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TWERD Power Electronics AFC200 User Manual

Frequency converter, 0,37-3,0 kw, single phase supply 230v
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TWERD Power Electronics
TWERD
Frequency converter
AFC200 type
0,37 - 3,0 kW
Single phase supply 230V
User's manual
Edition 3.3
twerd
www.
.pl

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Summary of Contents for TWERD Power Electronics AFC200

  • Page 1 ® TWERD Power Electronics TWERD Frequency converter AFC200 type 0,37 - 3,0 kW Single phase supply 230V User’s manual Edition 3.3 twerd www.
  • Page 3 Frequency converter AFC200 type 0,37 - 3,0 kW Single phase supply 230V User’s manual Edition 3.3...

  • Page 5: Table Of Contents

    Contents Contents Technical data of frequency converters AFC200..........7 1. Conditions of safe operation................9 1.1. Threats and warnings................9 1.2. Basic rules..................10 1.3. Operation list..................10 1.4. Disposal considerations..............10 1.5. Environmental conditions..............11 1.6. Limits of responsibility................11 2. Installation of the frequency converter............12 2.1.
  • Page 6 8.3. Failure log..................53 9. Restore factory parameters...............53 10. Periodic service..................54 Appendix A – AFC200 frequency converter parameters table.......55 Appendix B – Start / Stop control structure............70 Appendix C – Frequency referencing-unit structure........71 Appendix D – EU Declaration of Conformity..........72...

  • Page 7: Technical Data Of Frequency Converters Afc200

    Technical data of frequency converters AFC200 Technical data of frequency converters AFC200 Table 0.1. Technical data, common for frequency converters of the AFC200 series 1-phase: 230 V (-15%, +10%) / 45..66 Hz; Voltage U Power supply other voltage levels are available on request Voltage 3-phase: 0..U...
  • Page 8 Control of Checking the absence of “living null” in modes analog inputs 2..10V and 4..20mA Table 0.2. Technical data of frequency converters of the AFC200 series, depending on a type Constant-torque load Variable-torque load Type of a (permissible overload...

  • Page 9: Conditions Of Safe Operation

    Ignorance of these instructions can result in serious injury or death to personnel or damage to the frequency converter. 1.1. Threats and warnings Incorrect installation or use of the AFC200 frequency converter may cause a risk to life, human health or irreparable damage to the device. RISK OF ELECTRIC SHOCK •...

  • Page 10: Basic Rules

    1.4. Disposal considerations Equipment containing electrical and electronic components can not be removed into municipal waste containers. Such equip- ment must be separated from other wastes and attached to electrical and electronic waste in accordance with applicable local regulations. TWERD Power Electronics...

  • Page 11: Environmental Conditions

    106 kPa 1.6. Limits of responsibility • Despite all the efforts and due diligence, TWERD Power Electronics does not guarantee that the published data is error-free. • The User is obliged to read the information contained in this Manual be- fore using the device.

  • Page 12: Installation Of The Frequency Converter

    If a dif- ferential-current device is used, due to the different nature of the differential current, only circuit breakers of a B type are permitted. TWERD Power Electronics...
  • Page 13 It is necessary to wait 5 minutes before switching on the power strip of the frequency converter. The information about danger of such voltage is also placed on the terminal block cover. TWERD Power Electronics...

  • Page 14: Assembly Of The Frequency Converter

    To ensure appropriate air circulation, the converter must be mounted vertically with a free space around the device: 10 cm from the top and the bottom and 3 cm on both sides of the device. The dimensions of the AFC200 frequency converters are presented in figure 2.1. 3 cm 3 cm Fig.
  • Page 15 Section 2: Installation of the frequency converter Ø Ø Fig. 2.2. The dimensions of the AFC200 frequency converters Table 2.1. The dimensions of the AFC200 frequency converters Size Type: Weight [mm] AFC200/... [kg] Ø 0,37 kW 0,80 0,55 kW 0,80...

  • Page 16: Connecting The Power Circuit

    Section 2: Installation of the frequency converter 2.3. Connecting the power circuit • The AFC200 frequency converter is powered by a single phase voltage 230 VAC, 50 Hz. • Connect the frequency converter to electric motor using the shortest pos- sible symmetrical shielded cable.

  • Page 17: Connection Of Control Systems

    Analog Output 1 (current mode) X1:5 AGND Analog Ground Use only for connecting analog inputs/outputs signals X1:6 Analog input 1 (voltage Input impedance:  470 kOhm mode) X1:7 Analog input 2 (current Input impedance: mode) = 500 Ohm TWERD Power Electronics...

  • Page 18: Using Contactors And Circuit Breakers At The Frequency Converter Output

    (circuit breaker) must absolutely(!) be carried out in the voltageless state, when the converter is stopped (STOP state). Otherwise, there will be damage to the converter not covered by the warranty. TWERD Power Electronics...

  • Page 19: The Control Panel

    2: referencing-units and control, • group 3: failures, • group 4: access codes, settings of RS communication and the dis- play. Editing any parameter from groups 1 ... 4 takes place according to the scheme shown in fig. 3.3. TWERD Power Electronics...
  • Page 20 CURRENT [A] ↔ PAR. GROUP 1 ↔ VOLTAGE [V] ↔ PAR. GROUP 2 ↔ TEMPERATURE ↔ PAR. GROUP 3 ↔ REVOLUTIONS ↔ PAR. GROUP 4 ↔ FREQUENCY [Hz] ↔ THE QUICK PREVIEW Fig. 3.2. Control panel operation diagram TWERD Power Electronics...
  • Page 21 Groups 1 ... 4 only from changing ↔ ↑ ↓ the parameter value ↔ CHANGING THE PARAMETER NUMBER EDITING THE PARAMETER ↑ ↓ Saving the new parameter value PAR. GROUP 2 Fig. 3.3. An example of editing a parameter TWERD Power Electronics...
  • Page 22 FAULT Output frequency [Hz] Output current [A] FAULT FAULT Rotation speed DC voltage [V] [rpm] FAULT FAULT Temperature [ºC] FAULT Fig. 3.4. Quick view mode: required user actions using the keyboard and views of the display status TWERD Power Electronics...
  • Page 23 Example: changing the value of the parameter 3.02 Parameter for editing FAULT Going for editing Saving changes Discarding changes FAULT FAULT Changed The current parameter value parameter value - ready to save Fig. 3.5. Changing the parameter value 3.02 (group 3) TWERD Power Electronics...

  • Page 24: The First Start

    ……..…....<par.1.05> – nominal motor cos  …......…...<par. 1.06> After entering the above nominal motor data, the system is ready to operate in U/f scalar mode. The control takes place via the control panel (described in section 3). TWERD Power Electronics...

  • Page 25: Configuration Of The Frequency Converter

    - Constraint of control START / STOP Control place B - Digital inputs with RS-485 - RS-485 Possible control sources: - PI controller Par. 2.03 (ref.-unit) Par. 2.05 (start) Par. 2.01 Par. 2.07 (direction) Fig. 5.1. AFC200 simplified control structure TWERD Power Electronics...

  • Page 26: Control From The Control Panel

    2.31 and 2.32 should be set to "0" – Off. • Set parameter 2.08 - Remote start. It defines the functions of the control digital inputs according to the table 5.1. • Activate the desired control place with the parameter 2.01. TWERD Power Electronics...
  • Page 27 (according to the "or" logic gate) will cause the = START / STOP system to start. Applying voltage to the DI1 and DI2 digital inputs DI1 and DI2 (according to the "and" logic gate) will cause the = START / STOP system to start. TWERD Power Electronics...
  • Page 28 P connected to the analog input AI1. Start / stop is done with the switch S1 and change of direction with the switch S2. AGND +24V Fig. 5.2. Connections on the terminal block X1 for remote control of AFC200 TWERD Power Electronics...

  • Page 29: Shaping The Drive Dynamics

    U0 (par. 1.50), f0 (par. 1.51) and intermediate U1 (par. 1.52), f1 (par. 1.53). Fig. 5.3a shows the characteristics for linear and square-law U/f mode, and Fig. 5.3b shows how to shape the U/f characteristic using intermediate points U0, f0 and U1, f1. TWERD Power Electronics...

  • Page 30: Operation In Vector Mode

    In the "U/f square-law" operating mode, the characteristics are limited to the initial points U0, f0. 5.5. Operation in vector mode Vector sensorless operation mode is available on the AFC200 frequency converter. In order for the converter to operate in this mode, it is necessary to run an identification run beforehand.

  • Page 31: Analogue Inputs

    AI2 low pass filter Similarly as above 2.50 time constant AI1 input value Read-only. 0.40 E.g. for the 0..10V range, 5V corresponds to 50.0% Read-only. AI2 input value 0.41 E.g. for the 0..20mA range, 10mA corresponds to 50.0% TWERD Power Electronics...
  • Page 32 Value in [%] : -500.0 ... 500.0 % 2.44 referencing- unit scale Value in [%] : -500.0 ... 500.0 % 2.46 referencing- unit offset Value in [%] : -500.0 ... 500.0 % 2.47 referencing- unit offset TWERD Power Electronics...
  • Page 33 [%] and AI1= 30.0%, then A1 referencing-unit = 20.0% + 50.0% * 30.0% / 100.0% = 35.0% Read-only. 0.46 referencing- A2 referencing-unit = par. 2.47 + par. 2.44 * unit value [%] AI2 / 100.0% TWERD Power Electronics...

  • Page 34: Analog Output

    = 100.0% * 117/1000 = 11.7% (0 ... 10V) = 1.17 V AO1 low pass AO1 analog output filter. Details in Appendix A. U [%] filter time constant Filtered value 100% 2.86 Voltage t [s] Constant Filter TWERD Power Electronics...

  • Page 35: Constant Speeds Operation

    Constant speed No. 4, by default 30 Hz (par. 2.36) Constant speed No. 5, by default40 Hz (par. 2.37) Constant speed No. 6, by default 45 Hz (par. 2.38) Constant speed No. 7, by default 50 Hz (par. 2.39) TWERD Power Electronics...
  • Page 36 Constant speed No. 3, by default 25 Hz (para. 2.35) Note: The digital input DI4 is set by default as the external reset source, therefore before using it to set the constant speeds, parameter 3.70 should be changed to "0" - Disable. TWERD Power Electronics...
  • Page 37 Speed selection: applying 24Vdc voltage to digital inputs DI5 and/or DI6 according to table 5.6. (DI6) (DI1) (DI2) (DI3) (DI4) (DI5) (+24V) Change of START/ direction STOP Fig. 5.4. Connection system on terminal block X1 for three constant speeds TWERD Power Electronics...

  • Page 38: Motopotentiometer

    An example of how to connect the "increase" and "decrease" buttons is shown in Fig. 5.5a. The operation of the system is illustrated in Fig. 5.5b. TWERD Power Electronics...
  • Page 39 In the above-mentioned example, the digital inputs DI5 and DI6 were used, which corresponds to the settings: par. 2.20 = "5", par. = 2.21 "6". The change of the rise/fall time of the motopotentiometer referencing-unit in the range of 0.1..320.0 s. is made by par. 2.23. TWERD Power Electronics...

  • Page 40: Elimination Of Frequencies

    During acceleration and deceleration, the frequency range elimination function is inactive. f ref. f before elemination 1.93 1.90 1.91 1.92 1.94 1.95 Parameters 1.90 ... 1.95 . 5.6.Elimination bands - sample configuration. Bands 2 and 3 overlap TWERD Power Electronics...

  • Page 41: Electric Motor Rotation Direction Lock

    3.05 - time constant of motor heating. This is the time after which the motor temperature reaches 63% of the final temperature increase value. In practice, it is possible to set par. 3.05 = 120 * t6 [min], where t6 [s] is given by the motor manufacturer. TWERD Power Electronics...
  • Page 42 Par. 3.04 OPERATION AREA 105% 100% Ts – electric motor temperature 25Hz f [Hz] Time Constant heating time, par. 3.05 . 5.7. Defining long-term operation area (a), dependence of calculated motor temperature on current (b) and (c) TWERD Power Electronics...

  • Page 43: Operating At Frequencies Exceeding 50 Hz

    Maximum output frequency F max > Ref. max usually Fmax = Ref. max + 5 Hz Example settings of par. 2.12 and 1.40 for operation at 70 Hz par. 2.12 = 70 Hz par. 1.40 = 75 Hz TWERD Power Electronics...

  • Page 44: Pi Controller

    (par. 2.02 for control place A, or par. 2.03 for control place B) must be set to PI controller ("4" - OUT.PI). The referencing-unit value can be changed in the range from 0.0% to 100.0%. FAULT Fig. 6.2. Changing the PI controller ref.-unit value (keyboard ref.-unit: par 2.60 = 0) TWERD Power Electronics...
  • Page 45 The minimum value that the PI controller output can 2.67 Min.Out.PI reach (saturation limitation) Range: -3000.0 ... 0.0 % Resetting the PI output when the system is stopped: 2.68 PI reset 0: reset to STOP 1: the controller is always active TWERD Power Electronics...

  • Page 46: Frequency Converter Control Via Rs-485 Communication Link

    Fig. 7.1. Addressing parameters for the MODBUS protocol The figure above shows how to address parameters in the AFC200 frequency converter in the case of the MODBUS protocol. For example, parameter 1.01 corresponds to address (41001)d, parameter 2.12 corresponds to address (42012)d etc.

  • Page 47: Parameters Regarding Communication Via Rs-485

    If the RS control is blocked (par. 4.07) and the parameters 2.02, 2.03, 2.04 or 2.05 define the control as "RS", then the system remains in STOP mode or the referencing-unit of frequency will assume value 0. TWERD Power Electronics...

  • Page 48: Map Of Registers Accessible Through Rs-485 Link

    RS. Resolution 0,1Hz *), a range - 32000...32000 2001 Read/ write e.g. 2500 = 25.0 Hz clockwise rotation e.g.-1220 = 12.20 Hz anti-clockwise rotation *)CAUTION: in Vector mode, the value is expressed in revolutions per minute (rpm). TWERD Power Electronics...
  • Page 49 12 – 1 = START / STOP set through RS link bit 13 – 1 = he referencing-unit of frequency comes from communication link RS bit 14 – 1 = CONSTANT active frequency (f const) bit 15 – not used 2005 Not used Read only TWERD Power Electronics...
  • Page 50 42001 cor- Read / write responds to parameter 2.01. REMARKS as above 43xxx Parameters from group 3. REMARKS as above Read / write 44xxx Parameters from group 4. REMARKS as above Read / write TWERD Power Electronics...

  • Page 51: Handling Communication Errors

    80ºC. high. contamination). Too high voltage in Check mains supply. High voltage in DC the circuit, intensive Increase the braking E. 3 FAULT circuit braking of the electric time (deceleration) motor. in par. 1.31. TWERD Power Electronics...

  • Page 52: Deleting Failure Message

    FAULT signal is exceeded. mission are incor- ness of RS paramet- rectly set up. ers. Deleting failure message. 8.2. Manual deleting To delete the failure message press the stop button ( ) for at least 2 seconds. TWERD Power Electronics...

  • Page 53: Failure Log

    Thanks to this, the real number of fail - ures that can be stored increases. 9. Restore factory parameters To restore factory parameters set parameter 4.4 to "1". PD2 access level is required (par. 4.02). TWERD Power Electronics...

  • Page 54: Periodic Service

    The manufacturer is not responsible for any defects resulting from transport, misuse, faulty installation, inadequate environmental conditions (e. g. temperature, humidity, presence of caustic agents) and as a result of exceeding the nominal parameters. TWERD Power Electronics...

  • Page 55: Appendix A - Afc200 Frequency Converter Parameters Table

    Appendix A – AFC200 frequency converter parameters table Appendix A – AFC200 frequency converter parameters table The parameters numbers given in the appendix refer to the display on the control panel. When reading the record via the RS link, each parameter is read/written by a different register.
  • Page 56 Appendix A – AFC200 frequency converter parameters table Parameter Name Description 0.48 DI state State of all six digital inputs (for RS six youngest bits of the re- gister) 0.50 RS1 state It corresponds to the value written into the register 2000 through RS connection 0.51...
  • Page 57 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 1.20 Frequency con- 0-U/f lin.: operation in scalar mode Operating verter operating (linear characteristic) mode mode 1-U/f sq.: as above (square-law char-...
  • Page 58 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 1.53 F1 frequency 0.0 ... 25.0 % 25,0 % 1.60 Slip compensa- 0-NO: disabled tion...
  • Page 59 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 1.92 Minimum fre- 0.00 ... 320.0 Hz 0.00 Hz F elim2 min quency of fre-...
  • Page 60 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 2.02 Choice of a ref- 0-Keyb .: frequency ref.-unit from the Ref. A erencing-unit for...
  • Page 61 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 2.08 Variant of 0: DI1 = START/STOP, DI2 =direction Remote Start START/STOP 1: DI1 = START RIGHT, DI2 =...
  • Page 62 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 2.22 Motopoten- 0: sending STOP signal by pushing Motopot. tiometer mode STOP button causes resetting of...
  • Page 63 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 2.32 Source of W3 as above FConst2 src signal for referencing constant speeds 2.33 Constant fre- 0.00 ...
  • Page 64 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 2.46 Offset of analog -500.0 ... 500.0 % 0.0 % AI1 Offs. referencing- unit RefA1 2.47...
  • Page 65 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 2.68 Resetting PI out- 0: reset on STOP PI Out. reset put when the 1: controller is continuously active...
  • Page 66 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 2.90 Function 1 of the 0-Not active: relay inactive K1 funct. 1 K1 relay 1-Operation: active when there is...
  • Page 67 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 2.112 Emergency stop 0-Off: the emergency stop function Emergency from digital in- from digital inputs is disabled...
  • Page 68 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 3.70 Source of ex- 0-Off: no possibility of external eras- Ext. reset ternal reset ing of a failure 1-DI1 ..
  • Page 69 Appendix A – AFC200 frequency converter parameters table Parameter / Function Available options / measurement Factory Change Name unit / comments setting during opera- tion 4.09 Identification num- 0 ... 247 Unit no. ber of Modbus device 4.10 Value displayed 2: parameter 0.02 …...

  • Page 70: Appendix B - Start / Stop Control Structure

    Appendix B – Start / Stop control structure Appendix B – Start / Stop control structure TWERD Power Electronics...

  • Page 71: Appendix C - Frequency Referencing-Unit Structure

    Appendix C – Frequency referencing-unit structure Appendix C – Frequency referencing-unit structure TWERD Power Electronics...

  • Page 72: Appendix D - Eu Declaration Of Conformity

    Appendix D – EU Declaration of Conformity Appendix D – EU Declaration of Conformity en_afc200_edition-3.3_a5 / 2020-01-21 TWERD Power Electronics...
  • Page 74 Zakład Energoelektroniki TWERD Sp. z o.o. ul. Aleksandrowska 28-30 87-100 Toruń, PL tel. +48 56 654 60 91 e-mail: twerd@twerd.pl SCALONE FIGURY...

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