offer different interfaces. From these you tan select each one for control and programming. Controller interfaces for control and programming: Terminals The terminals are exclusively used to control the controller.

  • Page 62: I Controller Enable

    3.1 .l Controller enable Depending on the selected operating mode (Cool) different procedures are necessary to enable the controller. Terminal control, i.e. CO01 = -O-, -2-, -4- Apply a voltage between 13 and 30V across terminal 28. + STP in addition. In case of terminal control, CO40 serves as a display: CO40 = -0- means controller is inhibited.
  • Page 63 In case of control via the keypad or the LECOM interface, quick stop tan also be (de-)activated via C042. Parameter (Factory setting is printed in bold) Acceptance Quick stop not active/deactivate quick stop SH + PRG Quick stop activelactivate quick stop (CCW rotation).

  • Page 64: Configuration

    Configuration Using code CO05 you tan determine the internal control structure and the use of the setpoint and act. value inputs. The following configurations are possible: Open-loop Speed control: Acceptance Code Parameter Meaning Actual value Terminals 7/8, unipolar or not active not active [SH + PRG] LECOM (bipolar) or...

  • Page 65: Example Of How To Select A Configuration

    3.2.1 Example of how to select a configuration The direction of rotation of the motor in a System is to be determined by the sign of the analog setpoint rotating field, O...lOV for CCW rotating field). A closed-loop Speed control is to be used, for which a DC tacho serves as act.

  • Page 66: Signal-Flow Chart For Speed-Controlled Operation (Co05 = -O- To -15)

    Signal-flow Chart for Speed-controlled Operation (CO05 = -o-t0 -15) Keypad, LECOM Keypad. Digital frequency iT$ S c a l i n g Gatn dmax -0.. :2. ,- Feedback = 0...
  • Page 67 for quick stop Ramp generator output = Ramp generator input Keypad, LECOM Total setpoint Frequency Feedback = setpolnt Selectable Signal for digital frequency output X9 Selectable Signal for Window...

  • Page 68: Features Of Setpoint

    Features of setpoint 1 An analog entry of setpoint 1 is possible via input Xl/terminal 8, otherwise it is entered via the keypad or the LECOM interfaces. This depends on the selected operating mode (Cool). The independently of the operating mode, a digital frequency input. With terminal control you tan read setpoint 1 under code C046.
  • Page 69 3.4.2 Digital frequency input With the corresponding configuration (CO05) you tan use the two complementary Signals shifted by 90” are provided. If you use an HTL-encoder, it is sufficient to provide only the Signals A and B. The inputs A\ and B\ must then be bridged using +Vcc (pin 4). The maximum input frequency is 300 kHz for TTL encoders and 100 kHz for HTL encoders.

  • Page 70: Features Of Setpoint

    Features of setpoint 2 co49. is added to setpoint 1 .The ramp times of the ramp generator are set separately via C220 and C221. Code Name Parameter (Factory setting is printed in bold) Acceptance A c c e l e r a t i o n 5.0 s 1 .OO s ON-LINE 0.00 s...

  • Page 71: Digital Frequency Input

    Gain the Signal gain after the offset adjustment. First apply that Signal (see offset). Then select under CO25 the corresponding analog input. Adjust the Signal gain such that the desired setpoint is obtained. For the adjustment of the act. value see pages 75 and 77. Name Preselection: Analog input Xl/terminals...

  • Page 72: V/F-Characteristic Control

    The Io control, also referred to a “magnetizing-current control” characteristic control, without the motor being overexcited when the drive is deloaded. 3.7.1 V/f-characteristic control You have to Change from Io control (factory setiing) to V/f- characteristic control if you want to supply several drives with different loads or rated power from one controller.
  • Page 73 Vif-rated frequency With the V/f-rated frequency, the slope of the characteristic is set. The value to be entered under CO1 5 results from the motor ratings: 4 0 0 v V / f -- rated frequency = . rated motor frequency The values for the most common motor types tan be obtained from the following table.

  • Page 74: Io Control

    3.7.2 IO contra1 breakaway torque. Compared to the V/f-characteristic control it provides considerably larger torques up to the motor rated Point. The advantages of IO control tan be used especially for Single drives. lt is also possible for group drives, provided that the motors are of the same type and have the same load, e.g.

  • Page 75: Minimum Field Frequency Fdmin

    Minimum field You tan use Code CO10 to program a minimum output frequency. This changes the influence of the analog setpoint to setpoint 1 in the factory-set configuration CO05 = -0- (not for other configurations). ,analog setpoint 100% For fsetpoint inputs via keypad or LECOM interfaces, the fdmin setting is not effective.

  • Page 76: Acceleration And Deceleration Times Tir, Tif

    3.10 Acceleration and deceleration times Tir, Tlf The ramp generators (main setpoint, setpoint 2) are programmed using the acceleration and deceleration times. Under CO12 and CO1 3, the ramp generator for the main setpoint (Setpoint l/JOG frequency) receives its Standard setting. The acceleration and deceleration times refer to a Change of the field frequency from 0 to the maximum field frequency set under CO1 1.

  • Page 77: Closed-Loop Speed Control

    Closed-loop speed control For a number of applications, the accuracy which tan be obtained To avoid with open-loop often not sufficient. which occurs when an asynchronous motor is loaded, you tan select a configuration with a appropriate configuration depends on the way of setpoint input and the actual value input you want to use.

  • Page 78: Frequency Pilot Control

    Code Name Parameter (Factory setting is printed in bold) Acceptance CO26 Constant for ON-LINE C O 2 5 ( p r e s e l e c t i o n o f t h e a n a l o g i n p u t s ) : xxxx mV factory setting -1000 mV ( p r e s e l e c t i o n o f t h e d i g i t a l - f r e q u e n c y...
  • Page 79 Torque characteristic of the motor Stationary Operation Output frequency Pilot control of set-value/feedback Closed-loop control without Pilot control, closed-loop control of an application datum The Pl controller is normally used for the Speed control of the connected motor. The large setting ranges of the control Parameters also allow the control of an application datum if this depends on the drive Speed.

  • Page 80: Adjustment Of The Act. Value Gain

    Adjustment of the act. value gain entered the encoder constant as described under 4.2. (see page Fehler! Textmarke nicht definiert.) an adjustment of the act. value gain is not necessary. For tacho act. value, a gain adjustment is normally required. 4.4.1 Automatic adjustment To adjust the act.

  • Page 81: Setting Of The Controller Parameters

    Calculate the required act. value gain according to the following equation: measured Speed Required gain = active gain desired Speed Enter the calculated value after selecting the suitable act. value input (C025) under C027. Setting of the controller Parameters With the setting of the Controller Parameters, you adapt the Pl Controller to the drive.

  • Page 82: Additional Functions

    Additional functions For special applications, you tan use a variety of additional functions: Input integral action component = 0 Using this function, the integral action component (I-component) of the PI controller tan be reset to zero. You tan activate this additional function via one of the freely assignable digital inputs.

  • Page 83: Programming Of The Freely Assignable Inputs And Outputs

    Programming of the freely assignable inputs and Most of the inputs and outputs of the frequency controller are freely assignable via their own Codes, i.e. they tan be especially assigned to the required Signals. Furthermore, these Signals tan be adjusted in the best possible way by setting facilities. In factory setting, these inputs are already assigned to certain functions.

  • Page 84: Functions Of The Freely Assignable Digital Inputs

    [ C o d e IName Acceptance Function tan be changed via CO01 [SH + PRG] Function tan be activated via terminals Except for the functions “Enable JOG frequencies”, “Enable additional acceleration and decleration times” and “Select Parameter Set”, every function tan only be assigned to one terminal.

  • Page 85: Dc-Injection Brake

    5.2.3 DGinjection brake input. Please note that the braking time may vary each time. Before you tan use the DGinjection brake, set the brake voltage and therefore the brake torque. If the current limitation is activated by the brake current, reduce the brake voltage. To limit the time of the DC-injection brake, you tan program a holding time under C107.

  • Page 86: Jog Frequencies

    5.2.4 JOG frequencies programmed setpoints via the JOG frequencies. These JOG frequencies replace setpoint 1. Please note that in configurations with additional setpoints, the setpoint 2 is set to zero, as long as a JOG frequency is active. Programming of JOG frequencies The JOG frequencies are set in two Steps: Select a JOG frequency under CO38 selected JOG frequency...
  • Page 87 Enabling JOG frequencies With terminal control activate the assigned digital inputs according to the table below. The input with the smallest number is the first input, the input with the next highest number is the second input, etc. With terminal control, the active JOG frequency is displayed under co4.5.

  • Page 88: Additional Acceleration And Deceleration Times

    5.2.5 Additional acceleration and deceleration times For the ramp generator of the main setpoint (setpoint l/JOG frequency) you tan cal1 additonal acceleration and deceleration times from the memory, e.g. to Change the acceleration Speed of the drive as from a certain Speed. Programming of additional acceleration and deceleration times The ramp times are set in two Steps, under ClOO, one pair of...
  • Page 89 Enabling the additional acceleration and deceleration times With terminal control activate the assigned digital inputs according to the table below. A’ v 1 0 The input with the smallest number is the first input, the input with the next highest number is the second input, etc. (e.g.

  • Page 90: Ramp Generator Stop

    5.2.6 Ramp generator stop While the drive is accelerated via the ramp generator of the main setpoint, you tan hold the ramp generator using the assigned digital input, e.g. to wait for cet-tain actions before accelerating. With terminal control you tan read under Cl31 whether the ramp generator is stopped or not.
  • Page 91 5.2.9 You tan store up to four different Parameter Sets, for example you want to run different motors with one controller. Programming of Parameter sets To program several Parameter Sets, the following Steps are requ ired: Enter all settings for one application. Select code CO03 and save your Parameter set for example Enter all settings for another application (e.g.

  • Page 92: Reset 1-Component / D-Component - Dancer-Position Controller

    With control and programming via keypad or LECOM interfaces you tan Start the loading of a Parameter set under CO02. Under CO02 you tan also load the factory setting. Parameter (Factory setting is printed in bold) Code Name Acceptance Factory setting [SH + PRG] L o a d Parameter set -l-...

  • Page 93: Functions Of The Freely Assignable Digital Outputs

    Name Parameter (Facto- setting is printed in bold) Preselection: Digital output Al SH + PRG freely D i g i t a l o u t p u t A 2 assignable D i g i t a l o u t p u t A 3 d i g i t a l o u t p u t D i g i t a l o u t p u t A 4 Relay output Kl l/K14...

  • Page 94: Maximum Current Reached, Imax

    5.4.2 Maximum current reached, Imax When the output current has reached the maximum current limit which is programmed under C022, the red LED on the keypad is illuminated and the assigned output sends a message. In case of overload, the output frequency is automatically reduced at the set maximum current limit.

  • Page 95: Act. Value = Setpoint

    The status of “pulse inhibit” is indicated by the illuminated yellow LED on the keypad and the permanently assigned digital output terminal 45. Pulse inhibit means that the output of the frequency controller is inhibited. Possible Causes are: Controller inhibit Fault indication TRIP If you need the permanently assigned output terminal 45 with the polarity as required.

  • Page 96: Monitor Outputs

    Monitor Outputs The controller has two monitor Outputs (terminals 62 and 63), to output internal Signals as voltage or current Signals. The required entnehmen. Factory setting: output Functlon T e r m i n a l 6 2 Output frequency 1 O V c o r r e s p o n d s t o T e r m i n a l 6 3 Motor current...

  • Page 97: Digital Frequency Output X9 (Option)

    Digital frequency output X9 (Option) The connection of drives via digital frequency allows a simple and or Slave drives. Assignment of socket X9 Name Explanation output 2nd encoder Signal * O u t p u t 1st encoder Signal inverse output 1 s t e n c o d e r Signal Not used...

  • Page 98: Additional Open-Loop And Closed-Loop Control Functions

    Additional open-loop and closed-loop control Chopper frequency The controllers of the 8600 series offer the feature to adapt the chopper frequency of the controller to the noise and smooth running requirements of the motor. By increasing the chopper frequency you tan generally reduce the motor noises which are generated by the pulsating output voltage.

  • Page 99: Automatic Chopper Frequency Reduction

    6.1 .l Automatic chopper frequency reduction improved smooth running with low Speeds, you tan activate an automatic chopper frequency reduction, restricted to this range. For this, enter the output frequency under C143, below which the chopper frequency is to be reduced automatically to 2 kHz. When selecting the chopper frequencies “12kHz fixed”...

  • Page 100: S-Shaped Ramp Generator Characteristic

    S-shaped ramp generator characteristic For the ramp generator of the main setpoint you tan select two different characteristics under Cl 34: linear characteristic for all constant accelerations S-shaped characteristic for all jerk-free accelerations. Parameter Code Name Acceptance ( F a c t o r y s e t t i n g i s p r i n t e d i n b o l d ) [SH + PRG] characteristic S-shaped charactertstic...

  • Page 101: Overload Protections

    Overload protections Overload protection of the frequency controller The frequency controllers have an output current monitoring to maximum ambient temperature to be expected. The lower the max. ambient temperature, the higher the limit of the permissible continuous output current. The permissible continuous output powes rises the same way.

  • Page 102: Display Functions

    C :ode lame Parameter (Factoty setting is printed in bold) M o n i t o r i n g n o t a c t i v e Monitoring active, sets trip Monitoring active, sets warning Rated power for temperature range up to 50°C Increased power for temperature range up to 45°C...

  • Page 103: Language

    Language The Standard setting is German. Code Name Parameter (Factory setting is printed in bofd) Acceptance CO98 L a n g u a g e -O- German SH + PRG E n g l i s h Display of actual valuesAct. value Act.

  • Page 104: Dancer-Position Control

    Dancer-Position control Dancer-Position control with and without diameter Pilot control of centre winder textiles, foils, Paper, ribbon to one shaft) is possible Dancer-Position control for surface winders centre winderkiancer-controller surface centre winder (tandem winder)

  • Page 105: Line Drives

    9.1.2 Line drives Dancer-Position control with and without Pilot control of the line Dancer-Position control with Speed adaptation and Pilot control of the line Speed 9.1.3 Grinding and cutting-off wheel drives Grinding or cutting-oft wheel drives Important information about the dancer-Position control: always active, independently of the operating mode.

  • Page 106: Control Structure Of Dancer-Position Control With Pilot Control For Winding Drives

    Control structure of dancer-Position control with Pilot control for winding drives The following figure Shows the control structure of the dancer- on the diameter (CO05 = -2Ol- or -202-). f-sei + f-correction Set Position Vset Diameter f-set = Diameter distance 8600 Vset Block diagram: Winding with diameter detection and dancer...

  • Page 107: Dancer-Position Controller

    The controller divides the Speed setpoint by the actual winding diameter. The Speed setpoint tan either be provided by a JOG value, an analog input terminal X8, or by the digital frequency input X5. When changing the operating mode, also the operating unit or one of the LECOM interfaces are available.

  • Page 108: Adjustment Of Analog Inputs

    Adjustment of analog inputs Offset adjustment of the analog input terminals 7/8 (setpoint input 1) and terminals 1/2 (setpoint input 2): With the final configuration CO05 = -2Ol- or -202-, an unwanted Operation of the drive may occur during adjustment and activated controller enable. That means, the drive could accelerate to fmax while adjusting the inputs when the setting controller enable is activated, although only a very small setpoint was...
  • Page 109 The following codes at-e important for the setting of the analog inputs: Parameter (Factory setting i s printed in bold) Analog input Xl/terminals 1/2 incoder Analog input Xllterminals 3/4 Analog input Xlherminal 8 D i g i t a l frequency/incrementaI e n c o d e r input X5 -1 i-...

  • Page 110: Selection Of The Configuration

    The setting of CO05 determines which input channels and which controls will be activated: Configuration d a n c e r Signal Terminals 314 analog actual value o p e r a t i n g u n i t ( b i p o l a r ) -202- Terminals 1/2 Terminals 3/4...

  • Page 111: Signal Of The Ultrasonic Sensor: Radius Signal

    Distance (a) Code Cl 80 Distance (a) plus radius (r) Exarnple current radius (r) = minimum radius = 150mm current distance between ultrasonic Sensor and Voltage supplied by the ultrasonic Sensor For setting the diameter detection by means of an ultrasonic programmed via code Cl 80.

  • Page 112: Gain Adjustment - Radius Signal

    9.7.4 Gain adjustment - radius Signal When selecting the dancer-Position control with diameter evaluation of the setpoint, the gain of the radius Signal must be set such that an appropriate output frequency is generated when having a fixed setpoint and a certain radius. Coarse adjustment: 1.

  • Page 113: Limits Of The Radius Calculation

    The following Codes are important for the adjustment of the radius lame Analog input Xl/terminals 1/2 . n c o d e r Analog inbut Xliterminals 3/4 Analog input Xllterminal 8 Digital frequency/incrementaI encoder input X5 Digital frequency/incrementaI encoder for CO25 = -l-, -2-, -4- O N - L I N E (preselection of the analog inputs): 1 .ooo...

  • Page 114: Adjustment Of The Dancer-Position Controller

    Adjustment of the dancer-Position controller 9.8.1 Setpoint Provision The act. value Signal of the dancer-Position controller is set via the terminals 3 and 4. The input Signal is displayed as percentage under code CO51 with Cl72 = -O-. In this case IOV = 100%. The input Signal is resolved with 12 bits (iOV/4096 = 2.44mV) plus sign.

  • Page 115: Setting Of The Pid Controller

    9.8.2 Winding or unwinding Winding from above or from below The command “unwinding from above” or “unwinding from below” is given by the CW/CCW reversal (reversing command e.g. via terminals 21 and 22). Unwinding from above or from below For unwinding, the sign for the influence of the dancer-Position Controller must be inverted.

  • Page 116: Overlay Of Position Controller

    9.9.1 Overlay of Position controller The function “overlay of position for the controller” is necessary Position. The full effect of the dancer-Position controller could lead extreme operating conditions. the slow overlay Therefore output Signal is necessary when starting the winding-up process. The function “overlay of Position controller”...

  • Page 117: Conversion Of Modulation Of Dancer-Position Controller To Field Frequency

    9.9.2 Conversion of modulation of dancer-Position controller to field frequency Code Cl 91 is a calibration factor which is used to convert the modulation of the dancer-Position controller into a frequency. The corresponding field frequency with 1% modulation of the dancer- Example: With Cl 91 = 290 mHz/%, 100% modulation of the dancer-Position controller corresponds to a field frequency of 29 Hz.

  • Page 118: Reset Of The Diameter Compensator

    To activate the diameter compensator the threshold which is to be must set under C94 be decreased so that the dancer-Position controller tan be activated. With the setting of Cl 94 = 100 % (factory setting) the diameter compensator is disconnected from the dancer-Position controller.

  • Page 119: Sensorless Diameter Detection

    1.0s 1 0 . 0 s 1 0 s 1.00 s ON-LINE 1.0 s (100 ms} 1 0 s 100s 100 s 9 9 0 s Diameter compensator active SH + PRG Diameter compensator reset The diameter compensator tan also be used for indirect diameter detection where there is no diameter detection System.

  • Page 120: . ,; ., 9.12.2 Information About The Slave Drive

    9.12 Application: Tandem winder 9.13.1 Digital frequency output The digital frequency output is required e.g. for a master Slave coupling (two motors are connected by friction to one winder shaft). For master-Slave couplings it is important that, in case of Speed A frequency Signal which is proportional to the field frequency tan be supplied to terminal X9.

  • Page 121: Application: Loop Control With Speed Adaption

    9.13 material by means of two conveyor belts. The slack which occurs between the two conveyor belts is kept constant by the loop control. To ac:tivate the loop control the code Cl 89 must be set to -0- but only with activated controller inhibit. Usually the field frequency Pilot control is not used for the loop control.

  • Page 122: Signal Flow Chart For Dancer-Position Control (Co05 = -2Ol- Or -202-)

    9.14 Signal flow Chart for dancer-Position control (CO05 = -201- or -202-)

  • Page 124: Torque Controller

    10 Torque controller 10.1 Features The torque control is used to supply a torque which is proportional to the setpoint, depending on a torque reference at a connected AC asynchronous machine. For this, the torque setpoint is entered via an analog Signal input which is permanently compared with the torque supplied to the motor shaft.

  • Page 125: Setting Of The Torque Controller

    Block diagram Field frequency Conditions The torque control tan only be used in the motor mode and in the armature setting range (range of constant motor excitation from 0 to V/f-rated frequency). In this configuration, only one motor tan be connected. The torque control has an Optimum effect only with activated magnetization current control (CO06 = -1-) .

  • Page 126: Adjustment Of Analog Inputs

    lame Open-loop control, unipolar, O p e n - l o o p c o n t r o l , b i p o l a r w i t h a d d i t i o n a l O p e n - l o o p c o n t r o l w i t h d i g i t a l f r e q u e n c y a n d a d d i t i o n a l setpoint a c t .
  • Page 127 Master voltage or -lov to +lOV 1 2 b i t + s i g n (depending On switch Code CO51 tan be used to display the torque setpoint of terminals 3 and 4. When Cl72 is set to -0-, CO51 is displayed as a Parameter (Factory setting is printed in bold) Preselection: Analog input Xllterminals 112...

  • Page 128: Adjustment Of The Io Setpoint

    10.4 Adjustment of the Io setpoint that the Io current of the connected asynchronous It is important C o d e N a m e Parameter (Factory setting is printed in bold) Acceptance C o n t r o l m o d e -O- [SH + Rated setpoint (PN,,,~,~~ = PNunit) ON-LINE...
  • Page 129 The quality of the control behaviour is set via the Vp-gain factor CO77 and the adjustment time Tn C078. Therefore the field frequency is reduced with a reduction of the torque setpoint, until the ratio between Speed and torque is stable. Here, the field frequency input via terminal 8 or via the digital frequency input or via code CO46 is used to limit the maximum field frequency.

  • Page 130: Signal Flow Chart For Torque Control (Co05 = -2O- Or -2L-)

    10.7 Signal flow Chart for torque control (CO05 = -2O- or -21-) K e y p a d , L E C O M 250R . ..ZOmA I Gain Digital frequency ä _ K e y p a d . LECOM Gain input...
  • Page 131 for auick sh ramp generator input ramp Keypad, LECOM Ti tlmes 15 addit. PI wntroiier...

  • Page 132: Code Table

    Code table The following table Shows which settings you tan enter under which Codes. For detailed explanations of the Codes and their possible functions refer to the corresponding chapters. How to read the code table: Column Abbreviation Meanlng Code of the Standard C o d e Code of the extended code set Factory setting is printed in hold.
  • Page 133 Parameter (Factory setting is printed in hold) Open-loop control, unipolar, SH + PRG O p e n - l o o p c o n t r o l , b i p o l a r w i t h a d d i t i o n a l O p e n - l o o p c o n t r o l w i t h d i g i t a l f r e q u e n c y a n d a d d i t i o n a l setpoint -1 l-...
  • Page 134 Rated setpoint (PNmotor = PNunit) as from 100 A ( p r e s e l e c t i o n o f t h e a n a l o g i n p u t s ) : xxxx mV factory setting CO25 = -lO-, -ll- ( p r e s e l e c t i o n o f t h e d i g i t a l - f r e q u e n c y...
  • Page 135 C o d e N a m e Parameter Acceptance C o n s t a n t f o r -l- 512 pulses/Hz or Incrementslrev. SH + PRG d i g i t a l 1024 pulses/Hz or increments/rev. frequency 2048 pulses/Hz or increments/rev.
  • Page 136 Name Parameter cceptance Motor current x.x A INFO: Actual-value display F a u l t INFO: Display of a faulffwaming i n f o r m a t i o n O p e r a t i n g INFO: Only readable via LECOM C o n t r o l l e r state...
  • Page 137 Code Name Parameter Acceptance see Your page settlngs Cl00 P r e s e l e c t i o n : Pair of ramp times 1 S H +PRG 8 5 A d d i t i o n a l P a i r o f r a m p t i m e s 2 P a i r o f r a m p t i m e s 1 5 d e c e l e r a t i o n...
  • Page 138 Parameter Acceptance see Your page settings Preselection: digital input El S H +PRG 8 1 d i g i t a l i n p u t E 2 f r e e l y . . . a s s i g n a b l e d i g i t a l i n p u t d i g i t a l i n p u t E8 N o f u n c t i o n...
  • Page 139 ‘our Factory setting is printed in bold) P r e s e l e c t i o n : Digital input TRIP-Set SH + PRG M o n i t o r i n g P T C i n p u t Output power (1 t monitoring) SH + PRG C l 1 9...
  • Page 140 Name Parameter Acceptance see Your Code page settings Distance + -1 cl.oov C l 8 0 (0.01 V} V ON-LINE radius Cl 81’ Dancer- - 1 o . o o v (0.01 V} V ON-LINE 1 1 2 c o n t r o l l e r C l 8 2 Dancer- 100 ON-LINE...
  • Page 141 INFO: Process datum only readable via LECOM v a l u e...
  • Page 142 12 Serial interfaces The frequency controllers tan communicate with superimposed hosts (PLC and PC) and the Lenze operating units 323 and 324 via the serial interfaces LECOMl and LECOM2. 12.1 LECOMI interface X6 The LECOMl interface (X6 connector) tan be used to connect devices to the RS232C Standard (LECOM-A) or to the RS485 setting, monitoring, diagnosis, and simple controls.

  • Page 143: Lecom2 Interface (Option

    12.2 LECOM2 interface (Option) For more sophisticated applications, you tan use a field bus connecting interface. In the programming section, this interface is called LECOM2. For the bus System Interbus-S the connecting with DRIVECOM Profile. The modules 2110 and 2130 are available are Options and tan be integrated into the controller (See also page 52).

  • Page 144: History Of Reset Faults

    12.3.5 Baud rate (LECOMI) Code Parameter Meaning 4 8 0 0 baud 2 4 0 0 b a u d 1200 baud 12.3.6 History of reset faults last reset fault is displayed in Cl 61. 12.3.7 Code bank (LECOMI) With version 1 .O of the LECOM A/B protocol, Codes up to C255 tan be processed.

  • Page 145: High Resolution Data

    12.3.9 High resolution data act. value with a resolution of 14 bit plus sign. corresponds to 100% of the maximum field frequency. The inforrnation is identical with that under C046, with the differente that you tan read the controller value directly thus excluding conversion errors.

  • Page 146: Attribute Table

    NB) or LECOM2. L e g e n d Meaning Lenze code number Data structure S i n g l e v a r i a b l e (only o n e P a r a m e t e r e l e m e n t ) preselection or by LECOM sub Code).
  • Page 147 Code Form. Index FIX32 2 4 5 7 5 C O 0 1 FIX32 2 4 5 7 4 F I X 3 2 2 4 5 7 3 F I X 3 2 2 4 5 7 2 F I X 3 2 2 4 5 7 1 F I X 3 2 2 4 5 5 5...
  • Page 148 [ V D 2 4 4 0 7 Cl72 2 4 4 0 3 Cl76 2 4 3 9 9 2 4 3 6 5 c211 C 2 1 4 F I X 3 2 2 4 3 6 1 F I X 3 2 2 4 3 5 5 F I X 3 2...
  • Page 150 Service Fault indication When a fault occurs, the Operation of the frequency controller is immediately interrupted and the Signal “ready” is removed. The fault is displayed automatically under C067. The fault indication is flashing as long as the fault has not been reset. Fault reset: Press SH + PRG Reset fault indications are stored.
  • Page 151 List of fault indications Display on Display on Cause Remedy h o s t Short circuit/earth fault at the Check motor cable for short- E a r t h f a u l t motor side e.g. by c i r c u i t Separate motor cable from C o n t r o l l e r a n d c h e c k i n s u l a t i o n between U-V-W and PE...

  • Page 152: Warning

    Warning A warning is displayed automatically under C067. During a warning the Signal “ready” is removed, however, the Operation of the frequency controller is not interrupted. Press SH + PRG Reset of the warning: List of warnings Remedy Cause Display on Display on Fault keypad h o s t Overheat PTC Motor is overheated...
  • Page 153 Checking the power Stage The measurements described below are to be carried out only by indicate the nominal value. If they are different, there is a defective. Checking the mains rectifier Disconnect controller from the mains and wait until the DC bus has discharged (approx.
  • Page 154 Index Acceleration time 74 Brake resistors 38 Burst 37 Additional, Enabling with control via keypad or LECOM 87 Cable protection Additional. Enabling with terminal Fuses 49 control 87 Miniature circuit breakers 49 Additional 86 Changing the functions of terminals 21, Accessories 22 61 Brake resistors 38...

  • Page 155: Monitoring

    Group clrives 36 Deceleration time 74 keypad or LECOM 87 High resolution data Additional, Ti inputs 86 Additional, enabling with terminal Total setpoint 143 control 87 Additional. Programming 86 Additional 86 Diameter compensator 115 frequency 72 Diameter detection 104 Incremental encoder 75 Diameter detection, adjustment 111 Input of correction value 117 Digital frequency output 118...
  • Page 156 Optical fibre cables 53; 140 Output frequency 11 Output voltage 11 Outputs Level converter 2101 IP 53 Act. value = 0 80 Act. value = setpoint 80 Level converter 2101 IP 140 Analog 31 LECOM-LI 53 Digital 32; 34 Load-Change damping 98 Digital frequency 29;...
  • Page 157 Digital frequency 67 Quick stop 60 Master current 66 Setting Controller Parameters 79 Ramp generator Setting of the PID controller 113 Input = 0 (RFG/E=O) 88 fault 149 Input = 0, Keypad or LECOM 88 Sine filter 47 Input = 0, Terminal control 88 Advantages 47 Slip compensation 97 Stop, keypad or LECOM 88...
  • Page 158 Lenze GmbH Hans-Lenze-Straße 1, D-31855 Telefon (051 54) 82-0, Telefax (051 54) 82-21 11 E-Mail: LenzeQLenze.de . Internet: http://www.Lenze.de Technische Änderungen vorbehalten Printed in Gemany by Lenze 0998...

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