Delta inverter CH2000 manual

IABU Headquarters CH2000 Series User Manual Delta Electronics, Inc Taoyuan3 No.18, Xinglong Rd., Taoyuan City, Taoyuan County 330, Taiwan, R.O.C TEL: 886-3-362-6301 / FAX: 886-3-371-6301 Asia Delta Electronics (Jiangsu) Ltd Wujiang Plant3 1688 Jiangxing East Road, Wujiang Economic Development Zone Wujiang City, Jiang Su Province, People's Republic of China (Post code: 215200) TEL: 86-512-6340-3008 / FAX: 86-769-6340-7290 Delta Greentech (China) Co., Ltd 238 Min-Xia Road, Cao-Lu Industry Zone,Pudong, Shanghai, People's Republic of China Post code : 201209 TEL: 021-58635678 / FAX: 021-58630003 Delta Electronics (Japan), Inc Tokyo Office 2-1-14 Minato-ku Shibadaimon, Tokyo 105-0012, Japan TEL: 81-3-5733-1111 / FAX: 81-3-5733-1211 Delta Electronics (Korea), Inc 234-9, Duck Soo Building 7F, Nonhyun-Dong, Kangnam-Gu, Seoul, Korea 135-010 TEL: 82-2-515-5305 / FAX: 82-2-515-5302 Delta Electronics Int’l (S) Pte Ltd Kaki Bukit Ave 1, #05-05, Singapore 417939 TEL: 65-6747-5155 / FAX: 65-6744-9228 Delta Electronics (India) Pvt Ltd Plot No 43, Sector – 35, HSIIDC, Gurgaon122001, Haryana, India TEL: 1-919-767-3800 / FAX: 91-124-403-6045 Americas Delta Products Corporation (USA) Raleigh Office P.O Box 12173,5101 Davis Drive, Research Triangle Park, NC 27709, U.S.A TEL: 1-919-767-3800 / FAX: 1-919-767-8080 Delta Heavy Load Application Field Oriented Control Drive CH2000 Series User Manual Delta Greentech (Brasil) S.A Sao Paulo Office Rua Itapeva, 26-30 Andar Edificio Itapeva One-Bela Vista 01332-000-Sao Paulo-SP-Brazil TEL: +55 11 3568-3850/FAX: +55 11 3568-3865 Europe Deltronics (The Netherlands) B.V Eindhoven Office De Witbogt 15, 5652 AG Eindhoven, The Netherlands TEL: 31-40-2592850 / FAX: 31-40-2592851 5012614200 2012-05 C * We reserve the right to change the information in this catalogue without prior notice H E www.delta.com.tw/ia PLEASE READ PRIOR TO INSTALLATION FOR SAFETY  AC input power must be disconnected before any wiring to the AC motor drive is made DANGER  Even if the power has been turned off, a charge may still remain in the DC-link capacitors with hazardous voltages before the POWER LED is OFF Please not touch the internal circuit and components  There are highly sensitive MOS components on the printed circuit boards These components are especially sensitive to static electricity Please not touch these components or the circuit boards before taking anti-static measures Never reassemble internal components or wiring  Ground the AC motor drive using the ground terminal The grounding method must comply with the laws of the country where the AC motor drive is to be installed  DO NOT install the AC motor drive in a place subjected to high temperature, direct sunlight and inflammables  Never connect the AC motor drive output terminals U/T1, V/T2 and W/T3 CAU TION directly to the AC mains circuit power supply  Only qualified persons are allowed to install, wire and maintain the AC motor drives  Even if the 3-phase AC motor is stop, a charge may still remain in the main circuit terminals of the AC motor drive with hazardous voltages  If the AC motor drive is stored in no charge condition for more than months, the ambient temperature should not be higher than 30 °C Storage longer than one year is not recommended, it could result in the degradation of the electrolytic capacitors NOTE The content of this manual may be revised without prior notice Please consult our distributors or download the most updated version at http://www.delta.com.tw/industrialautomation Table of Contents CHAPTER INTRODUCTION 1-1 CHAPTER INSTALLATION 2-1 CHAPTER UNPACKING 3-1 CHAPTER WIRING 4-1 CHAPTER MAIN CIRCUIT TERMINALS 5-1 CHPATER CONTROL TERMINALS 6-1 CHAPTER OPTIONAL ACCESSORIES 7-1 CHAPTER OPTION CARDS 8-1 CHAPTER SPECIFICATION 9-1 CHAPTER 10 DIGITAL KEYPAD 10-1 CHAPTER 11 SUMMARPY OF PARAMETERS 11-1 CHPAPTER 12 DESCRIPTION OF PARAMETER SETTINGS 12-1 CHAPTER 13 WARNING CODES 13-1 CHAPTER 14 FAULT CODES AND DESCRIPTIONS 14-1 CHAPTER 15 CANOPEN OVERVIEW 15-1 CHAPTER 16 PLC FUNCTION 16-1 CHAPTER 17 HOW TO SELECT THE RIGHT AC MOTOR DIRVE 17-1 CHAPTER 18 SUGGESTIONS AND ERROR CORRECTIONS FOR STANDARD AC MOTOR DRIVES 18-1 CHAPTER 19 APPLICATION OF CH2000……………… ………………………………………… 19-1 Application Control BD V1.00; Keypad V1.01; Chapter IntroductionCH2000 Series Chapter Introduction Receiving and Inspection After receiving the AC motor drive, please check for the following: Please inspect the unit after unpacking to assure it was not damaged during shipment Make sure that the part number printed on the package corresponds with the part number indicated on the nameplate Make sure that the voltage for the wiring lie within the range as indicated on the nameplate Please install the AC motor drive according to this manual Before applying the power, please make sure that all the devices, including power, motor, control board and digital keypad, are connected correctly When wiring the AC motor drive, please make sure that the wiring of input terminals “R/L1, S/L2, T/L3” and output terminals”U/T1, V/T2, W/T3” are correct to prevent drive damage When power is applied, select the language and set parameter groups via the digital keypad (KPC-CC01) When executes trial run, please begin with a low speed and then gradually increases the speed untill the desired speed is reached Nameplate Information 1-1 Chapter IntroductionCH2000 Series Model Name Serial Number 1-2 Chapter IntroductionCH2000 Series RFI Jumper RFI Jumper: The AC motor drive may emit the electrical noise The RFI jumper is used to suppress the interference (Radio Frequency Interference) on the power line Frame A~C Screw Torque: 8~10kg-cm(6.9-8.7 lb -in.) Loosen the screws and remove the MOV-PLATE Fasten the screws back to the original position after MOV-PLATE is removed 1-3 Chapter IntroductionCH2000 Series Frame D~H Remove the MOV-PLATE by hands, no screws need to be loosen Main power isolated from earth: If the AC motor drive is supplied from an isolated power (IT power), the RFI jumper must be cut off Then the RFI capacities (filter capacitors) will be disconnected from ground to prevent circuit damage (according to IEC 61800-3) and reduce earth leakage current CAUTION! When power is applied to the AC motor drive, not cut off the RFI jumper Make sure main power is switched off before cutting the RFI jumper The gap discharge may occur when the transient voltage is higher than 1,000V Besides, electro-magnetic compatibility of the AC motor drives will be lower after cutting the RFI jumper Do NOT cut the RFI jumper when main power is connected to earth The RFI jumper cannot be cut when Hi-pot tests are performed The mains power and motor must be separated if high voltage test is performed and the leakage currents are too high To prevent drive damage, the RFI jumper connected to ground shall be cut off if the AC motor drive is installed on an ungrounded power system or a high resistance-grounded (over 30 ohms) power system or a corner grounded TN system 1-4 Chapter IntroductionCH2000 Series Dimensions Frame A VFD007CH23A-21, VFD015CH23A-21, VFD022CH23A-21, VFD037CH23A-21 VFD007CH43A-21, VFD015CH43A-21, VFD022CH43A-21, VFD037CH43A-21, VFD055CH43A-21 VFD007CH4EA-21,VFD015CH4EA-21, VFD022CH4EA-21, VFD037CH4EA-21, VFD055CH4EA-21 Unit: mm [inch] Frame A1 W H D W1 H1 D1* S1 Φ1 Φ2 Φ3 130.0 250.0 170.0 116.0 236.0 45.8 6.2 22.2 34.0 28.0 [5.12] [9.84] [6.69] [4.57] [9.29] [1.80] [0.24] [0.87] [1.34] [1.10] D1*: Flange mounting 1-5 Chapter IntroductionCH2000 Series Frame B VFD055CH23A-21,VFD075CH23A-21,VFD110CH23A-21, VFD075CH43A-21,VFD110CH43A-21, VFD150CH43A-21, VFD075CH4EA-21,VFD110CH4EA-21,VFD150CH4EA-21, See Detail A See Detail B Detail A (Mounting Hole) Detail B (Mounting Hole) Unit: mm [inch] Frame B1 W H D W1 H1 D1* S1 Φ1 Φ2 Φ3 190.0 320.0 190.0 173.0 303.0 77.9 8.5 22.2 34.0 28.0 [7.48] [12.60] [7.48] [6.81] [11.93] [3.07] [0.33] [0.87] [1.34] [1.10] D1*: Flange mounting 1-6 Chapter IntroductionCH2000 Series Frame C VFD150CH23A-21,VFD185CH23A-21 VFD185CH43A-21, VFD220CH43A-21,VFD300CH43A-21 VFD185CH4EA-21,VFD220CH4EA-21,VFD300CH4EA-21 See Detail A See Detail B Detail A (Mounting Hole) Detail B (Mounting Hole) Unit: mm [inch] Frame C1 W H D W1 H1 D1* S1 Φ1 Φ2 Φ3 250.0 400.0 210.0 231.0 381.0 92.9 8.5 22.2 34.0 50.0 [9.84] [15.75] [8.27] [9.09] [15.00] [3.66] [0.33] [0.87] [1.34] [1.97] D1*: Flange mounting 1-7 Chapter 12 Description of Parameter SettingsCH2000 Series 17-3 How to Choose a Suitable Motor Standard motor When using the AC Motor Drive to operate a standard 3-phase induction motor, take the following precautions: The energy loss is greater than for an inverter duty motor Avoid running motor at low speed for a long time Under this condition, the motor temperature may rise above the motor rating due to limited airflow produced by the motor’s fan Consider external forced motor cooling When the standard motor operates at low speed for long time, the output load must be decreased The load tolerance of a standard motor is as follows: Load duty-cycle 25% 40% 60% 100 torque(%) 82 70 60 50 continuous 20 Frequency (Hz) 60 If 100% continuous torque is required at low speed, it may be necessary to use a special inverter duty motor Motor dynamic balance and rotor endurance should be considered once the operating speed exceeds the rated speed (60Hz) of a standard motor Motor torque characteristics vary when an AC Motor Drive instead of commercial power supply drives the motor Check the load torque characteristics of the machine to be connected Because of the high carrier frequency PWM control of the VFD series, pay attention to the following motor vibration problems:  Resonant mechanical vibration: anti-vibration (damping) rubbers should be used to mount equipment that runs at varying speed  Motor imbalance: special care is required for operation at 50 or 60 Hz and higher frequency  To avoid resonances, use the Skip frequencies The motor fan will be very noisy when the motor speed exceeds 50 or 60Hz Special motors: Pole-changing (Dahlander) motor: The rated current is differs from that of a standard motor Please check before operation and select the capacity of the AC motor drive carefully When changing the pole number the motor needs to be stopped first If over current occurs during operation or regenerative voltage is too high, please let the motor free run to stop (coast) 17-5 Chapter 12 Description of Parameter SettingsCH2000 Series Submersible motor: The rated current is higher than that of a standard motor Please check before operation and choose the capacity of the AC motor drive carefully With long motor cable between AC motor drive and motor, available motor torque is reduced Explosion-proof (Ex) motor: Needs to be installed in a safe place and the wiring should comply with the (Ex) requirements Delta AC Motor Drives are not suitable for (Ex) areas with special precautions Gear reduction motor: The lubricating method of reduction gearbox and speed range for continuous operation will be different and depending on brand The lubricating function for operating long time at low speed and for high-speed operation needs to be considered carefully Synchronous motor: The rated current and starting current are higher than for standard motors Please check before operation and choose the capacity of the AC motor drive carefully When the AC motor drive operates more than one motor, please pay attention to starting and changing the motor Power Transmission Mechanism Pay attention to reduced lubrication when operating gear reduction motors, gearboxes, belts and chains, etc over longer periods at low speeds At high speeds of 50/60Hz and above, lifetime reducing noises and vibrations may occur Motor torque The torque characteristics of a motor operated by an AC motor drive and commercial mains power are different Below you’ll find the torque-speed characteristics of a standard motor (4-pole, 15kW): AC motor drive Motor 180 60 seconds 100 80 55 38 03 20 55 38 60 120 Frequency (Hz) Base freq.: 60Hz V/F for 220V/60Hz 180 150 60 seconds torque (%) torque (%) 100 20 60 120 Frequency (Hz) Base freq.: 60Hz V/F for 220V/60Hz 140 130 60 seconds 155 torque (%) torque (%) 180 155 140 100 85 68 45 35 60 seconds 100 80 45 35 20 50 120 Frequency (Hz) Base freq.: 50Hz V/F for 220V/50Hz 03 20 50 120 Frequency (Hz) Base freq.: 50Hz V/F for 220V/50Hz 17-6 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives 18-1 Maintenance and Inspections 18-2 Greasy Dirt Problem 18-3 Fiber Dust Problem 18-4 Erosion Problem 18-5 Industrial Dust Problem 18-6 Wiring and Installation Problem 18-7 Multi-function Input/Output Terminals Problem The AC motor drive has a comprehensive fault diagnostic system that includes several different alarms and fault messages Once a fault is detected, the corresponding protective functions will be activated The following faults are displayed as shown on the AC motor drive digital keypad display The six most recent faults can be read from the digital keypad or communication The AC motor drive is made up by numerous components, such as electronic components, including IC, resistor, capacity, transistor, and cooling fan, relay, etc These components can’t be used permanently They have limited-life even under normal operation Preventive maintenance is required to operate this AC motor drive in its optimal condition, and to ensure a long life Check your AC motor drive regularly to ensure there are no abnormalities during operation and follows the precautions:  Wait seconds after a fault has been cleared before performing reset via keypad of input terminal  When the power is off after minutes for ≦ 22kW models and 10 minutes for ≧ 30kW models, please confirm that the capacitors have fully discharged by measuring the voltage between + and - The voltage between + and - should be less than 25VDC  Only qualified personnel can install, wire and maintain drives Please take off any metal objects, such as watches and rings, before operation And only insulated tools are allowed  Never reassemble internal components or wiring  Make sure that installation environment comply with regulations without abnormal noise, vibration and smell 18-1 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series 18-1 Maintenance and Inspections Before the check-up, always turn off the AC input power and remove the cover Wait at least 10 minutes after all display lamps have gone out, and then confirm that the capacitors have fully discharged by measuring the voltage between DC+ and DC- The voltage between DC+ and DC-should be less than 25VDC Ambient environment Maintenance Check Items Methods and Criterion Check the ambient temperature, humidity, Visual inspection and vibration and see if there are any dust, gas, measurement with equipment oil or water drops with standard specification If there are any dangerous objects Visual inspection Period Half One Daily Year Year ○ ○ Voltage Maintenance Check if the voltage of main circuit and Period Half One Daily Year Year Measure with multimeter with ○ control circuit is correct standard specification Check Items Methods and Criterion Digital Keypad Display Maintenance Check Items Methods and Criterion Is the display clear for reading Visual inspection Any missing characters Visual inspection Period Half One Daily Year Year ○ ○ Mechanical parts Maintenance Check Items Methods and Criterion Period Half One Daily Year Year ○ If there is any abnormal sound or vibration Visual and aural inspection If there are any loose screws Tighten the screws ○ If any part is deformed or damaged Visual inspection ○ If there is any color change by overheating Visual inspection ○ If there is any dust or dirt Visual inspection ○ 18-2 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series Main circuit Maintenance Check Items If there are any loose or missing screws If machine or insulator is deformed, cracked, damaged or with color change due to overheating or ageing If there is any dust or dirt Methods and Criterion Tighten or replace the screw Period Half One Daily Year Year ○ Visual inspection NOTE: Please ignore the ○ color change of copper plate ○ Visual inspection Terminals and wiring of main circuit Maintenance Check Items If the terminal or the plate is color change or deformation due to overheat If the insulator of wiring is damaged or color change If there is any damage Methods and Criterion Visual inspection Period Half One Daily Year Year ○ ○ Visual inspection Visual inspection ○ DC capacity of main circuit Maintenance Check Items If there is any leak of liquid, color change, crack or deformation If the safety valve is not removed? If valve is inflated? Methods and Criterion Visual inspection Visual inspection Period Half One Daily Year Year ○ ○ ○ Measure static capacity when required Resistor of main circuit Maintenance Check Items If there is any peculiar smell or insulator cracks due to overheat If there is any disconnection If connection is damaged? Methods and Criterion Visual inspection, smell Period Half One Daily Year Year ○ Visual inspection ○ Measure with multimeter with ○ standard specification 18-3 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series Transformer and reactor of main circuit Maintenance Check Items Methods and Criterion If there is any abnormal vibration or peculiar Visual, aural inspection and smell smell Period Half One Daily Year Year ○ Magnetic contactor and relay of main circuit Maintenance Check Items Methods and Criterion If there are any loose screws Visual and aural inspection If the contact works correctly Visual inspection Period Half One Daily Year Year ○ ○ Printed circuit board and connector of main circuit Maintenance Check Items Methods and Criterion Tighten the screws and If there are any loose screws and connectors Period Half One Daily Year Year ○ press the connectors firmly in place If there is any peculiar smell and color change Visual and smell inspection ○ If there is any crack, damage, deformation or ○ Visual inspection corrosion If there is any liquid is leaked or deformation in capacity Visual inspection ○ Cooling fan of cooling system Maintenance Check Items Methods and Criterion Period Half One Daily Year Year Visual, aural inspection and turn the fan with hand (turn If there is any abnormal sound or vibration off the power before ○ operation) to see if it rotates smoothly If there is any loose screw Tighten the screw ○ If there is any color change due to overheat Change fan ○ 18-4 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series Ventilation channel of cooling system Maintenance Check Items If there is any obstruction in the heat sink, air intake or air outlet Methods and Criterion Visual inspection Period Half One Daily Year Year ○ NOTE Please use the neutral cloth for clean and use dust cleaner to remove dust when necessary 18-5 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series 18-2 Greasy Dirt Problem Serious greasy dirt problems generally occur in processing industries such as machine tools, punching machines and so on Please be aware of the possible damages that greasy oil may cause to your drive: Electronic components that silt up with greasy oil may cause the drive to burn out or even explode Most greasy dirt contains corrosive substances that may damage the drive Solution: Install the AC motor drive in a standard cabinet to keep it away from dirt Clean and remove greasy dirt regularly to prevent damage of the drive 18-6 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series 18-3 Fiber Dust Problem Serious fiber dust problems generally occur in the textile industry Please be aware of the possible damages that fiber may cause to your drives: Fiber that accumulates or adheres to the fans will lead to poor ventilation and cause overheating problems Plant environments in the textile industry have higher degrees of humidity that may cause the drive to burn out, become damaged or explode due to wet fiber dust adhering to the devices Solution: Install the AC motor drive in a standard cabinet to keep it away from fiber dust Clean and remove fiber dust regularly to prevent damage to the drive 18-7 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series 18-4 Erosion Problem Erosion problems may occur if any fluids flow into the drives Please be aware of the damages that erosion may cause to your drive Erosion of internal components may cause the drive to malfunction and possibility to explode Solution: Install the AC motor drive in a standard cabinet to keep it away from fluids Clean the drive regularly to prevent erosion 18-8 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series 18-5 Industrial Dust Problem Serious industrial dust pollution frequently occurs in stone processing plants, flour mills, cement plants, and so on Please be aware of the possible damage that industrial dust may cause to your drives: Dust accumulating on electronic components may cause overheating problem and shorten the service life of the drive Conductive dust may damage the circuit board and may even cause the drive to explode Solution: Install the AC motor drive in a standard cabinet and cover the drive with a dust cover Clean the cabinet and ventilation hole regularly for good ventilation 18-9 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series 18-6 Wiring and Installation Problem When wiring the drive, the most common problem is wrong wire installation or poor wiring Please be aware of the possible damages that poor wiring may cause to your drives: Screws are not fully fastened Occurrence of sparks as impedance increases If a customer has opened the drive and modified the internal circuit board, the internal components may have been damaged Solution: Ensure all screws are fastened when installing the AC motor drive If the AC motor drive functions abnormally, send it back to the repair station DO NOT try to reassemble the internal components or wire 18-10 Chapter 18 Suggestions and Error Corrections for Standard AC Motor Drives CH2000 Series 18-7 Multi-function Input/Output Terminals Problem Multi-function input/output terminal errors are generally caused by over usage of terminals and not following specifications Please be aware of the possible damages that errors on multi-function input/output terminals may cause to your drives: Input/output circuit may burns out when the terminal usage exceeds its limit Solution: Refer to the user manual for multi-function input output terminals usage and follow the specified voltage and current DO NOT exceed the specification limits 18-11 Chapter 19 Application of CH2000 Crane Application More flexible settings of crane function are added to CH2000 One of the features is that the checking conditions of mechanical brake can be set independently (by checking frequency or current) or relatively (by checking frequency and current) In addition, the open and close of mechanical brake also can be set independently, which means there can be one set of checking conditions for mechanical brake open and one set for mechanical brake close These two sets can be different Crane function Multi-functional output (MO= 42) Crane function combines multi-function output and time sequence setting This function works through checking frequency and current to trigger mechanical brake The output torque and mechanical braking torque can be switched smoothly via brake delay time to reduce the instability in the operation which can increase the efficiency and ensure the safety for crane hoist system Pr Explanation Settings Factory settings 02-32 Brake Delay Time Output Current Level Setting for Multi-function External Terminals Output frequency setting for multi-function output terminal Multi-function output terminal: Function 42: Brake Current Checking Point Multi-function output terminal: Function 42: Brake Frequency Checking Point 0.000~65.000 sec 0.000 0~100% 0.00~±60.00HZ 0.00 0~100% 0.00~±60.00HZ 0.00 02-33 02-34 02-57 02-58 19-1 Example: Mechanical Brake Open  When output frequency is greater than and equal to 02-34, and output current is greater than and equal to 02-33 02-32 (Brake delay time) will be triggered  When output frequency attains to 07-16, it will remain at the value of 07-16 until the time set in 07-15 In this sequence of time mechanical brake open from closing, but the mechanical brake will not wear because the output frequency maintains in the same level  After 07-15, motor drive starts to accelerate to command frequency Mechanical Brake Close  When output frequency is less than 02-58, or output current is less than 02-57 (one of the conditions is checked) 02-32 (Brake delay time) will start to count  When output frequency attains down to 07-18, it will remain at the value of 07-18 until the time set in 07-17 In this sequence of time mechanical brake close from opening, and the slipping can be avoided because the output frequency maintains in the same level  After 07-15, motor drive starts to decelerate to stop   If only frequency checking would be use, please set 1% at 02-57 If 02-57 is set at 0, then the mechanical brake close checking conditions will depend on 02-33 and 02-58 19-2 ... Remove the EPEs and manual Remove the crate cover, EPEs, rubber and manual Loosen the screws that fastened on the pallet and remove the wooden plate 3-1 Chapter Unpacking? ?CH2000 Series Lift the... and in total of 16 screws 3-2 Chapter Unpacking? ?CH2000 Series Remove the crate cover, EPEs and manual Remove the crate cover, EPEs, rubbers and manual Loosen the screws on the pallet as shown... figure below.) 4 5 6 1 2 Remove the crate cover, EPEs and manual Remove the crate cover, EPEs, rubber and manual 3-5 Chapter Unpacking? ?CH2000 Series Loosen the screws as shown in following figure: