Kostal INVEOR Drive Controller Operating Manual
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Kostal INVEOR Drive Controller Operating Manual

Kostal INVEOR Drive Controller Operating Manual

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INVEOR Drive Controller α

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  • Page 1 Operating manual INVEOR Drive Controller α...
  • Page 2 Exclus ion of li abi lity All general names, trade names, product names or other designations used in this manual may be legally protected even if not labelled as such (e.g. as a trademark). KOSTAL assumes no liability for their free usage.

  • Page 3: Table Of Contents

    Contents General information ..................... 6 Information about documentation ................. 7 1.1.1 Other applicable documents ..................7 1.1.2 Storing the documentation ................... 8 Notes in this manual ..................... 8 1.2.1 Warnings ........................8 1.2.2 Warning symbols used ....................9 1.2.3 Signal words ........................ 9 1.2.4 Information notes .......................
  • Page 4 C o n t e n t s Installing the wall-mounted drive controller ..............47 3.5.1 Suitable installation location for wall mounting ............. 47 3.5.2 Mechanical installation ....................48 3.5.3 Power connection ...................... 51 3.5.4 Control connections ....................51 Commissioning ......................52 Safety instructions for commissioning .................
  • Page 5 C o n t e n t s Disassembly and disposal..................115 Drive controller disassembly ..................116 Information on correct disposal ................. 116 Technical data ......................117 General data ......................118 8.1.1 General technical data for 230 V devices ..............118 8.1.2 Specification of interfaces ..................

  • Page 6: General Information

    1. General information Information about documentation ................. 7 1.1.1 Other applicable documents ..................7 1.1.2 Storing the documentation ................... 8 Notes in this manual ..................... 8 1.2.1 Warnings ........................8 1.2.2 Warning symbols used ....................9 1.2.3 Signal words ........................ 9 1.2.4 Information notes .......................

  • Page 7: Information About Documentation

    G e n e r a l i n f o r m a t i o n Thank you for choosing an INVEOR α drive controller from KOSTAL Industrie Elektrik GmbH! Our INVEOR α drive controller platform is designed to be universally usable with all common motor types.

  • Page 8: Storing The Documentation

    G e n e r a l i n f o r m a t i o n 1.1.2 Storing the documentation Store this operating manual and all other applicable documents carefully so they are available when needed. 1.2 Notes in this manual 1.2.1 Warnings The warnings refer to life-threatening dangers.

  • Page 9: Warning Symbols Used

    G e n e r a l i n f o r m a t i o n 1.2.2 Warning symbols used Symbol Meaning Danger Danger due to electrical shock and discharge Danger due to burns Danger due to electromagnetic fields 1.2.3 Signal words Signal words are used to identify the severity of the danger.

  • Page 10: Information Notes

    G e n e r a l i n f o r m a t i o n 1.2.4 Information notes Information notes contain important instructions for the installation and problem-free operation of the drive controller. These must be followed at all times. The information notes also point out that failure to observe can result in damage to property or financial damages.

  • Page 11: Symbols Used In This Manual

    G e n e r a l i n f o r m a t i o n 1.3 Symbols used in this manual Symbol Meaning 1., 1., 3. … Consecutive steps in a handling instruction  Effect of a handling instruction Final result of a handling instruction ...

  • Page 12: Labels On The Drive Controller

    G e n e r a l i n f o r m a t i o n 1.4 Labels on the drive controller Fig.: 5 Labels on the drive controller Signs and labels are affixed to the drive controller. These may not be altered or removed. Symbol Meaning Danger due to electrical shock and discharge...

  • Page 13: Qualified Staff

    Repairs may only be performed by authorised repair bodies. Independent and unauthorised intervention may result in death, injury or property damage. The warranty provided by KOSTAL will be invalidated in such cases. External mechanical loads such as stepping on the housing are not permitted!

  • Page 14: Responsibility

    Directive on Electromagnetic Compatibility (Directive 2004/108/EC of the Council EN 61800-  3:2004). Low Voltage Directive (Directive 2006/95/EC of the Council EN 61800-5-1:2003).  You can download the Declaration of Conformity from www.kostal-industrie-elektrik.com. Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...

  • Page 15: Safety Instructions

    They contain important information on the installation and operation of the drive controller. In particular, note the information in the "Important information" chapter. KOSTAL Industrie Elektrik GmbH assumes no liability for damages arising from the non-observance of this operating manual.
  • Page 16 G e n e r a l i n f o r m a t i o n DANGER! Risk of death due to electrical shock! Death or serious injury! De-energise drive controller and secure it against being restarted. DANGER! Risk of death due to revolving mechanical parts! Death or serious injury! De-energise drive controller and secure it against being restarted.

  • Page 17: Transport & Storage

    G e n e r a l i n f o r m a t i o n IMPORTANT INFORMATION Do not place flammable parts (e.g. cable ducts) directly or indirectly on the drive controller. 1.9.2 Transport & storage DAMAGE TO PROPERTY POSSIBLE Risk of damage to drive controller! Risk of damage to drive controller from improper transport, storage, installation and assembly! Transport the drive controller properly in its original packaging.

  • Page 18: Information About Commissioning

    G e n e r a l i n f o r m a t i o n 1.9.4 Information about commissioning DANGER! Risk of death due to electrical shock! Death or serious injury! De-energise drive controller and secure it against being restarted. Supply terminals X1: L ...

  • Page 19: Instructions Concerning Operation

    G e n e r a l i n f o r m a t i o n IMPORTANT INFORMATION If different voltages are used (e.g. +24 V/230 V), crossing cable runs are not permitted  under any circumstances. The operator must also ensure compliance with the applicable regulations (e.g.
  • Page 20 G e n e r a l i n f o r m a t i o n IMPORTANT INFORMATION Observe the following instructions during operation: The drive controller runs at high voltages.  When electrical devices are operated, some of their parts are always subject to dangerous ...

  • Page 21: Maintenance And Inspection

    The drive controllers may only be maintained and inspected by electricians with recognised training. Unless explicitly described in this operating manual, changes to hardware and software may only be undertaken by KOSTAL experts or persons authorised by KOSTAL. Cleaning the driv e control l ers Drive controllers are maintenance-free if operated as intended.

  • Page 22: Repairs

    Damage to property possible If the information is not observed, the drive controller could be damaged and destroyed during subsequent commissioning. Repairs to the drive controller may only be performed by the KOSTAL Service department.  CAUTION! Risk of burns from hot surfaces! Serious burns to the skin from hot surfaces! Allow the drive controller's cooling elements to cool sufficiently.

  • Page 23: Overview Of The Drive Controller

    2. Overview of the drive controller Model description ...................... 24 Scope of delivery ....................... 25 Description of INVEOR α drive controller ..............26 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...

  • Page 24: Model Description

    O v e r v i e w o f t h e d r i v e c o n t r o l l e r This chapter contains information on the scope of delivery for the drive controller and the function description.

  • Page 25: Scope Of Delivery

    O v e r v i e w o f t h e d r i v e c o n t r o l l e r 2.2 Scope of delivery Compare the scope of delivery of your product with that provided below. Fig.: 8 Scope of delivery INVEOR α...

  • Page 26: Description Of Inveor Α Drive Controller

    The permitted ambient temperatures specified in the technical data refer to operation at nominal load. In many cases, higher temperatures may be permitted after a detailed technical analysis. These have to be approved by KOSTAL on a case-by-case basis. Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...

  • Page 27: Installation

    3. Installation Safety instructions for installation ................28 Recommended preliminary fuses / line protection............28 Installation requirements ..................... 29 3.3.1 Suitable ambient conditions ..................29 3.3.2 Suitable installation location for the motor-integrated drive controller ......30 3.3.3 Basic connection versions ..................31 3.3.4 Short circuit and ground protection ................

  • Page 28: Safety Instructions For Installation

    I n s t a l l a t i o n 3.1 Safety instructions for installation DANGER! Risk of death due to revolving mechanical parts! Death or serious injury! De-energise drive controller and secure it against being restarted. Only allow appropriately qualified staff to install the drive controller. Only use staff who are trained in mounting, installation, commissioning and handling.

  • Page 29: Installation Requirements

    I n s t a l l a t i o n 3.3 Installation requirements 3.3.1 Suitable ambient conditions Conditions Values Altitude of the installation location: up to 1000 m above sea level / over 1000 m with reduced performance (1 % per 100 m) (max. 2000 m), see chapter 8.2 Ambient temperature: -10 °C to +40 °C (different ambient temperatures may be possible in individual cases), see chapter 8.2...

  • Page 30: Suitable Installation Location For The Motor-Integrated Drive Controller

    I n s t a l l a t i o n The standard colour is black RAL 9005 (black). Disassembling the circuit boards (even for the purpose of painting the housing sections) renders the warranty void! Mounting points and sealing surfaces must be kept free of paint for purposes of EMC and grounding! 3.3.2 Suitable installation location for the motor-integrated drive...

  • Page 31: Basic Connection Versions

    I n s t a l l a t i o n 3.3.3 Basic connection versions Triangl e connection var ian t Fig.: 10 Triangle connection with motor-integrated drive controller Triangle connection terminal assignment W2, U1 U2, V1 V2, W1 T1, T2 Connect bridge (see scope of delivery) DANGER!
  • Page 32 I n s t a l l a t i o n Star connection var iant Fig.: 11 Star connection with motor-integrated drive controller Motor connector Butt connector Star point Star connection terminal assignment T1, T2 Connect bridge (see scope of delivery) Star formation W2, U2, V2 DANGER!

  • Page 33: Short Circuit And Ground Protection

    I n s t a l l a t i o n DAMAGE TO PROPERTY POSSIBLE Risk of damage to the drive controller. Correct phase assignment must be observed when connecting the drive controller, otherwise the motor may be overloaded. The supplied assembly material can be used to connect core end sleeves and cable shoes.

  • Page 34: Wiring Instructions

    I n s t a l l a t i o n 3.3.5 Wiring instructions The control connections of the application card are located inside the drive control. The configuration may vary depending on the version. Control terminals (siz e α) Fig.: 12 Control terminals (size α) Size α...
  • Page 35 I n s t a l l a t i o n Power connections (size α) Fig.: 13 Power connections (size α) Size α The terminals for the mains cable are located inside the drive controller. The configuration may vary depending on the version. Core end sleeves with plastic collars and lugs are recommended.

  • Page 36: Preventing Electromagnetic Interferences

    I n s t a l l a t i o n 3.3.6 Preventing electromagnetic interferences Where possible use shielded lines for control circuits. The shielding should be applied to the line end with special care and without laying the leads across longer stretches without shielding.
  • Page 37 The standard adapter plate is a plate the underside of which is not reworked; i.e. no holes have been produced yet. You can order individually modified adapter plates from KOSTAL for selected motors. Modify the adapter plate (1) by producing the necessary holes for mounting on the motor.
  • Page 38 The commissioning technician is responsible for protection class compliance when sealing the adapter plate on the motor. If you have any questions, please ask your KOSTAL contact. Fit the seal (2). Lead the motor connection lines through the opening (3) in the adapter plate (1).
  • Page 39 I n s t a l l a t i o n IMPORTANT INFORMATION When mounting the adapter plates, ensure that all four screws, including the spring elements, are tightened to the necessary torque (M = 2 Nm)! Attach the motor lines (5) in the correct circuit to plug of motor plugs (6). 10.

  • Page 40: Power Connection

    I n s t a l l a t i o n 3.4.2 Power connection Fig.: 15 Mains connection cable connection Screw cable screw connection (1) into cooling elements (2) (M = 3 Nm). Guide mains connection cable (3) through cable screw connection (1) into cooling elements (2).
  • Page 41 I n s t a l l a t i o n Connect mains cables (4) to mains plug (5) as follows: 230 V connection Terminal no. Designation Assignment Mains phase Neutral wire Protective conductor Plug mains plug (5) onto mains connection socket X1. Operating manual for INVEOR α...

  • Page 42: Control Connections Of Application Board

    I n s t a l l a t i o n 3.4.3 Control connections of application board Fig.: 16 Control connections of application board Screw cable screw connection (1) into cooling elements (2) (M = 3 Nm). Guide control line (3) through cable screw connection (1) into cooling elements (2). Fix control line (3) by tightening (M = 3 Nm) rear section of cable screw connection (1).
  • Page 43 I n s t a l l a t i o n Control connection X5 Terminal no. Designation Assignment GND (ground) Ground En HW (enable) Enable hardware 24 V Out Int. power supply 24 V Out Int. power supply 10 V Out For ext.

  • Page 44: Placing Cooling Elements On Adapter Plate

    I n s t a l l a t i o n Relay X6 Designation Assignment Centre contact relay Normally open contact relay Normally closed contact For technical data on power connections, see page 35 3.4.4 Placing cooling elements on adapter plate Fig.: 17 Placing cooling elements on adapter plate Plug motor plug (1) onto motor terminal X411 (2).
  • Page 45 I n s t a l l a t i o n Carefully attach cooling elements (3) on adapter plate (4). DAMAGE TO PROPERTY POSSIBLE Failure to comply with the information may result in damage to the drive controller! When attaching a drive controller with a foil keypad, be absolutely sure that the flat ribbon cable is not pinched.

  • Page 46: Connection Diagram

    I n s t a l l a t i o n 3.4.5 Connection diagram Fig.: 18 Connection diagram Characters Explanation Drive controller type: INVEOR M α 2 (1~ 230 V) M6 grounding screw (connection for residual currents > 3.5 mA) RS485 internal programming interface (M12 plug) (optional) Internal potentiometer (optional) Motor protection switch or load break switch (optional)

  • Page 47: Installing The Wall-Mounted Drive Controller

    I n s t a l l a t i o n 3.5 Installing the wall-mounted drive controller 3.5.1 Suitable installation location for wall mounting Ensure that the installation location for an INVEOR α wall mounting meets the following conditions: The drive controller has to be mounted on an even and fixed surface.

  • Page 48: Mechanical Installation

    I n s t a l l a t i o n 3.5.2 Mechanical installation Fig.: 20 Wiring on the motor connection box Open the motor connection box. IMPORTANT INFORMATION Depending on the required motor voltage, the star or triangle connection must be made in the motor connection box! Use a suitable EMC screw connection to attach the shielded motor cable to the motor connection box!
  • Page 49 I n s t a l l a t i o n Fig.: 21 Placing flat seals on rear of adapter plate IMPORTANT INFORMATION The drive controller may not be installed without an adapter plate! Find a position that meets the required ambient conditions (see 3.3 "Installation requirements"...
  • Page 50 I n s t a l l a t i o n Fig.: 22 Fastening the adapter plate to the wall IMPORTANT INFORMATION The adapter plate must not be fitted overhead! Secure adapter plate (1) to your chosen base (2). Depending on the base, use appropriate retaining bolts* (3) and plain washers** (7) for securing.

  • Page 51: Power Connection

    I n s t a l l a t i o n Fig.: 23 Attaching drive controller (wall mounting) Place drive controller (4) on adapter plate (1). 10. Screw down cooling elements (4) to the adapter plate (1) with the help of the screws (5) provided (torque: M = 1.2 Nm).

  • Page 52: Commissioning

    4. Commissioning Safety instructions for commissioning ................. 53 Communication ......................54 Block diagram ......................55 Commissioning steps ....................56 4.4.1 Commissioning using the PC: ..................57 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...

  • Page 53: Safety Instructions For Commissioning

    C o m m i s s i o n i n g 4.1 Safety instructions for commissioning DAMAGE TO PROPERTY POSSIBLE If the information is not observed, the drive controller could be damaged and destroyed during subsequent commissioning. Commissioning may only be performed by qualified staff. Safety precautions and warnings must always be observed.

  • Page 54: Communication

    C o m m i s s i o n i n g 4.2 Communication The drive controller can be commissioned in the following ways: using the INVEORpc PC software  Fig.: 24 PC software – start screen using the INVEOR MMI handheld controller* ...

  • Page 55: Block Diagram

    C o m m i s s i o n i n g 4.3 Block diagram Fig.: 26 General structure of target value generation Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...

  • Page 56: Commissioning Steps

    C o m m i s s i o n i n g 4.4 Commissioning steps The commissioning can be performed using a PC communication cable USB at M12 plug with integrated interface converter RS485/RS232 (part no. 10023950) or using the INVEOR handheld controller MMI* with connection cable RJ9 at M12 plug (part no.

  • Page 57: Commissioning Using The Pc

    Commissioning using the PC: Please install the INVEORpc software. The programming software is available free of charge from the KOSTAL website. Operating system required: Windows XP or Windows 7 [32 / 64 bit]). We recommend undertaking the installation process as an administrator.
  • Page 58 C o m m i s s i o n i n g DAMAGE TO PROPERTY POSSIBLE The drive controller may be damaged if the notices are not observed! When pulling off the jack plug, do not move the  INVEOR α...

  • Page 59: Parameter

    5. Parameter Safety instructions for working with parameters ............60 General information on parameters ................60 5.2.1 Explanation of operating modes.................. 60 5.2.2 Structure of the parameter tables................64 Application parameters ....................65 5.3.1 Basic parameter ......................65 5.3.2 Fixed frequency......................73 5.3.3 Motor potentiometer ....................

  • Page 60: Safety Instructions For Working With Parameters

    Parameters This chapter contains the following: an introduction to the parameters  an overview of the most important commissioning and operation parameters  5.1 Safety instructions for working with parameters DANGER! Risk of death due to restarting motors! Death or serious injury! Non-observance may result in death, serious injury or damage.
  • Page 61 Parameters Frequency setting mode: The target values from the “target value source” (1.130) are rescaled into frequency target values. 0 % is the "minimum frequency" (1.020). 100 % is the "maximum frequency" (1.021). The target value's plus or minus sign is the decisive factor in rescaling. PID process control: The target value for the PID process controller is read in percentage steps as in the “frequency setting mode”.
  • Page 62 Parameters Stand-by function in PID process control This function can provide energy savings in applications such as booster stations where PID process control is used to control to a specific process value and the pump has to run at a "minimum frequency"...
  • Page 63 Parameters Fixed fr equency This operating mode controls the drive controller with up to 3 fixed target values. These are selected under parameter 2.050, where you can select how many fixed frequencies are to be used. Parameter Name Selection Function Number of options digital inputs...

  • Page 64: Structure Of The Parameter Tables

    Parameters 5.2.2 Structure of the parameter tables 1.100 Operating mode Unit: integer min: own value Relationship to Parameter manual Transfer status: (to be S. xy parameter: max: entered!) def.: 1.131 1.130 Selection of operating mode, see page ??? (reference to explanation in advance) 2.051 to 2.057 Following successful software enabling (1.131) and...

  • Page 65: Application Parameters

    Parameters 5.3 Application parameters 5.3.1 Basic parameter 1.020 Minimum frequency Unit: Hz Relationship Parameter Transfer status: min.: Own value (to be to parameter: manual: entered!) max.: 1.150 S.xy def.: 3.070 The minimum frequency is the frequency which is supplied by the drive 3.080 controller as soon as it is enabled and there is no additional target value.
  • Page 66 Parameters 1.051 Run up time 1 Unit: s Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1000 1.021 S.xy def.: 1.054 Run up time 1 is the time that the drive controller needs to accelerate from 0 Hz to the max.
  • Page 67 Parameters 1.054 Ramp selection Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1.050 1.053 P. xy def.: Selection of used ramp pair 0 = deceleration 1 (1.050) / acceleration 1 (1.051) 1 = deceleration 2 (1.052) / acceleration 2 (1.053) 2 = digital input 1 (false = ramp pair 1 / true = ramp pair 2) 3 = digital input 2 (false = ramp pair 1 / true = ramp pair 2) 6 = customer PLC...
  • Page 68 Parameters 1.100 Operating mode Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1.130 P. xy def.: 1.131 Selecting the operating mode 2.051 2.057 Following software enabling (1.131) and hardware enabling, the drive controller 3.050 3.071 runs as follows:...
  • Page 69 Parameters 1.131 Enable software Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1.132 P. xy def.: 1.150 2.050 DANGER! 4.030 The motor may start immediately, depending on the change made. 4.050 Selection of the source for the control release. 0 = digital input 1 1 = digital input 2 4 = analogue input 1 (must be selected in parameter 4.030)
  • Page 70 Parameters 1.132 Start protection Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1.131 P. xy def.: Selection of behaviour in response to enabling software (parameter 1.131). No effect if autostart was selected. 0 = immediate start with high signal at start input of control enable 1 = start only with rising flank at start input of control enable 2 = digital input 1 (function active with high signal)
  • Page 71 Parameters 1.180 Acknowledge function Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1.181 P. xy def.: 1.182 Selection of the source for error confirmation. Errors can only be acknowledged once the error is no longer present. Certain errors can only be acknowledged by switching the controller off and on, see list of errors.
  • Page 72 Parameters Number of automatic 1.182 Unit: acknowledgements Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1.180 P. xy def.: 1.181 In addition to the automatic acknowledgement function (1.181), it is possible to limit the maximum number of automatic acknowledgements here. = no restriction on automatic acknowledgements >...

  • Page 73: Fixed Frequency

    Parameters 5.3.2 Fixed frequency This mode has to be selected in parameter 1.100, see also the section on selecting the operating mode. 2.050 Fixed frequency mode Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1.100 P.

  • Page 74: Motor Potentiometer

    Parameters 5.3.3 Motor potentiometer This mode must be selected in parameter 1.130. The function can be used as a target value source for frequency mode and for the PID process controller. The motor potentiometer can be used to gradually increase / decrease the target value (PID/frequency).

  • Page 75: Pid Process Controller

    Parameters 2.153 MOP response time Unit: s Relationship Parameter Transfer status: min.: 0.02 Own value to parameter: manual: (to be entered!) max.: 1000 P. xy def.: Indicates the time for which the signal is considered permanent. 2.154 MOP reference memory Unit: integer Relationship Parameter...
  • Page 76 Parameters 3.052 PID-P amplification factor Unit: s Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1.100 P. xy def.: 1.130 Differential share of PID controller amplification factor 3.060 PID actual value Unit: integer Relationship Parameter Transfer status: min.:...
  • Page 77 Parameters 3.069 PID fixed target mode Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1.100 P. xy def.: 3.062 to 3.068 Selection of the digital inputs used for fixed frequencies 0 = Digital In 1 (PID fixed target value 1) (3.064) 1 = Digital In 1, 2 (PID fixed target values 1 –...
  • Page 78 Parameters 3.072 PID dry run time Unit: s Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 32767 P. xy def.: (V 03.70 and higher) After this set time, if the PID actual value has not reached at least 5 % and the controller is running at the max.
  • Page 79 Parameters 3.074 PID nominal value max. Unit: % Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: P. xy 3.073 def.: (V 03.70 and higher) The PID nominal value can be limited using 2 parameters. Example: 0 -10 V nominal value potentiometer Read Min PID nominal value = 20 % Read Max PID nominal value = 80 % (3.073)

  • Page 80: Analogue Input

    Parameters 5.3.5 Analogue input For analogue input 1 4.020 AI1 input type Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: P. xy def.: Function of analogue input 1. 1 = voltage input 2 = current input 4.021 AI1 standard.
  • Page 81 Parameters 4.023 AI1 dead time Unit: % Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: P. xy def.: Dead time as percentage of the range of the analogue inputs. 4.024 AI1 filter time Unit: s Relationship Parameter Transfer status:...
  • Page 82 Parameters 4.033 Al1 physical unit Unit: Relationship Parameter manual: Transfer status: min.: Own value to parameter: (to be entered!) max.: P. xy 4.034 def.: 4.035 Selection of different physical values to be displayed. mbar m³/h l/min ° C ° F 4.034 Al1 physical minimum Unit:...

  • Page 83: Digital Inputs

    Parameters 4.036 / 4.066 AI1 wire break time Unit: Relationship Parameter Transfer status: min.: 0 Own value to parameter: manual: (to be entered!) max.: 32767 P. xy def.: (V 03.70 and higher) Once the mains is activated, wire break detection is only activated after this set time 4.037 / 4.067 AIx inversely...

  • Page 84: Digital Output

    Parameters 5.3.7 Digital output For digital input 1 4.150 DO1 function Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 4.151 P. xy def.: 4.152 Selection of the process variable to which the output should switch. Not assigned / INVEOR soft PLC Intermediate circuit voltage Grid voltage...
  • Page 85 Parameters 4.150 DO1 function Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 4.151 P. xy def.: 4.152 Selection of the process variable to which the output should switch. Continuation of table STO channel 1 (V 03.70 and higher) STO channel 2 (V 03.70 and higher) Target frequency value after ramp (V 03.70 and higher) Target frequency value (V 03.70 and higher)

  • Page 86: Relay

    Parameters 5.3.8 Relay For relay 1 4.190 Rel.1 function Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 4.191 P. xy def.: 4.192 Selection of the process variable to which the output should switch. Not assigned / INVEOR soft PLC Intermediate circuit voltage Grid voltage...
  • Page 87 Parameters 4.190 DO1 function Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: P. xy 4.151 def.: 4.152 Selection of the process variable to which the output should switch. Continuation of table STO channel 1 (V 03.70 and higher) STO channel 2 (V 03.70 and higher) Target frequency value after ramp (V 03.70 and higher) Target frequency value (V 03.70 and higher)
  • Page 88 Parameters 4.192 Relay 1 off Unit: Relationship Parameter Transfer status: min: - 32767 Own value to parameter: manual: (to be entered!) max: 32767 4.190 P. xy def.: If the set process variable exceeds the switch-off limit, the output is again set to 0.

  • Page 89: Virtual Output

    Parameters 5.3.9 Virtual output The virtual output can be parameterised like a relay and is available as an option with the following parameters: 1.131 Software enable / 1.150 Direction of rotation / 1.054 Ramp selection / 5.090 Parameter set change / 5.010 + 5.011 External error 1 + 2 4.230 VO function Unit: integer...
  • Page 90 Parameters 4.230 VO function Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: P. xy 1.054 def.: 1.131 Selection of the process variable to which the output should switch. 1.150 Continuation of table 4.231 4.232 Analogue input 1 (V 3.60 and higher)

  • Page 91: External Fault

    Parameters 4.233 VO-On delay Unit: s Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 10000 P. xy 4.234 def.: Specifies the length of the switch-on delay. 4.234 VO-Off delay Unit: Relationship Parameter Transfer status: min.: Own value to parameter:...

  • Page 92: Motor Current Limit

    Parameters 5.3.11 Motor current limit This function limits the motor current to a parameterised maximum value after a parameterised current-time zone has been reached. This motor current limit is monitored at application level and thereby limits with relatively low dynamics. This has to be taken into consideration when selecting this function. The maximum value is determined using the “motor current limit as %”...

  • Page 93: Gearbox Factor

    Parameters Gearbox factor 5.075 Unit: Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1000 33.034 P. xy def.: A gearbox factor can be set here. The mechanical speed display can be adjusted using the gearbox factor. 5.4.1 Blocking detection 5.080...
  • Page 94 Parameters 5.082 Start-up error active Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 4.233 P. xy def.: (V 03.70 and higher) Start-up error is defined as follows: Actual value does reach 10 % of rated motor frequency after 30 seconds (if nominal frequency <...
  • Page 95 Parameters 5.090 Parameter set change Unit: integer Relationship Parameter Transfer status: min.: Own value (to to parameter: manual: be entered!) max.: 4.030 P. xy def.: 4.230 Selection of the active data set. Not used Data set 1 active Data set 2 active Digital input 1 Digital input 2 INVEOR soft PLC...

  • Page 96: Field Bus

    Parameters 5.201 Save MMI display Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: P. xy def.: (V 03.80 and higher) The status screen displayed in the MMI can be selected here. 1 = status 01: Target / actual frequency / motor current 2 = status 02: Speed / motor current / process value 1 3 = status 03: Speed / motor current / process value 2 4 = status 04: Speed / PID target value / PID actual value...
  • Page 97 Parameters 6.061 Set field bus baud rate Unit: integer Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: P. xy def.: Only for CanOpen: 0 = 1 MBit, 2 = 500 kBit, 3 = 250 kBit, 4 = 125 kBit, 6 = 50 kBit, 7 = 20 kBit,...

  • Page 98: Performance Parameters

    Parameters 6.070 / Target / nominal value deviation Unit: % 6.071 Relationsh Parameter Transfer status: min.: 0 % / 0 sec. Own value ip to manual: (to be entered!) max.: 100 % / 32767 sec. parameter: P. xy def.: 0 % / 0 sec. 4.150 A target / actual value comparison can be undertaken with this function.
  • Page 99 Parameters 33.015 R optimisation Unit: % Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: P. xy def.: If necessary, this parameter can be used to optimise the start-up behaviour. 33.016 Motor phases monitoring Unit: integer Relationship Parameter Transfer status:...
  • Page 100 Parameters 33.034 Motor speed Unit: rpm Relationship Parameter Transfer status: min: Own value to parameter: manual: (to be entered!) max: 10000 34.120 P. xy def.: 5.075 The value from the motor's type plate data has to be entered here for the nominal motor rotation speed n 33.035 Motor frequency...
  • Page 101 Parameters 33.110 Motor voltage Unit: V Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1500 P. xy def.: Only for asynchronous motors. This is used to set the nominal motor voltage U for either the star or triangle connection.

  • Page 102: I 2 T

    Parameters 5.5.2 33.010 T fact. motor Unit: % Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 1000 33.031 P. xy def.: 33.011 The percentage current threshold (in relation to motor current 33.031) at the start of integration can be set here.

  • Page 103: Switching Frequency

    Parameters 5.5.3 Switching frequency The internal switching frequency can be changed in order to control the power element. A high setting reduces noise in the motor but results in increased EMC emissions and losses in the drive controller. 34.030 Switching frequency Unit: Hz Relationship Parameter...
  • Page 104 Parameters 34.021 Catch time Unit: ms Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 10 000 P. xy def.: The catch time can be optimised here, if the automatically determined results (of the motor identification) are insufficient. 34.090 Speed controller K Unit: mA / rad / s...

  • Page 105: Quadratic Characteristic Curve

    Parameters 34.110 Slip trimmer Unit: Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 33.034 P. xy def.: Only for asynchronous motors. This parameter can be used to optimise or deactivate slippage compensation. 0 = disable (performance as on the grid) 1 = compensation for slippage.

  • Page 106: Synchronous Motor Controller Data

    Parameters 34.121 Flux adjustment Unit: % Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 34.120 P. xy def.: Only for asynchronous motors. The percentage by which the flux is to be reduced can be set here. An overvoltage shutdown can occur if there are any major changes in operation.
  • Page 107 Parameters 34.227 Init time Unit: s Relationship Parameter Transfer status: min.: Own value to parameter: manual: (to be entered!) max.: 34.226 P. xy def.: 0.25 For synchronous motors only. Here the time during which the start up current 34.226 is stamped can be set. 34.228 –...

  • Page 108: Error Detection And Troubleshooting

    6. Error detection and troubleshooting List of the LED flash codes for error recognition ............110 List of errors and system errors ................111 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...
  • Page 109 Error det ection and troubl eshooting This chapter contains the following: A list of the LED flash codes for error recognition  A description of error recognition using PC tools  A list of errors and system errors  Notes on error detection with the MMI ...

  • Page 110: List Of The Led Flash Codes For Error Recognition

    Error det ection and troubl eshooting 6.1 List of the LED flash codes for error recognition When an error occurs, the LEDs on the drive controller display a flashing code that allows the errors to be diagnosed. The following table contains an overview: Green State Boot loader active (flashing in turn)

  • Page 111: List Of Errors And System Errors

    Errors must always be rectified before acknowledgement, otherwise the drive controller may be damaged. The following section contains a list of possible error messages. Please contact the KOSTAL service department if you encounter errors that are not listed here. Error name Description of error...
  • Page 112 Error det ection and troubl eshooting Error name Description of error Possible causes/remedy Parameter distributor The internal distribution of Parameter set is incomplete parameters during initialisation failed Time-out power The power part does not Operation with 24 V without respond mains feed-in Cable break at analogue Current or voltage is less than...
  • Page 113 Error det ection and troubl eshooting Error name Description of error Possible causes/remedy Trip IGBT ** Protection of the IGBT module Short circuit in the motor or against overcurrent has been motor feed line / controller triggered settings Overvoltage of intermediate The maximum intermediate Feedback by motor in circuit **...
  • Page 114 Error det ection and troubl eshooting Error name Description of error Possible causes/remedy Ground leak ** Ground leak during a motor Insulation fault phase Motor connection disrupted No motor current in spite of No motor connected or not control through frequency completely connected.

  • Page 115: Disassembly And Disposal

    7. Disassembly and disposal Drive controller disassembly ..................116 Information on correct disposal ................. 116 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...

  • Page 116: Drive Controller Disassembly

    Disassembly and disposal This chapter contains the following: A description of how to disassemble the drive controller  Information on correct disposal  7.1 Drive controller disassembly CAUTION! Risk of burns from hot surfaces! Serious burns to the skin from hot surfaces! Allow the drive controller's cooling elements to cool sufficiently DANGER! Risk of death due to electrical shock!

  • Page 117: Technical Data

    8. Technical data General data ......................118 8.1.1 General technical data for 230 V devices ..............118 8.1.2 Specification of interfaces ..................119 Derating of output power ..................120 8.2.1 Derating due to increased ambient temperature ............120 8.2.2 Derating due to installation altitude ................121 8.2.3 Derating due to switching frequency .................

  • Page 118: General Data

    Techni cal data 8.1 General data 8.1.1 General technical data for 230 V devices Size M α 0.25 kW 0.37 kW 0.55 kW 0.75 kW Recommended motor rating [kW] 1 x 100 VAC -15 %...230 VAC +10 % Supply voltage 140 VDC -15 %...320 VDC +10 % Grid frequency 50/60 Hz ±...

  • Page 119: Specification Of Interfaces

    Techni cal data 8.1.2 Specification of interfaces Designation Function Digital inputs 1 – 2 Switching level low < 5 V / high > 15 V Imax (at 24 V) = 3 mA Rin = 8.6 kOhm Hardware approval Switching level low < 3 V / high > 18 V for input Imax (at 24 V) = 8 mA Analogue inputs 1...

  • Page 120: Derating Of Output Power

    Techni cal data 8.2 Derating of output power Drive controllers of the INVEOR α series have two integrated PTC resistors as standard which monitor both the heat sink temperature and the inner temperature. As soon as a permissible IGBT temperature of 95°C or a permissible inner temperature of 85°C is exceeded, the drive controller shuts down.

  • Page 121: Derating Due To Installation Altitude

     reduce the input voltage.  Please contact the KOSTAL Service department. The respective max. output values can be determined from the following characteristic curves. installaion altitude [m] Fig.: 33 Derating of maximum output current as a result of installation altitude...

  • Page 122: Derating Due To Switching Frequency

    Techni cal data installaion altitude [m] Fig.: 34 Derating of maximum input voltage as a result of installation altitude 8.2.3 Derating due to switching frequency The following diagram shows the output current, depending on switching frequency. To limit the thermal losses in the drive controller, the output current must be reduced. Note: The switching frequency is not reduced automatically! The max.

  • Page 123: Optional Accessories

    9. Optional accessories Adapter plates ......................124 9.1.1 Motor adapter plates ....................124 9.1.2 Motor adapter plates (specific) .................. 125 9.1.3 Wand adapter plates (standard) ................126 Foil keypad ......................127 MMI* handheld controller including a 3 m RJ9 connection cable with M12 plug ..132 9.3.1 MMI/connecting cable PIN assignment ..............

  • Page 124: Adapter Plates

    Blind hole depth, diameter and thread type of attachment points IMPORTANT INFORMATION KOSTAL Industrie Elektrik GmbH assumes no liability for the connection between the motor and INVEOR! Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...

  • Page 125: Motor Adapter Plates (Specific)

    Optional accessor ies Fig.: 36 Hole pattern for size α standard adapter plate When using cylindrical head screws (cf. DIN 912 / DIN 6912) or flat head screws (cf. DIN EN ISO 7380), the hole pattern must be drilled on the INVEOR mounting frame in compliance with the applicable drawing.

  • Page 126: Wand Adapter Plates (Standard)

    Wall adapter plates (standard) A standard wall adapter plate is available for each INVEOR α size. Download the 3D files for INVEOR and adapter plates from www.kostal-industrie-elektrik.com. Four holes for mounting the adapter plate are present. INVEOR size M α...

  • Page 127: Foil Keypad

    Optional accessor ies 9.2 Foil keypad As an option, the devices of the INVEOR α family are also available as a variant with an integrated foil keypad. This keypad can be used to operate the drive controller locally. Fig.: 38 Standard foil keypad Start Reversal of direction of rotation Stop...
  • Page 128 Optional accessor ies The following functionalities can be realised using the integrated foil keypad: Motor potentiometer: A motor potentiometer (parameter 2.150) can be realised using the  configurable function keys (5) and (6) (MOP digit. input) integrated in the foil keypad. This function can be used to increase or decrease the target value.
  • Page 129 Optional accessor ies Target value approval: The start (1) and stop (3) keys integrated in the foil keypad (select foil  keypad) can be used to approve the drive software (parameter 1.131). Direction of rotation V1: The direction of rotation (parameter 1.150) can be changed using ...
  • Page 130 Optional accessor ies Direction of rotation V3: The direction of rotation (parameter 1.150) can be changed using  keys (6) and (5) integrated in the foil keypad (select foil keypad, key I clockwise/key II anti- clockwise always). The direction of rotation can be changed when the motor is running and stationary.
  • Page 131 Optional accessor ies Fixed frequency: Two fixed frequencies (parameter 2.050) can be realised using the  configurable keys (6) and (5) integrated in the foil keypad (MOP digit. input). This function can be used to increase or decrease the target value. The integrated LEDs indicate the target value currently selected.

  • Page 132: Mmi* Handheld Controller Including A 3 M Rj9 Connection Cable With M12 Plug

    Optional accessor ies 9.3 MMI* handheld controller including a 3 m RJ9 connection cable with M12 plug Fig.: 39 MMI handheld controller IMPORTANT INFORMATION The MMI handheld controller (part. no. 10004768) may only ever be used with an INVEOR α. The MMI handheld controller is connected to the integrated jack plug of the INVEOR α.

  • Page 133: Mmi/Connecting Cable Pin Assignment

    Optional accessor ies 9.3.1 MMI/connecting cable PIN assignment Description: Round plug connector (plug) 4-pin M12 A-coded. M12 plug assignment Signal 24 V RS485 - A RS485 - B Fig. 1: M12 plug PIN assignment Description: RJ9 plug connector Signal yellow green brown Attention: The colours may vary!

  • Page 134: Pc Communication Cable Usb On M12/Rs485 Plug (Converter Integrated)

    "INVEOR α adapter cable", the PC communication cable can be connected via the M12 socket (art. no. 10118216) (JST plug). The INVEORpc software is available free of charge from the KOSTAL homepage at www.kostal-industrie-elektrik.com Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...

  • Page 135: Inveor Α Adapter Cable

    Optional accessor ies 9.5 INVEOR α adapter cable Fig.: 41 INVEOR α adapter cable The "INVEOR α adapter cable" is needed to connect the MMI handheld controller or PC communication cable with the INVEOR α. IMPORTANT INFORMATION The "INVEOR α adapter cable" (art.

  • Page 136: Mmi M12 Plug (Jst Plug)

    Optional accessor ies 9.7 MMI M12 plug (JST plug) Fig.: 43 MMI M12 plug (JST plug) Round plug connector (socket) 4-pin M12 A-coded. The MMI M12 connection cable (art. no.: 10118216) is only intended for fitting in the cooling elements. The MMI M12 connection cable can be used to permanently connect the drive controller with the MMI or PC.

  • Page 137: Canopen Connection Cable

    Optional accessor ies 9.8 CANopen connection cable Fig.: 44 CANopen connection cable The CANopen connection cable (art. no.: 10118224) is only intended for fitting in the cooling elements. The drive controller can be connected to a CANopen bus system via the connection. CANopen connection cable pin assignment JST plug Line colour...

  • Page 138: Connection And Screw-In Information For "Optional Accessories

    Optional accessor ies 9.9 Connection and screw-in information for "Optional accessories" Connection and screw-in information for "Optional accessories" Optional accessories Possible connection screw-in position position on I/O board MMI M12 (art. no.: 10118216) 1, 4, 5 CANopen (art. no.: 10118224) 1, 4, 5 Potentiometer (art.

  • Page 139: Cable Set Extension

    Optional accessor ies 9.10 Cable set extension Quantity Name 3-pin connection terminal 2-pin connection terminal Ground; 1.0 mm approx. 200 mm with crimped M4 cable shoe Ground; 1.0 mm approx. 200 mm with crimped M5 cable shoe Phases 1.0 mm approx.

  • Page 140: Approvals, Standards And Guidelines

    10. Approvals, standards and guidelines 10.1 EMC limit classes ..................... 141 10.2 Classification acc. to IEC/EN 61800-3 ..............141 10.3 Standards and guidelines ..................142 10.4 UL approval ......................143 10.4.1 UL Specification (English version) ................143 10.4.2 Homologation CL (Version en française) ..............144 Operating manual for INVEOR α...

  • Page 141: Emc Limit Classes

    Approvals, standards and guidel ines This chapter contains information about electromagnetic compatibility (EMC), and applicable guidelines, norms and standards. For binding information about the relevant drive controller approvals, please refer to the relevant type plate! 10.1 EMC limit classes Please note that EMC limit classes are only reached if the standard switching frequency of 8 kHz is complied with.

  • Page 142: Standards And Guidelines

    Approvals, standards and guidel ines Definition of environment First environment (residential, commercial and industrial area): All “areas” that are directly supplied by a public low-voltage connection, such as: residential area, e.g. houses, apartments etc.  retail area, e.g. shops, supermarkets ...

  • Page 143: Ul Approval

    Approvals, standards and guidel ines 10.4 UL approval 10.4.1 UL Specification (English version) Maximum Ambient Temperature: Electronic Adapter Ambient α α INV M 2 0.25 ADP M WDM * 50 °C [122 °F] α α INV M 2 0.37 ADP M WDM * 45 °C [113 °F] α...

  • Page 144: Homologation Cl (Version En Française)

    Approvals, standards and guidel ines 10.4.2 Homologation CL (Version en française) Température ambiante maximale: Électronic Adaptateur Ambiante α α 50 °C [122 °F] INV M 2 0.25 ADP M α α 45 °C [113 °F] INV M 2 0.37 ADP M α...

  • Page 145: Quickstart Guide

    11. Quickstart guide 11.1 Quickstart guide for asynchronous motors ..............146 11.2 Quickstart guide for synchronous motors ..............147 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...

  • Page 146: Quickstart Guide For Asynchronous Motors

    Quickst art guide 11.1 Quickstart guide for asynchronous motors Adapt adapter plate to motor and secure Motor and PTC connection T1, T2, U, V, W, PE on X411 L1, N, PE mains connection Terminals 1 – 3 on X1 Activate grid Communication Installation of INVEORpc...

  • Page 147: Quickstart Guide For Synchronous Motors

    Quickst art guide 11.2 Quickstart guide for synchronous motors Adapt adapter plate to motor and secure Motor and PTC connection T1, T2, U, V, W, PE on X411 L1, N, PE mains connection Terminals 1 – 3 on X1 Activate grid Communication Installation of INVEORpc...

  • Page 148: Index

    12. Index ......................71 Acknowledge function Ambient conditions ......................... 29 Ambient temperature ......................120 Analogue input ........................80 Application parameters ......................65 ............... 71, 72 Automatic acknowledgement function Block diagram ......................... 55 Blocking detection ........................93 Cable screw connections......................29 Cable shoes ..........................
  • Page 149 Index EMC limit classes ........................140 EMC screw connections ......................141 EMC standard ........................140 ........................69 Enable software Energy-saving function ......................62 Error detection ......................108, 114 Excess temperature ...................... 112, 113 External fault ........................... 91 Factory setting ........................64 Field bus ..........................
  • Page 150 Index Mains activations ........................20 ......................65 Maximum frequency Mechanical installation ......................48 Mechanical installation of size α ..................... 36 ......................65 Minimum frequency MMI ..........................54, 132 Model description ........................24 Motor ............................25 Motor adapter plates ......................124 ........................
  • Page 151 Index Quadratic characteristic curve ....................105 Quickstart guide ........................145 ..........................65, 67 Ramp Relay ............................86 Repairs ............................ 22 ......................... 70 Rotation direction ......................... 100 Rotation speed Safety instructions ......................15, 28 ......................... 97 Set bus time-out ...................... 97 Set field bus baud rate ............................
  • Page 152 Index UL 143 Undervoltage ........................ 111, 113 Wall adapter plates ....................... 126 Wiring instructions ........................34 Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...

  • Page 153: List Of Figures

    13. List of figures Fig.: 1 Structure of warnings ....................... 8 Fig.: 2 Example of an information note ..................10 Fig.: 3 Symbols within the information notes ................10 Fig.: 4 Symbols and icons used ....................11 Fig.: 5 Labels on the drive controller ..................12 Fig.: 6 Insulation test on the power board ..................
  • Page 154 List of figures Fig.: 33 Derating of maximum output current as a result of installation altitude ......121 Fig.: 34 Derating of maximum input voltage as a result of installation altitude ......122 Fig.: 35 Derating of maximum output current as a result of switching frequency ......122 Fig.: 36 Hole pattern for size α...
  • Page 155 Notes Operating manual for INVEOR α | DOC01539818 - 0004 | 2017-01 | V2.0 EN...
  • Page 156 KOSTAL Industrie Elektrik GmbH Lange Eck 11 58099 Hagen Germany Service-Hotline: +49 2331 8040-848 Phone: +49 2331 8040-800 Fax: +49 2331 8040-602 www.kostal-industrie-elektrik.com...

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