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Elettronica Santerno SINUS K User Manual

Full digital inverter
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Updated 13/04/07
R. 07
•
This manual is integrant and essential to the product. Carefully read the instructions contained herein as they
provide important hints for use and maintenance safety.
•
This device is to be used only for the purposes it has been designed to. Other uses should be considered improper
and dangerous. The manufacturer is not responsible for possible damages caused by improper, erroneous and
irrational uses.
•
Elettronica Santerno is responsible for the device in its original setting.
•
Any changes to the structure or operating cycle of the device must be performed or authorized by the Engineering
Department of Elettronica Santerno.
•
Elettronica Santerno assumes no responsibility for the consequences resulting by the use of non-original spare-
parts.
•
Elettronica Santerno reserves the right to make any technical changes to this manual and to the device without
prior notice. If printing errors or similar are detected, the corrections will be included in the new releases of the
manual.
•
Elettronica Santerno is responsible for the information contained in the original version of the Italian manual.
•
The information contained herein is the property of Elettronica Santerno and cannot be reproduced. Elettronica
Santerno enforces its rights on the drawings and catalogues according to the law.
• 15P0095B2 •
SINUS K
FULL DIGITAL INVERTER
USER MANUAL

-Installation Instructions-

Elettronica Santerno S.p.A.
Via G. Di Vittorio, 3 - 40020 Casalfiumanese (Bo) Italy
Tel. +39 0542 668611 - Fax +39 0542 668622
www.elettronicasanterno.it sales@elettronicasanterno.it
E n g l i s h

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Summary of Contents for Elettronica Santerno SINUS K

  • Page 1: Installation Instructions

    • Elettronica Santerno reserves the right to make any technical changes to this manual and to the device without prior notice. If printing errors or similar are detected, the corrections will be included in the new releases of the manual.

  • Page 2: Table Of Contents

    Installation and Wiring of a Modular Inverter (S65) ..............50 7.6. Standard Mounting and Fixing Points for IP54 Stand-Alone Models (S05-S30) ......51 7.7. Through-panel Assembly and Fixing Points (Stand-Alone Models S05-S50)........52 7.7.1. SINUS K S05 ........................52 7.7.2. SINUS K S10 ........................53 7.7.3. SINUS K S12 ........................54 7.7.4.
  • Page 3 SINUS K INSTALLATION INSTRUCTIONS 8.2.1. Connection of Modular Inverters ..................62 8.2.2. External Connections for S64 Modular Inverters ..............63 8.2.3. 12-Phase Connection for Modular Inverters .................64 8.2.4. Internal Connections for Modular Inverters (S65)..............65 8.2.5. Internal Connections for S64 Modular Inverters..............72 8.3.
  • Page 4 SINUS K INSTALLATION INSTRUCTIONS 13.1.2.2. 75 Ohm/1300W Model ...................118 13.1.2.3. Models from 1100W to 2200W ................119 13.1.2.4. 4kW-8kW-12kW Models ..................120 13.1.2.5. Models of IP23 Box Resistors, 4kW-64kW ..............121 13.2. Braking Unit BU200 .........................123 13.2.1. Inspection upon Receipt of the Goods................123 13.2.1.1.

  • Page 5: Figures

    Figure 11: Mounting the accessories for the through-panel assembly of SINUS K S05........52 Figure 12: Fixing points of the mounting panel for the through-panel assembly of SINUS K S05.....52 Figure 13: Mounting the accessories for the through-panel assembly of SINUS K S10........53 Figure 14: Fixing points of the mounting panel for the through-panel assembly of SINUS K S10.

  • Page 6: Tables

    Figure 89: Configuring the dip-switch for RS485 terminator................175 Figure 90: Wiring inverters with optional “LOC-0-REM” key selector switch and emergency push-button..177 Figure 91: Disturbance sources in a power drive system equipped with an inverter........182 Figure 92: Toroid filter connection for Sinus K....................185 0.3. Tables Table 1: Max.

  • Page 7: General Description

    Inverters manufactured by ELETTRONICA SANTERNO fully meet these adjustment and control requirements and incorporate a wide range of the latest technologies to fit any application requirement.

  • Page 8: Feature List

    SINUS K 0025 4TBA2X2 22kW 18.5kW 15kW 11kW • Built-in filters for the whole SINUS K range in compliance with regulation EN61800-3, issue 2 concerning emission limits. • No line contactor included. The new hardware configuration is standard supplied with...

  • Page 9: Equipment Description And Installation

    1.2. EQUIPMENT DESCRIPTION AND INSTALLATION The inverters of the SINUS K series are full digital inverters for the speed regulation of asynchronous motors up to 900 kW. The inverters of the SINUS K series are designed and manufactured in Italy by the technicians of Elettronica Santerno;...

  • Page 10: Caution Statements

    SINUS K INSTALLATION INSTRUCTIONS CAUTION STATEMENTS This section contains safety statements. The non-observance of these safety instructions may cause serious injury or death and equipment failure. Carefully read the instructions below before installing, starting and operating the inverter. Only competent personnel must carry out the equipment installation.
  • Page 11 SINUS K INSTALLATION INSTRUCTIONS Do not connect supply voltages exceeding the equipment rated voltage to avoid damaging the internal circuits. If the inverter is installed in environments exposed to flammable and/or explosive substances (zones AD according to standards IEC 64-2), please refer to IEC 64-2, EN 60079-10 and related standards.

  • Page 12: Inspection Upon Receipt Of The Goods

    SINUS K INSTALLATION INSTRUCTIONS INSPECTION UPON RECEIPT OF THE GOODS Make sure the equipment is not damaged and it complies with the equipment you ordered by referring to the nameplate located on the inverter front part. The inverter nameplate is described below. If the equipment is damaged, contact the supplier or the insurance company concerned.

  • Page 13: Inverter Nameplate

    SINUS K INSTALLATION INSTRUCTIONS 3.1. INVERTER NAMEPLATE Figure 1: Example of a nameplate placed on a 2T SINUS K inverter. Figure 2: Example of a nameplate placed on a 4T SINUS K inverter. 13/191...

  • Page 14: Using The Display/Keypad

    INSTRUCTIONS USING THE DISPLAY/KEYPAD For the parameter programming and view a display/keypad is located on the front part of SINUS K inverters. The keypad includes 4 LEDs, an LCD display and 8 function keys. During the inverter operation, the display shows the parameter values, the alarm messages (if any) and the value of the measures processed by the inverter.

  • Page 15: Adjusting The Display Contrast

    SINUS K INSTALLATION INSTRUCTIONS The keypad includes the following keys: PROG, ↓, ↑, SAVE, MENU, RESET, START, STOP. They are detailed below. allows entering and quitting the menus and submenus and enables altering the inverter PROG parameters (when switching from parameter display to parameter programming, the cursor starts flashing);...

  • Page 16: Startup Procedures

    SINUS K INSTALLATION INSTRUCTIONS STARTUP PROCEDURES The startup procedures described below relate to commands sent via terminal board (factory setting). For the configuration of the terminal board, see the Control Terminals section. Before changing the equipment connections, shut off the inverter and wait at least DANGER 5 minutes to allow for the discharge of the capacitors in the DC-link.

  • Page 17: Startup Procedure For Vtc Software

    SINUS K INSTALLATION INSTRUCTIONS 5.2. Startup Procedure for VTC Software The startup procedures described below relate to commands sent via terminal board (factory setting). For the configuration of the terminal board, see the Control Terminals section. 1) Connection: Follow the instructions stated in the CAUTION STATEMENTS and WIRING sections.

  • Page 18: Technical Specifications

    S30 = 0.8÷10kHz (5kHz for 0150 and 0162) • Operating atmospheric pressure ≥S40 = 0.8÷4kHz 86÷106kPa • Cooling system: VTC SW: 5kHz Forced air-cooling For DC supply of S60 and S65 SINUS K inverters, please contact Elettronica NOTE Santerno. 18/191...
  • Page 19 SINUS K INSTALLATION INSTRUCTIONS IFD – LIFT = Space vector modulation (vectorial modulation PWM with V/f curve) Control method VTC = Vector Torque Control (Sensorless vectorial, direct torque control) Digital reference: 0.1Hz (IFD SW); 1 rpm (VTC SW) Frequency/speed setting...

  • Page 20: Choosing The Product

    The tables contained in the following pages state the power of the motors to be connected to SINUS K inverters based on their overload classes. NOTE The data items contained in the tables below apply to standard 4-pole motors.

  • Page 21: Technical Sheet For Light Applications: Overload Up To 120

    SINUS K INSTALLATION INSTRUCTIONS 6.1.1. LIGHT A ECHNICAL HEET FOR PPLICATIONS VERLOAD 120% UP TO Ipeak Applicable Motor Power Inom Imax (3 s.) Size Inverter Model 200-240Vac 380-415Vac 440-460Vac 480-500Vac SINUS 0005 10.2 10.5 11.5 SINUS 0007 11.2 11.2 12.5 11.8...
  • Page 22 SINUS K INSTALLATION INSTRUCTIONS (continued) SINUS 0312 160 220 280 380 315 430 355 480 SINUS 0366 185 250 315 430 375 510 400 550 SINUS 0399 200 270 375 510 400 550 450 610 SINUS 0457 250 340 400 550...

  • Page 23: Technical Sheet For Standard Applications: Overload Up To 140

    SINUS K INSTALLATION INSTRUCTIONS 6.1.2. STANDARD A ECHNICAL HEET FOR PPLICATIONS 140% VERLOAD UP TO Applicable Motor Power Ipeak Size Inverter Model Inom Imax 200-240Vac 380-415Vac 440-460Vac 480-500Vac (3 s.) SINUS 0005 10.5 11.5 SINUS 0007 2.2 10.2 12.5 13.5 SINUS 0008 11.2...
  • Page 24 SINUS K INSTALLATION INSTRUCTIONS (continued) SINUS 0312 150 315 430 330 450 SINUS 0366 160 355 480 375 510 SINUS 0399 185 375 510 400 550 SINUS 0457 220 450 610 500 680 1056 SINUS 0524 260 500 680 560 770...

  • Page 25: Technical Sheet For Heavy Applications: Overload Up To 175

    SINUS K INSTALLATION INSTRUCTIONS 6.1.3. HEAVY A ECHNICAL HEET FOR PPLICATIONS 175% VERLOAD UP TO Applicable Motor Power Ipeak Size Inverter Model Inom Imax 200-240Vac 380-415Vac 440-460Vac 480-500Vac (3 s.) SINUS 0005 10.5 11.5 SINUS 0007 1.8 2.5 5.5 7.5 12.5...
  • Page 26 SINUS K INSTALLATION INSTRUCTIONS (continued) SINUS 0312 132 180 220 300 260 350 300 400 SINUS 0366 150 200 250 340 300 400 330 450 SINUS 0399 160 220 280 380 330 450 355 480 SINUS 0457 200 270 315 430...

  • Page 27: Technical Sheet For Strong Applications: Overload Up To 200

    SINUS K INSTALLATION INSTRUCTIONS 6.1.4. STRONG A ECHNICAL HEET FOR PPLICATIONS 200% VERLOAD UP TO Applicable Motor Power Ipeak Size Inverter Model Inom Imax 200-240Vac 380-415Vac 440-460Vac 480-500Vac (3s) SINUS 0005 10.5 11.5 SINUS 0007 1.5 12.5 13.5 SINUS 0008 1.8 19.5...
  • Page 28 SINUS K INSTALLATION INSTRUCTIONS (continued) SINUS 0312 110 150 185 250 220 300 SINUS 0366 120 165 200 270 250 340 SINUS 0399 132 180 220 300 260 350 SINUS 0457 160 220 280 380 330 450 1056 SINUS 0524 185 250...

  • Page 29: Carrier Frequency Setting (Ifd Sw Only) And Peak Currents

    SINUS K INSTALLATION INSTRUCTIONS 6.2. Carrier Frequency Setting (IFD SW only) and Peak Currents The continuous current generated by the inverter in continuous operation type S1 at 40°C depends on carrier frequency. Do not exceed the carrier values stated in the table below. Carrier values may be set through parameters C01 and C02, Carrier Frequency submenu.
  • Page 30 SINUS K INSTALLATION INSTRUCTIONS (continued) 12.8 12.8 0060 12.8 0067 12.8 12.8 12.8 0074 12.8 12.8 12.8 0086 12.8 12.8 0113 0129 0150 0162 0179 0200 0216 1033 0250 1153 0312 1444 0366 1589 0399 1733 1056 0457 2078 1152...

  • Page 31: Operating Temperatures Based On Application Classes

    APPLICATION CLASSES The operating temperature of the inverters of the SINUS K series is maximum 40 °C at rated current and can reach max. 50 °C if the operating current is reduced. The operating temperature of some SINUS K models can even exceed 40 °C at rated current.
  • Page 32 SINUS K INSTALLATION INSTRUCTIONS (continued) 0179 0200 0216 0250 0312 0366 0399 0457 0524 0598 0748 0831 32/191...

  • Page 33: Installing The Equipment

    INSTRUCTIONS INSTALLING THE EQUIPMENT The inverters of the SINUS K series - degree of protection IP20 – are capable of being installed inside another enclosure. Only models with degree of protection IP54 may be wall-mounted. The inverter must be installed vertically.

  • Page 34: Air Cooling

    Δt is the difference between the temperature measured inside the enclosure and the ambient temperature (temperatures are expressed in degrees centigrade). Example: Enclosure with no other component installed, SINUS K 0113. Total power to be dissipated within the enclosure Pti: generated by the inverter...

  • Page 35: Size, Weight And Dissipated Power

    SINUS K INSTALLATION INSTRUCTIONS 7.3. Size, Weight and Dissipated Power 7.3.1. IP20 IP00 STAND-ALONE M (S05-S60) 2T ODELS LASS Power Dissipated at Size MODEL Inom. SINUS K 0007 SINUS K 0008 SINUS K 0010 SINUS K 0013 SINUS K 0015...

  • Page 36: Ip20 And Ip00 Stand-Alone Models (S05 - S60) 4T Class

    SINUS K INSTALLATION INSTRUCTIONS 7.3.2. IP20 IP00 STAND-ALONE M (S05 – S60) ODELS 4T C LASS Power Dissipated at Size MODEL Inom. SINUS K 0005 SINUS K 0007 SINUS K 0009 SINUS K 0011 SINUS K 0014 SINUS K 0016 10.5...

  • Page 37: Modular Ip00 Stand-Alone Models (S65)

    Version with integrated control unit; • Version with integrated auxiliary power supply unit (to be used for Sinus K models which are not equipped with the feeder module—S64). Match the elements above to obtain the proper inverter dimensioning for your application.
  • Page 38 SINUS K INSTALLATION INSTRUCTIONS b) Inverter modules and supply modules Configuration: power supply delivered from the mains Power dissipated at Modules Dimensions Weight Inom LxHxD LxHxD 0598 2T-4T 2.25 9.75 230x1400x480 980x1400x560 110 110 440 0748 2T-4T 2.75 10.75 0831 2T-4T 12.9...
  • Page 39 SINUS K INSTALLATION INSTRUCTIONS d) Inverter modules only Configuration: inverter powered directly from a DC power supply source. Power Dissipated Modules Dimensions Weight at Inom LxHxD LxHxD 0598 2T-4T 230x1400 730x1400 0748 2T-4T 2.75 8.25 x480(*) x560 0831 2T-4T (*) When housing the control unit or the auxiliary power supply unit, the module depth is 560 mm.

  • Page 40: Ip54 Stand-Alone Models (S05-S30) 2T Class

    SINUS K INSTALLATION INSTRUCTIONS 7.3.4. IP54 STAND-ALONE M (S05-S30) 2T C ODELS LASS Power Dissipated at Size MODEL Inom. SINUS K 0007 15.7 SINUS K 0008 15.7 SINUS K 0010 15.7 SINUS K 0013 15.7 SINUS K 0015 15.7 SINUS K 0016 15.7...

  • Page 41: Ip54 Stand-Alone Models (S05-S30) 4T Class

    SINUS K INSTALLATION INSTRUCTIONS 7.3.5. IP54 STAND-ALONE MODELS (S05-S30) 4T C LASS Power Dissipated at Size MODEL Inom. SINUS K 0005 15.7 SINUS K 0007 15.7 SINUS K 0009 15.7 SINUS K 0011 15.7 SINUS K 0014 15.7 SINUS K 0016 22.3...

  • Page 42: Ip54 Box Models (S05-S20) 2T Class

    SINUS K INSTALLATION INSTRUCTIONS 7.3.6. IP54 BOX MODELS (S05-S20) 2T C LASS Wgt Power Dissipated at Inom. Size MODEL mm mm mm SINUS BOX K 0007 27.9 SINUS BOX K 0008 27.9 SINUS BOX K 0010 27.9 S05B 400 600 250...

  • Page 43: Ip54 Box Models (S05-S20) 4T Class

    SINUS K INSTALLATION INSTRUCTIONS 7.3.7. IP54 BOX MODELS (S05-S20) 4T C LASS Power Dissipated at Size MODEL Inom. SINUS BOX K 0005 27.9 SINUS BOX K 0007 27.9 S05B SINUS BOX K 0009 400 600 27.9 SINUS BOX K 0011 27.9...

  • Page 44: Ip24 - Ip54 Cabinet Models (S15-S65)

    SINUS K INSTALLATION INSTRUCTIONS 7.3.8. IP24 - IP54 CABINET M (S15-S65) ODELS Power Weight Dissipated at Size MODEL Voltage Class Inom. S15C SINUS CABINET K 0049 2T-4T 2000 SINUS CABINET K 0060 1050 SINUS CABINET K 0067 1250 S20C 2T-4T...

  • Page 45: Standard Mounting And Fixing Points For Ip20 And Ip00 Stand-Alone Models (S05-S60)

    SINUS K INSTALLATION INSTRUCTIONS 7.4. Standard Mounting and Fixing Points for IP20 and IP00 Stand-Alone Models (S05-S60) Fixing Points (mm) (Standard Mounting) SINUS K Size Fastening Screws 12.5 12.5 M8-M10 1238 M10-M12 Figure 4: Fixing points for STAND-ALONE models from S05 to S50 included.

  • Page 46: Figure 5: Fixing Points For Stand-Alone Models (S60)

    SINUS K INSTALLATION INSTRUCTIONS Size S60 has an IP00 open cabinet and can be installed only inside the equipment enclosure. Figure 5: Fixing points for stand-alone models (S60). 46/191...

  • Page 47: Standard Mounting And Fixing Points For Ip00 Modular Stand-Alone Models (S64-S65)

    SINUS K INSTALLATION INSTRUCTIONS 7.5. Standard Mounting and Fixing Points for IP00 Modular Stand–Alone Models (S64-S65) High-power inverters include single function modules. Their control unit may be installed separately or inside a module. Mounting options are shown below: a) Control unit integrated into the inverter...

  • Page 48: Figure 6: Fixing Points For Modular Units

    SINUS K INSTALLATION INSTRUCTIONS Supply Module Inverter Module Inverter Module with Control Unit Figure 6: Fixing points for modular units. Figure 7: Fixing points for stand-alone control unit. 48/191...

  • Page 49: Figure 8: Installation Example Of A Sinus K S64 – S65

    SINUS K INSTALLATION INSTRUCTIONS Figure 8: Installation Example of a SINUS K S64 – S65. 49/191...

  • Page 50: Installation And Wiring Of A Modular Inverter (S65)

    SINUS K INSTALLATION INSTRUCTIONS 7.5.1. NSTALLATION AND IRING OF A ODULAR NVERTER (S65) Figure 9: S65 inverter installed inside an enclosure. 50/191...

  • Page 51: Standard Mounting And Fixing Points For Ip54 Stand-Alone Models (S05-S30)

    SINUS K INSTALLATION INSTRUCTIONS 7.6. Standard Mounting and Fixing Points for IP54 Stand-Alone Models (S05-S30) Fixing Points (mm) (Standard Mounting) SINUS K (IP54) Fastening Screws S10/S12 602.5 Figure 10: Fixing points for IP54 SINUS K. 51/191...

  • Page 52: Through-Panel Assembly And Fixing Points (Stand-Alone Models S05-S50)

    M4 for the inverter mounting and two slots (142 x 76 mm and 142 x 46 mm) for the air-cooling of the power section. Figure 12: Fixing points of the mounting panel for the through-panel assembly of SINUS K S05. 52/191...

  • Page 53: Sinus K S10

    (218 x 420 mm) as well as the equipment side view with two air flows (air flow “A” for the control section and air flow “B” for the power section). Figure 14: Fixing points of the mounting panel for the through-panel assembly of SINUS K S10. 53/191...

  • Page 54: Sinus K S12

    (5) M4 self-forming screws (see Figure 15: Fittings for the through-panel assembly for SINUS K S12.). Figure 15: Fittings for the through-panel assembly for SINUS K S12.

  • Page 55: Sinus K S15-S20-S30

    7.7.4. SINUS K S15-S20-S30 No additional mechanical component is required for the through-panel assembly of these three SINUS K sizes. The piercing template shown in the figure below is to be made on the mounting panel. Measures are shown in the table.

  • Page 56: Sinus K S40

    The figure also shows the side view of the equipment through-panel assembly. The air flows and the front and rear projections are highlighted as well (with relevant measures). Figure 19: Through-panel assembly and fixing points for SINUS K S40. 56/191...

  • Page 57: Sinus K S50

    The figure also shows the side view of the through-panel assembly of the equipment. The air flows and the front and rear projections are highlighted as well (with relevant measures). Figure 21: Through-panel assembly and fixing points for SINUS K S50. 57/191...

  • Page 58: Connections To Control Terminals And Power Terminals (Ip20/Ip00)

    SINUS K INSTALLATION INSTRUCTIONS 7.8. Connections to Control Terminals and Power Terminals (IP20/IP00) To access to the control terminals, remove the cover by removing its fastening screws (see figure below). Figure 22: Access to the control terminals and power terminals.

  • Page 59: Connections To Control Terminals And Power Terminals (Ip54 Models)

    SINUS K INSTALLATION INSTRUCTIONS 7.9. Connections to Control Terminals and Power Terminals (IP54 Models) To reach the control terminals and power terminals, remove the front panel by removing its fastening screws. The following can be accessed: - control terminals, - power terminals, - serial interface connector.

  • Page 60: Wiring

    SINUS K INSTALLATION INSTRUCTIONS WIRING Before changing the equipment connections, shut off the inverter and wait at least 5 minutes to allow for the discharge of the capacitors in the DC-link. DANGER Use only B-type differential circuit breakers. Connect the power supply line to supply terminals only. The connection of the power supply line to any other terminal will damage the inverter.

  • Page 61: Wiring Diagram (S05-S60)

    Please refer to the OPTIONAL INPUT-OUTPUT REACTORS section for the NOTE applicable input and output reactors. When ordering Sinus K drives ranging from S20 to S60, please state if reactors are to be installed on the equipment.. The wiring diagram relates to factory-setting. Please refer to the Power Terminal NOTE Lay-out section for the ID numbers of the wiring terminals.

  • Page 62: Wiring Diagram For Modular Models (S65)

    SINUS K INSTALLATION INSTRUCTIONS 8.2. Wiring Diagram for Modular Models (S65) 8.2.1. ONNECTION OF ODULAR NVERTERS Figure 24: External connections for modular inverters. In case of fuse line protection, always install the fuse failure detection device, CAUTION which must disable the inverter to avoid single-phase operation of the equipment.

  • Page 63: External Connections For S64 Modular Inverters

    SINUS K INSTALLATION INSTRUCTIONS 8.2.2. S64 M XTERNAL ONNECTIONS FOR ODULAR NVERTERS Figure 25: External connections for S64 modular inverters. The capacitors inside the DC power supply unit must always be precharged. CAUTION Failure to do so will damage the inverter as well as its power supply unit.

  • Page 64: 12-Phase Connection For Modular Inverters

    SINUS K INSTALLATION INSTRUCTIONS 8.2.3. 12-P HASE ONNECTION FOR ODULAR NVERTERS A 12-phase connection allows reducing current harmonics in the inverter supply line. The basic wiring diagram of a 12-phase connection is shown below. Figure 26: Lay-out of a 12-phase connection.

  • Page 65: Internal Connections For Modular Inverters (S65)

    SINUS K INSTALLATION INSTRUCTIONS 8.2.4. (S65) NTERNAL ONNECTIONS FOR ODULAR NVERTERS The following connections are needed: N. 2 power connections to 60*10mm copper bar between supply and inverter modules. N. 4 connections with 9-pole screened cable (S65). Type of cable: screened cable n.

  • Page 66: Figure 28: Double Optical Fibre Connector

    SINUS K INSTALLATION INSTRUCTIONS N° 4 optical fibre connections, 1 mm, standard double plastic material (typical attenuation: 0.22dB/m) with Agilent HFBR-4516 connectors. Figure 28: Double optical fibre connector. Connections required: from control unit to arm U driver board (IGBT top and bottom control signals)
  • Page 67 SINUS K INSTALLATION INSTRUCTIONS INTERNAL CONNECTIONS FOR S65 Signal Type of Cable Component Board Connector Component Board Connector connection marking Control signals, 9-pole Control unit ES842 Supply module 1 ES840 C-PS1 supply module 1 screened cable Control signals, 9-pole Control unit...

  • Page 68: Figure 29: Internal Connections For Sinus K S65

    SINUS K INSTALLATION INSTRUCTIONS The diagram below illustrates the connections required for the components of modular inverters. Figure 29: Internal connections for SINUS K S65. 68/191...

  • Page 69: Figure 30: Es840 Supply Control Board

    SINUS K INSTALLATION INSTRUCTIONS Do the following to obtain the internal connections: 1) Gain access to boards ES840, ES841 and ES843. Board ES840 is located on the front part of the supply module; boards ES81 and ES843 are located on the front part of each inverter module. Remove the front covers made of Lexan by loosening the cover fastening screws;...

  • Page 70: Figure 32: Es843 Inverter Module

    SINUS K INSTALLATION INSTRUCTIONS DATA OP1 IGBT STATUS OP2 VB Figure 32: ES843 inverter module. 2) Gain access to ES842 located on the control unit; do the following: a) Remove the keypad (if fitted) (see the Remoting the Keypad section)

  • Page 71: Figure 33: Es842 Control Unit

    SINUS K INSTALLATION INSTRUCTIONS CN3: POWER SUPPLY 2 SIGNAL CONNECTOR CN2: POWER SUPPLY 1 SIGNAL CONNECTOR OP2: VB OP6: IGBT STATUS W OP5: IGBT FAULT W CN8: INVERTER MODULE W SIGNAL CONNECTOR OP8 OP9: GATE W OP11: IGBT STATUS V...

  • Page 72: Internal Connections For S64 Modular Inverters

    SINUS K INSTALLATION INSTRUCTIONS 8.2.5. S64 M NTERNAL ONNECTIONS FOR ODULAR NVERTERS The following links are required: N. 2 power connections with 60*10mm copper bar between the inverter arms in order to deliver DC voltage. N. 4 connections with a 9-pole shielded cable.

  • Page 73: Figure 35: Double Optical-Fibre Connector

    SINUS K INSTALLATION INSTRUCTIONS The following links are required: from control unit to driver board in inverter arm U (U fault signal) from control unit to driver board in inverter arm V (V fault signal) from control unit to driver board in inverter arm W (W fault signal) from control unit to bus voltage detecting board installed on inverter arm U (VB signal) N.
  • Page 74 SINUS K INSTALLATION INSTRUCTIONS INTERNAL CONNECTIONS FOR S64 Type of Cable Signal Component Board Connector Component Board Connector Connection Marking inverter arm auxiliary control signals for with 9-pole shielded power auxiliary power CPS-1 control unit ES842 auxiliary cable supply supply...

  • Page 75: Figure 36: Internal Wiring For S64 Inverters

    SINUS K INSTALLATION INSTRUCTIONS Make sure that links are correct, as incorrect links cause the inverter CAUTION malfunctioning. CAUTION NEVER power the inverter when the optical-fibre connectors are not connected. The figure below shows the links required for the components of the modular inverter.

  • Page 76: Control Terminals

    SINUS K INSTALLATION INSTRUCTIONS 8.3. Control Terminals Term. Name Description I/O Features Jumpers IFD parameters VTC Parameters 0V for main reference. Control board zero volt VREF1 Input for voltage Vref1 main Vmax: ±10V, P16, P17, P18, P16, P17, P18, Ω...
  • Page 77 SINUS K INSTALLATION INSTRUCTIONS 0V for auxiliary analog input. Control board zero volt. IREF Input for main current reference Ω P19, P20, P19, P20, Rin: 100 (0 20mA, 4÷20mA). C29, C30: C23, C24: Resolution: 10 bits (factory setting: (factory setting: not used).

  • Page 78: Grounding The Shield Of Signal Screened Cables

    CREENED ABLES All inverters of the SINUS K series are provided with a cable support bar including cable-glands connected to the inverter grounding. The cable support bar is located next to the control terminals. The cable-glands fasten the cables preventing them from disconnecting from the terminals; they also connect the shield of the signal screened cables to the grounding system.

  • Page 79: Power Terminals

    SINUS K INSTALLATION INSTRUCTIONS 8.4. POWER TERMINALS 8.4.1. S05 – S50 OUT OF THE OWER TERMINALS FOR SYMBOLS 41/R – 42/S – 43/T Inputs for three-phase supply (the phase sequence is not important) 44/U – 45/V – 46/W Three-phase motor outputs Link to the DC voltage positive pole.
  • Page 80 SINUS K INSTALLATION INSTRUCTIONS S30 Terminal board: 48/B 50/+ 41/R 42/S 43/T 44/U 45/V 46/W 47/+ 49/- Connect the external braking unit to terminals 50/+ and 48/B. NOTE Avoid using terminals 48 and 50 for DC power supply. S40 Terminal board:...

  • Page 81: Connecting Bars For S60 - S65

    Figure 38: Connecting bars for S60. Figure 38 shows the location and dimension of the bars connecting S60 SINUS K drives to the mains and the motor. The figure also shows the position and the wiring instructions for the built-in power supply transformer.

  • Page 82: Figure 39: Connecting Bars For S64 – S65

    INSTALLATION INSTRUCTIONS Lay-out of the auxiliary power supply terminals The auxiliary power supply terminals are provided in the Sinus K models requiring auxiliary power supply links to be used to power air-cooling systems or to power internal circuits. NAME Inverter...

  • Page 83: Grounding The Inverter And The Motor

    SINUS K INSTALLATION INSTRUCTIONS 8.4.3. ROUNDING THE NVERTER AND THE OTOR A screw nut for the grounding of the inverter frame is located next to the power terminals. The grounding screw is marked with the symbol below: Connect the inverter to a grounding system in compliance with the regulations in force. To limit disturbance and radiated interference produced by the inverter, connect the motor ground wire directly to the inverter ground.

  • Page 84: Cross Sections Of Power Connection Wire And Size Of Protection Devices

    The cross-section values given in the tables below apply to copper cables. The links between the motor and the Sinus K must have the same lengths and must follow the same paths. Use 3-phase cables where possible.

  • Page 85: Voltage Class: 2T

    SINUS K INSTALLATION INSTRUCTIONS 9.1. VOLTAGE CLASS: 2T Wire Cross- Fast Fuses Terminal section, Magnetic (700V)+ SINUS K Cross-section Mains Side and Switch Contactor Disc. Switches Model Motor Side (AWG/kcmils) (AWG/kcmils) 12.5 1.2-1.5 0007 2.5 (13AWG) 0008 1.2-1.5 0010 1.2-1.5 4 (10AWG) 0.5÷10...
  • Page 86 SINUS K INSTALLATION INSTRUCTIONS (continued) Wire Cross- Fast Fuses Terminal section, Magnetic (700V)+ SINUS K Cross-section Mains Side and Switch Contactor Disc. Switches Model Motor Side (AWG/kcmils) (AWG/kcmils) 0179 25-30 (400kcmils) 70÷240 0200 25-30 (2/0AWG÷ (400kcmils) 500kcmils) 0216 25-30 (500kcmils)

  • Page 87: Voltage Class: 4T

    SINUS K INSTALLATION INSTRUCTIONS 9.2. VOLTAGE CLASS: 4T Wire Cross- Fast Fuses Terminal section, Magnetic (700V)+ SINUS K Cross-section Mains Side and Switch Contactor Disc. Switches Model Motor Side (AWG/kcmils) (AWG/kcmils) 0005 10.5 1.2-1.5 2.5 (13AWG) 0007 12.5 1.2-1.5 0.5÷10 16.5...
  • Page 88 SINUS K INSTALLATION INSTRUCTIONS (continued) Wire Cross- Fast Fuses Terminal section, Magnetic (700V)+ SINUS K Cross-section Mains Side and Switch Contactor Disc. Switches Model Motor Side (AWG/kcmils) (AWG/kcmils) 25-30 0179 (400kcmils) 70÷240 25-30 (2/0AWG÷ 0200 (400kcmils) 500kcmils) 0216 25-30 (500kcmils)

  • Page 89: Ul-Approved Fuses - 2T Voltage Class

    9.3. UL-APPROVED FUSES – 2T VOLTAGE CLASS The UL-marked fuses for the protection of semiconductors to be used with SINUS K inverters are listed in the table below. In multiple-cable installations, just insert one fuse per phase (not one fuse per conductor). Fuses for the protection of semiconductors manufactured by other manufacturers may be used, provided that the system ratings are not exceeded and that fuses are marked as “UL R/C Special Purpose Fuses (JFHR2)”.

  • Page 90: Ul-Approved Fuses - 4T Voltage Class

    9.4. UL-APPROVED FUSES – 4T VOLTAGE CLASS The UL-marked fuses for the protection of semiconductors to be used with SINUS K inverters are listed in the table below. In multiple-cable installations, just insert one fuse per phase (not one fuse per conductor). Fuses for the protection of semiconductors manufactured by other manufacturers may be used, provided that the system ratings are not exceeded and that fuses are marked as “UL R/C Special Purpose Fuses (JFHR2)”.

  • Page 91: Input - Output Features

    SINUS K INSTALLATION INSTRUCTIONS 10. INPUT - OUTPUT FEATURES 10.1. Digital Input Features (Terminals 6 to 13) All digital inputs are galvanic insulated with respect to zero volt of the inverter control board (ES778). Consider power supply on terminals 14 and 15 before activating the inverter digital inputs.

  • Page 92: Enable (Terminal 6)

    C14 (VTC SW) is set to Kpd (command sent via keypad), the START input is disabled and its functionality is performed by the inverter remotable keypad (see the COMMANDS MENU in Sinus K’s Programming Instructions Manual). If the REV function ("reverse rotation") is active, the START input may be used only when the REV input is inactive;...

  • Page 93: Mdi-Multifunction Digital Inputs (Terminals 9 To 13)

    SINUS K INSTALLATION INSTRUCTIONS 10.1.4. MDI-M ULTIFUNCTION IGITAL NPUTS ERMINALS The programmable digital input functionality is detailed in the SINUS K’s Programming Manual. 10.1.5. M (PTC T OTOR HERMAL ROTECTION NPUT ERMINAL The inverter manages the signal sent from a thermistor (PTC) incorporated in the motor windings to obtain a hardware thermal protection of the motor.

  • Page 94: Digital Output Features

    SINUS K INSTALLATION INSTRUCTIONS 10.3. Digital Output Features An OPEN COLLECTOR output is available on terminals 24 (collector) and 25 (common terminal). The OC output is galvanically insulated from zero volt of the control board and is capable of driving a load up to 50mA with 48V power supply.

  • Page 95: Relay Outputs (Terminals 24 To 31)

    SINUS K INSTALLATION INSTRUCTIONS 10.3.1. R ELAY UTPUTS ERMINALS Two relay outputs are available: - terminals 26, 27, 28: relay RL1; reverse contact (250 VAC, 3A; 30 VDC, 3A) - terminals 29, 30, 31: relay RL2; reverse contact (250 VAC, 3A; 30 VDC, 3A) Parameters P61 (RL1 Opr) and P62 (RL2 Opr) in the Digital Output submenu affect the relay output functionality.

  • Page 96: Signals And Programming For Es778 Control Board

    SINUS K INSTALLATION INSTRUCTIONS 11. SIGNALS AND PROGRAMMING FOR ES778 CONTROL BOARD L1= +5V VBLIM=DC BUS voltage limit L2= -15V IMLIM=Current limit L4= +15V RUN=Inverter enabled J3, J4, J6 J5, J7, J8 Figure 42: Location of the jumpers on ES778 control board.

  • Page 97: Indicator Leds

    SINUS K INSTALLATION INSTRUCTIONS 11.1. Indicator Leds L3 LED, red (VBLIM): voltage limiting activation during deceleration; “on” when VDC within the equipment exceeds by 20% the rated value during dynamic braking. L5 LED, red (IMLIM): current limiting activation during acceleration or due to overload conditions; “on” if the motor current exceeds the values set in C41 and C43 (Limits submenu) during acceleration and at constant frequency (IFD SW) respectively.

  • Page 98: Figure 43: Location Of Sw1 Dip-Switch And Rs485 Connector For Sinus K S05 To S20

    INSTALLATION INSTRUCTIONS Figure 43: Location of SW1 dip-switch and RS485 connector for Sinus K S05 to S20. Sizes S30 to S60: RS485 interface connector and SW1 dip-switch are located on the inverter bottom next to the front cover of the control terminals.

  • Page 99: Serial Communications

    Figure 45: Example of multidrop and direct connection. The Sinus K is supplied with a connector which is equipped with 2 pins for each signal of the RS485 pair, thus allowing easier multidrop links with no need to connect two conductors to the same pin, and thus avoiding creating a star network, which is not recommended for this type of bus.

  • Page 100: Direct Connection

    ETWORK ONNECTION SINUS K inverters may be connected to a network through electrical standard RS485, allowing a bus-type control of each device; up to 247 inverters may be interconnected depending on the link length and baud rate. Each inverter has its own identification number, which can be set in the “Serial network” submenu as a unique code in the network connected to the PC.

  • Page 101: Figure 46: Recommended Wiring Diagram For "2-Wire" Modbus Wiring

    SINUS K INSTALLATION INSTRUCTIONS The basic wiring recommended from MODBUS-IDA association for the connection of 2-wire devices is as follows: Figure 46: Recommended wiring diagram for “2-wire” MODBUS wiring. Note that the network composed of the termination resistor and the polarization resistors is integrated into the inverter and can be activated via appropriate dip-switches.

  • Page 102: Line Terminators

    Line terminator is to be installed on the first device and the last device. In serial link 0, the terminator is selected through dip-switch SW1 for SINUS K inverters (see the Jumpers and Dip-Switches section). The line master (computer) is typically placed at the beginning or at the end of a multidrop connection; in that case, the line terminator of the farthest inverter from the master computer (or the only inverter in case of direct connection to the master computer) shall be enabled: dip-switch SW1 in position ON.

  • Page 103: Communication Ratings

    SINUS K INSTALLATION INSTRUCTIONS 12.3. Communication Ratings IFD SW VTC SW Parameters Parameters Electrical standard: RS485 Protocol: MODBUS RTU Supported functions: 03h (Read Holding Registers) 10h (Preset Multiple Registers) Device address: configurable between 1 and 247 (default address: 1) Inverter response delay:...

  • Page 104: Accessories

    ABLES From size S05 to size S30, SINUS K inverters are supplied with a built-in braking unit. The braking resistor is to be incorporated in the inverter and connected to terminal B and terminal + (see the WIRING section). For IFD SW only, the braking unit is enabled through programming parameter C57, Special Functions submenu.

  • Page 105: Braking Resistors For Applications With A Braking Duty Cycle Of 10% And 380-500Vac Supply Voltage

    SINUS K INSTALLATION INSTRUCTIONS 13.1.1.1. R A K I N G E S I S T O R S F O R P P L I C A T I O N S W I T H A R A K I N G...
  • Page 106 SINUS K INSTALLATION INSTRUCTIONS (continued) 0598 BU1440 2T-4T 0.48 1.2Ohm/64000W(*) IP23 RE4562120 0748 BU1440 2T-4T 0.48 1.2Ohm/64000W(*) IP23 RE4562120 0831 BU1440 2T-4T 0.48 2*1.6Ohm/48000W(*) IP23 2*RE4462160 (*): For the connection of BU200 and the braking resistor, please refer to the relevant section in this manual.

  • Page 107: Braking Resistors For Applications With A Braking Duty Cycle Of 20% And 380-500Vac Supply Voltage

    SINUS K INSTALLATION INSTRUCTIONS 13.1.1.2. R A K I N G E S I S T O R S F O R P P L I C A T I O N S W I T H A R A K I N G...
  • Page 108 SINUS K INSTALLATION INSTRUCTIONS (continued) 0598 BU1440 2T-4T 0.48 IP23 2*RE4562240 2*2.4Ω-64000W(***) 0748 BU1440 2T-4T 0.48 IP23 2*RE4562240 2*2.4Ω-64000W(***) 0831 BU1440 2T-4T 0.48 IP23 2*RE4562160 2*1.6Ω-64000W(***) (*): Two series-connected resistors, 3.3Ohm/8000W (**): Two parallel-connected resistors, 10Ohm/12000W (***): For the connection of BU200 and the braking resistor, please refer to the relevant section in this manual.

  • Page 109: Braking Resistors For Applications With A Braking Duty Cycle Of 50% And 380-500Vac Supply Voltage

    380-500VAC S A N D U P P L Y O L T A G E Min. Resistor to be Applied BRAKING RESISTOR WITH 50% DUTY CYCLE SINUS K Model Size Braking Unit to the BU 4T Class Ω Type...
  • Page 110 SINUS K INSTALLATION INSTRUCTIONS (continued) 0598 BU1440 2T-4T 0.48 IP23 4*RE4562120 4*1.2Ω-64000W(*) 0748 BU1440 2T-4T 0.48 4*1.2Ω-64000W(*) IP23 4*RE4562120 0831 BU1440 2T-4T 0.48 4*0.8Ω-64000W(*) IP23 4*RE4561800 (*): For the connection of BU200 and the braking resistor, please refer to the relevant section in this manual.

  • Page 111: Braking Resistors For Applications With A Braking Duty Cycle Of 10% And 200-240Vac Supply Voltage

    200-240VAC S A N D U P P L Y O L T A G E Min. Resistor to be Applied to BRAKING RESISTOR WITH 10% DUTY CYCLE SINUS K Model Size Braking Unit the BU 2T Class Ω Type...
  • Page 112 SINUS K INSTALLATION INSTRUCTIONS DANGER Braking resistors may reach temperatures higher than 200°C. Power dissipated by braking resistors may be equal to approx. 10% of the rated CAUTION power of the connected motor. Use a proper air-cooling system. Do not install braking resistors near heat-sensitive equipment or objects.

  • Page 113: Braking Resistors For Applications With A Braking Duty Cycle Of 20% And 200-240Vac Supply Voltage

    SINUS K INSTALLATION INSTRUCTIONS 13.1.1.5. R A K I N G E S I S T O R S F O R P P L I C A T I O N S W I T H A R A K I N G...
  • Page 114 SINUS K INSTALLATION INSTRUCTIONS DANGER Braking resistors may reach temperatures higher than 200°C. Power dissipated by braking resistors may be equal to approx. 20% of the CAUTION connected motor rated power. Use a proper air-cooling system. Do not install braking resistors near heat-sensitive equipment or objects.

  • Page 115: Braking Resistors For Applications With A Braking Duty Cycle Of 50% And 200-240Vac Supply Voltage

    SINUS K INSTALLATION INSTRUCTIONS 13.1.1.6. R A K I N G E S I S T O R S F O R P P L I C A T I O N S W I T H A R A K I N G...
  • Page 116 SINUS K INSTALLATION INSTRUCTIONS DANGER Braking resistors may reach temperatures higher than 200°C. Power dissipated by braking resistors may be equal to approx. 50% of the CAUTION connected motor rated power. Use a proper air-cooling system. Do not install braking resistors near heat-sensitive equipment or objects.

  • Page 117: Available Models

    SINUS K INSTALLATION INSTRUCTIONS 13.1.2. A VAILABLE ODELS The specifications given for each resistor model also include the mean power to be dissipated and the max. operating time, depending on the inverter voltage class. Based on these values, parameters C67 and C68 (IFD SW) OR C59 and C60 (VTC SW) (concerning braking features) in the Resistor Braking menu can be set up.

  • Page 118: Ohm/1300W Model

    SINUS K INSTALLATION INSTRUCTIONS Max. Duration of Mean Power that can Degree of Continuous Operation at Type be Dissipated Protection 200-240VAC (s)* 56 Ohm/350W IP55 RE2643560 100 Ohm/350W IP55 RE2644100 (*) max. value to be set for the Brake Enable parameter (C68 (IFD SW) or C60 (VTC SW)). Set Brake Disable C67 (IFD SW) or C59 (VTC SW) so as not to exceed the max.

  • Page 119: Models From 1100W To 2200W

    SINUS K INSTALLATION INSTRUCTIONS 13.1.2.3. 1100W 2200W O D E L S F R O M M 0 0 6 1 9 - 0 Figure 49: Overall dimensions and mechanical features for braking resistors from 1100W to 2200W. Max. Duration of...

  • Page 120: 4Kw-8Kw-12Kw Models

    SINUS K INSTALLATION INSTRUCTIONS 13.1.2.4. W-12 O D E L S Figure 50: Overall dimensions for 4kW, 8kW, 12kW braking resistors. Mean Max. Duration of Power that Wire Cross- Continuous Operation Degree of RESISTOR can be section (mm) (mm) (mm)

  • Page 121: Models Of Ip23 Box Resistors, 4Kw-64Kw

    SINUS K INSTALLATION INSTRUCTIONS 13.1.2.5. IP23 B W-64 O D E L S O F E S I S T O R S Eyebolts for power ratings over 24,000W included Nameplate M8 Grounding bolt Grid panel Grid panel fastening fastening...
  • Page 122 SINUS K INSTALLATION INSTRUCTIONS Max. Duration of Continuous Operation Wire Cross- (s)(*) section (mm RESISTOR Operation Operation Operation Operation (mm) (mm) (mm) (mm) (mm) (Kg) at 200- at 380- at 500- at a 660- 240Vac 500Vac 575Vac 690Vac 50Ω/4KW 710 320 375...

  • Page 123: Braking Unit Bu200

    SINUS K INSTALLATION INSTRUCTIONS 13.2. Braking Unit BU200 A braking module is available to be connected to terminals + and – (see the WIRING section) of the inverter for sizes S40 to S65. Braking modules can be used when a high braking torque is needed, particularly when a prompt braking is needed for high inertial loads (e.g.

  • Page 124: Nameplate Of Bu200

    SINUS K INSTALLATION INSTRUCTIONS 13.2.1.1. BU200 A M E P L A T E O F Figure 53: Nameplate of BU200. Numbered items in the figure above: 1. Model: BU200-braking unit 2. Voltage class: List of applicable voltage classes 3. Supply ratings 200÷800 VDC (DC supply voltage produced by the inverter terminals)

  • Page 125: Operation

    SINUS K INSTALLATION INSTRUCTIONS 13.2.2. O PERATION The basic size of the braking unit can be used with a braking resistor avoiding exceeding a max. instant current of 130 A, corresponding to a peak braking power of approx. 97.5 kW (4T class) and to an average power of 60 kW (4T class).

  • Page 126: Adjusting Trimmers

    230-500 Max. values in the table above are theoretical values for special applications CAUTION!! only; their use must be authorized by Elettronica Santerno. For standard applications, never change the factory-set rated value. Rv2 Rv3 Rv4 Rv5 Figure 55: Positions of BU200 adjusting trimmers.

  • Page 127: Indicator Leds

    SINUS K INSTALLATION INSTRUCTIONS 13.2.2.3. N D I C A T O R The indicator LEDs below are located on the front part of the braking units: OK LED Normally “on”; the equipment is running smoothly. This LED turns off due to overcurrent or power circuit failure.

  • Page 128: Installation

    SINUS K INSTALLATION INSTRUCTIONS 13.2.4. I NSTALLATION 13.2.4.1. O U N T I N G • Install vertically; • Make sure to allow a min. clearance of 5 cm on both sides and 10 cm on top and bottom; •...

  • Page 129: Mounting

    Distance between Fixing Type of Dimensions (mm) Weight (Kg) Points (mm) Screws Figure 57: Dimensions and fixing points of BU200. Elettronica Santerno reserves the right to make any technical changes to this NOTE manual and to the device without prior notice. 129/191...

  • Page 130: Wiring

    SINUS K INSTALLATION INSTRUCTIONS 13.2.4.2. I R I N G WIRING DIAGRAM The braking unit must be connected to the inverter and the braking resistor. The braking unit is connected directly to the inverter terminals (or copper bars for sizes greater than S40) of the DC output, while the braking resistor must be connected to the inverter on one side and to the braking unit on the other side.
  • Page 131 SINUS K INSTALLATION INSTRUCTIONS MASTER – SLAVE CONNECTION The Master-Slave connection must be used when multiple braking units are connected to the same inverter. An additional connection must be done between the Master output signal (terminal 8 in M1) and the Slave input signal (terminal 4 in M1);...

  • Page 132: Figure 60: Terminals In Bu200

    SINUS K INSTALLATION INSTRUCTIONS LAY-OUT OF POWER TERMINALS AND SIGNAL TERMINALS Remove the cover of the braking unit to gain access to its terminal blocks. Just loosen the four fixing screws of the cover located on the front side and on the bottom side of the braking unit.

  • Page 133: Figure 61: Max. Allowable Duty-Cycle (Depending On Ton) For The Connected Braking Resistor

    SINUS K INSTALLATION INSTRUCTIONS WIRE CROSS-SECTIONS Use 25 sqmm wires for power connection wirings and 0.5 or 1sqmm wires for signal wiring. When connecting the conductor to the braking resistor, consider that the latter can reach a temperature of 200 °C.

  • Page 134: Figure 62: Peak Power And Average Power (Depending On Ton) Dissipated To The Braking Resistor

    SINUS K INSTALLATION INSTRUCTIONS The figure below shows the value of the peak power and the average power dissipated to the braking resistor depending on the actual braking time. The selection of the resistor power depends both on the average dissipated power and on the peak power the resistor shall be capable of withstanding.

  • Page 135: Braking Unit For Modular Inverters (Bu720-Bu1440)

    SINUS K INSTALLATION INSTRUCTIONS 13.3. Braking Unit for Modular Inverters (BU720- BU1440) A braking unit to be applied to modular inverters only is available. The inverter size must be equal to S65. 13.3.1. I NSPECTION UPON ECEIPT OF THE OODS Make sure that the equipment is not damaged and that it complies with the equipment you ordered by referring to the nameplate located on the inverter front part (see figure below).

  • Page 136: Operation

    SINUS K INSTALLATION INSTRUCTIONS 13.3.2. O PERATION Each size of the braking unit can be used with a braking resistor avoiding exceeding the max. instant current stated in its specifications. The braking unit is controlled directly by the control unit. Braking units cannot be parallel-connected when applied to modular inverters.

  • Page 137: Installation

    SINUS K INSTALLATION INSTRUCTIONS 13.3.4. I NSTALLATION 13.3.4.1. O U N T I N G Install vertically; Make sure to allow a min. clearance of 2 cm on both sides and 10 cm on top and bottom; Use Lexan cable-glands to maintain degree of protection IP20.

  • Page 138: Standard Mounting

    Dimensions (mm) Fixing Points (mm) Screws (Kg) 110' 1400 Figure 64: Dimensions and fixing points of BU720-1440. Elettronica Santerno reserves the right to make any technical changes to this NOTE manual and to the device described herein without prior notice. 138/191...

  • Page 139: Wiring

    SINUS K INSTALLATION INSTRUCTIONS 13.3.4.3. I R I N G WIRING DIAGRAM a) Power unit The braking unit must be connected to the inverter and the braking resistor. The connection to the inverter is direct through 60*10mm copper plates connecting the different inverter modules.
  • Page 140 SINUS K INSTALLATION INSTRUCTIONS Wire braking resistors as stated in the tables below. Voltage class: 2T Applications with a braking duty cycle of 10% Braking Resistors Inverter Size Braking Unit Recommended Wire Cross-Section Quantity Power (W) Rating (Ohm) Mm² (Kcmils)
  • Page 141 SINUS K INSTALLATION INSTRUCTIONS Voltage class: 4T Applications with a braking duty cycle of 10% Braking Resistors Inverter Size Braking Unit Recommended Wire Cross-Section Quantity Power(W) Resistor Wiring Rating (Ohm) Mm² (Kcmils) 0598 BU1440 2T-4T 1.2Ohm 64000 120 (250) 0748 BU1440 2T-4T 1.2Ohm...

  • Page 142: Figure 66: Es841 Gate Unit Board For The Braking Unit

    SINUS K INSTALLATION INSTRUCTIONS b) Signal wiring Make sure that the control device is properly set-up when using the braking arm. CAUTION!! When ordering the inverter, always state the inverter configuration you want to obtain. Because the braking arm is controlled directly by the control device, the following links are required:...

  • Page 143: Figure 67: Wiring Points Of The Optical Fibres In Es482 Control Board

    SINUS K INSTALLATION INSTRUCTIONS OP4: BRAKING IGBT GATE COMMAND OP3: FAULT IGBT SIGNAL Figure 67: Wiring points of the optical fibres in ES482 control board. The figure below shows the internal wiring of S65 inverters provided with an integrated braking unit.

  • Page 144: Figure 68: Internal Wiring Of S65 Inverters Provided With An Integrated Braking Unit

    SINUS K INSTALLATION INSTRUCTIONS Figure 68: Internal wiring of S65 inverters provided with an integrated braking unit. 144/191...

  • Page 145: Keypad Remoting Kit

    SINUS K INSTALLATION INSTRUCTIONS 13.4. KEYPAD REMOTING KIT 13.4.1. R EMOTING THE EYPAD The REMOTING KIT is required to remote the keypad. The remoting kit includes: Plastic shell Keypad mounting plate Fastening brackets Remoting wire (length: 5 m) The cable length can be 3m or 5m (state cable length when ordering the NOTE equipment).

  • Page 146: Figure 69: Removing The Display/Keypad

    SINUS K INSTALLATION INSTRUCTIONS 3 – Fit the plastic shell in the relevant slot. 4 - Fasten the plastic shell using the brackets supplied and tighten the fastening screws. Four self-threaded screws are supplied to fasten the brackets to the mounting plate; four fastening screws are also supplied to fix the shell to the panel.

  • Page 147: Figure 70: Front View/Rear View Of The Keypad

    Never connect and disconnect the keypad when the inverter is on. Temporary CAUTION overload may lock the inverter due to alarm trip. Only use wires supplied by Elettronica Santerno for the keypad wiring. Wires with a different contactor arrangement will cause irreparable damages to the inverter and CAUTION the display/keypad.

  • Page 148: Optional Input-Output Reactors

    SINUS K INSTALLATION INSTRUCTIONS 13.5. OPTIONAL INPUT-OUTPUT REACTORS 13.5.1. I NPUT EACTOR We suggest that a three-phase inductance, or a DCBUS DC inductance be installed on the supply line to obtain the following benefits: - limit input current peaks on the input circuit of the inverter and value di/dt due to the input rectifier and to the capacitive load of the capacitors set;...
  • Page 149 SINUS K INSTALLATION INSTRUCTIONS Solving the problem Harmonic current amplitude decreases when frequency increases; as a result, reducing high-amplitude components determines the filtering of low-frequency components. The better way is to increase low-frequency impedance by installing an inductance. Power drive systems with no mains-side inductance generate larger harmonic currents than power drives which do have an inductance.

  • Page 150: Figure 72: Amplitude Of Harmonic Currents (Approximate Values)

    NOTE The ratings stated in this manual fit most applications. For special applications, please contact Elettronica Santerno’s After-sales service. For inverter sizes lower than S40 included, always use an input inductance under the following circumstances: mains instability; converters installed for DC motors;...

  • Page 151: 12-Phase Connection

    SINUS K INSTALLATION INSTRUCTIONS 13.5.2. 12- PHASE CONNECTION For >500kW drives, a 12-pulse rectifier is normally used. This suppresses the lowest harmonic current in the supply line. A 12-pulse inductance suppresses 5th and 7th harmonics; harmonics left are the 11th and the 13th, followed by the 23th, the 25th and so on, with their relevant low levels.

  • Page 152: Output Inductance

    SINUS K INSTALLATION INSTRUCTIONS 13.5.3. O UTPUT NDUCTANCE Installations requiring a longer distance between the inverter and the motor may cause overcurrent protections to frequently trip. This is due to the wire parasite capacity generating current pulses at the inverter output. This current peak may be limited by an inductance installed on the inverter output.

  • Page 153: Figure 74: Connection Of An Output Inductance

    SINUS K INSTALLATION INSTRUCTIONS Motor wiring with screened cables 2-4-6-pole MOTORS Size Up toS10 Up toS30 Up toS40 FromS40 Cable Length >80 8-10 pole MOTORS Size Up toS10 Up toS30 Up toS40 FromS40 Cable Length > 80 No output inductance is required...

  • Page 154: Applying The Inductance To The Inverters

    SINUS K INSTALLATION INSTRUCTIONS 13.5.4. A PPLYING THE NDUCTANCE TO THE NVERTERS 13.5.4.1. 2T CLASS – AC / DC INDUCTANCE INVERTER INVERTER INPUT AC 3-PHASE DC SINGLE-PHASE OUTPUT INDUCTANCE SIZE MODEL INDUCTANCE INDUCTANCE IM0126004 IM0140054 IM0126004 0007 2.0mH–11Arms 8mH-10.5Arms/12.8Apeak 2.0mH–11Arms (AC 3-phase)

  • Page 155: Class - Ac / Dc Inductance

    SINUS K INSTALLATION INSTRUCTIONS 13.5.4.2. 4T CLASS – AC / DC INDUCTANCE INVERTER INVERTER INPUT AC 3-PHASE DC SINGLE-PHASE OUTPUT INDUCTANCE SIZE MODEL INDUCTANCE INDUCTANCE IM0126004 IM0126004 0005 Not applicable 2.0mH–11Arms 2.0mH–11Arms (AC 3-phase) 0007 0009 IM0126044 IM0126044 1.27mH – 17Arms Not applicable 1.27mH–17Arms (AC 3-phase)

  • Page 156: 4T Class, Interphase Inductance

    SINUS K INSTALLATION INSTRUCTIONS When installing S40 inverters or smaller, use L2 inductance under the following circumstances: mains instability; thyristor converters, loads generating strong voltage variations at startup; power factor correction systems; mains power exceeding 500 KVA. CAUTION When installing S50 size inverters or bigger, always install line inductance, unless they are powered through a dedicated transformer.

  • Page 157: Figure 75: Mechanical Features Of An Ac 3-Phase Inductance

    SINUS K INSTALLATION INSTRUCTIONS Figure 75: Mechanical features of an AC 3-phase inductance. 157/191...

  • Page 158: Ac 3-Phase Inductance, 2T And 4T Class In Ip54 Cabinet

    SINUS K INSTALLATION INSTRUCTIONS 13.5.6. AC 3- , 2T 4T C IP54 PHASE NDUCTANCE LASS IN ABINET MECHANICAL DIMENSIONS WEIGHT LEAKAGE INVERTER INVERTER INDUCTANCE INDUCTANCE (see figure on next SIZE MODEL MODEL TYPE page) TYPE 0005 ZZ0112010 AC 3-PHASE 0007...

  • Page 159: Figure 76: Mechanical Features Of An Ac 3-Phase Inductance, 2T-4T Class In Ip54 Cabinet

    SINUS K INSTALLATION INSTRUCTIONS Figure 76: Mechanical features of an AC 3-phase inductance, 2T-4T Class in IP54 cabinet. 159/191...

  • Page 160: Es836/2 Encoder Board

    PULL outputs and single-ended NPN, PNP, PUSH- ES836/2 24VDC PULL outputs 13.6.1. E NVIRONMENTAL EQUIREMENTS Operating temperature 0 to + 50° C ambient temperature (contact Elettronica Santerno for higher ambient temperatures) Relative humidity 5 to 95% (non condensing) Max. operating altitude 4000 (a.s.l.) 160/191...

  • Page 161: Electric Specifications

    SINUS K INSTALLATION INSTRUCTIONS 13.6.2. E LECTRIC PECIFICATIONS Ratings Electric Specifications Min. Type Max. Unit Encoder supply current, + 24 V, protected with resettable fuse Electronically protected encoder supply current, +12V Electronically protected encoder supply current, +5V Adjustment range for encoder supply voltage (5V mode) Adjustment range for encoder supply voltage (12V mode) 10.3...

  • Page 162: Installing The Encoder Board On The Inverter

    4) Configure the dip-switch and the jumper located on the encoder board based on the type of encoder being used. Check that supply voltage in terminal board output is correct. 5) Turn on the inverter and set the parameters relating to the encoder feedback (see Sinus K’s Programming Instructions Manual).

  • Page 163: Encoder Board Terminals

    SINUS K INSTALLATION INSTRUCTIONS 13.6.4. E NCODER OARD ERMINALS Terminal board, pitch 3.81 mm in two separate extractable sections (6-pole and 3-pole sections) Terminal Signal Type and Features Encoder input channel A true polarity Encoder input channel A inverse polarity...

  • Page 164: Jumper For Encoder Supply

    SINUS K INSTALLATION INSTRUCTIONS Dip-switch functionality and factory-settings are detailed in the table below. Switch (factory- OFF - open ON - closed setting) SW2.1 (on) Channel B, type NPN or PNP Channel B, type Line driver or Push-Pull SW2.2 (off)

  • Page 165: Tuning Trimmer

    Zero notch connection is optional and is required only for particular software applications. However, for those applications that do not require any zero notch, NOTE its connection does not affect the inverter operation. See SINUS K’s Programming Instructions Manual for details. 165/191...

  • Page 166: Figure 81: Line Driver Or Push-Pull Encoder With Complementary Outputs

    SINUS K INSTALLATION INSTRUCTIONS ES836/2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 Encoder LINE DRIVER or PUSH-PULL with EncEEncod complementary outputs P000590-B Figure 81: LINE DRIVER or PUSH-PULL encoder with complementary outputs.

  • Page 167: Figure 82: Push-Pull Encoder With Single-Ended Outputs

    SINUS K INSTALLATION INSTRUCTIONS ES836/2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 Encoder PUSH-PULL single-ended EncEEncod P000591-B Figure 82: PUSH-PULL encoder with single-ended outputs. Because settings required for a single-ended encoder deliver a reference voltage CAUTION to terminals 2, 4, 6, the latter are not to be connected.

  • Page 168: Figure 83: Pnp Or Npn Encoder With Single-Ended Outputs And Load Resistors With External Wiring

    SINUS K INSTALLATION INSTRUCTIONS ES836/2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 R pull R pull R pull Encoder with PNP or NPN outputs EncEEncod P000592-B Figure 83: PNP or NPN encoder with single-ended outputs and load resistors with external wiring.

  • Page 169: Figure 84: Pnp Or Npn Encoder With Single-Ended Outputs And Internal Load Resistors

    SINUS K INSTALLATION INSTRUCTIONS ES836/2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 Encoder with PNP or NPN outputs EncEEncod P000593-B Figure 84: PNP or NPN encoder with single-ended outputs and internal load resistors.

  • Page 170: Wiring The Encoder Cable

    SINUS K INSTALLATION INSTRUCTIONS 13.6.9. W IRING THE NCODER ABLE Use a screened cable to connect the encoder to the board. Screening should be grounded to both ends of the cable. Use the special clamp to fasten the encoder wire and ground the cable screening to the inverter.

  • Page 171: Es822/1 Isolated Serial Board

    INSTRUCTIONS 13.7. ES822/1 ISOLATED SERIAL BOARD Isolated serial board RS232/485 controlling SINUS K inverters. It permits to connect a computer via RS232 interface or permits the multidrop connection of modbus devices via RS485 interface. Interface signals are galvanically isolated with respect to the control board ground and the common of the control board terminals.

  • Page 172: Environmental Requirements

    SINUS K INSTALLATION INSTRUCTIONS 13.7.1. E NVIRONMENTAL EQUIREMENTS Operating temperatures: 0 to + 50 °C ambient temperature (for higher temperatures, please contact Elettronica Santerno) Relative humidity: 5 to 95% (non-condensing) Max. operating altitude 4000 (a.s.l.) 13.7.2. E LECTRICAL EATURES CONNECTION: When board ES822 is fitted, RS485 connector automatically disables;...

  • Page 173: Installing Es822 Board

    SINUS K INSTALLATION INSTRUCTIONS 13.7.3. I ES822 B NSTALLING OARD 1) Remove voltage from the inverter and wait at least 5 minutes. 2) Remove the cover allowing to gain access to the inverter control terminals. The mounting columns for the encoder board and signal connector are located on the right.

  • Page 174: Configuring Es822 Isolated Board

    SINUS K INSTALLATION INSTRUCTIONS 13.7.4. C ES822 I ONFIGURING SOLATED OARD 13.7.4.1. RS232/RS485 U M P E R E L E C T I N G Jumper J1 configures ES822 as RS485 or RS232 interface. Its positions are silk-screened on ES822 board.

  • Page 175: Dip-Switch Enabling Rs485 Terminator

    SINUS K INSTALLATION INSTRUCTIONS 13.7.4.2. RS485 T W IT C H N A B L IN G ER M I N A T O R (See the SERIAL COMMUNICATIONS section): For RS485 serial link in ES822 board, the terminator is selected with SW1 dip-switch as shown in the figure below.

  • Page 176: Loc-0-Rem" Key Selector Switch And Emergency Push-Button For Ip54 Models

    The ground of multifunction digital inputs is available also on terminal 2 in the NOTE auxiliary terminal board. When the key selector switch and the emergency push-button are installed, digital inputs cannot be used with a “PNP” command. If “PNP” command must be used, please contact Elettronica Santerno Spa. 176/191...

  • Page 177: Wiring Inverters With "Loc-0-Rem" Key Selector Switch And Emergency Push-Button

    SINUS K INSTALLATION INSTRUCTIONS 13.8.1. W “LOC-0-REM” K IRING NVERTERS WITH ELECTOR WITCH AND MERGENCY BUTTON Figure 90: Wiring inverters with optional “LOC-0-REM” key selector switch and emergency push-button. 177/191...

  • Page 178: Normative References

    Standards EN55011 and 50082, as well as standard EN61800-3, define immunity and emission levels required for devices designed to operate in different environments. Drives manufactured by ELETTRONICA SANTERNO are designed to operate under the most different conditions, so they all ensure high immunity against RFI and high reliability in any environment.
  • Page 179 SINUS K INSTALLATION INSTRUCTIONS Emission Limits The standards in force also define the allowable emission level for different environments. The diagrams below show emission limits allowed by Pr CEI EN 61800-3 issue 2 (corresponding to EN61800- 3/A11). A1 = EN 61800-3 issue 2 FIRST ENVIROMENT, Category C2, EN55011 gr.1 cl. A, EN50081-2, EN61800-3/A11.
  • Page 180 B emission suppression for PDS installed in the FIRST ENVIRONMENT, Category C1. ELETTRONICA SANTERNO is the only manufacturer offering power drive systems with built-in A2-level filters up to 1200kW. All those classes are provided with the Declaration of European Conformity.
  • Page 181 EN50178 (1997-10) Electronic equipment for power systems. ELETTRONICA SANTERNO is capable of providing Declaration CE of Conformity according to the requirements of LOW VOLTAGE DIRECTIVE 73/23/CEE-93/68/CEE and to MACHINES DIRECTIVE, 89/392/CEE, 91368/CEE-93/44/CEE (reproduced on the last pages of this manual).

  • Page 182: Radiofrequency Disturbance

    SINUS K INSTALLATION INSTRUCTIONS 14.1. Radiofrequency Disturbance Radiofrequency disturbance (RFI) may occur where the inverter is installed. Electromagnetic emissions produced by the electrical components installed inside a cabinet may occur as conduction, radiation, inductive coupling or capacitive coupling. Emissions disturbance can be the following: a) Radiated interference from electrical components or power wiring cables inside the cabinet;...

  • Page 183: Mains

    Mains disturbance may be limited by installing a mains filter to reduce RFI. ELETTRONICA SANTERNO adopted this solution to suppress RFI. Incorporated filters installed in the inverters are shown in section Input and Output Filters. Unpainted...

  • Page 184: Cabinet

    SINUS K INSTALLATION INSTRUCTIONS 14.1.2. O UTPUT OROID ILTERS Ferrite is a simple radiofrequency filter. Ferrite cores are high-permeable ferromagnetic materials used to weaken cable disturbance: • in case of three-phase conductors, all phases must go through ferrite; • in case of single-phase conductors (or 2wire line) both phases must go through ferrite (incoming and outcoming conductor cables that are to be filtered must go through ferrite).

  • Page 185: Output Toroid Filters

    UTPUT ILTERS The inverters of the SINUS K series may be delivered with incorporated input filters; in that case, models are marked with A1, A2, B in the ID number. If built-in filters are fitted, disturbance amplitude ranges between allowable emission limits (see section NORMATIVE REFERENCES).

  • Page 186: Declarations Of Conformity

    SINUS K INSTALLATION INSTRUCTIONS 15. DECLARATIONS OF CONFORMITY 186/191...
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