Do you have a question about the KINESYS HFI-MM and is the answer not in the manual?
Questions and answers
Summary of Contents for Hydac KINESYS HFI-MM
Page 1
Operating manual HFI – MM Frequency inverter...
Page 2
Operating manual HYDAC International GmbH Industriestraße D-66280 Sulzbach/Saar kinesys@hydac.com NOTE This operating manual was made to the best of our knowledge. Nevertheless and despite the greatest care, it cannot be excluded that mistakes could have crept in. Therefore please understand that in the absence of any provisions to the contrary hereinafter our warranty and liability –...
Suitable installation location for the motor-integrated drive controller ......19 Basic connection versions .................... 19 Short circuit and ground protection ................22 Wiring instructions ......................22 Preventing electromagnetic interferences ..............24 Installing the drive controller integrated in the motor ............25 Mechanical installation ....................25 kinesys@hydac.com...
Page 4
Switching frequency ..................... 68 Controller data ......................68 Quadratic characteristic curve ..................70 Synchronous motor controller data ................70 Field bus ........................71 Error detection and troubleshooting ..................72 List of the LED flash codes for error recognition ..............72 kinesys@hydac.com...
Page 5
Approvals, standards and guidelines .................. 84 EMC limit classes ........................ 84 Classification acc. to IEC/EN 61800-3 ................. 84 Standards and guidelines ....................84 UL approval ........................85 UL Specification (English version) ................85 Homologation CL (Version en française) ..............87 Index ............................. 91 kinesys@hydac.com...
We assume no liability for any damage resulting from non-observance of this manual. This manual is an integral part of the product and applies exclusively to the HFI-MM from HYDAC. Provide the operator of the system with this manual so it is available when needed.
The drive controller may only be assembled, operated, maintained and installed by trained and qualified staff. Fig.: 2 Example of an information note Symbols within the information notes Important information Damage to property possible Other notes INFORMATION Enlarged representation kinesys@hydac.com...
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 Danger due to electrical shock and discharge. Wait two minutes (discharge time of the capacitors) after shut-down kinesys@hydac.com...
In the context of this operating manual, qualified staff refers to electronics specialists who are familiar with the installation, assembly, commissioning and operation of the drive controller and the dangers involved, and whose specialist training and knowledge of relevant standards and regulations provide them with the necessary abilities. kinesys@hydac.com...
This drive controller may not be operated in areas where there is a danger of explosion. 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 HYDAC will be invalidated in such cases.
They contain important information on the installation and operation of the drive controller. In particular, note the information in the "Important information" chapter. HYDAC assumes no liability for damages arising from the non-observance of this operating manual.
The following terminals may lead to dangerous currents even when the motor is not running: Supply terminals X1: L1, L2, L3 Motor connection terminals X2: U, V, W Connecting terminals X6, X7: Relay contacts for relays 1 and 2 PTC terminals T1/ T2 kinesys@hydac.com...
D (11 to 22 kW). Certain parameter settings may result in the drive controller restarting automatically after the supply voltage has failed. Damage to property possible If the information is not observed, the drive controller could be damaged and destroyed kinesys@hydac.com...
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 HYDAC experts or persons authorised by HYDAC. Cleaning the drive controllers Drive controllers are maintenance-free if operated as intended.
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 HYDAC Service department. DANGER Risk of death due to electrical shock! Death or serious injury! De-energise drive controller and secure it against being switched back on.
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 HYDAC on a case-by-case basis. kinesys@hydac.com...
- Size A – C (4 x M4 x 28) 2 Nm, - Size D (4 x M6 x 28) 4 Nm. Although the drive controller can, in principle, be painted later on, the user must nevertheless check the material compatibility of the intended paint. kinesys@hydac.com...
Ensure that the motor with a motor-integrated drive controller is only installed and operated if aligned as shown in the following diagram. Fig. 3: Motor installation location/permitted alignments Basic connection versions Fig. 4: Star or triangle connection for drive controllers integrated in the motor kinesys@hydac.com...
Page 20
Death or serious injury! De-energise drive controller and secure it against being switched back on. IMPORTANT INFORMATION Regularly check that the nuts (1) are secure! Star connection variant 1. Nut M = 5 Nm Plain washer 2. Circlip Cable shoe kinesys@hydac.com...
Page 21
PTC in the delivery state has to be removed. The cross-section of the supply line must be designed according to the transfer category and maximum permitted current. The contractor commissioning the device must ensure protection for the power line. kinesys@hydac.com...
0.75 to 1.5 mm², fine-wired, AWG 18 to AWG 14 Connection cross-section: 0.5 to 1.0 mm², fine-wired (core end sleeves with and without plastic collars) Length of stripped insulation: 9 to 10 mm Power connections (sizes A – C) kinesys@hydac.com...
Page 23
0.25 mm² 2 conductors of the same cross-section, flexible max. 1.5 mm² with TWIN-AEH with plastic sleeve Conductor cross-section AWG/kcmil min. 24 max. 8 Length of stripped insulation: 15 mm Mounting temperature: -5°C to +100°C Power connections (size D) kinesys@hydac.com...
Power connections between the drive controller and motor should always be shielded or reinforced, and the shielding must have large-scale grounding at both ends! The use of EMC cable screw connections is recommended. These are not part of the scope of delivery. Wiring suitable for EMC must be ensured. kinesys@hydac.com...
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 HYDAC for selected motors. 5. Modify the adapter plate (1) by producing the necessary holes (2) for mounting on the motor.
Page 26
Fig. 6: Bridging contact 8. If present, wire the connection cable of the motor PTC/Klixxon to the T1 and T2 terminals (1) (torque: 0.6 Nm). IMPORTANT INFORMATION During assembly, ensure that the connection cable is not crushed! kinesys@hydac.com...
Page 27
When the bridge is in place, the temperature of the motor is not monitored! 9. Plug the drive controller (3) onto the adapter plate (4) and fasten it evenly using the four lateral bolts (5) (sizes A – C) (torque: 4.0 Nm). kinesys@hydac.com...
Page 28
HFI-MM /adapter plate support HFI-MM INFORMATION 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 HYDAC for selected motors. kinesys@hydac.com...
Page 29
The commissioning technician alone is responsible for this. If you have any questions, please ask your HYDAC contact. 4. Fit the seal (3). 5. Screw the adapter plate (1) on to the motor with the four retaining bolts (10) and four spring elements (torques: M4 to 2.4 Nm, M5 to 5.0 Nm, M6 to 8.5 Nm).
Page 30
10. Carefully attach the drive controller to the support (6) and secure it evenly with two M8 screws (11) (torque: max. 25.0 Nm). Fig. 8: Bridging contact IMPORTANT INFORMATION During assembly, ensure that the connection cable is not crushed! kinesys@hydac.com...
2. Guide the mains connection cable through the cable screw connection (1). 3. Connect the cables with the terminals as follows: 230 V connection 400 V connection IMPORTANT INFORMATION When connecting a brake resistor to an optional braking module, cables with shielding and double insulation must be used! kinesys@hydac.com...
Page 33
When connecting a brake resistor to an optional braking module, cables with shielding and double insulation must be used! Terminal no. Designation Assignment Mains phase 1 Mains phase 2 Mains phase 3 Protective conductor Tab. 4: 3~ 400 V terminal assignment X1 kinesys@hydac.com...
A - C 2 Nm (4 x M4 x 28) 4 Nm (4 x M6 x 28) WICHTIGE INFORMATION The standard configuration of the application board defined below is invalid when it is shown differently in the form of an E-plan. kinesys@hydac.com...
Page 36
Ground 24 V Out Int. power supply Target value enable (parameter 1.131) Dig. In 1 Dig. In 2 Free (not assigned) Dig. In 3 Free (not assigned) Dig. In 4 Error reset (parameter 1.180) En HW (enable) Enable hardware kinesys@hydac.com...
Page 37
Assignment Centre contact relay 1 Normally open relay 1 Normally closed relay 1 Tab. 9: Terminal assignment X6 (relay 1) INFORMATION In the factory setting, relay 1 is programmed as “relay error” (parameter 4.190). (also see 4.3.5 connection diagram) kinesys@hydac.com...
Page 38
A GND (ground 10 V) Ground Dig. Out Fault message (parameter 4.150) 10 V Out For ext. voltage divider 24 V Out Int. power supply 24 V Out Int. power supply En HW (enable) Enable hardware GND (ground) Ground kinesys@hydac.com...
The drive controller may only be mounted on non-flammable bases. There must be clearance of 200 mm around the drive controller to ensure free convection. The following figure shows the assembly dimensions and the free spaces required for installing the drive controller. kinesys@hydac.com...
2. Use a suitable EMC screw connection to attach the shielded cable to the motor connection box! Ensure that the shielding contact is in order (large surface)! 3. Connect the prescribed PE connection in the motor connection box! 4. Close the motor connection box. kinesys@hydac.com...
Page 41
To achieve optimum self-convection of the drive controller, ensure that the (EMC) screw connection (1) is facing upwards during installation. If there is no additional ventilation for the HFI-MM (optional for size C), only vertical installation is permitted. Fig. 17: Wiring kinesys@hydac.com...
Page 42
8. Position the drive controller (9) on the adapter plate (3) so that the collar of the adapter dips into the opening on the floor of the cooling element. 9. Fasten the drive controller (9) to the adapter plate (3) with the help of the screws (10) provided (torque: 4.0 Nm). kinesys@hydac.com...
The brake connections should be designed as described in section 4.3 ff. "Installing the drive controller integrated in the motor". Control connections The control connections should be designed as described in section 4.3 ff. "Installing the drive controller integrated in the motor". kinesys@hydac.com...
The drive controller must be grounded with the motor according to relevant regulations. Non- compliance may result in serious injury. Communication The drive controller can be commissioned in the following ways: using the HMM-Start-Up PC software Fig. 19: PC software – start screen kinesys@hydac.com...
The drive controller has a 24 V low-voltage input for this purpose, which can supply the electric system without requiring mains power. The commissioning can be performed using a PC parametration cable USB at plug M12 with integrated interface converter RS485/RS232 (part no. 10023950). kinesys@hydac.com...
Page 46
Commissioning Commissioning using the PC: 1. Install the HMM-Start-Up software (you can obtain programming software from HYDAC free of charge). Operating system required: Windows XP or Windows 7 [32 / 64 bit]). We recommend undertaking the installation process as an administrator.
(corresponding to the “maximum frequency” (1.021)). PID inverted: The PID actual value can be inverted using parameter 3.061. The actual value is imported inversely, i.e. 0 V…10 V correspond internally to 100%…0%. Please note that the target value must also be defined inversely. kinesys@hydac.com...
Page 48
“PID stand-by time” (3.070) with the “minimum frequency” (1.020). Once the actual value deviates from the target value by the set % value, the “PID stand-by hysteresis” (3.071), the control (the motor) is started again. Fig. 22: Stand-by function in PID process control kinesys@hydac.com...
0 = frequency setting mode, with the target value of the selected target value source (1.130), 1 = PID process controller, with the target value of the PID process controller, 2 = fixed frequencies, with the frequencies defined in parameters 2.051 – 2.057 Fig. 23: Example of a parameter table kinesys@hydac.com...
Page 50
Explanation of the parameter Transfer status Other parameters related 0 = switch drive controller off and to this parameter. on for transfer 1 = at speed of 0 2 = during operation Value range (from – to factory setting) kinesys@hydac.com...
Run up time 2 is the time that the drive controller needs to accelerate from 0 Hz to the max. frequency. 1.054 The acceleration time can be increased as a result of certain circumstances, e.g. if the drive controller is overloaded. kinesys@hydac.com...
Page 52
2 = analogue input 2 3 = PC 4 = SAS 6 = motor potentiometer 7= sum of analogue inputs 1 and 2 8 = PID fixed target values (3.062 to 3.069) 9 = field bus 10 = HFI-MM soft PLC kinesys@hydac.com...
Page 53
3 = digital input 2 (function active with high signal) 4 = digital input 3 (function active with high signal) 5 = digital input 4 (function active with high signal) 6 HFI-MM soft PLC 7 = analogue input 1 8 = analogue input 2 kinesys@hydac.com...
Page 54
P. xy def.: In addition to the automatic acknowledgement function (1.181), it is possible to limit the maximum number of 1.180 automatic acknowledgements here. 1.181 = no restriction on automatic acknowledgements > 0 = maximum number of automatic acknowledgements permitted kinesys@hydac.com...
8 = foil keypad (key 1 - / key 2 +) 2.151 MOP step range Unit: % Relationship Parameter manual: Transfer status: min.: value parameter: entered!) max.: P. xy def.: Increments at which the target value changes per keystroke. 1.020 1.021 kinesys@hydac.com...
P. xy def.: Specifies the maximum value of the analogue inputs as a percentage of the range. Example: 0…10 V and/or 0…20 mA = 0 %...100 % 2…10 V and/or 4…20 mA = 20 %...100 % kinesys@hydac.com...
Page 59
Transfer status: min.: - 10000 value parameter: entered!) max.: + 10000 P. xy def.: Selection of the lower limit of a physical value to be displayed. 4.033 / 4.063 4.035 / 4.065 4.035 / 4.065 Alx physical maximum Unit: kinesys@hydac.com...
AO1 standard Low Unit: Relationship Parameter manual: Transfer status: min.: - 10000 value parameter: entered!) max.:+ 10000 P. xy def.: Describes which area is to be broken down into the 0-10 V output voltage or the 0-20 mA output current. 4.100 kinesys@hydac.com...
4.151 / 4.171 DOx on Unit: Relationship Parameter manual: Transfer status: min.: - 32767 value parameter: entered!) max.: 32767 P. xy def.: If the set process variable exceeds the switch-on limit, the output is set to 1. 4.150 / 4.170 kinesys@hydac.com...
32767 P. xy def.: If the set process variable exceeds the switch-on limit, the output is set to 1. 4.190 / 4.210 4.192 / 4.212 Rel.x off Unit: Relationship Parameter manual: Transfer status: min: - 32767 value kinesys@hydac.com...
(5.071) and the fixed overcurrent of 50% of the required motor current limit. As soon as this current-time zone is exceeded, the motor current is restricted to the limit value by reducing the speed. If the output current of the drive controller exceeds the motor current (parameter kinesys@hydac.com...
This parameter can be used to activate stall detection. 5.081 0 = disable 1 = enable 5.081 Blocking time Unit: s Relationship Parameter manual: Transfer status: min.: value parameter: entered!) max.: P. xy def.: Indicates the time after which a blockage is detected. 5.080 kinesys@hydac.com...
5.070 33.032 Motor rating Unit: W Relationship Parameter manual: Transfer status: min.: value parameter: entered!) max.: 55000 P. xy def.: A performance value [W] P has to be set here that corresponds to the nominal motor rating. kinesys@hydac.com...
Page 66
P. xy def.: Only for asynchronous motors. The value from the motor's type plate data has to be entered here for the power factor cos phi. 33.200 Stator inductance Unit: H Relationship Parameter manual: Transfer status: min.: value max.: kinesys@hydac.com...
Page 67
Relationship Parameter manual: Transfer status: min.: value parameter: entered!) max.: 3600 P. xy def.: Only for asynchronous motors. 33.010 This is the time during which the drive is held at continuous current after the brake ramp has been completed. kinesys@hydac.com...
Selection of the line count of the sensor used. 34.011 34.013 34.013 Encoder offset Unit: ° Relationship Parameter manual: Transfer status: min.: value parameter: entered!) max.: P. xy def.: 34.010 An encoder offset for the sensor can be set here. 34.011 34.013 kinesys@hydac.com...
Page 69
Example: 4 pole asynchronous motor at 1410 rpm, target frequency 50 Hz Motor idling 0 = approx. 1500 rpm 1 = 1500 rpm Motor at nominal point 0 = 1410 rpm 1 = 1500 rpm 50 Hz is always displayed as the actual frequency. kinesys@hydac.com...
Transfer status: min.: value parameter: entered!) max.: 1000 P. xy def.: For synchronous motors only. 34.227 Here the current which was stamped in the motor before starting the control can be adjusted. Value as % of nominal motor current. kinesys@hydac.com...
Bus time-out in seconds. The time-out counter is activated if the bus was selected for the motor current's 1.130 target value source and a target value other than "0" is specified. The time-out is deactivated when 0 = > bus time-out. kinesys@hydac.com...
Ready for operation (activate En_HW for operation) Operation / ready Warning Error Identification of motor data Initialisation Firmware update Bus error operation Bus error ready for operation Tab. 12: LED flash codes LED off LED on LED flashing LED flashing quickly kinesys@hydac.com...
via field bus (CANOpen, Profibus DP, EtherCAT) The following section contains a list of possible error messages. Please contact the HYDAC service department if you encounter errors that are not listed here. Error name...
Page 74
Please enter the motor data according to the type plate Power class restriction Max. overload of the drive controller exceeded Check application / reduce load / use larger for more than 60 sec. drive controller Tab. 13: Error detection kinesys@hydac.com...
Information on correct disposal Dispose of drive controller, packaging and replaced parts in accordance with the regulations of the country in which the drive controller has been installed. The drive controller may not be disposed of with household waste. kinesys@hydac.com...
(DIN EN 60068-2-27) Tab. 14: Technical data for 400 V devices (subject to technical changes) in accordance with UL standard 508 C see chapter 10.4! feed-in reduction of around 50 % possible (reduced output power) Subject to technical changes. kinesys@hydac.com...
(DIN EN 60068-2-27) Tab. 15: Technical data for 230 V devices (subject to technical changes) in accordance with UL standard 508 C see chapter 10.4! feed-in reduction of around 50 % possible (reduced output power) Subject to technical changes. kinesys@hydac.com...
A permanently increased heat sink temperature, caused by a blocked air flow or a thermal blockage (dirty cooling ribs). Depending on the type of assembly, permanently excessive ambient temperature. The respective max. output values can be determined from the following characteristic curves. kinesys@hydac.com...
Abb. 24: Derating for drive controller fitted on motor due overload Derating due to increased ambient temperature Fig. 25: Derating for drive controller fitted on motor (all sizes) Fig. 26: Derating for drive controller fitted on wall (sizes A - C) kinesys@hydac.com...
Fig. 27: Derating for drive controller fitted on wall (size C with fan option and size D) Derating due to installation altitude Fig. 28: Derating of maximum output current as a result of installation altitude Fig. 29: Derating of maximum input voltage as a result of installation altitude kinesys@hydac.com...
Motor adapter plates A standard motor adapter plate (with an integrated terminal board for size A up to C) is available for each HFI-MM size. Download the 3D files (.stp) for HFI-MM and adapter plates from www.kinesys@hydac.com. HFI-MM size Output 0.55 to 1.5...
Page 82
Technical data Fig. 31: Hole pattern for size A standard adapter plate Fig. 32: Hole pattern for size B standard adapter plate Fig. 33: Hole pattern for size C standard adapter plate kinesys@hydac.com...
If the existing flat seals are in a good condition, they should be reused. Motor adapter plates (specific) In addition to the standard motor adapter plates (with integrated terminal boards for sizes A to C), there are also specific versions available for various motor suppliers (on request). kinesys@hydac.com...
Industrial environments with their own supply network that is separated from the public low-voltage supply by a transformer. Standards and guidelines The following specifically apply: 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) kinesys@hydac.com...
“Warning” – Use fuses rated 600 V/70 A for INV MD 4 only. Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the Manufacturer Instructions, National Electrical Code and any additional local codes. kinesys@hydac.com...
Page 86
3. Suitability of grounding for the combination of drive and heatsink needs to be verified in accordance with the end-use standard. 4. Temperature test was not conducted on models INV MD 4. Suitability of drive - heatsink combination shall be determined by subjecting to temperature test in the end-use. kinesys@hydac.com...
55° C HFI-MM D 15.0 6150654 50° C HFI-MM D 18.5 6150654 40° C HFI-MM D 22.0 6150654 35° C Température environnante maximale : Électronic Adaptateur Ambiante Suffixe HFI-MM C 5.5 6150653 40° C HFI-MM C 7.5 6150653 35° C kinesys@hydac.com...
Page 88
INSTALLÉE CÔTÉ LIGNE DE CET ÉQUIPEMENT ET AVOIR UNE VALEUR NOMINALE DE 277 V (PHASE-TERRE), 480 V (PHASE-PHASE), EN COMPATIBILITÉ AVEC LA CATÉGORIE DE SURTENSION III, ET DOIT OFFRIR UNE PROTECTION CONTRE UN PIC DE TENSION ASSIGNÉE DE TENUE AUX CHOCS DE 2,5 kV kinesys@hydac.com...
Page 89
La possibilité de mise à la terre de la combinaison entraînement et dissipateur doit être vérifiée conformément à la norme d'utilisation finale. Le test de température n'a pas été conduit sur les modèles INV MD 4. Déterminer si la combinaison entraînement - dissipateur est appropriée à l'aide d'un test de température en utilisation finale. kinesys@hydac.com...
Page 90
INSTALLÉE CÔTÉ LIGNE DE CET ÉQUIPEMENT ET AVOIR UNE VALEUR NOMINALE DE 277 V (PHASE-TERRE), 480 V (PHASE-PHASE), EN COMPATIBILITÉ AVEC LA CATÉGORIE DE SURTENSION III, ET DOIT OFFRIR UNE PROTECTION CONTRE UN PIC DE TENSION ASSIGNÉE DE TENUE AUX CHOCS DE 2,5 kV kinesys@hydac.com...
Excess temperature ..............................73, 74 External fault ..................................63 Factory setting ................................50 Fan....................................18 FI protection switch ................................13 Field bus................................... 71 Field weakening ................................70 Fixed frequency ................................49 Flying restart ................................69 Frequency ..................................36 Frequency setting mode ..............................47 kinesys@hydac.com...
Page 92
Performance parameters ..............................65 PID inverted ................................47, 57 PID process control ................................47 PID process controller............................... 56 Power connection for size D ............................. 33 Power connection for sizes A - C ..........................31 Quadratic characteristic curve ............................70 kinesys@hydac.com...
Page 93
Stator resistance ................................66 Switching frequency ..............................68, 81 Synchronous motor controller data........................... 70 System error ..................................73 Target value source ............................... 52 Technical data .................................. 76 Transport & storage ................................. 12 Undervoltage ................................73, 74 Wiring instructions ................................22 kinesys@hydac.com...
Need help?
Do you have a question about the KINESYS HFI-MM and is the answer not in the manual?
Questions and answers