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Altivar 78

Users Manual

Variable Speed Drive

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AT LEAST THE 10 FOLLOWING STEPS OF THE START-UP QUICK GUIDE MUST BE PERFORMED DURING THE INSTALLATION AND COMMISSIONING. IF ANY PROBLEMS OCCUR, PLEASE CONTACT YOUR LOCAL SCHNEIDER ELECTRIC SALES OFFICE. Start-up Quick Guide
1. Check that the delivery corresponds to your order. 2. Before taking any commissioning actions read carefully the safety instructions

in Chapter SAFETY.
3. Before the mechanical installation, check the minimum clearances around the

unit and check the ambient conditions in Chapter INSTALLATION.


4. Check the size of the motor cable, mains cable, mains fuses and check the

cable connections, read Chapters 6.1.1.1 to 6.1.1.3.


5. Follow the installation instructions, see Chapter 6.1.2. 6. Control cable sizes and the grounding system are explained in Chapter 6.2.1. 7. If the Start-Up wizard is active, select the language of the keypad and the

application you want to use and confirm by pressing the enterbutton. If the Start-Up wizard is not active, follow the instructions 7a and 7b. 7a. Select the language of the keypad from the Menu M6, page 6.1. Instructions on using the keypad are given in Chapter CONTROL KEYPAD 7b. Select the application you want to use from the Menu M6, page 6.2. Instructions on using the keypad are given in Chapter CONTROL KEYPAD.
8. All parameters have factory default values. In order to ensure proper

operation, check the rating plate data for the values below and the corresponding parameters of parameter group G2.1. nominal voltage of the motor nominal frequency of the motor nominal speed of the motor nominal current of the motor motor cos All parameters are explained in the programming manual (CD).
9.

Follow the commissioning instructions, see Chapter COMMISSIONING.

10. The ATV78 Variable Speed Drive is now ready for use.

Telemecanique is not responsible for the use of the Variable Speed Drives against the instructions.

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CONTENTS ATV78 USERS MANUAL


INDEX 1 2 3 4 5 6 7 8 9 SAFETY EU DIRECTIVE RECEIPT OF DELIVERY TECHNICAL DATA INSTALLATION CABLING AND CONNECTIONS CONTROL KEYPAD COMMISSIONING FAULT TRACING

ATV78 PROGRAMMING MANUAL (CD)


1 2 3 4 5 6 7 BASIC APPLICATION STANDARD APPLICATION LOCAL/REMOTE CONTROL APPLICATION MULTI-STEP SPEED CONTROL APPLICATION PID CONTROL APPLICATION MULTI-PURPOSE CONTROL APPLICATION PUMP AND FAN CONTROL APPLICATION

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ABOUT THE ATV78 USER'S MANUAL AND THE PROGRAMMING MANUAL (CD) Congratulations for choosing the Smooth Control provided by ATV78 Variable Speed Drives! The User's Manual will provide you with the necessary information about the installation, commissioning and operation of ATV78 Variable Speed Drives. We recommend that you carefully study these instructions before powering up the Variable Speed Drive for the first time.

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ATV78 User's Manual


Index 1. SAFETY ............................................................................................................................................. 7 1.1 Warnings.................................................................................................................................. 7 1.2 Safety instructions.................................................................................................................... 7 1.3 Earthing and earth fault protection ........................................................................................... 7 1.4 Running the motor ................................................................................................................... 8 2. EU DIRECTIVE .................................................................................................................................. 9 2.1 CE marking .............................................................................................................................. 9 2.2 EMC directive........................................................................................................................... 9 2.2.1 General........................................................................................................................................... 9 2.2.2 Technical criteria............................................................................................................................. 9 2.2.3 EMC Classification.......................................................................................................................... 9 3. RECEIPT OF DELIVERY.................................................................................................................. 10 3.1 Storage .................................................................................................................................. 10 3.2 Maintenance .......................................................................................................................... 10 3.3 Warranty ................................................................................................................................ 10 4. TECHNICAL DATA........................................................................................................................... 11 4.1 Introduction ............................................................................................................................ 11 4.2 Power ratings ......................................................................................................................... 13 4.2.1 Power ratings for standard torque application - Mains voltage 525690 V .................................. 13 4.2.2 Power ratings for constant torque application - Mains voltage 525690 V ................................... 15 4.3 Technical data........................................................................................................................ 16 5. INSTALLATION................................................................................................................................ 18 5.1 Mounting ................................................................................................................................ 18 5.2 Cooling................................................................................................................................... 22 5.2.1 Frames ATV78(F)U22Y to ATV78(F)C16Y ................................................................................... 22 5.2.2 ATV78(F)C20YATV78C31Y ...................................................................................................... 23 5.3 Power loss ............................................................................................................................. 24 5.3.1 Power loss as function of switching frequency .............................................................................. 24 5.4 Changing EMC protection class from L to N........................................................................... 25 6. CABLING AND CONNECTIONS ...................................................................................................... 27 6.1 Power unit.............................................................................................................................. 27 6.1.1 Power connections ....................................................................................................................... 30 6.1.1.1 Mains and motor cables .............................................................................................30 6.1.1.2 DC supply and brake resistor cables ............................................................................31 6.1.1.3 Control cable ............................................................................................................31 6.1.1.4 Cable and fuse sizes..................................................................................................31 6.1.2 Installation instructions.................................................................................................................. 32 6.1.2.1 Stripping lengths of motor and mains cables.................................................................33 6.1.2.2 ATV78 frames and installation of cables.......................................................................34 6.1.3 Cable installation and the UL standards........................................................................................ 39 6.1.4 Cable and motor insulation checks ............................................................................................... 39 6.2 Control unit ............................................................................................................................ 40 6.2.1 Control connections ...................................................................................................................... 41 6.2.1.1 Control cables ...........................................................................................................42

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6.2.1.2 Galvanic isolation barriers..........................................................................................42 6.2.2 Control terminal signals ................................................................................................................ 43 6.2.2.1 Digital input signal inversions......................................................................................44 6.2.2.2 Jumper selections on the VW3A78201 basic board ......................................................45 7. CONTROL KEYPAD......................................................................................................................... 47 7.1 Indications on the Keypad display .......................................................................................... 47 7.1.1 Drive status indications ................................................................................................................. 47 7.1.2 Control place indications............................................................................................................... 48 7.1.3 Status LEDs (green green red) ............................................................................................... 48 7.1.4 Text lines ...................................................................................................................................... 48 7.2 Keypad push-buttons ............................................................................................................. 49 7.2.1 Button descriptions ....................................................................................................................... 49 7.3 Navigation on the control keypad ........................................................................................... 50 7.3.1 Monitoring menu (M1)................................................................................................................... 52 7.3.2 Parameter menu (M2)................................................................................................................... 53 7.3.3 Keypad control menu (M3)............................................................................................................ 54 7.3.3.1 Selection of control place ...........................................................................................54 7.3.3.2 Keypad reference ......................................................................................................55 7.3.3.3 Keypad direction .......................................................................................................55 7.3.3.4 Stop button activated .................................................................................................55 7.3.4 Active faults menu (M4) ................................................................................................................ 55 7.3.4.1 Fault types ................................................................................................................56 7.3.4.2 Fault codes ...............................................................................................................57 7.3.4.3 Fault time data record ................................................................................................60 7.3.5 Fault history menu (M5) ................................................................................................................ 61 7.3.6 System menu (M6) ....................................................................................................................... 61 7.3.6.1 Language selection ....................................................................................................64 7.3.6.2 Application selection..................................................................................................64 7.3.6.3 Copy parameters.......................................................................................................65 7.3.6.4 Parameter comparison ...............................................................................................67 7.3.6.5 Security ....................................................................................................................68 7.3.6.6 Keypad settings .........................................................................................................69 7.3.6.7 Hardware settings......................................................................................................71 7.3.6.8 System info ...............................................................................................................73 7.3.7 Expander board menu (M7) .......................................................................................................... 76 7.4 Further keypad functions........................................................................................................ 76 8. COMMISSIONING............................................................................................................................ 77 8.1 Safety .................................................................................................................................... 77 8.2 Commissioning of the Variable Speed Drive .......................................................................... 77 9. FAULT TRACING ............................................................................................................................. 80

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Safety 1. SAFETY
ONLY A COMPETENT ELECTRICIAN MAY CARRY OUT THE ELECTRICAL INSTALLATION

1.1 Warnings

1 2 3 4 5 1

The components of the power unit of the Variable Speed Drive are live when ATV78 is connected to mains potential. Coming into contact with this voltage is extremely dangerous and may cause death or severe injury. The control unit is isolated from the potential. The motor terminals U, V, W and the DC-link/brake resistor terminals /+ are live when ATV78 is connected to mains, even if the motor is not running. The control I/O-terminals are isolated from the mains potential. However, the relay outputs and other I/O-terminals may have a dangerous control voltage present even when ATV78 is disconnected from mains. If the Variable Speed Drive is used as a part of a machine, the machine manufacturer is responsible for providing the machine with a main switch (EN 60204-1). Only spare parts delivered by Telemecanique can be used.

1.2 Safety instructions


After disconnecting the Variable Speed Drive from the mains, wait until the fan stops and the indicators on the keypad go out (if no keypad is attached see the indicators on the cover). Wait 5 more minutes before doing any work on ATV78 connections. Do not even open the cover before this time has expired. Prior to measurements on the motor or the motor cable, disconnect the motor cable from the Variable Speed Drive. Do not touch the IC-circuits on the circuit boards. Static voltage discharge may damage the components. Before connecting the Variable Speed Drive to mains make sure that the ATV78 front and cable covers are closed.

2 3 4

1.3 Earthing and earth fault protection


The ATV78 Variable Speed Drive must always be earthed with an earthing conductor connected to the earthing terminal . The earth fault protection inside the Variable Speed Drive protects only the converter itself against earth faults in the motor or the motor cable. Due to the high capacitive currents present in the Variable Speed Drive, fault current protective switches may not function properly. If fault current protective switches are used they must be tested with the drive with earth fault currents that are possible to arise in fault situations.

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Safety 1.4 Running the motor


Warning symbols For your own safety, please pay special attention to the instructions marked with the following symbols: = Dangerous voltage = General warning = Hot surface Risk of burn
HOT SURFACE

MOTOR RUN CHECK LIST Before starting the motor, check that the motor is mounted properly a ensure that the machine connected to the motor allows the motor to started. Set the maximum motor speed (frequency) according to the motor and the machine connected to it. Before reversing the motor shaft rotation direction make sure that this can be done safely. Make sure that no power correction capacitors are connected to the motor cable. Make sure that the motor terminals are not connected to mains potential.

1 2 3 4 5

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Receipt of delivery 2. EU DIRECTIVE

2.1 CE marking
The CE marking on the product guarantees the free movement of the product within the EEA (European Economic Area). It also guarantees that the product meets the various requirements placed upon it (such as the EMC Directive and possibly other directives according to the so-called new procedure). ATV78 Variable Speed Drives carry the CE label as a proof of compliance with the Low Voltage Directive (LVD) and the Electro Magnetic Compatibility (EMC). The company http://www.sgsfimko.com/ has acted as the Competent Body.

2.2 EMC directive


2.2.1

General

The EMC Directive provides that the electrical apparatus must not excessively disturb the environment it is used in, and, on the other hand, it shall have an adequate level of immunity toward other disturbances from the same environment. The compliance of ATV78 Variable Speed Drives with the EMC directive is verified with Technical Construction Files (TCF) checked and approved by SGS FIMKO, which is a Competent Body. The Technical Construction Files are used to authenticate the comformity of Telemecanique Variable Speed Drives with the Directive because such a large-sized product family is impossible to be tested in a laboratory environment and because the combinations of installation vary greatly. 2.2.2

Technical criteria

Our basic idea was to develop a range of Variable Speed Drives offering the best possible usability and cost-efficiency. EMC compliance was a major consideration from the outset of the design. ATV78 Variable Speed Drives are marketed throughout the world, a fact which makes the EMC requirements of customers different. As far as the immunity is concerned, all ATV78 Variable Speed Drives are designed to fulfil even the strictest requirements, while as regards the emission level, the customer may want to upgrade Telemecanique's already high ability to filter electro-magnetic disturbances. 2.2.3

EMC Classification

Class L (up to 160 KW): Provides filtering for the 2nd environment, restricted distribution according to EN 61800-3+A11 (IEC 18003). Class N (more than 200KW): The drives of this class do not provide EMC emission protection. This kind of drives are mounted in enclosures. All ATV78 Variable Speed Drives fulfil all EMC immunity requirements (standards EN 61000-6-1, EN 61000-6-2 and EN 61800-3+A11). Warning: This is a product of the restricted sales distribution class according to IEC 61800-3. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. Note: For changing the EMC protection class of your ATV78 Variable Speed Drive from class L to class N, please refer to the instructions given in Chapter 5.4.

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Receipt of delivery 3. RECEIPT OF DELIVERY

ATV78 Variable Speed Drives have undergone scrupulous tests and quality checks at the factory before they are delivered to the customer. However, after unpacking the product, check that no signs of transport damages are to be found on the product and that the delivery is complete. Should the drive have been damaged during the shipping, please contact primarily the cargo insurance company or the carrier. If the delivery does not correspond to your order, contact the supplier immediately.

3.1 Storage
If the Variable Speed Drive is to be kept in store before use make sure that the ambient conditions are acceptable: Storing temperature 40+70C Relative humidity <95%, no condensation

3.2 Maintenance
In normal conditions, ATV78 Variable Speed Drives are maintenance-free. However, we recommend to clean the heatsink with compressed air whenever necessary. The cooling fan can easily be changed if necessary. It may also be necessary to check the tightening torques of the main power terminals at intervals.

3.3 Warranty
Only manufacturing defects are covered by the warranty. The manufacturer assumes no responsibility for damages caused during or resulting from transport, receipt of the delivery, installation, commissioning or use. The manufacturer shall in no event and under no circumstances be held responsible for damages and failures resulting from misuse, wrong installation, unacceptable ambient temperature, dust, corrosive substances or operation outside the rated specifications. Neither can the manufacturer be held responsible for consequential damages. In all matters concerning the warranty, please contact the local Schneider electric sales office.

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Technical data 4. TECHNICAL DATA

4.1 Introduction
Brake resistor* modu le

1) Main s
L1 L2 L3

Brake C hopper*

Integrat ed i nput module

Rectifier

3~
Charg.res.

3) IGBT Inverter Current Sensors

Motor
U Outpu t V EM C r W fil te

2)

3~

Fan

Power Supply

Measurements Gate Drivers Voltage Sensors ATV78F

Control Keypad Motor and Application Control Motor Control ASIC

Control modu le Control I/O Control I/O

Control I/O

Control I/O

Control I/O

*Brake resistor is available as optionnal equipment. *Brake resistori s avail abl e as optional equipment for classes (FR4 to FR9). How er, t he br is standard equipment in classes ATV78 to FR6 to ATV78 Brakeevchopperake resist or can be installed internally in classes FR4 U22Yand is installed C16Y, externally in classes FR7 to FR9. whileke chopper belongs to t(he standard equipment in classes FR4 to chopper is required. Bra in greater classes above ATV78C20Y) an external FR6, while in greater classes (FR7 to F R9) it is optional.

Figure 4-1. ATV78 block diagram Figure 4-1 presents the block diagram of the ATV78 Variable Speed Drive. The Variable Speed Drive mechanically consists of two units, the Power Unit and the Control Unit. Pictures of the mechanical assemblage on pages 34 to 39 The three-phase AC-choke (1) at the mains end together with the DC-link capacitor (2) form an LC-filter, which, again, together with the diode bridge produce the DC-voltage supply to the IGBT Inverter Bridge (3) block. The AC-choke also functions as a filter against High Frequency disturbances from the mains as well as against those caused by the Variable Speed Drive to the mains. It, in addition, enhances the waveform of the input current to the Variable Speed Drive. The entire power drawn by the Variable Speed Drive from the mains is active power. The IGBT Inverter Bridge produces a symmetrical, 3-phase PWM-modulated AC-voltage to the motor. The Motor and Application Control Block is based on microprocessor software. The microprocessor controls the motor basing on the information it receives through measurements, parameter settings, control I/O and control keypad. The motor and application control block controls the motor control ASIC which, in turn, calculates the IGBT positions. Gate drivers amplify these signals for driving the IGBT inverter bridge.

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Technical data
The control keypad constitutes a link between the user and the Variable Speed Drive. The control keypad is used for parameter setting, reading status data and giving control commands. It is detachable and can be operated externally and connected via a cable to the Variable Speed Drive. Instead of the control keypad, also a PC can be used to control the Variable Speed Drive if connected through a similar cable. You can have your Variable Speed Drive equipped with a control I/O board which is either isolated or not isolated from the ground. The basic control interface and the parameters (the Basic Application) are easy to use. If a more versatile interface or parameters are required, a more suitable application can be chosen from the Application Package (CD). See the programming manual (CD) for more information on the different applications. A brake resistor is available as external option for ATV78 ATV78F. Optional I/O expander boards that increase the number of inputs and outputs to be used are also available. The input and output EMC filters have no influence on the basic functions of the Variable Speed Drive. They are, however, necessary for the fulfilment of the EMC directives.

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Technical data 4.2 Power ratings


4.2.1

Power ratings for standard torque application - Mains voltage 525690 V

Low overload = Max current, 2 sec/20 sec, 110% overloadability, 1 min/10 min Following continuous operation at rated output current, 110% rated output current for 1 min, followed by a period of load current less than rated current, and of such duration that the rms output current, over the duty cycle, does not exceed rated output current. All sizes up to ATV78C16Y available with IP21 and IP54 enclosures. Above ATV78C20Y either IP00 or built into enclosure. Reference Maxi. Motor power rating in kW Motor power Transient according to mains voltage rating in HP current for mains voltage 525 V 550 V 660 V 690 V 575 V A ATV78U22Y 2,3 2,4 2,9 3 3,0 6,7 ATV78U30Y 3,0 3,2 3,8 4 3,0 9,0 ATV78U40Y 4,2 4,4 5,3 5,5 5,0 11,0 ATV78U55Y 5,7 6,0 7,2 7,5 7,5 15,0 ATV78U75Y 8,4 8,8 10,5 11 11 20,0 ATV78D11Y 11,4 12,0 14,3 15 15 27 ATV78D15Y 14,1 14,7 17,7 18,5 20 36 ATV78D18Y 16,7 17,5 21,0 22 25 44 ATV78D22Y 22,8 23,9 28,7 30 30 54 ATV78D30Y 28,5 29,9 35,9 37,5 40 68 ATV78D37Y 34 36 43 45 50 82 ATV78D45Y 42 44 53 55 60 104 ATV78D55Y 57 60 72 75 75 124 ATV78D75Y 68 72 86 90 100 160 ATV78D90Y 84 88 105 110 125 200 ATV78C11Y 100 105 126 132 150 250 ATV78C13Y 122 128 153 160 150 288 ATV78C16Y 152 159 191 200 200 300 ATV780C20Y 190 199 239 250 250 370 ATV780C25Y 240 251 301 315 300 440 ATV780C31Y 270 283 340 355 400 585 ATV780C35Y (1) 342 359 430 450 450 693 ATV780C45Y (1) 380 399 478 500 500 828 ATV780C50Y (1) 426 446 536 560 600 1004 ATV780C56Y (1) 479 502 603 630 650 1170 ATV780C63Y (1) 540 566 679 710 800 1170 ATV780C71Y (1) 609 638 765 800 800 1170 ATV780C80Y (1) 761 797 957 1000 1100 1410 ATV780M10Y (1) 0 0 0 1250 2060 0 0 0 1250 2360 0 0 0 2360 0 0 0 1500 2600 Table 4-1 power rating of ATV78 for standard torque application
Add

2 for IP21, 5 for IP54 1) Consult the local Schneider sales office for the availability of ATV780C35Y to ATV780M10Y

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Technical data
Note: The rated currents in given ambient temperatures are achieved only when the switching frequency is equal to or less than the factory default.

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Technical data
4.2.2

Power ratings for constant torque application - Mains voltage 525690 V


High overload = Max current, 2 sec/20 sec, 150% overloadability, 1 min/10 min Following continuous operation at rated output current, 150 % rated output current for 1 min, followed by a period of load current less than rated current, and of such duration that the rms output current, over the duty cycle, does not exceed rated output current. Motor power rating in kW according to mains voltage Motor power rating in HP for mains voltage 575 V 2,0 3,0 3,0 5,0 7,5 11 15 20 25 30 40 50 60 75 100 125 150 150 200 250 300 400 450 500 600 650 800 800 1100 1250 Maxi. Transient current A 6,7 9,0 11,0 15,0 20,0 27 36 44 54 68 82 104 124 160 200 250 288 300 370 440 585 693 828 1004 1170 1170 1170 1410 2060 2360 2360 2600 Reference

525 V 550 V 660 V 690 V 1,7 1,8 2,1 2,2 2,3 2,4 2,9 3 3,0 3,2 3,8 4 4,2 4,4 5,3 5,5 5,7 6,0 7,2 7,5 8 9 11 11 11 12 14 15 14 15 18 18,5 17 18 21 22 23 24 29 30 29 30 36 37,5 34 36 43 45 42 44 53 55 57 60 72 75 68 72 86 90 84 88 105 110 100 105 126 132 122 128 153 160 152 159 191 200 190 199 239 250 240 251 301 315 270 283 340 355 342 359 430 450 380 399 478 500 426 446 536 560 479 502 603 630 540 566 679 710 609 638 765 800 761 797 957 1000 0 0 0 0 0 0 0 0 0 1250 Table 4-2 power rating of ATV78 for constant torque application

ATV78(F)U22Y ATV78(F)U30Y ATV78(F)U40Y ATV78(F)U55Y ATV78(F)U75Y ATV78(F)D11Y ATV78(F)D15Y ATV78(F)D18Y ATV78(F)D22Y ATV78(F)D30Y ATV78(F)D37Y ATV78(F)D45Y ATV78(F)D55Y ATV78(F)D75Y ATV78(F)D90Y ATV78(F)C11Y ATV78(F)C13Y ATV78(F)C16Y ATV780(F)C20Y ATV780(F)C25Y ATV780(F)C31Y ATV780(F)C35Y (1) ATV780(F)C45Y (1) ATV780(F)C50Y (1) ATV780(F)C56Y (1) ATV780(F)C63Y (1) ATV780(F)C71Y (1) ATV780(F)C80Y (1) ATV780(F)M10Y (1)

Add 2 for IP21, 5 for IP54 1) Consult the local Schneider sales office for the availability of ATV780C35Y to ATV780M10Y

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Technical data 4.3 Technical data


Mains connection Input voltage U Input frequency Connection to mains Starting delay Output voltage Continuous output current Starting torque Peak current Output frequency Frequency resolution Control method 525690V; 10%+10% 4566 Hz Once per minute or less (normal case)
2s (U22Y-D90Y) 5s ( C11Y and greater)

Motor connection

Control characteristics

Switching frequency (see parameter 2.6.9) Frequency reference Analogue input Panel reference Field weakening point Acceleration time Deceleration time Braking torque Ambient operating temperature Storage temperature Relative humidity Air quality: - chemical vapours - mechanical particles Altitude Vibration EN50178/EN60068-2-6 Shock EN50178, EN60068-2-27 Enclosure class

0U Standard torque: Ambient temperature max. +40C, overload 1.1 x I (1 min./10 min.) Constant torque: Ambient temperature max. +50C, overload 1.5 x I (1 min./10 min.) Imax for two seconds, torque motor dependent Imax for 2 s every 20 s 0320 Hz (ATV78); 0.01 Hz (ATV78); Application dependent (ATV78F) Frequency control U/f Open Loop Sensorless Vector Control Closed Loop Frequency Control Closed Loop Vector Control (ATV78F only) ATV78 16 kHz; Factory default 1.5 kHz

Ambient conditions

Resolution 0.1% (10-bit), accuracy 1% Resolution 0.01 Hz 30320 Hz 03000 sec 03000 sec DC brake: 30% * TN (without brake option) 10C (no frost)+50C: Constant torque 10C (no frost)+40C: Standard torque 40C+70C 0 to 95% RH, non-condensing, non-corrosive, no dripping water IEC 60721-3-3, unit in operation, class 3C2 IEC 60721-3-3, unit in operation, class 3S2 100% load capacity (no derating) up to 1000 m 1% derating for each 100m above 1000.; max. 3000m 5150 Hz Displacement amplitude 1 mm (peak) at 315.8 Hz Max acceleration amplitude 1 G at 15.8150 Hz UPS Drop Test (for applicable UPS weights) Storage and shipping: max 15 G, 11 ms (in package) IP21/NEMA1 standard up to ATV78C16Y. IP54/NEMA12 option up to ATV78C16Y. Note! Keypad installation required for IP54

(Continues on next page)

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Technical data

EMC (at default settings) Safety

Immunity Emissions

Control connections

Analogue input voltage Analogue input current Digital inputs Auxiliary voltage Output reference voltage Analogue output Digital outputs Relay outputs

Protections

Overcurrent protection Overvoltage protection Undervoltage protection Earth fault protection

Mains supervision Motor phase supervision Unit overtemperature protection Motor overload protection Motor stall protection Motor underload protection Short-circuit protection of +24V and +10V reference voltages Table 4-1. Technical data

Fulfil all EMC immunity requirements EMC level L: EN 61800-3 (1996)+A11 (2000)(2nd environment) EN 50178 (1997), EN 60204-1 (1996), EN 60950 (2000, 3rd edition) (as relevant), CE, UL, CSA, FI, GOST R, IEC 61800-5; (see unit nameplate for more detailed approvals) 0+10V, R = 200k, (10V+10V joystick control) Resolution 0.1%, accuracy 1% 0(4)20 mA, R = 250 differential Positive or negative logic; 1830VDC +24V, 15%, max. 250mA +10V, +3%, max. load 10mA 0(4)20mA; RL max. 500; Resolution 10 bit; Accuracy 2% Open collector output, 50mA/48V 2 programmable change-over relay outputs Switching capacity: 24VDC/8A, 250VAC/8A, 125VDC/0.4A Min.switching load: 5V/10mA Trip limit 4.0*I instantaneously 1200VDC 460 VDC In case of earth fault in motor or motor cable, only the Variable Speed Drive is protected Trips if any of the input phases is missing Trips if any of the output phases is missing Yes Yes Yes Yes Yes

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Installation 5. INSTALLATION

5.1 Mounting
The Variable Speed Drive can be mounted in either vertical or horizontal position on the wall or on the back plane of a cubicle. Enough space shall be reserved around the Variable Speed Drive in order to ensure a sufficient cooling, see Figure 5-5, Table 5-6 and Table 5-7. Also see to that the mounting plane is relatively even. The Variable Speed Drive shall be fixed with four screws (or bolts, depending on the unit size). The dimensions of installation are presented in Figure 5-5 and Table 5-6. Lift units bigger than FR7 out of the package using a jib crane. ATV78(F)U22YATV78(F)D90Y
W2

D1

H1 H2

H3 W1

E1

Figure 5-1. ATV78 dimensions, IP21 Dimensions [mm] W1 W2 H1 H2 H3 D1 148 558 541 519 237 ATV78U22YATV78D22Y 195 190 630 614 591 292 ATV78D30YATV78D37Y 237 255 755 732 721 312 ATV78D55YATV78D90Y 285 Table 5-1. Dimensions for different Variable Speed Drive types, IP21 Type 9 9 9 E1 3 x 37 3 x 47 3 x 59

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Installation
ATV78(F)C11YATV78(F)C16Y

D1

D2

H4 W4

H3 W4

W1

W3

W2

H2 D3 H1

H3

Figure 5-2. The dimensions ATV78, FR9 Type W1 W2 W3 W4 H1


1150*

Dimensions [mm] H2 H3 H4 1120 721 205

D1 362

D2

D3

ATV78C11Y 480 400 165 9 ATV78C16Y Table 5-2. The dimensions ATV78, FR9

21

340 285

*Brake resistor terminal box (202.5 mm) not included, see page 36.

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Installation
ATV78(F)20YATV78(F)C31Y

W1

W2
1

W4 H6

H4 H1

H3 H2

H5 D1 W3

Figure 5-3. ATV78 dimensions, FR10 Note: Dimension of choke not included Type W1 ATV78C20Y ATV78C31Y W2 W3 W4 30 H1 500 425 325 Dimensions [mm] H2 H3 H4 H5 850 761 300 H6 17 D1 446 1 12 2 23

1120 879

Table 5-3. The dimensions ATV78, FR10

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Installation
Installation of input chokes in C20Y and above The input choke carries out several functions in the ATV frequency converter. The input choke is needed as an essential component for motor control, to protect the input and DC-link components against abrupt changes of current and voltage as well as to function as a protection against harmonics. The input chokes are included in the standard delivery of the ATV frequency converters. The chokes listed below are used in the ATV frequency converter frame FR10:
Frequency converter (690VAC) ATV78C20Y ATV78C25Y ATV78C31Y Choke type Therm. current [Ith/A] 261 400 Nominal inductance/ Supply voltage [L/H] 575-690V(terminal) 187 (3) 126 (3) Calculated loss [W] 460 570

CHK0261N6A0 CHK0400N6A0

Table 5-4. FR10 input chokes


W1

D3

Cable connections Always connect the supply cables to the choke terminals marked with #1 (see Figure 5-4). Choose the converter connection according to the table below:
Supply voltage 575-690Vac Converter connection (terminals) 3

1
S2

H1

3 2
W2

3 2

3 2
S1 D2 D1

Terminal numbers

Figure 5-4. FR10 input chokes

W3

W3

Choke type CHK0261N6A0 CHK0400N6A0

H1 [mm] 311 384

W1 [mm] 354 350

W2 [mm] 150 150

W3 [mm] 120 120

D1 [mm] 190 222

D2 [mm] 109 141

D3 [mm] 156 184

S1 9*14 (4 St.) 9*14 (4 St.)

S2 9 (9 St.) 11 (9 St.)

Weight [kg] 53 84

Table 5-5. Choke dimensions

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Installation 5.2 Cooling


5.2.1

Frames ATV78(F)U22Y to ATV78(F)C16Y

Enough free space shall be left around the Variable Speed Drive to ensure sufficient air circulation and cooling. You will find the required dimensions for free space in the table below. If several units are mounted above each other the required free space equals C + D (see figure below). Moreover, the outlet air used for cooling by the lower unit must be directed away from the inlet air to be used by the upper unit. Type Dimensions [mm] A A2 B C D C 30 20 160 80 ATV78U22Y ATV78D22Y 80 300 100 80 ATV78D30Y ATV78D55Y 80 150 80 300 200 ATV78U75Y ATV78D90Y 50 80 400 250 ATV78C11Y B B (350**) ATV78C16Y Table 5-6. Mounting space dimensions A A2 ** B C D = clearance around the freq. converter (see also A2 and B) = clearance needed on either side of the Variable Speed Drive for fan change (without disconneting the motor cables) = min. clearance for fan change = distance from one Variable Speed Drive to another or distance to cabinet wall = free space above the Variable Speed Drive = free space underneath the Variable Speed Drive
A A A2 A2

Figure 5-5. Installation space

Type ATV78U22YATV78D22Y ATV78D30YATV78D55Y ATV78D75YATV78D90Y ATV78C11YATV78C16Y Table 5-7. Required cooling air.

Cooling air required [m3/h) 425 425 650 1300

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Cabling and connections


5.2.2

ATV78(F)C20YATV78C31Y

The variable speed drives of frame FR10 and bigger are mounted in a cabinet. Enough space according to the table below must be left above and in front of the cabinet to ensure sufficient cooling and space for maintenance.

200 mm

800 mm

Figure 5-6. Space to be left free above (left) and in front of (right) the cabinet Cooling air required [m3/h) 2600

Type ATV78C20Y ATV78C31Y

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Cabling and connections 5.3 Power loss


5.3.1

Power loss as function of switching frequency

If the operator wants to raise the switching frequency of the drive for some reason (typically e.g. in order to reduce the motor noise), this inevitably affects the power losses and cooling requirements according to the graphs below. Power losses for a Power losses for a switching frequency of switching frequency of 1,5 kHz 3,6 kHz W W 88,39 123,36 ATV78U22Y ATV78U30Y 99,84 139,33 ATV78U40Y 119,34 166,55 ATV78U55Y 160,26 223,65 ATV78U75Y 192,33 268,40 ATV78D11Y 289,00 403,31 ATV78D15Y 384,79 537,00 ATV78D18Y 408,32 569,83 ATV78D22Y 519,14 724,48 602,28 840,51 ATV78D30Y ATV78D37Y 762,35 1063,90 981,10 1369,18 ATV78D45Y ATV78D55Y 1412,42 1971,12 ATV78D75Y 1982,46 2766,63 ATV78D90Y 1933,16 2697,84 2534,46 3536,99 ATV78C11Y ATV78C13Y 3076,81 4293,86 ATV78C16Y 3604,00 5029,59 ATV780C20Y 4060,51 5666,67 ATV780C25Y 4785,16 6677,96 ATV780C31Y 5546,49 7740,44 ATV780C35Y 5993,09 8363,69 Table 5-8. Power loss Reference

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Cabling and connections 5.4 Changing EMC protection class from L to N


The EMC protection level of ATV78 Variable Speed Drives can be changed from class L to class N with a simple procedure presented in the following figures. ATV78(F)U22YATV78(F)D22Y:

Remove this screw

Figure 5-7. Changing of EMC protection class, ATV78(F)U22YATV78(F)D22Y ATV78(F)D30YATV78(F)D37Y: Remove this screw and replace with plastic screw M4

Figure 5-8. Changing of EMC protection class, ATV78(F)D30YATV78(F)D37Y

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Remove this screw

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Cabling and connections


ATV78(F)D45YATV78(F)D90Y:

Remove this screw

Figure 5-9. Changing of EMC protection class, ATV78(F)D45YATV78(F)D90Y

NOTE! Only a Telemecanique service person may change the EMC protection class of ATV78, ATV78(F)C11YATV78(F)C31Y.

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Cabling and connections

6.

CABLING AND CONNECTIONS

6.1 Power unit


The following wiring diagrams show the mains and motor connections of the Variable Speed Drive.

Power board

RFI filter L1 L2 L3 B- B+/R+ R- U V W

BR option

L1* L2* L3 M 3~

Figure 6-1. Principal wiring diagram of ATV78 power unit, ATV78(F)U22YATV78(F)D22Y (690V)

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Cabling and connections

Power board

RFI filter L1 L2 L3 B- B+/R+ R- U V W

BR (option)

L1* L2* L3

M 3~

Figure 6-2.Principal wiring diagram of ATV78 power unit, ATV78(F)D30YATV78(F)C16Y *When using 1-phase supply, connect the cables to terminals L1 and L2.

k6 4 fh8

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Cabling and connections

Power board

L1 L2 L3

B- B+/R+

R-

BR (option)

L1* L2* L3

M 3~

Figure 6-3. Principal wiring diagram of ATV power unit, ATV78(F)C20YATV78(F)C31Y The dotted lines refer to option component.

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Cabling and connections


6.1.1

Power connections 6.1.1.1 Mains and motor cables

The mains cables are connected to terminals L1, L2 and L3 (to L1 and L2, if 1-phase supply is used) and the motor cables to terminals marked with U, V and W. See Figure 6-1 to Figure 6-3. A cable entry flange should be used when installing the motor cable at both ends in order to reach the EMC levels. See Table 6-1 for the cable recommmendations. Use cables with heat resistance of at least +60C. The cables and the fuses must be dimensioned according to the Variable Speed Drive nominal OUTPUT current which you can find on the rating plate. Dimensioning according to the output current is recommended because the Variable Speed Drive input current never significantly exceeds the output current. Installation of cables according to UL regulations is presented in Chapter 6.1.3. Table 6-2 shows the minimum dimensions of the Cu-cables and the corresponding fuse sizes. The dimensions of the fuses in the table have been given taking their function as a cable overload protection into account. Recommended fuse types: gG/gL (for FR6 to FR9), see Table 6-2. If the motor temperature protection of the drive (see ATV78 programming manual (CD)) is used as an overload protection, the cable shall be chosen accordingly. If three or more cables are used in parallel for bigger units each cable requires a separate overload protection. These instructions apply only to cases with one motor and one cable connection from the Variable Speed Drive to the motor. In any other case, ask the factory for more information. 2nd environment Cable type Level L Level N Mains cable 1 1 Motor cable 2 1 Control cable 4 4 Table 6-1. Cable types required to meet standards. Level L Level N: 1 = EN61800-3, 2nd environment. See page 9. = Power cable intended for fixed installation and the specific mains voltage. Shielded cable not required. = Power cable equipped with concentric protection wire and intended for the specific mains voltage. = Power cable equipped with compact lowimpedance shield and intended for the specific mains voltage. *360 earthing of both motor and FC connection required to meet the standard = Screened cable equipped with compact lowimpedance shield.

2 3

Note: The EMC requirements are fulfilled at factory defaults of switching frequencies (all frames).

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Cabling and connections 6.1.1.2 DC supply and brake resistor cables


Telemecanique Variable Speed Drives are equipped with terminals for the DC supply and an optional external brake resistor. These terminals are marked with B, B+/R+ and R. The DC bus connection is made to terminals B and B+ and the brake resistor connection to R+ and R. See Figures 6-1 to 6-3.

6.1.1.3 Control cable


For information on control cables see Chapter 6.2.1.1 and Table 6-1.

6.1.1.4 Cable and fuse sizes


Frame FR6 Type ATV78D11Y ATV78D15Y ATV78D18Y ATV78D22Y ATV78D30Y IL [A] 18 22 27 34 41 Fuse [A] 20 25 35 50 Mains and motor cable Cu [mm2] 3*4+4 3*6+6 3*10+10 3*10+10 3*16+16 3*25+16 3*35+16 3*50+25 3*95+50 3*150+70 Terminal cable size Earth Main terminal terminal 2 [mm ] [mm2] 1.516 1.516 1.516 1.516 1.516 2.550 Cu 650 Al 2.550 Cu 650 Al 2595 Cu/Al 1.516 650 650 2595

FR7

52 ATV78D37Y 63 62 ATV78D45Y FR8 80 80 ATV78D55Y 100 100 ATV78D75Y 125 125 ATV78D90Y FR9 ATV78C11Y 144 160 170 200 ATV78C13Y 208 250 ATV78C16Y Table 6-2. Cable and fuse sizes for ATV78

95-185 Cu/Al2

595

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Cabling and connections


6.1.2

Installation instructions

1 2 3

Before starting the installation, check that none of the components of the Variable Speed Drive is live. If the Variable Speed Drive is installed outside a switchgear, separate cubicle or electrical room, it must be equipped with a protection cover (see e.g. Figure 6-5) as provided by the regulations for IP21 protection class. For installations in a switchgear, separate cubicle or electrical room, the cable protection plate is normally not necessary. Place the motor cables sufficiently far from other cables: Avoid placing the motor cables in long parallel lines with other cables If the motor cables run in parallel with other cables, note the minimum distances between the motor cables and other cables given in table below. The given distances also apply between the motor cables and signal cables of other systems. The maximum length of the motor cables is 300 m. For longer cables, use an output choke. The motor cables should cross other cables at an angle of 90 degrees.

D is tance between cable s [m ] 0.3 1.0

S hielded cable [m ] 50 200

4 5

If cable insulation checks are needed, see Chapter 6.1.4. Connect the cables: Strip the motor and mains cables as advised in Table 6-3 and Figure 6-4. Remove the screws of the cable protection plate. Do not open the cover of the power unit! Make holes into and pass the cables through the rubber grommets on the bottom of the power unit (see e.g. Figure 6-6) Connect the mains, motor and control cables into their respective terminals (see e.g. Figure 6-6) For information on the installation of greater units, please contact the factory or your local distributor. For Information on cable installation according to UL regulations see Chapter 6.1.3. Make sure that the control cable wires do not come in contact with the electronic components of the unit. If an external brake resistor (option) is used, connect its cable to the appropriate terminal. Check the connection of the earth cable to the motor and the Variable Speed Drive terminals marked with . Connect the separate shield of the power cable to the earth terminals of the Variable Speed Drive, motor and the supply centre. Attach the cable protection plate with the screws. Ensure that the control cables or the cables of the unit are not trapped between the frame and the protection plate.

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Cabling and connections 6.1.2.1 Stripping lengths of motor and mains cables
Earth conductor Earth conductor

A1

C1

A2

C2

B1

D1

B2

D2

MAINS

MOTOR
nk6141 fh8

Figure 6-4. Stripping of cables Frame A1 B1 C1 ATV78(F)U22YD22Y 20 90 15 ATV78(F)D30YD45Y 25 120 25 ATV78(F)D55Y 23 240 23 ATV78(F)D75YD90Y 28 240 28 ATV78(F)C11YC16Y 28 295 28 Table 6-3. Cables stripping lengths [mm] D1 60 120 240 240 295 A2 20 25 23 28 28 B2 90 120 240 240 295 C2 15 25 23 28 28 D2 60 120 240 240 295

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Cabling and connections 6.1.2.2 ATV78 frames and installation of cables


ATV78(F)U22YD22Y IP21

Figure 6-5. ATV78, FR6. Protection class IP21.

Brake resistor DC terminals terminals

Brake resistor Earth terminals terminals

Mains cable Mains cable Motor cable Figure 6-6. Cable installation in ATV78, FR6

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Cabling and connections


ATV78(F)D30YD37Y IP21

Figure 6-7. ATV78, FR7. Protection class IP21.

DC terminals

Brake resistor terminals

Earth terminals Mains cable

Motor cable Figure 6-8. Cable installation in ATV78, FR7

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Cabling and connections


ATV78(F)D45YD90Y IP21

Motor cable Mains cable Earth terminal

Figure 6-9. Cable installation in ATV, FR8

Figure 6-10. ATV, FR8. Protection class IP21

DC terminals

Brake resistor terminals

Figure 6-11. Kit VW3 A78701

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Cabling and connections


ATV78(F)C11YC16Y IP21

Figure 6-12. ATV78, FR9

Mains cable, , see table 6-2

Motor cables, see table 6-2

Earth terminals

Figure 6-13. Cable installation in ATV78, FR9

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Cabling and connections

R R+/B+ B

Figure 6-14. DC and brake resistor terminals on FR9; DC terminals marked with B and B+, brake resistor terminals marked with R and R+. When using brake resistor terminals on FR9 you must add braking unit kit VW3A78702.

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Cabling and connections


6.1.3

Cable installation and the UL standards

To meet the UL (http://www.ul.com/) regulations, a UL-approved copper cable with a minimum heatresistance of +60/75C must be used. The tightening torques of the terminals are given in Table 6-4. Type ATV78U22YATV78D22Y ATV78D30YATV78D37Y ATV78D45YATV78D55Y ATV78D75YATV78D90Y ATV78C11YATV78C16Y Frame FR6 FR7 FR8 FR9 Tightening torque [Nm] 4 10 20/9* 40/22* 40/22* 70/40**

FR10 ATV78C20YATV78C31Y Table 6-4. Tightening torques of terminals

* Tightening torque of terminal connection to the isolative base in Nm/in-lbs. ** Apply counter torque to the nut on the other side of the terminal when tightening/loosening the terminal screw in order to avoid damage to the terminal mounting. 6.1.4

Cable and motor insulation checks

1. Motor cable insulation checks Disconnect the motor cable from terminals U, V and W of the Variable Speed Drive and from the motor. Measure the insulation resistance of the motor cable between each phase conductor as well as between each phase conductor and the protective ground conductor. The insulation resistance must be >1M. 2. Mains cable insulation checks Disconnect the mains cable from terminals L1, L2 and L3 of the Variable Speed Drive and from the mains. Measure the insulation resistance of the mains cable between each phase conductor as well as between each phase conductor and the protective ground conductor. The insulation resistance must be >1M. 3. Motor insulation checks Disconnect the motor cable from the motor and open the bridging connections in the motor connection box. Measure the insulation resistance of each motor winding. The measurement voltage must equal at least the motor nominal voltage but not exceed 1000 V. The insulation resistance must be >1M.

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Cabling and connections 6.2 Control unit


The control unit of the Variable Speed Drive consists roughly of the control board and additional boards (see Figure 6-15 and figure 6-16) connected to the five slot connectors (A to E) of the control board. The control board is connected to the power unit through a D-connector (1).

Figure 6-15. ATV control board on the control board

Figure 6-16. Basic and option board connections

Usually, when the Variable Speed Drive is delivered from the factory, the control unit includes at least the standard compilation of two basic boards (I/O board and relay board) which are normally installed in slots A and B. On the next pages you will find the arrangement of the IOpalkit of the two basic boards, the wiringdiagrams and the terminalsignals. The I/O boards mounted at the factory are indicated in the type code. For more information on the option boards, see ATV78 option board manual. The control board can be powered externally (+24V) by connecting the external power source to the bidirectional terminal #6, see page 43. This voltage is sufficient for parameter setting and for keeping the fieldbus active. Note! If the 24V inputs of several Variable Speed Drives are parallelly connected we recommend to use a diode in terminal #6 in order to avoid the current to flow in opposite direction. This might damage the control board. See picture below.
External +24V

#6

#7

#6

#7

#6

#7

#6

#7

nk6_17

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Cabling and connections


6.2.1

Control connections

The basic control connections are shown in Chapter 6.2.2. The signal descriptions of the Standard Application are presented in Chapter 2 of the programming manual(CD). If you use some other application check the programming manual for the signal descriptions of the respective application.
1 +10Vref 2 AI1+ 3 GND 4 AI2+ 5 AI26 24Vout 7 GND 8 DIN1 9 DIN2 10 DIN3 Basic I/O board 11 CMA VW3A78201 NXOPTA1 12 24Vout 13 GND 14 DIN4 15 DIN5 16 DIN6 17 CMB 18 AO1+ 19 AO120 DO1
in s l o t B VW3A78202

Reference (voltage) Reference (current)

24 V GND

24 V GND 0(4)/20mA RL<500 9 + U<+48V I<50mA

in s lo t A VW3A78201

Dotted line indicates the connection with inverted signals

Figure 6-17. The I/O terminals of the two basic boards

Figure 6-18 General wiring diagram of the basic I/O (VW3A78201)

21 22 23 24 25 26

RO1/1 1/2 RO1/3 RC ca/cc RO2/1 2/2 RO2/3


Switching: <8A/24Vdc, <0.4A/125Vdc, <2kVA/250Vac Continuously: <2Arms

Basic relay board VW3A78202 NXOPTA2

Figure 6-19. General wiring diagram of the basic relay boards (VW3A78202)

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Cabling and connections 6.2.1.1 Control cables


The control cables shall be at least 0.5 mm2 screened multicore cables, see Table 6-1. The maximum terminal wire size is 2.5 mm2 for the relay terminals and 1.5 mm2 for other terminals. Find the tightening torques of the option board terminals in Table below. Tightening torque Terminal screw Nm lb-in. Relay and thermistor 0.5 4.5 terminals (screw M3) Other terminals 0.2 1.8 (screw M2.6) Table 6-5. Tightening torques of terminals

6.2.1.2 Galvanic isolation barriers


The control connections are isolated from the mains potential and the GND terminals are permanently connected to ground. See Figure 6-20. The digital inputs are galvanically isolated from the I/O ground. The relay outputs are additionally doubleisolated from each other at 300VAC (EN-50178).

1 0Vr ef GND +24 V GND AI1 AI2 + AI2 DIN1... DIN3 CM A DIN4... DIN6 CM B A O1+ A O2 DO1 RO1 /1 RO1 /2 RO1 /3 RO2 /1 RO2 /2 RO2 /3 TI1 + TI1 -

Gate drivers
C ont ro l I/O gr ou nd

L1 L2 L3

Di gita l in put group A Di gita l in put group B Analo gu e output Di gita l output

Control panel

Control board

Control board

U V W

Figure 6-20. Galvanic isolation barriers

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Cabling and connections


6.2.2

Control terminal signals


VW3A78201 Terminal Signal +10 Vref Reference voltage AI1+ Analogue input, voltage or current Technical information Maximum current 10 mA jumpperit (see page 46): Default: 0 +10V (Ri = 200 k) (-10V..+10V Joy-stick control, selected with a jumper) 0 20mA (Ri = 250 ) Differential input if not connected to ground; Allows 20V differential mode voltage to GND jumpperit (see page 46): Default: 0 20mA (Ri = 250 ) 0 +10V (Ri = 200 k) (-10V..+10V Joy-stick control, selected with a jumper) Differential input if not connected to ground; Allows 20V differential mode voltage to GND 15%, maximum current 250mA (all boards total);150mA (from single board); Can also be used as external power backup for the control unit (and fieldbus) Ground for reference and controls Ri = min. 5k 1830V = "1" Must be connected to GND or 24V of I/O terminal or to external 24V or GND jumpperit (see page 46): Same as terminal #6

1 2

3 4

GND/AI1 AI2+

Analogue input common Analogue input, voltage or current

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

GND/AI2 24 Vout (bidirectional) GND DIN1 DIN2 DIN3 CMA 24 Vout (bidirectional) GND DIN4 DIN5 DIN6 CMB AO1+ AO1 DO1

Analogue input common 24V auxiliary voltage I/O ground Digital input 1 Digital input 2 Digital input 3 Digital input common A for DIN1, DIN2 and DIN3. 24V auxiliary voltage

I/O ground Same as terminal #7 Digital input 4 Ri = min. 5k Digital input 5 1830V = "1" Digital input 6 Digital input common B for Must be connected to GND or 24V of I/O terminal or DIN4, DIN5 and DIN6 to external 24V or GND jumpperit (see page 46) Analogue signal (+output) Output signal range: Analogue output common Current 0(4)20mA, RL max 500 or Voltage 010V, RL >1k jumpperit (see page 46) Open collector output Maximum Uin = 48VDC Maximum current = 50 mA

Table 6-6. Control I/O terminal signals on basic I/O board VW3A78201

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Cabling and connections

21 22 23 24 25 26

VW3A78202 RO1/1 1 RO1/2 RO1/3 RO2/1 RO2/2 RO2/3 2

Relay output Switching capacity Min.switching load Relay output Switching capacity Min.switching load

24VDC/8A 250VAC/8A 125VDC/0.4A 5V/10mA 24VDC/8A 250VAC/8A 125VDC/0.4A 5V/10mA

Table 6-7. Control I/O terminal signals on basic relay board VW3A78202

6.2.2.1 Digital input signal inversions


The active signal level depends on which potential the common inputs CMA and CMB (terminals 11 and 17) are connected to. The alternatives are either +24V or ground (0 V). See Figure 6-21. The 24-volt control voltage and the ground for the digital inputs and the common inputs (CMA, CMB) can be either internal or external.

+24V DIN1 DIN2 DIN3 Ground CMA

Ground DIN1 DIN2 DIN3 +24V CMA


Negative logic (0V is the active signal) = the input is active when the switch is closed

Positive logic (+24V is the active signal) = the input is active when the switch is closed

Figure 6-21. Positive/Negative logic

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Cabling and connections 6.2.2.2 Jumper selections on the VW3A78201 basic board
The user is able to customise the functions of the Variable Speed Drive to better suit his needs by selecting certain positions for the jumpers on the VW3A78201 board. The positions of the jumpers determine the signal type of analogue and digital inputs. On the A1 basic board, there are four jumper blocks X1, X2, X3 and X6 each containing eight pins and two jumpers. The selectable positions of the jumpers are shown in Figure 6-23.

Figure 6-22. Jumper blocks

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Cabling and connections

Jumper block X1: AI1 mode


A B C D

Jumper block X2: AI2 mode


A B C D

AI1 mode: 0...20mA; Current input


A B C D

AI2 mode: 0...20mA; Current input


A B C D

AI1 mode: Voltage input; 0...10V


A B C D

AI2 mode: Voltage input; 0...10V


A B C D

AI1 mode: Voltage input; 0...10V (differential)


A B C D

AI2 mode: Voltage input; 0...10V (differential)


A B C D

AI1 mode: Voltage input; -10...10V

AI2 mode: Voltage input; -10...10V

Jumper block X6: AO1 mode


A B C D

Jumper block X3: CMA and CMB grounding


CMB connected to GND CMA connected to GND CMB isolated from GND CMA isolated from GND CMB and CMA internally connected together, isolated from GND

AO1 mode: 0...20mA; Current output


A B C D

AO1 mode: Voltage output; 0...10V

= Factory default

Figure 6-23. Jumper selection for VW3A78201

NOTE

! !

Check the correct positions of the jumpers. Running the motor with signal settings different from the jumper positions will not harm the Variable Speed Drive but may damage the motor. If you change the AI signal content also remember to change the corresponding board parameter in M7.

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Control keypad 7. CONTROL KEYPAD

The control keypad is the link between the ATV78 Variable Speed Drive and the user. The ATV78 control , READY, keypad features an alphanumeric display with seven indicators for the Run status (RUN, STOP, ALARM, FAULT) and three indicators for the control place (I/O term/ Keypad/BusComm). There are also three Status Indicator LEDs (green - green - red), see Status LEDs (green green red) below. The control information, i.e. the number of menu, description of menu or the displayed value and the numeric information are presented on three text lines. The Variable Speed Drive is operable through the nine push-buttons of the control keypad. Furthermore, the buttons serve the purposes of parameter setting and value monitoring. The keypad is detachable and isolated from the input line potential.

7.1 Indications on the Keypad display

RUN

STOP READY ALARM FAULT


I/O term Keypad Bus/Comm


ready

run

fault

II

III

Figure 7-1. Telemecanique control keypad and drive status indications Drive status indications controlkeypad 7.1.1 The drive status indications tell the user what the status of the motor and the drive is and whether the motor control software has detected irregularities in motor or Variable Speed Drive functions. 1 RUN = Motor is running; Blinks when the stop command has been given but the frequency is still ramping down. = Indicates the direction of motor rotation. STOP = Indicates that the drive is not running.

2 3 4 5 6

READY = Lights when AC power is on. In case of a trip, the symbol will not light up. ALARM = Indicates that the drive is running outside a certain limit and a warning is given. FAULT = Indicates that unsafe operating conditions were encountered due to which the drive was stopped.

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Control keypad
7.1.2

Control place indications controlkeypad

The symbols I/O term, Keypad and Bus/Comm (see Figure 7-1) indicate the choice of control place made in the Keypad control menu (M3) (see chapter 7.3.3). a I/O term b Keypad c Bus/Comm 7.1.3 = I/O terminals are the selected control place; i.e. START/STOP commands or reference values etc. are given through the I/O terminals. = Control keypad is the selected control place; i.e. the motor can be started or stopped, or its reference values etc. altered from the keypad. = The Variable Speed Drive is controlled through a fieldbus.

Status LEDs (green green red) controlkeypad

The status LEDs light up in connection with the READY, RUN and FAULT drive status indicators. I II III = Illuminates with the AC power connected to the drive. Simultaneously, the drive status indicator READY is lit up. = Illuminates when the drive is running. Blinks when the STOP button has been pushed and the drive is ramping down. = Illuminates when unsafe operating conditions were encountered due to which the drive was stopped (Fault Trip). Simultaneously, the drive status indicator FAULT blinks on the display and the fault description can be seen, see chapter 7.3.4, Active Faults.

7.1.4

Text lines controlkeypad

The three text lines (, , ) provide the user with information on his present location in the keypad menu structure as well as with information related to the operation of the drive.

= Location indication; displays the symbol and number of menu, parameter etc. Example: M2 = Menu 2 (Parameters); P2.1.3 = Acceleration time = Description line; Displays the description of menu, value or fault. = Value line; Displays the numerical and textual values of references, parameters etc. and the number of submenus available in each menu.

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Control keypad 7.2 Keypad push-buttons


The ATV78 alphanumeric control keypad features 9 push-buttons that are used for the control of the Variable Speed Drive (and motor), parameter setting and value monitoring.

Figure 7-2. Keypad push-buttons 7.2.1

Button descriptions
reset select enter = = = This button is used to reset active faults (see Chapter 7.3.4). This button is used to switch between two latest displays. May be useful when you want to see how the changed new value influences some other value. The Enter button serves for: 1) Confirmation of selections 2) Fault history reset (23 seconds) Browser button up Browse the main menu and the pages of different submenus. Edit values. Browser button down Browse the main menu and the pages of different submenus. Edit values. Menu button left Move backward in menu. Move cursor left (in parametermenu). Exit edit mode. Hold down for 23 seconds to return to main menu. Move forward in menu. Move cursor right (in parametermenu). Enter edit mode.

3 4

Menu button right

start

Start button. Pressing this button starts the motor if the keypad is the active control place. See Chapter 7.3.3. Stop button. Pressing this button stops the motor (unless disabled by parameter R3.4/R3.6). See Chapter 7.3.3.

stop

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Control keypad 7.3 Navigation on the control keypad


The data on the control keypad are arranged in menus and submenus. The menus are used for example for the display and editing of measurement and control signals, parameter settings (chapter 7.3.2), reference values and fault displays (chapter 7.3.4). Through the menus, you can also adjust the contrast of the display (page 70).

RUN

READY
Local

Location Description Number of items available; Item

Monitor

V1 V14

The first menu level consists of menus M1 to M7 and is called the Main menu. The user can navigate in the main menu using the browser up and down. The desired submenu can be entered from the main menu using the menubuttonleft. When there still are pages to enter under the currently displayed menu or page, you can see an arrow ( ) in the lower right corner of the display and by pressing the Menu button right, you can reach the next menu level. The control keypad navigation chart is shown on the next page. Please note that the menu M1 is located in the lower left corner. From there you will be able to navigate your way up to the desired menu using the menu and browser buttons. More detailed descriptions of the menus you will find later in this Chapter.

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Control keypad

R ADY E

M7

R EADY

READY

I / Ot er m

Expander boards

G7.1

I / O te r m

G7.1.1

I/ Ot erm

G1 G5
ST O P
I/O te rm

A: VW3A78201

Parameters

G1

G1

P1 P3

M6

R EAD Y

S.6.1

STOP
I /Ot e r m

R EADY

Syste m Menu

Language

enter

Change value

S1 S 9

E n gl i sh

Browse

READ Y

M5

I / te rm O

H.5.1

REA DY
I /O t e r m

READY

T.5.1.1 I/Ot erm

Fault history

H 1 H3

11 Output phase

T1 T7

Operation days

17

M4

ST O P
I/O te rm

FAU LT

F1

STOP
I /O te rm

FA ULT

T1

STOP
I/Ot erm

FAUL T

Activ e faults

or:

1 1 Output phase

F0

T1

T7

Operation days

17

ST OP

R EADY

M3

I /O t e r m

P.3.1

STOP
I /O t e r m

READY

Keypad control

Control Place

enter

P1 P 3

I/O Terminal

Browse

Change value

R EADY

R EADY

R EADY

M2

I/O t e r m

G.2.1

I/O te rm

P.2.1.1

Loc al

enter

Parameters

G 1 G9

Basic parameters

P1 P15

Min Frequency

13.95 Hz

B rowse Change value

M1

RU N
I /O t e r m

R EADY

RUN

REA DY
I / O te r m

V.1.1

Monitor

Output frequency

V1 V 1 5
Figure 7-3. Keypad navigation chart

13.95 Hz

No editing !

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Control keypad
7.3.1

Monitoring menu (M1)

You can enter the Monitoring menu from the Main menu by pushing the Menu button right when the location indication M1 is visible on the first line of the display. How to browse through the monitored values is presented in Figure 7-4. The monitored signals carry the indication V#.# and they are listed in Table 7-1. The values are updated once every 0.3 seconds. This menu is meant only for signal checking. The values cannot be altered here. For changing values of parameters see Chapter 7.3.2.

RUN

R EADY
Lo ca l

V.1.2

FreqReference

13.95 Hz
RU N RE A D Y Lo cal RU N READ Y Local

M1

V.1.1

Moni to r

Output frequency

V1 V14
Figure 7-4. Monitoring menu Code Signal name Output frequency Frequency reference Motor speed Motor current Motor torque Motor power Motor voltage DC-link voltage Unit temperature Motor temperature Voltage input Current input DIN1, DIN2, DIN3 DIN4, DIN5, DIN6 DO1, RO1, RO2 Analogue output M1.1 Multimonitoring items 7 Table 7-1. Monitored signals Unit Hz Hz rpm A % % V V C % V mA

13.95 Hz
Description Frequency to the motor Calculated motor speed Measured motor current Calculated actual torque/nominal torque of the unit Calculated actual power/nominal power of the unit Calculated motor voltage Measured DC-link voltage Heat sink temperature Calculated motor temperature AI1 AI2 Digital input statuses Digital input statuses Digital and relay output statuses AO1 Displays three selectable monitoring values. See chapter 7.3.6.5.

mA

Note: The applications embody more monitoring values.

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Control keypad
7.3.2

Parameter menu (M2)

Parameters are the way of conveying the commands of the user to the Variable Speed Drive. The parameter values can be edited by entering the Parameter Menu from the Main Menu when the location indication M2 is visible on the first line of the display. The value editing procedure is presented in Figure 7-5. Push the Menu button right once to move into the Parameter Group Menu (G#). Locate the parameter group desired by using the browser and push the Menu button right again to enter the group and its parameters. Use again the browser to find the parameter (P#) you want to edit. From here you can proceed in two different ways: Pushing the Menu button right takes you to the edit mode. As a sign of this, the parameter value starts to blink. You can now change the value in two different manners:

1 Just set the new desired value with the browser and confirm the change with the enterbutton.
Consequently, the blinking stops and the new value is visible in the value field.

2 Push the Menu button right once again. Now you will be able to edit the value digit by digit. This

editing manner may come in handy, when a relatively greater or smaller value than that on the display is desired. Confirm the change with the enterbutton.

The value will not change unless the Enter button is pushed. Pressing the menubuttonleft takes you back to the previous menu. Several parameters are locked, i.e. uneditable, when the drive is in RUN status. If you try to change the value of such a parameter the text *Locked* will appear on the display. The Variable Speed Drive must be stopped in order to edit these parameters. The parameters values can also be locked using the function in menu M6 (see Chapter Parameter lock (P6.5.2)). You can return to the Main menu anytime by pressing the menubuttonleft for 12 seconds. The basic application package includes seven applications with different sets of parameters. You will find the parameter lists in the Application Section of this manual. Once in the last parameter of a parameter group, you can move directly to the first parameter of that group by pushing the browser. See the diagram for parameter value change procedure on page 53. Note: Instead of connecting power to the Variable Speed Drive you can power up the control board from an external power source by connecting the external power source to bidirectional terminal #6 of the VW3A78201 board (see page 43) or to the corresponding +24V terminal on any other option board. This voltage is high enough for you to set parameter values or to keep the fieldbus active.

READY Keypad

Input signals

P1 P8
READY READY

READY

Parameters

M2

Keypad

G2.1

Keypad

G1 G8
READY

Basic parameters

P2.1.1

Keypad

P1 P18
READY

Min Frequency

13.95 Hz

P2.1.1

Keypad

Min Frequency

P2.1.1
enter

Keypad

13.95 Hz

Min Frequency

14.45 Hz

Figure 7-5. Parameter value change procedure

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Control keypad
7.3.3

Keypad control menu (M3)

In the Keypad Controls Menu, you can choose the control place, edit the frequency reference and change the direction of the motor. Enter the submenu level with the Menu button right. NOTE! There are some special functions that can be performed when in the M3 menu: button pushed Select the keypad as the active control place by keeping the down for 3 seconds when the motor is running. The keypad will become the active control place and the current frequency reference and direction will be copied to the keypad. button pushed Select the keypad as the active control place by keeping the down for 3 seconds when the motor is stopped. The keypad will become the active control place and the current frequency reference and direction will be copied to the keypad. Copy the frequency reference set elsewhere (I/O, fieldbus) to the panel by keeping the
enter
stop start

button pushed down for 3 seconds.

Note that if you are in any other than M3 menu these functions will not work. If you are in some other than M3 menu and try to start the motor by pressing the START button when the keypad is not selected as the active control place you will get an error message Keypad Control NOT ACTIVE.

7.3.3.1 Selection of control place


There are three different places (sources) which the Variable Speed Drive can be controlled from. For each control place, a different symbol will appear on the alphanumeric display: Control place I/O terminals Keypad (panel) Fieldbus Symbol I/O term Keypad
Bus/Comm

Change the control place by entering the edit mode with the Menu button right. The options can then be browsed through with the browser. Select the desired control place with the enterbutton. See the diagram on the next page. See also 7.3.3 above.
ST O P
I / O te rm

RE A D Y
I / O te rm

STOP

READ Y
I/ O te rm

ST OP

READ Y

M3 Ke y p a d c o n t r o l

P3.1 C o n trol Place

P3.1 Control Place

P1
ST O P
I/ O t e rm

P4
RE A D Y

I /O Remote
STOP
K eyp ad

I/O Remote

READ Y

P3.1 C o n t ro l P l a c e

e nt e r

P3.1 C o n trol Place

K eyp ad

K e y pad

Figure 7-6. Selection of control place

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Control keypad 7.3.3.2 Keypad reference


The keypad reference submenu (P3.2) displays and allows the operator to edit the frequency reference. The changes will take place immediately. This reference value will not, however, influence the rotation speed of the motor unless the keypad has been selected as the active control place. NOTE: The maximum difference between the output frequency and the keypad reference is 6 Hz. The application software monitors the keypad frequency automatically. See also 7.3.3 above. See Figure 7-5 for how to edit the reference value (pressing the enterbutton is not, however, necessary).

7.3.3.3 Keypad direction


The keypad direction submenu displays and allows the operator to change the rotating direction of the motor. This setting will not, however, influence the rotation direction of the motor unless the keypad has been selected as the active control place. See also 7.3.3 above. See Figure 7-6 for how to change the rotation direction. Note: Information on controlling the motor with the keypad is given in Chapters 7.2.1, 7.3.3 and 8.2

7.3.3.4 Stop button activated


By default, pushing the STOP button will always stop the motor regardless of the selected control place. You can disable this function by giving parameter 3.4 the value 0. If the value of this parameter is 0, the STOP button will stop the motor only when the keypad has been selected as the active control place. 7.3.4

Active faults menu (M4)

The Active faults menu can be entered from the Main menu by pushing the Menu button right when the location indication M4 is visible on the first line of the keypad display. When a fault brings the Variable Speed Drive to a stop, the location indication F1, the fault code, a short description of the fault and the fault type symbol (see Chapter 7.3.4.1) will appear on the display. In addition, the indication FAULT or ALARM (see Figure 7-1 or Chapter 7.1.1) is displayed and, in case of a FAULT, the redled on the keypad starts to blink. If several faults occur simultaneously, the list of active faults can be browsed with the browser. The memory of active faults can store the maximum of 10 faults in the order of appearance. The display can be cleared with the resetbutton and the read-out will return to the same state it was before the fault trip. The fault remains active until it is cleared with the Reset button or with a reset signal from the I/O terminal. Note! Remove external Start signal before resetting the fault to prevent unintentional restart of the drive. Normal state, no faults:
READY

M4

I/Oterm

Ac tive faults

F0

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Control keypad 7.3.4.1 Fault types


In the ATV78, there are four different types of faults. These types differ from each other on the basis of the subsequent behaviour of the drive. See Table 7-2.

STOP
I/Oterm

FAULT

Operation hours

34:21:05
STOP

STOP

FAULT

FAULT

Fault type symbol

F1

I/Oterm

11 Output phase

T1

T13

Operations days

T1

I/O term

17

Figure 7-7. Fault display Fault type symbol A (Alarm) F (Fault) AR (Fault Autoreset) FT (Fault Trip) Table 7-2. Fault types Meaning This type of fault is a sign of an unusual operating condition. It does not cause the drive to stop, nor does it require any special actions. The 'A fault' remains in the display for about 30 seconds. An 'F fault' is a kind of fault that makes the drive stop. Actions need to be taken in order to restart the drive. If an 'AR fault' occurs the drive will also stop immediately. The fault is reset automatically and the drive tries to restart the motor. Finally, if the restart is not successful, a fault trip (FT, see below) occurs. If the drive is unable to restart the motor after an AR fault an FT fault occurs. The effect of the 'FT fault' is basically the same as that of the F fault: the drive is stopped.

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Control keypad 7.3.4.2 Fault codes


The fault codes, their causes and correcting actions are presented in the table below. The shadowed faults are A faults only. The items written in white on black background present faults for which you can program different responses in the application. See parameter group Protections. Note: When contacting local Schneider electric sales office because of a fault condition, always write down all texts and codes on the keypad display. Fault code 1 Fault Overcurrent Possible cause Variable Speed Drive has detected too high a current (>4*In) in the motor cable: sudden heavy load increase short circuit in motor cables unsuitable motor The DC-link voltage has exceeded the limits defined in Table 4-1. too short a deceleration time high overvoltage spikes in supply Current measurement has detected that the sum of motor phase current is not zero. insulation failure in cables or motor The charging switch is open, when the START command has been given. faulty operation component failure Stop signal has been given from the option board. Various causes: - defective component - Brake resistor short.circuit or overload Correcting measures Check loading. Check motor. Check cables.

Overvoltage

Earth fault

Make the deceleration time longer. Use brake chopper or brake resistor (available as options up to FR10) Check motor cables and motor.

Charging switch

Reset the fault resetbuttonand restart. Should the fault re-occur, contact the distributor near to you.

6 7

Emergency stop Saturation trip

System fault

- component failure - faulty operation Note exceptional fault data record, see 7.3.4.3. DC-link voltage is under the voltage limits defined in Table 4-1. most probable cause: too low a supply voltage Variable Speed Drive internal fault Input line phase is missing. Current measurement has detected that there is no current in one motor phase.

Cannot be reset from the keypad. Switch off power. DO NOT RE-CONNECT POWER! Contact your local Schneider electric sales office. If this fault appears simultaneously with Fault 1, check motor cables and motor Reset the fault resetbuttonand restart. Should the fault re-occur, contact your local Schneider electric sales office.

Undervoltage

10 11

Input line supervision Output phase supervision

Check supply voltage and cable. Check motor cable and motor.

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Control keypad
Fault code Fault Possible cause Correcting measures

12

Brake chopper supervision Variable Speed Drive undertemperature Variable Speed Drive overtemperature

no brake resistor installed brake resistor is broken brake chopper failure

Check brake resistor. If the resistor is ok, the chopper is faulty. Contact the distributor near to you.

13 14

Heatsink temperature is under 10C Heatsink temperature is over 90C. Overtemperature warning is issued when the heatsink temperature exceeds 85C. Check the correct amount and flow of cooling air. Check the heatsink for dust. Check the ambient temperature. Make sure that the switching frequency is not too high in relation to ambient temperature and motor load. Check motor. Decrease the motor load. If no motor overload exists, check the temperature model parameters.

15 16

Motor stalled Motor overtemperature Motor underload EEPROM checksum fault Counter fault Microprocessor watchdog fault

17 22

24 25

Motor stall protection has tripped. Motor overheating has been detected by Variable Speed Drive motor temperature model. Motor is overloaded. Motor underload protection has tripped. Parameter save fault faulty operation component failure Values displayed on counters are incorrect faulty operation component failure

Reset the fault resetbuttonand restart. Should the fault re-occur, contact the distributor near to you. Cancel prevention of start-up. Check motor cooling and loading Check thermistor connection (If thermistor input of the option board is not in use it has to be short circuited) Check loading. Check motor size. Contact your local Schneider electric sales office. Ensure that there is another device on the bus with the same configuration. Change control unit

26 29

Start-up prevented Thermistor fault

Start-up of the drive has been prevented. The thermistor input of option board has detected increase of the motor temperature IGBT Inverter Bridge overtemperature protection has detected too high a short term overload current Cooling fan of the Variable Speed Drive does not start, when ON command is given Sent message not acknowledged. ATV78 Control Unit can not control

31 32 34 36

IGBT temperature (hardware) Fan cooling CAN bus communication Control unit

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Control keypad
Fault code 37 38 39 40 41 42 Fault Device Device added (same type) Device removed Device unknown IGBT temperature Encoder fault Possible cause ATV78F Power Unit and vice versa Option board or control unit changed same type of board or same power rating of drive Option board or drive added. Drive of same power rating or same type of board added. Option board removed. Drive removed. Unknown option board or drive. IGBT Inverter Bridge overtemperature protection has detected too high a short term overload current Note the exceptional Fault data record. See 7.3.4.3. Additional codes: 1 = Encoder 1 channel A is missing 2 = Encoder 1 channel B is missing 3 = Both encoder 1 channels are missing 4 = Encoder reversed Option board or control unit changed. Option board of different type or different power rating of drive. Option board or drive added. Option board of different type or drive of different power rating added. Current at the analogue input is < 4mA. control cable is broken or loose signal source has failed Digital input fault. The connection between the control keypad and the Variable Speed Drive is broken. The data connection between the fieldbus Master and the fieldbus board is broken Defective option board or slot Temperature limit values set for the PT100 board parameters have been exceeded Correcting measures Reset Reset Note: No fault time data record! Reset Note: No fault time data record! Contact your local Schneider electric sales office. Check loading. Check motor size. Check encoder channel connections. Check the encoder board.

43

Device changed (different type) Device added (different type) Analogue input Iin < 4mA (sel. signal range 4 to 20 mA) External fault Keypad communication fault Fieldbus fault

44

50

Reset Note: No fault time data record! Note: Application parameter values restored to default. Reset Note: No fault time data record! Note: Application parameter values restored to default. Check the current loop circuitry.

51 52 53

Check keypad connection and possible keypad cable. Check installation. If installation is correct contact your local Schneider electric sales office. Check board and slot. Contact your local Schneider electric sales office. Find the cause of temperature rise

54 56

Slot fault PT100 board temp. fault

Table 7-3. Fault codes

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Control keypad 7.3.4.3 Fault time data record


When a fault occurs the information described above in 7.3.4 is displayed. By pushing the Menu button right here you will enter the Fault time data record menu indicated by T.1 T.13. In this menu, some selected important data valid at the time of the fault are recorded. This feature is intended to help the user or the service person to determine the cause of fault. The data available are: Counted operation days T.1 (Fault 43: Additional code) Counted operation hours T.2 (Fault 43: Counted operation days) Output frequency (Fault 43: Counted operation T.3 hours) T.4 Motor current T.5 Motor voltage T.6 Motor power T.7 Motor torque T.8 DC voltage T.9 Unit temperature T.10 Run status T.11 Direction T.12 Warnings T.13 0-speed* Table 7-4. Fault time recorded data

d hh:mm:ss (d) Hz (hh:mm:ss ) A V % % V C

* Tells the user if the drive was at zero speed (< 0.01 Hz) when the fault occurred
Real time record If real time is set to run on the Variable Speed Drive the data items T1 and T2 will appear as follows: T.1 Counted operation days yyyy-mm-dd T.2 Counted operation hours hh:mm:ss, sss

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Control keypad
7.3.5

Fault history menu (M5)

The Fault history menu can be entered from the Main menu by pushing the Menu button right when the location indication M5 is visible on the first line of the keypad display. All faults are stored in the Fault history menu in which you can browse through them using the browser. Additionally, the Fault time data record pages (see Chapter 7.3.4.3) are accessible at each fault. You can return to the previous menu anytime by pushing the menubuttonleft. The memory of the Variable Speed Drive can store a maximum of 30 faults in the order of appearance. The number of faults currently in the fault history is shown on the valueline of the main page (H1 H#). The order of the faults is indicated by the location in the upper left corner of the display. The latest fault carries the indication F5.1, the second latest F5.2 etc. If there are 30 uncleared faults in the memory the next occurring fault will erase the oldest from the memory. Pressing the enterbutton for about 2 to 3 seconds resets the whole fault history. Then, the symbol H# will change to 0.

R EADY
I/O t erm I/ O t er m

R EA DY

5 ChargeSwitch

Operation hours

13:25: 43
READY

READY

READY

F5

I/O term

Fau lt h is tory

H5.1

I/Oterm

11 Output phase

T5.1.1

I/Ot erm

Op eration days

H1 H 3
PUSH
Figure 7-8. Fault history menu 7.3.6

T1 T7
enter

17

to reset

System menu (M6)

The System menu can be entered from the main menu by pushing the Menu button right when the location indication M6 is visible on the display. The controls associated with the general use of the Variable Speed Drive, such as application selection, customised parameter sets or information about the hardware and software are located under the System menu. The number of submenus and subpages is shown with the symbol S (or P) on the valueline. On page 62 you will find a list of the functions available in the System menu.

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Control keypad
Functions in the System menu
Code S6.1 Function Min Max Unit Default English Cust Selections English Deutsch Italiano Franais Basic Application Standard Application Local/Remote control Appl. Multi-Step Application PID Control Application Multi-Purpose Control Appl. Pump and Fan Control Appl. Store set 1 Load set 1 Store set 2 Load set 2 Load factory defaults All parameters All parameters All but motor parameters Application parameters Yes No

Language selection

S6.2

Application selection

Basic Application

S6.3

Copy parameters Parameter sets Load up to keypad Load down from keypad Parameter backup Parameter comparison Security Password Parameter locko Start-up wizard Multimonitoring items Keypad settings Default page Default page /Operate menu 0 65535 Timeout time 0 31 Contrast Always 65535 Backlight time Hardware settings Internal brake resistor Fan control HMI acknowledge. timeout HMI number of retries
200 1 5000 10 ms No

S6.3.1

S6.3.2 S6.3.3 P6.3.4 S6.4 S6.5 S6.5.1 P6.5.2 S6.5.3 S6.5.4 S6.6 P6.6.1 P6.6.2 P6.6.3 P6.6.4 P6.6.5 S6.7 P6.7.1 P6.7.2 P6.7.3 P6.7.4

Not used Change Enabled

0=Not used Change Enabled Change Disabled No Yes Change Enabled Change Disabled

s min

30 18 10

Connected Continuous 200 5

Not connected Connected Continuous Temperature

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Control keypad
S6.8 S6.8.1

C6.8.1.1 C6.8.1.2 C6.8.1.3


S6.8.2 T6.8.2.1

System information Total counters MWH counter Power On day counter Power on hours counter

kWh

hh:mm:ss

Trip counters MWH counter Clear MWH trip T6.8.2.2 counter Operating days T6.8.2.3 trip counter Operating hours T6.8.2.4 trip counter Clear operating T6.8.2.5 time counter S6.8.3 Software info Software S6.8.3.1 package System software S6.8.3.2 version Firmware S6.8.3.3 interface S6.8.3.4 System load S6.8.4 Applications Name of S6.8.4.# application D6.8.4.#.1 Application ID Applications: D6.8.4.#.2 Version Applications: D6.8.4.#.3 Firmware interface S6.8.5 Hardware I6.8.5.1 Info:Unit power I6.8.5.2 Info: Unit voltage Info: Brake I6.8.5.3 chopper Info: Brake I6.8.5.4 resistor S6.8.6 Expander boards Table 7-5. System menu functions

kWh

hh:mm:ss

kW V

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Control keypad 7.3.6.1 Language selection


The Telemecanique HMI control keypad offers you the possibility to control the Variable Speed Drive through the keypad in the language of your choice. Locate the language selection page under the System menu. Its location indication is S6.1. Press the menu button right once to enter the edit mode. As the name of the language starts to blink you are able to choose another language for the keypad texts. Confirm the selection by pushing the enterbutton. The blinking stops and all textual information on the keypad is presented in the language you chose. You can return to the previous menu anytime by pushing the menubuttonleft.
R E A DY READY

System Menu

M6

I/Ot erm

S6.1

I/Oterm

Language

S1 S11
R E A DY I/Ot erm

English
R EADY I/Oterm

S6.1

L anguage

S6.1
enter

Langue

English
Figure 7-9. Selection of language

Francais

7.3.6.2 Application selection


The user can select the application desired by entering the Application selection page (S6.2). This is done by pushing the Menu button right when on the first page of the System menu. Change then the application by pushing the Menu button right once again. The name of the application starts to blink. Now you can browse through the applications with the browser and select another application with the enterbutton. In this phase, you will be asked if you want the parameters of the new application to be uploaded to the keypad. If you wish this to happen push the enterbutton. Pushing any other button leaves the parameters of the previously used application saved in the keypadd. For more information, see Chapter 7.3.6.3. For more information about the Application Package, see ATV78 programming manual (CD).
STOP READY STOP READY

M6

I/Oterm

System Menu

S6.2

I/Oterm

Application

S1 S11
STOP READY

Standard
STOP READY

S6.2

I/Oterm

Application

S6.2
enter

I/Oterm

Application

Standard
Figure 7-10. Change of application

Multi-step

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Control keypad

7.3.6.3 Copy parameters


The parameter copy function is used when the operator wants to copy one or all parameter groups from one drive to another. All the parameter groups are first uploaded to the keypad, then the keypad is connected to another drive and then the parameter groups are downloaded to it (or possibly back to the same drive). Before any parameters can successfully be copied from one drive to another the drive has to be stopped when the parameters are downloaded to it: The parameter copy menu (S6.3) embodies four functions: Parameter sets (S6.3.1) The ATV78 Variable Speed Drive features a possibility for the user to load back the factory default parameter values and to store and load two customised parameter sets (all parameters included in the application). On Parameter sets page (S6.3.1), push the Menu button right to enter the Edit menu. The text LoadFactDef begins to blink and you can confirm the loading of factory defaults by pushing the Enter button. The drive resets automatically. Alternatively you can choose any other of the storing or loading functions with the browser. Confirm with the enterbutton. Wait until 'OK' appears on the display.

READY

READY

S6.3.1

I/O term

S6.3.1

I/Oterm

enter

CONFI RM

Parameter sets

Parameter sets

Sele ct
RE ADY

LoadFactDef
READY

CANCEL

S6.3.1 I/Oterm

S6.3.1 I/Oterm

Parameter sets

Parameter sets

Wait...

OK

Figure 7-11. Storing and loading of parameter sets

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Control keypad
Upload parameters to keypad (To keypad, S6.3.2) This function uploads all existing parameter groups to the keypad provided that the drive is stopped. Enter the To keypad page (S6.3.2) from the Parameter copy menu. Push the Menu button right to enter the edit mode. Use the browser to select the option All parameters and press the enterbutton. Wait until 'OK' appears on the display.

RE ADY

READY

READY

S6.3

I/Oter m

Cop y Parameters

S6.3.2

I/Oter m

Up to keypad

S6.3.2

I/Oterm

e n te r

CONFIRM CHANGE VALUE C ANCEL

Up to keypad

P1 P4
RE ADY

Select
READY

All param.

S6.3.2

I/Oter m

Up to keypad

S6.3.2

I/Oter m

Up to keypad

Wait...

OK

Figure 7-12. Parameter copy to keypad Download parameters to drive (From keypad, S6.3.3) This function downloads one or all parameter groups uploaded to the keypad to a drive provided that the drive is in STOP status. Enter the From keypad page (S6.3.3) from the Parameter copy menu. Push the Menu button right to enter the edit mode. Use the browser to select either the option All parameters or Application parameters and press the enterbutton. Wait until 'OK' appears on the display. The procedure to download the parameters from keypad to drive is similar to that of from drive to keypad. See page 65.

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Control keypad
Automatic parameter backup (P6.3.4) On this page you can activate or inactivate the parameter backup function. Enter the edit mode by pressing the Menu button right. Choose Yes or No with the browser. When the Parameter backup function is activated ATV78 control keypad makes a copy of the parameters of the presently used application. When applications are changed, you will be asked if you wish the parameters of the new application to be uploaded to the keypad. For this to happen, push the enterbutton. If you wish to keep the copy of the parameters of the previously used application saved in the keypad push any other button. Now you will be able to download these parameters to the drive following the instructions given in chapter 7.3.6.3. If you want the parameters of the new application to be automatically uploaded to the keypad you have to do this for the parameters of the new application once on page 6.3.2 as instructed. Otherwise the panel will always ask for the permission to upload the parameters. Note: Parameters saved in the parameter settings on page S6.3.1 will be deleted when applications are changed. If you want to transfer the parameters from one application to another you have to upload them first to the keypad.

7.3.6.4 Parameter comparison


In the Parameter comparison submenu (S6.4), you can compare the actual parameter values to the values of your customised parameter sets and those loaded to the control keypad. The comparison is performed by pushing the Menu button right when in the Compare parameters submenu. The actual parameter values are first compared to those of the customised parameter Set1. If no differences are detected a '0' is displayed on the lowermost line. But if any of the parameter values differ from those of the Set1 the number of the deviations is displayed together with symbol P (e.g. P1 P5 = five deviating values). By pressing the Menu button right once again you can still enter the pages where you can see both the actual value and the value it was compared to. In this display, the value on the descriptionline (in the middle) is the default value and the one on the valueline (lowermost) is the edited value. Furthermore, you can also edit the actual value with the browser in the edit mode that you can reach by pushing the Menu button right once again. In the same way, you can perform the comparison of the actual values to Set2, Factory Settings and Keypad Set.
R E AD Y RE ADY

S6.4

I/Oterm

ParamComparison

S6.4.1 I/Oterm

S et1

C1

C3
OR

0
READY READY

S6.4.1 I/Oterm

S6.4.1.1 I/Oterm

Set1

P2.1.2= 50.0

P1
I/Oterm

P6
REA DY

20.0 Hz
EDIT VALUE

P2.1.2= 50.0

20.0 Hz
Figure 7-13. Parameter comparison

enter

CONFIRM CHANGE

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Control keypad 7.3.6.5 Security


NOTE: The Security submenu is protected with a password. Store the password in a safe place! Password (S6.5.1) The application selection can be protected against unauthorised changes with the Password function (S6.5.1). By default, the password function is not in use. If you want to activate the function, enter the edit mode by pushing the Menu button right. A blinking zero appears in the display and now you can set a password with the browser. The password can be any number between 1 and 65535. Note that you can also set the password by digits. In the edit mode, push the Menu button right once again and another zero appears on the display. Now set first the units. Then push the menubuttonleft and you can set the tens etc. Finally, confirm the password setting with the enterbutton. After this, you have to wait until the Timeout time (P6.6.3) (see page 70) has expired before the password function is activated. If you now try to change applications or the password itself you will be prompted for the current password. The password will be entered with the browser. Deactivate the password function by entering the value 0.
READY READY READY enter

S6.5.1

I/O term

Pas swor d

S6.5.1

I/O term

Pas sword

S6.5. 1

I/Oterm

enter

OR:

Password

Not in use
Figure 7-14. Password setting

00

Note! Store the password in a secure location! No changes can be made unless a valid password is entered! Parameter lock (P6.5.2) This function allows the user to prohibit changes to the parameters. If the parameter lock is activated the text *locked* will appear on the display if you try to edit a parameter value. NOTE: This function does not prevent unauthorised editing of parameter values. Enter the edit mode by pushing the Menu button right. Use the browser to change the parameter lock status. Accept the change with the enterbutton or return to the previous level with the menubuttonleft.

RE A D Y

READ Y

READ Y

M6

I/O term

S 6.5

I/Oterm

S6.5.2

I/Oterm

System Menu

Security

Parameter Loc k

S1 S 9
RE A D Y

P1 P4
READ Y

ChangeEnab le

S6.5.2

I/O term

S 6.5.2
en ter

I/Oterm

Para meter Lock

Parameter Lock

Cha nge Enab le


Figure 7-15. Parameter locking

ChangeDisabl

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Control keypad
Start-up Wizard (P6.5.3) The Start-up Wizard is a feature of the control keypad to facilitate the commissioning of the Variable Speed Drive. If selected active, the Start-up Wizard prompts the operator for the language and application of his/her choice and then returns to the starting menu or page. Set the Start-up Wizard active in the following way: In the System Menu, find page P6.5.3. Press the Menu button right once to reach the edit mode. Use the browser to set value Yes and confirm the selection with the enterbutton. If you want to deactivate the function follow the same procedure and give the parameter value No.
READ Y READY READ Y

P6.5.3

I/O ter m

P6.5.3

I/O term

P6.5.3

I/O term

St ar tu p wiz ard

Star tup wizard

Startup wizard

enter

CONFIRM CANCEL

No

No

Yes

Figure 7-16. Activation of Start-up wizard Multimonitoring items (P6.5.4) Telemecanique alpha-numeric keypad features a display where you can monitor even three actual values at the same time (see chapter 7.3.1 and chapter Monitoring values in the manual of the application you are using). On page P6.5.4 of the System Menu you can define if it is possible for the operator to replace the values monitored with other values. See below.

RE A D Y

READ Y

RE A D Y

P6.5.4

I/O term

P6.5.4

I/Oterm

P6.5.4
enter

I/O term

Multi mon . items

Mul timon. items

Multim on. items

ChangeEnable

ChangeEnable

Chan geDisable

Figure 7-17. Enabling the change of multimonitoring items

7.3.6.6 Keypad settings


In the Keypad settings submenu under the System menu you can further customise your Variable Speed Drive operator interface. Locate the Keypad settings submenu (S6.6). Under the submenu, there are four pages (P#) associated with the keypad operation:

REA D Y

READY

S 6.6

I/O ter m

P6.6.1

I/O term

Keypad settings

Default page

P1 P5
Figure 7-18. Keypad settings submenu

0.

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Control keypad
Default page (P6.6.1) Here you can set the location (page) to which the display automatically moves as the Timeout time (see page 70) has expired or as the power is switched on to the keypad. If the Default Page value is 0 the function is not activated, i.e. the last displayed page remains on the keypad display. Press the Menu button right once to enter the edit mode. Change the number of the Main menu with the Browser buttons. Pressing the Menu button right once again makes you able to edit the number of the submenu/page. If the page you want to move to by default is at the third level repeat the procedure. Confirm the new default page value with the Enter button. You can return to the previous step anytime by pushing the Menu button left.
R E AD Y RE ADY REA DY

P6.6.1I/Oter m

P6.6.1 I/Oter m

P6.6.1I/Oterm

enter

C ON FIR M CHANGE R EPEAT TO SET D EFAU LT SUBMENU/PAGE C ANC EL

Defau lt page

Defau lt page

Default page

0.
Figure 7-19. Default page function

0.

1.

Default page in the operating menu (P6.6.2) Here you can set the location (page) in the Operating menu (in special applications only) to which the display automatically moves as the set Timeout time (see below) has expired or as the power is switched on to the keypad. See setting of Default page above. Timeout time (P6.6.3) The Timeout time setting defines the time after which the keypad display returns to the Default page (P6.6.1) see above. Move to the Edit menu by pressing the Menu button right. Set the timeout time you want and confirm the change with the Enter button. You can return to the previous step anytime by pushing the menubuttonleft.
READY READY READY

P6.6.3

I/O term

Timeout time

P6.6.3

I/Oter m

Timeout time

P6.6.3

I/Oterm

Timeout time

e n ter

CONFIRM CHANGE C ANCEL

90 s
Figure 7-20. Timeout time setting

90 s.

60 s.

Note: If the Default page value is 0 the Timeout time setting has no effect. Contrast adjustment (P6.6.4) In case the display is unclear you can adjust its contrast through the same procedure as that for the timeout time setting (see page 70). Backlight time (P6.6.5) Giving a value for the Backlight time, you can determine how long the backlight stays on before going out. You can select here any time between 1 and 65535 minutes or 'Forever'. For the value setting procedure seeTimeout time (P6.6.3).

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Control keypad 7.3.6.7 Hardware settings


NOTE: The Hardware settings submenu is protected with a password. Store the password in a safe place! In the Hardware settings submenu (S6.7) under the System menu you can further control some functions of the hardware in your Variable Speed Drive. The functions available in this menu are Internal brake resistor connection, Fan control, HMI acknowledge timeout and HMI retry. Fan control (P6.7.2) This function allows you to control the Variable Speed Drives cooling fan. You can set the fan to run continuously when the power is switched on or depending on the temperature of the unit. If the latter function has been selected the fan is switched on automatically when the heat sink temperature reaches 60C. The fan receives a stop command when the heat sink temperature falls to 55C. However, the fan runs for about a minute after receiving the stop command or switching on the power, as well as after changing the value from Continuous to Temperature. Note! The fan runs always when the drive is in RUN state. Enter the edit mode by pushing the Menu button right. The present mode shown starts to blink. Use the browser to change the fan mode. Accept the change with the enterbutton or return to the previous level with the menubuttonleft.

READY

READY

READY

P6.7.2

I/O ter m

P6.7.2

I/O ter m

P6.7.2
enter

I/Oterm

Fan control

Fan control

Fan control

Con tinuo us

Con tinuous

Temperatu re

Figure 7-21. Fan control function

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Control keypad
HMI acknowledge timeout (P6.7.3) This function allows the user to change the timeout of the HMI acknowledgement time. Note! If the Variable Speed Drive has been connected to the PC with a normal cable, the default values of parametres 6.7.3 and 6.7.4 (200 and 5) must not be changed. If the Variable Speed Drive has been connected to the PC via a modem and there is delay in transferring messages, the value of par. 6.7.3 must be set according to the delay as follows: Example: Transfer delay between the Variable Speed Drive and the PC = 600 ms The value of par. 6.7.3 is set to 1200 ms (2 x 600, sending delay + receiving delay) The corresponding setting shall be entered in the [Misc]-part of the file PCsoftware.ini: Retries = 5 AckTimeOut = 1200 TimeOut = 6000

It must also be considered that intervals shorter than the AckTimeOut-time cannot be used in PC software monitoring. Enter the edit mode by pushing the Menu button right. Use the browser to change the acknowledgement time. Accept the change with the enterbutton or return to the previous level with the menubuttonleft.

READ Y

READY

P6.7.3

I/O ter m

HMI ACK ti meout

P6.7.3

I/O term

HMI ACK timeout

enter

200ms

200ms

Figure 7-22. HMI acknowledge timeout Number of retries to receive HMI acknowledgement (P6.7.4) With this parameter you can set the number of times the drive will try receive acknowledgement if this does not succeed within the acknowledgement time (P6.7.3) or if the received acknowledgement is faulty. Enter the edit mode by pushing the Menu button right. The present value shown starts to blink. Use the browser to change the amount of retries. Accept the change with the enterbutton or return to the previous level with the menubuttonleft. See Figure 7-22 for the procedure of changing the value.

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Control keypad 7.3.6.8 System info


In the System info submenu (S6.8) you can find Variable Speed Drive-related hardware and software information as well as operation-related information. Total counters (S6.8.1) In the Total counters page (S6.8.1) you can find information related to the Variable Speed Drive operation times, i.e. the total numbers of MWh, operation days and operation hours passed so far. Unlike the counters in the Trip counters , these counters cannot be reset. Note! The Power On time counter (days and hours) runs always, when the power is on. Page Counter C6.8.1.1. MWh counter C6.8.1.2. Power On day counter C6.8.1.3. Power On hour counter Table 7-6. Counter pages Trip counters (S6.8.2) Trip counters (menu S6.8.2) are counters the values of which can be reset i.e. restored to zero. You have the following resettable counters at your disposal: Note! The trip counters run only when the motor is running. Page Counter T6.8.2.1 MWh counter T6.8.2.3 Operation day counter T6.8.2.4 Operation hour counter Table 7-7. Resettable counters The counters can be reset on pages 6.8.2.2 (Clear MWh counter) and 6.8.2.5 (Clear Operation time counter). Example: When you want to reset the operation counters you should do the following:
STOP READY
I/Oter m

STOP

READY

READY

S6.8.2

P6.8.2.5

I/Oterm

P6.8.2.5

I/Oterm

Tr ip c o unte r s

C lr Optime cntr

Clr Optime cnt r

T1 T5
STOP READY

Not reset
STOP READY

Not reset
STOP READY

P6.8.2.5

I/O term

P6.8.2.5 I/Oterm
enter

P6.8.2.5

I/Oterm

C lr Optim e cnt r

C lr Optime cntr

Clr Optime cnt r

Reset
Figure 7-23. Counter reset

Reset

Not reset

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Control keypad
Software (S6.8.3) The Software information page includes information on the following Variable Speed Drive software related topics: Page Content 6.8.3.1 Software package 6.8.3.2 System software version 6.8.3.3 Firmware interface 6.8.3.4 System load Table 7-8. Software information pages Applications (S6.8.4) At location S6.8.4 you can find the Applications submenu containing information about not only the application currently in use but also all other applications loaded into the Variable Speed Drive. The information available is: Page Content Name of application 6.8.4.# 6.8.4.#.1 Application ID 6.8.4.#.2 Version 6.8.4.#.3 Firmware interface Table 7-9. Applications information pages

RE ADY
I / Oterm I/ Ot e rm

READY

Standard

D1 D3
READY

Versio n

2. 01
RE ADY

R EADY

S6.8.4

I/Oter m

Appl ica tions

A6. .4.1 8

I/Oterm

A1

A7

Basic

D1

D3

Application id

A6. .4.1.1 8

I/Oter m

Figure 7-24. Applications info page In the Applications information page, push the Menu button right to enter the Application pages of which there are as many as there are applications loaded into the Variable Speed Drive. Locate the application you want information about with the browser and then enter the Information pages with the Menu button right. Use again the Browser buttons to see the different pages.

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Control keypad
Hardware (S6.8.5) The Hardware information page provides information on the following hardware-related topics: Page Content 6.8.5.1 Nominal power of the unit 6.8.5.2 Nominal voltage of the unit 6.8.5.3 Brake chopper 6.8.5.4 Brake resistor Table 7-10. Hardware information pages Expander boards (S6.8.6) In the Expander boards pages you find information about the basic and option boards connected to the control board (see Chapter 6.2). You can check the status of each board slot by entering the Expander boards page with the Menu button right and using the browser to choose the board whose status you wish to check. Push the Menu button right again to display the status of the board. The keypad will also display the program version of the respective board when you push either one of the browser. If no board is connected to the slot the text 'no board' will be shown. If a board is connected to a slot but the connection is somehow lost the text 'no conn.' is displayed. See Chapter 6.2 and Figure 6-15 and 6-16 for more information. For more information on the expander board-related parameters, see Chapter 7.3.7.

READY
I/Oterm I / O t erm

R EADY

B:VW3A78306 VW3A78202

Soft ware version

E1 E2
READY

10001.0
E6.8.6.1.1
RE AD Y
I/O ter m

RE AD Y

S6.8.6

I/O ter m

Expander bo ards

E1 E5

E6.8.6.1 VW3A78201 A:VW3A78307

I/O term

E1 E2

State

Run

Figure 7-25. Expander board information menus Debug menu (S6.8.7) This menu is meant for advanced users and application designers. Contact factory for any assistance needed.

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Control keypad
7.3.7 Expander board menu (M7)

The Expander board menu makes it possible for the user 1) to see what expander boards are connected to the control board and 2) to reach and edit the parameters associated with the expander board. Enter the following menu level (G#) with the Menu button right. At this level, you can browse through slots (see page 40) A to E with the browser to see what expander boards are connected. On the lowermost line of the display you also see the number of parameters associated with the board. You can view and edit the parameter values in the same way as described in chapter 7.3.2. See Table 7-11 and Figure 7-26. Expander board parameters
Code
P7.1.1.1 P7.1.1.2 P7.1.1.3

Parameter
AI1 mode AI2 mode AO1 mode

Min
1 1 1

Max
5 5 4

Default
3 1 1

Cust

Selections 1=020 mA 2=420 mA 3=010 V 4=210 V 5=10+10 V See P7.1.1.1 1=020 mA 2=420 mA 3=010 V 4=210 V

Table 7-11. Expander board parameters (board VW3A78201)

R EA DY I/Ot erm I/Oterm

R E A DY

D:VW3A78307

Monitor

G1
RE ADY

G2
READY

V1

V2
RE ADY

M7

I/Oter m

G7.3

I/Oterm

G7.3.1 I/Oterm

Expander boards

G1
G7.3.1.1I/Oter m

G5

C:VW3A78306

Paramet ers

G1
G7.3.1.1 I/Oterm

G2
READY

P1 P 4
CHANG E VA L U E
enter

RE ADY

Slave address

Slave address

126
R E A DY I / Ot erm

126

CONFI RM CH A N GE

Baud rate

Au to
Figure 7-26. Expander board information menu

7.4 Further keypad functions


The ATV78 control keypad embodies additional application-related functions. See ATV78 Application Package for more information.

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Commissioning 8. COMMISSIONING

8.1 Safety
Before commissioning, note the following directions and warnings: 1 Internal components and circuit boards of the Variable Speed Drive (except for the galvanically isolated I/O terminals) are live when ATV78 is connected to mains potential. Coming into contact with this voltage is extremely dangerous and may cause death or severe injury. The motor terminals U, V, W and the DC-link/brake resistor terminals /+ are live when ATV78 is connected to mains, even if the motor is not running. The control I/O-terminals are isolated from the mains potential. However, the relay outputs and other I/O-terminals may have a dangerous control voltage present even when ATV78 is disconnected from mains. Do not make any connections with the Variable Speed Drive connected to the mains. After having disconnected the Variable Speed Drive from the mains, wait until the fan stops and the indicators on the keypad go out (if no keypad is attached see the indicator through the keypad base). Wait 5 more minutes before doing any work on ATV78 connections. Do not even open the cover before this time has expired. Before connecting the Variable Speed Drive to mains make sure that the ATV78 front cover is closed. When run ning, the side of converter FR8 is burning hot. Do not touch with hands! When running, the back of Variable Speed Drive FR6 is burning hot. Therefore it MUST NOT be mounted onto a surface which is not fireproof.

4 5

6 7
HOT SURFACE

8.2 Commissioning of the Variable Speed Drive 1 2


Read carefully the safety instructions in Chapter 1 and above and follow them. After the installation, pay attention to: that both the Variable Speed Drive and the motor are grounded. that the mains and motor cables comply with the requirements given in Chapter 6.1.1. that the control cables are located as far as possible from the power cables (see Chapter 6.1.2, step 3) , the shields of the shielded cables are connected to protective earth wires may not touch the electrical components of the Variable Speed Drive. . The

that the common inputs of digital input groups are connected to +24V or ground of the I/O terminal or the external supply.

3 4 5 6

Check the quality and quantity of cooling air (chapter 5.2 and Table 5-7). Check the inside of the Variable Speed Drive for condensation. Check that all Start/Stop switches connected to the I/O terminals are in Stop-position. Connect the Variable Speed Drive to mains.

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Commissioning 7
Set the parameters of group 1 (See ATV78 programming manual (CD)) according to the requirements of your application. At least the following parameters should be set: motor nominal voltage motor nominal frequency motor nominal speed motor nominal current

You will find the values needed for the parameters on the motor rating plate.

Perform run test without motor Perform either Test A or Test B: A Controls from the I/O terminals:

a) Turn the Start/Stop switch to ON position. b) Change the frequency reference (potentiometer) c) Check in the Monitoring menu M1 that the value of Output frequency changes according to the change
of frequency reference.

d) Turn the Start/Stop switch to OFF position.


B Control from the control keypad:

a) Change the control from the I/O terminals to the keypad as advised in Chapter 7.3.3.1. b) Push the startbutton on the keypad
change the
start

. reference using the browser

c) Move over to the Keypad control menu (M3) and Keypad Reference submenu (Chapter 7.3.3.2) and
frequency

d) Check in the Monitoring menu M1 that the value of Output frequency changes according to the change
of frequency reference.
stop

e) Push the stopbutton on the keypad 9

Run the start-up tests without the motor being connected to the process, if possible. If this is not possible, secure the safety of each test prior to running it. Inform your co-workers of the tests.

a) Switch off the supply voltage and wait up until the drive has stopped as advised at Chapter 8.1, step
5.

b) Connect the motor cable to the motor and to the motor cable terminals of the Variable Speed Drive. c) See to that all Start/Stop switches are in Stop positions. d) Switch the mains ON e) Repeat test 8A or 8B. 10 Connect the motor to the process (if the startup test was run without the motor being connected) a) Before running the tests, make sure that this can be done safely. b) Inform your co-workers of the tests.

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Commissioning c) Repeat test 8A or 8B.

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Fault tracing 9. FAULT TRACING

When a fault is detected by the Variable Speed Drive control electronics, the drive is stopped and the symbol F together with the ordinal number of the fault, the fault code and a short fault description appear on the display. The fault can be reset with the resetbutton on the control keypad or via the I/O terminal. The faults are stored in the Fault history menu (M5) which can be browsed. The different fault codes you will find in the table below. The fault codes, their causes and correcting actions are presented in the table below. The shadowed faults are A faults only. The items written in white on black background present faults for which you can program different responses in the application. See parameter group Protections. Note: When contacting distributor or factory because of a fault condition, always write down all texts and codes on the keypad display. Fault code 1 Fault Overcurrent Possible cause Variable Speed Drive has detected too high a current (>4*In) in the motor cable: sudden heavy load increase short circuit in motor cables unsuitable motor The DC-link voltage has exceeded the limits defined in Table 4-1. too short a deceleration time high overvoltage spikes in supply Current measurement has detected that the sum of motor phase current is not zero. insulation failure in cables or motor The charging switch is open, when the START command has been given. faulty operation component failure Stop signal has been given from the option board. Various causes, e.g. defective component Brake resistor short circuit or overload Correcting measures Check loading. Check motor. Check cables.

Overvoltage

Make the deceleration time longer. Use brake chopper or brake resistor (available as options) Check motor cables and motor.

Earth fault

Charging switch

Reset the fault resetbuttonand restart. Should the fault re-occur, contact the distributor near to you.

6 7

Emergency stop Saturation trip

System fault

Cannot be reset from the keypad. Switch off power. DO NOT RE-CONNECT POWER! Contact factory. If this fault appears simultaneously with Fault 1, check motor cables and motor Reset the fault resetbuttonand - component failure restart. - faulty operation Note exceptional fault data record, Should the fault re-occur, contact the distributor near to you. see 7.3.4.3.

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Fault tracing

Undervoltage

DC-link voltage is under the voltage limits defined in Table 4-1. most probable cause: too low a supply voltage Variable Speed Drive internal fault

10 11 12

Input line Input line phase is missing. supervision Output phase Current measurement has detected supervision that there is no current in one motor phase. Brake no brake resistor installed chopper brake resistor is broken supervision brake chopper failure Variable Speed Drive undertemperature Variable Speed Drive overtemperatu re Heatsink temperature is under 10C

In case of temporary supply voltage break reset the faultresetbuttonand restart the Variable Speed Drive. Check the supply voltage. If it is adequate, an internal failure has occurred. Contact the distributor near to you. Check supply voltage and cable. Check motor cable and motor. Check brake resistor. If the resistor is ok, the chopper is faulty. Contact the distributor near to you.

13

14

Heatsink temperature is over 90C. Overtemperature warning is issued when the heatsink temperature exceeds 85C.

15 16

17 22

24 25

26 29

Motor stall protection has tripped. Motor overheating has been detected by Variable Speed Drive motor temperature model. Motor is overloaded. Motor Motor underload protection has underload tripped. Parameter save fault EEPROM checksum faulty operation fault component failure Counter fault Values displayed on counters are incorrect Microprocess Reset the fault resetbuttonand faulty operation or watchdog component failure restart. fault Should the fault re-occur, contact the distributor near to you. Start-up Start-up of the drive has been Cancel prevention of start-up. prevented prevented. Thermistor The thermistor input of option board Check motor cooling and loading fault has detected increase of the motor Check thermistor connection temperature (If thermistor input of the option board is not in use it has to be short circuited)

Motor stalled Motor overtemperatu re

Check the correct amount and flow of cooling air. Check the heatsink for dust. Check the ambient temperature. Make sure that the switching frequency is not too high in relation to ambient temperature and motor load. Check motor. Decrease the motor load. If no motor overload exists, check the temperature model parameters.

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Fault tracing

31 32 34 36 37 38 39 40 41 42 43

IGBT temperature (hardware) Fan cooling

IGBT Inverter Bridge overtemperature protection has detected too high a short term overload current Cooling fan of the Variable Speed Drive does not start, when ON command is given CAN bus Sent message not acknowledged. communication Control unit Device changed (same type) Device added (same type) Device removed Device unknown IGBT temperature

Check loading. Check motor size. Contact the distributor near to you.

Ensure that there is another device on the bus with the same configuration. ATV78 Control Unit can not control Change control unit ATV78F Power Unit and vice versa Option board or control unit changed. Reset Same type of board or same power Note: No fault time data record! rating of drive. Option board or drive added. Reset Drive of same power rating or same Note: No fault time data record! type of board added. Option board removed. Reset Drive removed. Note: No fault time data record! Unknown option board or drive. Contact the distributor near to you. Check loading. Check motor size. Set the deceleration time longer. Use external brake resistor. Check encoder channel connections. Check the encoder board.

44

IGBT Inverter Bridge overtemperature protection has detected too high a short term overload current Brake resistor Brake resistor overtemperature overtemperatur protection has detected too heavy e braking Encoder fault Note the exceptional Fault data record. See 7.3.4.3. Additional codes: 1 = Encoder 1 channel A is missing 2 = Encoder 1 channel B is missing 3 = Both encoder 1 channels are missing 4 = Encoder reversed Device Option board or control unit changed. changed Option board of different type or (different type) different power rating of drive.

45

50

51 52

Reset Note: No fault time data record! Note: Application parameter values restored to default. Device added Option board or drive added. Reset (different type) Option board of different type or drive Note: No fault time data record! of different power rating added. Note: Application parameter values restored to default. Analogue input Current at the analogue input is < Check the current loop circuitry. Iin < 4mA (sel. 4mA. signal range 4 control cable is broken or loose to 20 mA) signal source has failed External fault Digital input fault. Keypad The connection between the control Check keypad connection and communication keypad and the Variable Speed Drive possible keypad cable. fault is broken.

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Fault tracing

53 54 56

Fieldbus fault Slot fault PT100 board temp. fault

The data connection between the Check installation. fieldbus Master and the fieldbus board If installation is correct contact the is broken nearest Telemecanique distributor. Check board and slot. Contact the nearest Telemecanique distributor. Temperature limit values set for the Find the cause of temperature rise PT100 board parameters have been exceeded

Table 9-1. Fault codes

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DIA2ED3031101 FR 2003-11

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www.barr-thorp.com