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motortronics CSD Series Operation & Service Manual

Variable frequency ac drive
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CSD Series
Variable Frequency AC Drive
Solid State AC Motor Control
CSD Series
Variable Frequency
AC Drive
½ - 30 HP
OPERATION & SERVICE MANUAL
REV2
7080601MN
MOTORTRONICS
- 73 -

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  • Page 1 CSD Series Variable Frequency AC Drive MOTORTRONICS Solid State AC Motor Control CSD Series Variable Frequency AC Drive ½ - 30 HP OPERATION & SERVICE MANUAL REV2 7080601MN MOTORTRONICS - 73 -...
  • Page 2 CSD Series Variable Frequency AC Drive MOTORTRONICS - 74 -...
  • Page 3 CSD Series Variable Frequency AC Drive Table of Contents Chapter 1: Introduction ....................1 1.1 General 1.2 Receiving 1.3 Warning 1.4 Theory of Operation Chapter 2: Installation/Specifications ................. 4 2.1 Location 2.2 Mounting Dimensions 2.3 Specifications Chapter 3: Wiring ......................8 3.1 Main Power Wiring...
  • Page 4 CSD Series Variable Frequency AC Drive MOTORTRONICS - 76 -...
  • Page 5 Series adjustable frequency AC drive. For basic start up instructions see the “Quick Startup” Manual. General The CSD Series is a compact AC drive featuring front panel keypad and display, plus an easy to use keypad mounted potentiometer. The CSD Series combines application flexibility with ease of operation.
  • Page 6 CSD Series Variable Frequency AC Drive This speed is described by this simple formula: Voltage 120 x Frequency Operating Point Synchronous Speed = 460 V # of Poles Where: 230 V • Synchronous speed is in RPMs (Revolutions Per Minute) •...
  • Page 7 CSD Series Variable Frequency AC Drive The CSD Series unit offers an optional function called dynamic braking. Dynamic braking, in adjustable frequency drives, allows the motor to produce 100% braking torque for a 10% duty cycle for four-quadrant operation (like DC regenerative drives). With dynamic braking, the...
  • Page 8 Shielded from direct sunshine • Free from metallic particles and corrosive gas. Make sure there is sufficient clearance around the CSD Series unit for Figure 2 - 1 Location and Positioning cooling, wiring and maintenance purposes. To maximize the effective air flow (and cooling), the inverter should be installed with its heatsink ribs oriented vertically.
  • Page 9 CSD Series Variable Frequency AC Drive 2.2 Dimensions Dim. Mounting Dim. Overall Dimensions Enclosure Ref. # NEMA 1 Figure 2 - 2A 11.3 11.9 NEMA 1 Dimensions 15.2 15.8 0.21 10.8 0.21 11.8 0.28 NEMA 4/4X 0.28 15.7 12.2 16.3 10.2...
  • Page 10 CSD Series Variable Frequency AC Drive 2.3 Specifications Rated Rated Rated Input Output Model Motor Current Output Voltage Voltage (KW) (KVA) CSD-2P5* CSD-201* 0.75 CSD-202* 1 or 3 CSD-203* 10.5 Phase 200-230V 3 Phase CSD-205 17.5 +10% 200-230V CSD-207 50/60 Hz CSD-210 13.3...
  • Page 11 CSD Series Variable Frequency AC Drive Carrier Frequency 1 - 12 KHz Frequency Control Range 0.1 - 400 Hz Digital: 0.01% Frequency Accuracy Analog: 0.4% 0.01 HZ with computer of PLC control, 0.1 Hz with keypad control with frequency Frequency Resolution...
  • Page 12 CSD Series Variable Frequency AC Drive Chapter 3 - Wiring This chapter deals with the recommended wiring practices for the CSD Series adjustable frequency drive. Please remember, you must always conform to the National Electrical Code (NEC) and any applicable local codes.
  • Page 13 CSD Series Variable Frequency AC Drive • NEVER CONNECT THE INPUT POWER WIRING TO DRIVE OUTPUT TERMINALS T1, T2, T3. IF YOU DO, THE UNIT WILL BE DAMAGED. • DO NOT touch any circuit components while AC power is on or immediately after the main AC power is disconnected from the unit.
  • Page 14 CSD Series Variable Frequency AC Drive 3.2 Grounding Always be sure to make a positive ground connection to the Earth terminal of the drive. This is necessary for both protection of personnel and for reliable, trouble free operation. Following are additional guidelines for proper grounding: •...
  • Page 15 CSD Series Variable Frequency AC Drive 3.4 Control Terminal Function Figure 3 - 2 Control Terminal Function MOTORTRONICS - 11 -...
  • Page 16 Variable Frequency AC Drive 3.5 Brake Motor Magnetic Contactor The CSD Series generates a variable voltage output. For this reason, when using a brake motor with the drive, the brake power supply must be connected directly to the AC line power. DO NOT take the power from the drive output.
  • Page 17 CSD Series Variable Frequency AC Drive Typical Components AC Coils DC Coils DC Snubber AC Snubber Ratings *Current > Coil VA Coil Voltage Voltage > 2 X Coil Diode Ratings Figure 3 - 4 Table 3 C 3.6 Line Reactors •...
  • Page 18 CSD Series Variable Frequency AC Drive 3.6.1 Initial Power Up • For initial test run procedure, see Chapter 7. • For initial start-up procedure, see Chapter 6. 3.7 External Brake Resistor Ratings Standard braking torque for all models is 20%. For 100% braking torque external braking transistors, resistors and/or a braking module may need to be added.
  • Page 19 Variable Frequency AC Drive 3.8 Power Terminal Block (TM1) Description The control part of the CSD Series drive is the TM1 or Power Terminal Block (the large terminal block on the bottom PC board). Listed in Table 3 F are the function descriptions of TM1. The symbols in parentheses are the European equivalent codes.
  • Page 20 CSD enclosure. Connections 3-9 are dry contacts only. Dry contact control wire connections must be less than 10 feet in length. Motortronics recommends using shielded cable or twisted pairs. Note TM2 torque specs is 7IN-LB. As you finish each connection, complete the accompanying programming.
  • Page 21 CSD Series Variable Frequency AC Drive 4.1.1 Terminals 1 & 2 Function: Fault/Trip Relay Normally Open = Program Fn98 to 0000 Relay Contact to output alarm signal when protective circuit is activated. Normally Closed = Program Fn98 to 0100. Contact Rating: 250 VAC/1 Amp or 30 VDC/1 Amp Refer to Fn 97 - Fn98 for programming the functionality of the fault relay.
  • Page 22 CSD Series Variable Frequency AC Drive 4.1.2c Momentary Start/Stop Switches and Maintain FWD/REV Switch The diagrammed connections allow remote control to momentarily Program Fn10 to 0001 start/stop and maintain the motor direction. A Momentary Normally and Fn3 to 0010 Open (N.O.) switch is required for starting. A Momentary Normally Closed (N.C.) switch is required for stopping.
  • Page 23 CSD Series Variable Frequency AC Drive 4.1.5 Terminal 11 Function: Multifunction Output (Contact rated for 50mA at 35VDC maximum) This terminal is used for the drive’s programmable function, open- collector output. This output can serve any of three purposes, depending upon the value programmed into Fn61: Fn61 = 00 - 05: transistor is normally off.
  • Page 24 CSD Series Variable Frequency AC Drive Remote Analog Frequency Command Jumpers Jumpers 1 and 2 can be used to select remote frequency command signal (See Figures 4 - 3 & 4 - 4). JP1 JP2 Figure 4 - 3 Jumper Locations...
  • Page 25 CSD Series Variable Frequency AC Drive 4.2.3 Remote 0-10VDC Analog Control Signal This allows motor speed control from a remote analog 10VDC signal Program Fn11 to 0002 connected as shown. Connect the positive lead of the control signal to TM2-13 and the negative lead of the control signal to TM2-14.
  • Page 26 Variable Frequency AC Drive Chapter 5 - Digital Operator Control/Keypad Operation 5.1 Introduction This chapter explains the command keys, LED Display, flashing lights and shows how easy the CSD Series is to program. SEQ FRQ FWD REV Command Keys 8 8 8 8 VOLT 1.
  • Page 27 CSD Series Variable Frequency AC Drive 5.1.1 The CSD Function List The following list includes the basic information on each function within the CSD. For detailed function information, review the referenced page. Also, the Function Notes, in and at the end of this section, are for any additional operator notes.
  • Page 28 CSD Series Variable Frequency AC Drive Notes: *1: Settings can be changed during run mode *2: Settings cannot be changed in communication mode *3: Settings will not change when returning to factory defaults. *4: SETTINGS RANGE: The settings of accel/decel time and fre- quency are only four digits when set by keypad (for example: 3599 sec/399.9 Hz), but 5 digits (for example: 3599.9 sec or 399.99 Hz)
  • Page 29 CSD Series Variable Frequency AC Drive Notes: *1: Settings can be changed during run mode *2: Settings cannot be changed in communication mode *3: Settings will not change when returning to factory defaults. *4: SETTINGS RANGE: The settings of accel/decel time and fre- quency are only four digits when set by keypad (for example: 3599 sec/399.9 Hz), but 5 digits (for example: 3599.9 sec or 399.99 Hz)
  • Page 30 CSD Series Variable Frequency AC Drive MOTORTRONICS - 26 -...
  • Page 31 CSD Series Variable Frequency AC Drive Notes: *1: Settings can be changed during run mode *2: Settings cannot be changed in communication mode *3: Settings will not change when returning to factory defaults. *4: SETTINGS RANGE: The settings of accel/decel time and fre- quency are only four digits when set by keypad (for example: 3599 sec/399.9 Hz), but 5 digits (for example: 3599.9 sec or 399.99 Hz)
  • Page 32 CSD Series Variable Frequency AC Drive MOTORTRONICS - 28 -...
  • Page 33 CSD Series Variable Frequency AC Drive 5.2 Function Parameter Setting (Effective in Program Mode) 5.2.1 Changing the Function Parameter (Also review diagram in Section 5.1) Table 5 C - Changing Parameters 5.3 Function Descriptions Fn00 = Drive Capacity Selection Fn00 defines the drive model number to the microprocessor. Fn00 is set at the factory for the model number of the drive.
  • Page 34 CSD Series Variable Frequency AC Drive 2. There is a second accel/decel time available. This can be adjusted by changing Fn49 and Fn50. The selection of accel or decel times 1 or 2 is made by changing one of the multifunction digital input termi- nals to an accel/decel time selection contact.
  • Page 35 Protects all other parameters except the preset speeds Fn05 = V/f Pattern Selection - Factory Setting = 9; Range = 0 - 18 The CSD Series drive offers 18 preprogrammed V/f patterns for a variety of applications. Fn05 determines which pattern is applied. In addition to the 18 predefined patterns the user can custom design a V/f pattern when Fn05=18.
  • Page 36 CSD Series Variable Frequency AC Drive Fn06 = Frequency output upper limit - Factory Setting = 60 Hz; Range = 0 - 400 Hz Fn07 = Frequency output lower limit - Factory Setting = 0; Range = 0 - 400 Hz Fn06 and Fn07 program maximum and minimum allowable frequencies.
  • Page 37 CSD Series Variable Frequency AC Drive *For 0-5 VDC analog command signal control: connect the command signal positive to TM2-13 and the command signal negative toTM2-14. Also install the shorting plug on JP1 pins 1 and 2. *For 0-10 VDC analog command signal control: connect the command signal positive to TM2-13 and the command signal negative to TM2- 14.
  • Page 38 CSD Series Variable Frequency AC Drive Fn13 = Stall prevention level during accel - Factory Setting = 110%; Range = 30% - 200% Fn13 determines the level of current (measured in percent of drive rated current) at which stall prevention will activate when the drive is in the acceleration mode.
  • Page 39 CSD Series Variable Frequency AC Drive Fn17 - Fn23 = 0 - 400 Hz: Multispeed 1 - 7 Fn17 - Fn23 are seven preset speed settings. When Fn56 - 58 changes from 0 to 2, the switches connected to TM2 pins 6 - 8 can control the speed of the drive.
  • Page 40 CSD Series Variable Frequency AC Drive Fn24 = Jog frequency reference - Factory Setting = 2.0 Hz; Range = 0 - 400 Hz Fn24 sets the jog speed. The jog speed can be activated by one of the multiple function input switches TM1 pins 6 - 8 by programming Fn56 - Fn58 = 3.
  • Page 41 CSD Series Variable Frequency AC Drive Fn30 = Voltage of Power Supply Fn30 must be programmed to the supply voltage. Fn30 provides the correct voltage to the motor for the various V/f patterns. It also determines the braking transistor setpoint.
  • Page 42 CSD Series Variable Frequency AC Drive Fn37 to Fn41: Custom Program V/f Pattern Setpoints. If there is not a suitable preprogrammed V/f pattern for the application, change Fn5 = 18 and select the required values for Fn37 to Fn41 that will satisfy the requirements of the application.
  • Page 43 CSD Series Variable Frequency AC Drive Fn44 = Stopping Mode and Braking Resistor Protection - Factory Setting = 0000 Controls the stopping style and the brake resistor protection circuit. XXX0: Decel to stop with a stop command. XXX1: Free run (coast) to stop with a stop command.
  • Page 44 CSD Series Variable Frequency AC Drive XX1X: Stop key ineffective in remote control mode - disables the above feature. The speed search is used in windmilling applications. The drive will find the operational speed of the motor and start. X0XX: Speed search controlled by terminals on TM2 - allows the user to enable speed search at all times or only through one of the multifunction inputs on TM2 pins 6 - 8.
  • Page 45 CSD Series Variable Frequency AC Drive Fn52 = Line speed display in accordance with maximum output frequency (Fn06) Stopping Mode The CSD drive, after decelerating the load to zero speed applies a small amount of DC current into the motor to bring the motor to a final stop.
  • Page 46 CSD Series Variable Frequency AC Drive 05/21: External emergency stop Defines this terminal as an emergency stop command. By programming one of the multifunction switches as an emergency stop the customer can override a run command and force the drive to decelerate to a stop.
  • Page 47 CSD Series Variable Frequency AC Drive parameters can be changed by the external communication source. The keypad and TM2 signals for run/stop and frequency control will be disabled. The keypad can still be used for displaying voltage/current/ frequency or emergency stop but the keypad can not be used for changing function parameters.
  • Page 48 CSD Series Variable Frequency AC Drive 16-31: Changes 00-15 N.O. (normally open) contact to N.C. (normally closed) contact Fn59 - Fn 60 = Reserved Fn61 = Digital Multifunction Output - Factory Setting = 00; Range = 00 - 11 The open collector transistor output of TM1 pins 10 & 11 are used for several indications.
  • Page 49 CSD Series Variable Frequency AC Drive Whenever the output of the drive is < Fn08 the transistor will be on. 04/10: Frequency detection < Fn08 Places the open collector output transistor in the frequency detection less than mode. When the output of the drive is < Fn08 the transistor will be on.
  • Page 50 CSD Series Variable Frequency AC Drive Fn69 = Factory Setting = 0000 Controls four parameters of motor protection. The first digit controls whether motor protection is provided by the drive or by another outside source. XXX0: Electronic thermal motor protection effective...
  • Page 51 CSD Series Variable Frequency AC Drive Fn70 = Electronic thermal overload reference current (motor rated current) Defines the motor rated current for the drive to set up the overload protection curves as well as for slip compensation. Program the motor rated current (FLA) into Fn70.
  • Page 52 CSD Series Variable Frequency AC Drive Overtorque Control Fn77 - Fn79 define the characteristics of the drive’s overtorque control. The drive will detect an overtorque condition if the motor current is above the detection level defined by Fn78 for the time defined by Fn79.
  • Page 53 CSD Series Variable Frequency AC Drive Energy Savings Control Fn82 and Fn83 provide energy savings for variable torque applications. In variable torque applications the load is usually a high inertia load that requires large starting torques but lower running torque.
  • Page 54 CSD Series Variable Frequency AC Drive Figure 5 - 10B 2nd Process Time Parameter Note: A new speed setting or timer setting cannot be inserted into an ongoing timer and speed function. The priority of the preset speed signals is as follows: Jog >> Multiple Speed >> Digital Operator. The jog contact has the highest priority and the digital operator has the lowest priority.
  • Page 55 CSD Series Variable Frequency AC Drive Fn98: XXX0: Fault contact is not energized after overtorque (OL3) is detected. XXX1: Fault contact is energized after overtorque (OL3) is detected XX0X: Fault contact is not energized after electronic thermal motor protection (OL1) is acting.
  • Page 56 CSD Series Variable Frequency AC Drive Fn123 = 1111: Revert to Factory Setting The parameters of the drive can be set back to factory settings (with the exception of Fn0, 5, 6, 30, 100-106, 124) by programming Fn123 = 1111.
  • Page 57 CSD Series Variable Frequency AC Drive Chapter 6 - Initial Start Up This chapter deals with the basic start up of the drive. The procedures range from the first power off checks to actual motor operation. It assumes all of the program settings are left at the factory values.
  • Page 58 CSD Series Variable Frequency AC Drive Keypad Start-up Display Example 1. Apply AC power. After a five second power up 05.00 6.3 Keypad Operation the display will indicate as shown. After the direction of motor rotation is verified you are ready to operate the drive 2.
  • Page 59 For further detailed descriptions of parameter programming see Chapter 5. Initial Programming This section details recommended programming. The CSD Series is provided with factory preset parameters that are suitable for most applications. Review the factory settings for each parameter before making any changes.
  • Page 60 CSD Series Variable Frequency AC Drive 6.6.4 Auto Restart After Fault Trip Factory Setting: Fn16 = 0000 (Restart disabled) Fn34 = 0 (Restart interval. Range: 0-800 sec.) Fn35 = 0 (Number of attempts. Range: 0-10) The unit can be programed to automatically attempt a restart after a...
  • Page 61 CSD Series Variable Frequency AC Drive Chapter 7 - Failure Indication 7.1 Failure which cannot be manually reset. Fault Content Probable Cause What to Do Code Install RC type CPU software suppressor on all High electronic noise error contactor/brake coils See section 3.5.2...
  • Page 62 CSD Series Variable Frequency AC Drive 7.3 Failure which can be auto reset or manually reset. Note: When braking resistor is overloaded during deceleration, the drive will stop braking and will display OH1. When heat is dissipated, OH1 will disappear and the drive will start braking again.
  • Page 63 CSD Series Variable Frequency AC Drive 7.5 Operation Error Indications 7.6 One Final Fault Note If the circuit breaker did not trip, remove power, wait 1 minute, reapply power and see if the trip condition clears. If the condition has not cleared, replace the drive.
  • Page 64 CSD Series Variable Frequency AC Drive Chapter 8 - Troubleshooting 8.1 General Troubleshooting If the drive malfunctions, find the cause and take the corrective actions by following the flowcharts. If the cause cannot be located in the flowcharts contact MOTORTRONICS.
  • Page 65 CSD Series Variable Frequency AC Drive MOTORTRONICS - 61 -...
  • Page 66 Table 8 A - Power Connection Troubleshooting 8.3 Maintenance The CSD Series drive requires no routine checks. It will function efficiently and its normal operation lifetime will be longer if it is kept clean, cool and dry. However, loose electrical connections will cause...
  • Page 67 CSD Series Variable Frequency AC Drive 8.3.1 Mega Test Check for tightness of electrical connections, discoloration or other signs of overheating. During service inspection, turn off AC main circuit power and wait for charging indicator LED 101 to extinguish (or at least 10 minutes) before touching any circuit components.
  • Page 68 Figure 9-1 - Measuring Volage and Current 9.2 Electromagnetic Compatibility of AC Drives Similar to all modern PWM variable speed drives the CSD Series AC Drives uses fast switching of high voltage and currents to achieve high efficiency and reduced motor acoustic noise. This results in electromagnetic interference (EMI) and radio frequency interference (RFI) that occurs at the switching frequency and harmonics of this frequency.
  • Page 69 CSD Series Variable Frequency AC Drive Filtering - The use of filters in suppressing EMI and RFI is aimed at preventing interference passing down power lines and changing impedance conditions so EMI on the ground system is redirected back to its source. A filter on the input side can use capacitors and chokes and has significant benefits in reducing EMI.
  • Page 70 Table 9 C - AC Drive Model Definitions Extension Keypad Remote Cable There are two (2) keypad sizes for the CSD series inverters. Please see Table 9 D for the appropriate extension keypad remote cable and then refer to the corresponding assembly diagram.
  • Page 71 CSD Series Variable Frequency AC Drive 9.4.1 Digital Operator Remote Cable Connection (CSDW300X) A. Plastic housing for digital operator front side 1 rear side 3 B. Digital Operator 2 C. Remote cable 4 CSDW 3001 (1 meter) CSDW 3002 (2 meter) CSDW 3003 (3 meter) D.
  • Page 72 CSD Series Variable Frequency AC Drive 9.4.2 Digital Operator Remote Cable Connection (CSDW 300XA) A. NDOP-02 Digital Operator 1 B. Remote cable 2 CSDW 3001 A (1 meter) CSDWW 3002 A (2 meter) CSDWW 3003 A (3 meter) C. Remote cable adapter 3 D.
  • Page 73 CSD Series Variable Frequency AC Drive 9.5 Drive Settings - The following chart may be used to record the changes made to the factory settings. Fn XX Function Page Set To Check Revised Check Capacity 01 -02 Accel / Decel Time Remote Operation Select / Rev.
  • Page 74 CSD Series Variable Frequency AC Drive Prepared By: Date: Set By: Date: Received By: Date: MOTORTRONICS - 70 -...
  • Page 75 Variable Frequency AC Drive Warranty Policy Motortronics warrants its products to be free from defects in material and/or workmanship for a period of one year from date of installation, to a maximum of 18 months from the date of shipment as indicated by the unit's date code.
  • Page 76 CSD Series Variable Frequency AC Drive 1600 Sunshine Drive, Clearwater, FL USA 33765 Phone: 727.573.1819 or 888.767.7792 Fax: 727.573.1803 or 800.548.4104 E-mail: Motorctrl@aol.com www.motortronics.com MOTORTRONICS - 72 -...

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