Lenze 8200 series Operating Instructions Manual
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Lenze 8200 series Operating Instructions Manual

Global drive frequency inverters
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EDB8200UE
00398283

Operating Instructions

Global Drive
Frequency inverters
8200 series
K35.0110-3

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Summary of Contents for Lenze 8200 series

  • Page 1: Operating Instructions

    EDB8200UE 00398283 Operating Instructions K35.0110-3 Global Drive Frequency inverters 8200 series...
  • Page 2 These Operating Instructions are valid for the 82XX controllers of the versions: 33.820X- (8201 - 8204) 33.8202- -V002 reduced assembly depth (8202) Type Design: B = Module C = Cold Plate E = Enclosure IP20 Hardware level and index Software level and index Variant Explanation Corresponds to the German edition of 16/06/1997...

  • Page 3: Table Of Contents

    Contents 1 Preface and general information ......1- 1 1.1 About these Operating Instructions ..
  • Page 4 Contents 5 Commissioning ......... 5- 1 5.1 Before you switch on .

  • Page 5: Preface And General Information

    1.1.1 Terminology used Term In the following text used for 82XX Any frequency inverter of the series 8200, 8210, 8220, 8240 Controller 82XX frequency inverter Drive system Drive systems with 82XX frequency inverters and other Lenze drive components 820XBA1097...

  • Page 6: What Is New

    1 82XX frequency inverter After receipt of the delivery, check immediately whether the scope of supply matches with the accompanying 1 Operating Instructions papers. Lenze does not accept any liability for deficiencies 1 accessory kit (components for claimed subsequently. the mechanical and electric...

  • Page 7: Legal Regulations

    1.3 Legal regulations Labelling Labelling Nameplate CE mark Manufacturer Conforms to the EC Low Voltage Lenze GmbH & Co KG Directive Postfach 101352 D-31763 Hameln Application 82XX frequency inverter as directed must only be operated under the conditions prescribed in these Instructions.
  • Page 8 Operating Instructions. The specifications, processes, and circuitry described in these Operating Instructions are for guidance only and must be adapted to your own specific application. Lenze does not take responsibility for the suitability of the process and circuit proposals.

  • Page 9: Safety Information

    Safety information 2 Safety information 2.1 General safety information Safety and application notes for controllers (to: Low-Voltage Directive 73/23/EEC) 1. General to the regulations of the EC Directive 89/392/EEC (Machinery Directive); EN 60204 must be observed. During operation, drive controllers may have, according Commissioning (i.e.
  • Page 10 Safety information inappropriate handling. Electrical components must not 6. Operation be damaged or destroyed mechanically (health risks are Systems where drive controllers are installed must be possible!). equipped, if necessary, with additional monitoring and protective devices according to the valid safety regulations, e.g.

  • Page 11: Layout Of The Safety Information

    Safety information 2.2 Layout of the safety information All safety notes have a uniform layout: - The icon characterizes the type of danger. - The signal word characterizes the severity of danger. - The note describes the danger and suggests how to avoid the danger.

  • Page 12: Residual Hazards

    Safety information 2.3 Residual hazards Operator’s safety After mains disconnections, the power terminals U, V, W and + U , -U remain live for at least three minutes. Before working on the controller, check that no voltage is applied to the power terminals. Protection of Cyclic connection and disconnection of the controller supply voltage at L1, L2, L3 or + U devices...

  • Page 13: Technical Data

    Technical Data 3 Technical data 3.1 General data/application conditions Field Values Vibration resistance Germanischer Lloyd, general conditions Humidity class Humidity class F without condensation (average relative humidity 85 %) ˜ ¤ ˜ Permissible Permissible during transport of the controller: + 70 temperature ranges temperature ranges ˜...

  • Page 14: Rated Data (Operation With 150 % Overload)

    Technical Data 3.2 Rated data (Operation with 150 % overload) 3.2.1 Types 8201 to 8204 150 % overload Type 8201 8202 8203 8204 Order no. EVF8201-E EVF8202-E EVF8203-E EVF8204-E Variant ”reduced assembly Variant ”reduced assembly Type 8202-V002 depth” depth” Order no. EVF8202-E- V002 á...
  • Page 15 Technical Data 150 % overload Type 8201 8202 8203 8204 Order no. EVF8201-E EVF8202-E EVF8203-E EVF8204-E Variant ”reduced assembly Variant ”reduced assembly Type 8202-V002 depth” depth” Order no. EVF8202-E- V002 ˜ ˜ Power derating [%/K] C < T < 50 C: 2,5%/K [%/m] 1000 m a.m.s.l.

  • Page 16: Fuses And Cable Cross-Sections

    Technical Data 3.3 Fuses and cable cross-sections 3.3.1 Single drives with 150 % overload The table values are valid for the operation of 82XX controllers as single drives with a matching motor and 150 % overload. Type Type Mains input L1, N, PE / motor connection U, V, W, PE Operation without mains filter/mains choke Operation with mains filter/mains choke Fuse...

  • Page 17: Installation

    Installation 4 Installation 4.1 Mechanical installation 4.1.1 Important notes Use the controllers only as built-in devices! If the cooling air contains pollutants (dust, fluff, grease, aggressive gases): - take suitable preventive measures , e.g. separate air duct, installation of filters, regular cleaning, etc. Observe free space! - You can install several controllers next to each other without free space in a control cabinet.
  • Page 18 Installation Possible mounting positions In vertical position at the back of the control cabinet, terminals point to the front: - With attached fixing rails. - With special fixing unit on one or two DIN rails. ˜ Turned by 90 (flat assembly on the backside of the control cabinet): - Insert the attached fixing rail into the guides at the heat sink.

  • Page 19: Standard Assembly With Fixing Rails Or Fixing Angles

    Installation 4.1.2 Standard assembly with fixing rails or fixing angles 4.1.2.1 Types 8201 to 8204 Lenze P o st fac h10 135 2 , 3 17 63 H AM EL N K35.0074 FIG 4-1 Dimensions 8201 - 8204: Standard assembly...

  • Page 20: Type 8202-V002 (Reduced Assembly Depth)

    Installation 4.1.2.2 Type 8202-V002 (reduced assembly depth) This variant is equipped with a heat sink with a smaller surface. Observe the following points to comply with the technical data: Assembly on an unpainted, metallic assembly board. Area > 0.15 m Sheet thickness at least 2 mm.

  • Page 21: Din-Rail Assembly

    Installation 4.1.3 DIN-rail assembly Lenze P os t fac h 101 352,3176 3 H AMELN > K35.0071 FIG 4-2 Dimensions 8201 - 8204: DIN-rail assembly 8201/8202: Assembly on a DIN rail (middle) or on two DIN rails (top and bottom) possible...

  • Page 22: Electrical Installation

    With isolated neutral Operation with recommended Mains filter will be destroyed if (IT mains) mains filters is not possible ”earth fault” occurs. Contact Lenze. With grounded phase Operation only possible with one Contact Lenze variant DC supply via + U...

  • Page 23: Power Connections

    Installation 4.2.2 Power connections 4.2.2.1 Mains connection Connect the mains cables with the screw terminals L1, L2, L3. - Tightening torques Terminals L1, L2, L3, + UG, -UG PE connection Type 8201 - 8204 0.5 ... 0.6 Nm (4.4 ... 5.3 lbin) 3.4 Nm (30 lbin) 4.2.2.2 Motor connection Because of the EMC safety we recommend the use of screened...
  • Page 24 No. of motor cables - When using unscreened motor cables, the data indicated in FIG 4-3 are valid for the double motor-cable length. - Please contact Lenze when the absolute or resulting motor-cable lengths are > 200 m. Type Permissible control mode C014...

  • Page 25: Connection Diagram

    Installation 4.2.2.3 Connection diagram Fuse F2* Fuse only for supply with 2AC / PE / 190-260V K10 Mains contactor K10* Mains contactor only for supply with 2AC / PE / 190-260V Mains filter/mains choke, see Accessories ϑ Motor filter/sine filter, see Accessories Brake chopper/brake module, see Accessories...

  • Page 26: Control Connections

    Installation 4.2.3 Control connections 4.2.3.1 Control cables We recommend the unilateral screening of all cables for analog signals to avoid signal distortion. Connect the screens of the control cables as follows: - 820X: On the front FAST-ON connector. If the control cables are interrupted (terminal strips, relays), the screens must be reconnected over the shortest possible distance.
  • Page 27 Installation Terminal Level Data (Factory setting is printed in bold) Analog GND 1 inputs inputs Setpoint input, 5 - 6 0 to 20 mA Resolution: 9 bit reference: ™ 5 - 6 4 to 20 mA Linearity fault: 0.5 % Terminal 7 3 - 4 0 to 5 V...

  • Page 28: Connection Diagrams

    Installation 4.2.3.3 Connection diagrams ≥ K35.0077-3 FIG 4-6 Control connections: Supply with internal control voltage K35.0077-4 ≥ FIG 4-7 Control connections: External voltage supply (+12 V ... +30 V) GND1 Reference for internal voltages GND2 Reference for external voltages GND1 and GND2 have a potential isolation inside the unit. 4-12 820XBA1097...

  • Page 29: Installation Of A Ce-Typical Drive System

    Installation 4.3 Installation of a CE-typical drive system General The user is responsible for the compliance of his application with the EC directives. notes - If you observe the following measure you can be sure that the drive system will not cause any EMC problems, i.e.
  • Page 30 Installation Screening Connect the screen of the motor cable with the controller - to the screen connection of the controller. - additionally to the mounting plate with a surface as large as possible. - Recommendation: For the connection, use ground clamps on bare metal mounting surfaces. If contactors, motor-protecting switches or terminals are located in the motor cable: - Connect the screens of the connected cables also to the mounting plate, with a surface as large as possible.
  • Page 31 Installation K35.0082 FIG 4-8 Example for an installation in accordance with the EMC regulations: Fuse Mains contactor Mains filter ”A” or ”B”, see Accessories Motor filter/sine filter, see Accessories Brake module/brake chopper, see Accessories Terminal strip in control cabinet Brake resistor HF screen because of a PE connection with a surface as large as possible (see ”Screening”...
  • Page 32 Installation 4-16 820XBA1097...

  • Page 33: Commissioning

    Commissioning 5 Commissioning The controllers are factory-set to drive a corresponding four-pole standard motor with 230/400V , 50Hz. Further settings are not necessary. Only a few settings via the 8201 BB operating module or a fieldbus module are necessary to adapt your drive to your application. The steps required are summarized in chapter 5.3 and in chapter 5.4.

  • Page 34: Short Set-Up (Factory Setting)

    Commissioning In case of condensation connect the controller to mains voltage only after the visible humidity has evaporated. The plug-in power terminals of the 820X controller must only be connected or disconnected when no voltage is applied. Maintain the switch-on sequence! 5.2 Short set-up (Factory setting) 5.2.1 Switch-on sequence...

  • Page 35: Factory Setting Of The Most Important Drive Parameters

    Commissioning 5.2.2 Factory setting of the most important drive parameters Setting Code Factory setting Adaption to application Operating mode C001 Setpoint selection via terminal 8 See code table, Control via terminals chapter 7.2 Parameter setting via 8201BB Terminal configuration C007 See code table, CW/CCWDC injection brake JOG1/2/3...

  • Page 36: Adapt Machine Data

    Commissioning 5.3 Adapt machine data 5.3.1 Determine speed range (f dmin, dmax) Code Name Possible settings IMPORTANT Lenze Selection Info C010 Minimum field {0.1Hz} 480.0 frequency C011 Maximum field 50.0 30.0 {0.1Hz} 480.0 frequency Function The speed range required for the application can be selected here by determing the...
  • Page 37 Commissioning Important With the setting of f > f the field frequency is limited to f dmin dmax dmax When selecting the setpoint by means of JOG values, f acts as limitation. dmax is an internal standardization variable: dmax - Use the LECOM interface only for important modifications, when the controller is inhibited.

  • Page 38: Adjustment Of Acceleration And Deceleration Times (Tir , T If)

    Commissioning 5.3.2 Adjustment of acceleration and deceleration times (T Code Name Possible settings IMPORTANT Lenze Selection Info C012 Acceleration time {0.1s} 999.0 T C013 Deceleration time {0.1s} 999.0 T Function The accleration and deceleration times determine the time required by the drive to follow a setpoint change.

  • Page 39: Setting Of The Current Limit (Imax)

    Commissioning 5.3.3 Setting of the current limit (I Code Name Possible settings IMPORTANT Lenze Selection Info C022 I limit {1 %} motor mode C023 I limit {1 %} generator mode Function The controllers are equipped with a current-limit control which determines the dynamic response under load.

  • Page 40: Optimisation Of The Operating Characteristic Of The Drive

    In chapter 5.4.1 you will find some more information to help you with the selection. 5.4.1 Select the control mode Code Name Possible settings IMPORTANT Lenze Selection Info § C014 Operating mode Linear characteristic V with Control auto boost...
  • Page 41 Commissioning C014 = -0- C014 = -1- Linear characteristic Square-law characteristic (e. g. for pumps, fans) V o u t V o u t 1 0 0 % 1 0 0 % A u t o b o o s t V m i n A u t o b o o s t...
  • Page 42 Commissioning Help for decision Motor cable screened > 25 m screened 25 m unscreened > 50 m unscreened 50 m C014 recommended alternatively recommended alternatively Single drives With constant load With changing loads With heavy start conditions High dynamic posotioning and feed drives Lifts and hoists Pumps and fan drives Three-phase reluctance motors...

  • Page 43: Optimisation Of V/F-Characteristic Control With Auto Boost

    Commissioning 5.4.1.1 Optimisation of V/f-characteristic control with auto boost Codes required Code Name Possible settings IMPORTANT Lenze Selection Info C015 V/f-rated 50.0 30.0 {0.1Hz} 960.0 frequency C016 V setting {1 %} * type dependent C021 Slip {1 %} compensation Setting sequence 1.
  • Page 44 Commissioning 3. Set the Vmin boost Load-dependentboost of the motor voltage in the field-frequency range below the (C016). V/f-rated frequency. C016 acts as gain factor of the auto-boost function. Adjustment In general, an adjustment is not necessary. An optimisation can be advantageous: For drives with very high starting torques: A Operate the motor under load.

  • Page 45: Optimisation Of V/F-Characteristic Control

    Commissioning 5.4.1.2 Optimisation of V/f-characteristic control Codes required Code Name Possible settings IMPORTANT Lenze Selection Info C015 V/f-rated 50.0 30.0 {0.1Hz} 960.0 frequency C016 V setting {1 %} * type dependent C021 Slip {1 %} compensation Setting sequence 1. If necessary, select V/f characteristic (C014).
  • Page 46 Commissioning 3. Set the Vmin boost Load-independentboost of the motor voltage for field frequencies below the (C016). U/f-rated frequency. You can thus optimize the torque performance of the inverter drive. It is absolutely necessary to adapt the asynchronous motor used, since otherwise, the motor can be destroyed by overtemperatue: Adjustment Please note the thermal characteristic of the connected motor under small field...

  • Page 47: During Operation

    During operation 6 During operation Replace defective fuses with the prescribed type only when no voltage is applied. There are no fuses in the controller. Cyclic mains switching: - Do not switch on the controller more than every 3 minutes, otherwise the internal initial-current limitation can be overloaded.
  • Page 48 During operation If you use the function CW/CCW (selection of the direction of rotation) with the configuration C007 = -0- to -13-: - The drive can reverse the direction of rotation in the event of a control-voltage failure or a cable break. If you use the function ”Flying-restart circuit”...

  • Page 49: Configuration

    Configuration 7 Configuration 7.1 Basics The configuration of the controller is used to adapt the drive to your applications. For this, you have the following functions available: - Operating functions - Control function - Display functions - Monitoring functions The possible function settings are organized in codes: - Codes are numerically sorted, starting from the code with the smallest number to the one with the highest number.

  • Page 50: Code Table

    Name Name of the code. 820X Unit-specific setting possibilites (here for 820X). Without unit designation the code is valid for all unit types. Lenze Factory setting of the code The column ”Important” contains further information Selection {1 %} 99 Minimum value...
  • Page 51 Configuration Possible settings Code Code Name Name IMPORTANT IMPORTANT Lenze Selection Info C001 Operating mode Setpoint selection via term. 8 § Control via terminals Parameter setting via 8201BB Setpoint selection via 8201BB or via LECOM Control via terminals Parameter setting via 8201BB Setpoint selection via term.
  • Page 52 Configuration Code Code Name Name Possible settings IMPORTANT IMPORTANT Lenze Selection Info [C007 Terminal CW = CW configuration rotation CW/CCWDC brake JOG1/2/3 CCW = CW/CCWPAR JOG1/2/3 CW/CCWQSP JOG1/2/3 rotation CW/CCWPAR DC brake JOG1 DC brake = CW/CCWQSP JOG1 CW/CCWDC brake Trip set...
  • Page 53 Configuration Code Code Name Name Possible settings IMPORTANT IMPORTANT Lenze Selection Info C009* Device address Only for LECOM applications C010 Minimum field {0.1Hz} 480.0 frequency C011 Maximum field frequency 820X 50.0 30.0 {0.1Hz} 480.0 821X 50.0 {0.1Hz} 480.0 (Software 2x) 30.0...
  • Page 54 Configuration Code Code Name Name Possible settings IMPORTANT IMPORTANT Lenze Selection Info C016 V C016 setting 820X {1 %} * depends on the unit 821X/822X {1 %} / 824X C017 Threshold Q {0.1Hz} 480.0 C018 Chopper § § frequency 821X/822X/824...
  • Page 55 Configuration Code Code Name Name Possible settings IMPORTANT IMPORTANT Lenze Selection Info C038 JOG value 2 {1Hz} C039 JOG value 3 {1Hz} C050* Output Only display frequency C052* Motor voltage Only display C054* Motor current Only display C056* Controller load...
  • Page 56 Configuration Code Code Name Name Possible settings IMPORTANT IMPORTANT Lenze Selection Info C099* Software version Only display 820X 82 1x (Software 1x) 821X 82 2x (Software 2x) 82 1x (Software 1x) 822X/824X 82 1x (Software 1x) C105 Deceleration time quick stop 5.00...
  • Page 57 Configuration Code Code Name Name Possible settings IMPORTANT IMPORTANT Lenze Selection Info C117 Function relay § Ready for operation 822X/824X TRIP fault message Motor is running Motor is running / CW rotation Motor is running / CCW rotation Field frequency f...
  • Page 58 {1s} Auto-TRIP-Reset C178* Operating time Only display C179* Mains switch-on Only display time C377 Gain Zk-voltage Should only detection be changed by the Lenze 822X/824X Service! C500* Display factor application datum numerator 821X/822X/824 2000 1 25000 C501* Display factor for process...

  • Page 59: Troubleshooting And Fault Elimination

    Troubleshooting and fault elimination 8 Troubleshooting and fault elimination Faults are immediately indicated via the display or status information (chapter 8.1). The fault can be analysed by using the history buffer (chapter 8.2) and the list in chapter 8.3. The list helps you with the elimination of faults.

  • Page 60: Maloperation Of The Drive

    Troubleshooting and fault elimination 8.1.3 Maloperation of the drive Maloperation Possible causes Motor does not rotate DC-bus voltage too low (red LED is blinking every 0.4 s; message LU is displayed) Controller inhibited (green LED is blinking, display of the operating module: OFF, STOP or AS_LC) Setpoint = 0 DC braking active...

  • Page 61: Fault Indications

    No fault External fault (TRIP-Set) A digital input assigned to the Check external encoder TRIP-Set function has been activated Internal fault Contact Lenze Undervoltage DC-bus voltage too low Check mains voltage Check supply module Short circuit Short circuit Find out cause of short circuit; check...
  • Page 62 Troubleshooting and fault elimination Display Fault Cause Remedy Heat sink temperature is Ambient temperature Allow controller to cool and ensure higher than the value set ˜ ˜ > + 40 C or + 50 ventilation in the controller Check the ambient temperature in the control cabinet Heat sink very dirty Clean heat sink...

  • Page 63: Reset Of Fault Indications

    TRIP. Note! If the TRIP source is still active, the TRIP cannot be reset. Code Name Possible settings IMPORTANT Lenze Selection Info § C170 TRIP-reset TRIP-reset by pressing the STP selection key or a LOW signal at ctrl.
  • Page 64 Troubleshooting and fault elimination Function You can select whether the active fault is to be reset automatically or manually. Auto-Trip reset does not reset all faults automatically. Activation C170 = -0-: Manual TRIP-reset STP key LOW signal at terminal 28 C170 = -1-: Auto-Trip reset resets the following fault messages after the time set under C171: - OC3 (overload during acceleration)

  • Page 65: Accessories (Overview)

    Accessories 9 Accessories (Overview) 9.1 Accessories for all types Name Order number 8201BB operating module EMZ8201BB Diagnosis terminal (2.5 m cable) EMZ8272BB-V001 Diagnosis terminal (5.0 m cable) EMZ8272BB-V002 Diagnosis terminal (10 m cable) EMZ8272BB-V003 Digital display EPD203 Setpoint potentiometer ERPD0001k0001W Rotary button for potentiometer ERZ0001 Scale for potentiometer...

  • Page 66: Software

    Accessories 9.2 Software Name Order number PC program for Global Drive controllers ESP-GDC 1 9.3 Type-specific accessories Name Order number 8201 8202 8203 8204 E.l.c.b. EFA1C10A EFA1C16A EFA1C20A EFA1C20A Fuse EFSM-0100ASB EFSM-0150ASB EFSM-0200ASC EFSM-0200ASC Fuse holder EFH30001 EFH30001 EFH30001 EFH30001 Mains filter type “A”...

  • Page 67: Index

    Index Index Connection Control, Connection diagram, 4-12 Acceleration times, 5-6 Control cables, 4-10 Adapt the motor, 5-8 Mains, 4-7 Application, as directed, 1-3 Motor, 4-7 Power, Circuit diagram, 4-9 Application conditions, 2-1 Connection diagram Applications as directed, 1-3 Control connections, 4-12 Approvals, 2-1 Power connection, 4-9 Assembly...
  • Page 68 Index Fault analysis, 8-2 Fault messages, 8-3 Deceleration times, 5-6 Reset, 8-5 Definitions of terminology used, 1-1 Field frequency Maximum, 5-4 Degree of pollution, 2-1 Minimum, 5-4 Dimensions Frequency inverter. Siehe Controller 8202-V002 reduced assembly depth, 4-4 Fuses, Single drives, 3-4 820X with fixing rail, 4-3 Controller, 3-4 150 % overload, 3-4...
  • Page 69 Index Operation, Status display, 8-1 Operator’s safety, 2-4 Jumper, Analog setpoint selection, 4-11 Outputs, Analog, 4-11 Overspeeds, 2-4 Labelling, Controller, 1-3 LED, 8-1 Packaging, 2-1 Legal regulations, 1-3 Power connections, 4-7 Liability, 1-4 Rated data, Types 8201-8204, 150 % Mains connection, 4-7 overload, 3-2 Mains-voltage compensation, 5-11, 5-13 Relay output, 4-11...
  • Page 70 Index Technical data, 2-1 Unit protection, 2-4 General data/application conditions, 2-1 Temperature ranges, 2-1 Transport, storage, 2-1 Variant, V002, 4-4 TRIP, 8-5 Vibration resistance, 2-1 Troubleshooting, 8-1 Display at the operating module , 8-1 Vmin setting, Drives with special motors, Fault analysis using the history buffer , 8-2 5-12 Fault indication, 8-3...

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