REFUdrive 500 RD52 Drive Control Devices Field-oriented vector control. Operating Instructions

Transcription

1 REFUdrive 500 RD52 Drive Control Devices Field-oriented vector control Operating Instructions

2 About this Documentation Title Type of Documentation REFUdrive 500 RD52 Drive Control Devices Field-oriented vector control Operating Instructions Document Typecode DOK-RD500*-RD52*******-IB2-EN-P Internal File Reference Document Number, B304-02/DE Purpose of Documentation This documentation explains the frequency converters of the drive series REFUdrive 500 RD52. It provides information... for planning the mechanical control cabinet construction. for planning the electrical control cabinet construction. for commissioning the drive controls. for basic parameterization of the drive controls. to fault messages and notes to cause and remedy. Record of Revisions Description Release Date Notes DOK-RD500*-RD52*******-IB01-EN-P First edition Revision Copyright 2001 Indramat Refu GmbH Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). Validity All rights are reserved with respect to the content of this documentation and the availability of the product. Published by Indramat Refu GmbH Uracher Strasse 75 D Lohr a. Main Telephone 07123/969-0 Fax 07123/ Dept. Development E (jr) Note This document has been printed on chlorine-free bleached paper..

3 REDUdrive 500 RD52 Inhaltsverzeichnis I Inhaltsverzeichnis 1 Safety Instructions for Electric Servo Drives and Controls Introduction Explanations Hazards due to inappropriate use General information Protection against contact with electrical parts Protection against electrical shock by protective low voltage (PELV) Protection against dangerous movements Protection against magnetic and electromagnetic fields during operations and mounting Protection against contact with hot parts Protection during handling and installation Battery safety Protection against pressurized systems Precautionary measures when handling components which can be destroyed by electrostatic discharge (ESDS) Description The REFUdrive 500 drive series Handling Electromagnetic compatibility Technical features Rating plate Important information for use Correct use Non-correct use Technical data Technical data for pulse frequencies f p = 4 khz Technical data for pulse frequencies f p = 4 khz Technical data for pulse frequencies f p = 8 khz Technical data for pulse frequencies f p = 8 khz (* for 110 kw f p = 6 khz) Technical data for pulse frequencies f p = 12 khz Technical data for pulse frequencies f p = 12 khz Circuit principle Type code Type code, basic drive unit Type code, configuration Mounting Storage and mounting Operating Instructions

4 II Inhaltsverzeichnis REDUdrive 500 RD52 Storage Minimum requirements at the installation location Installation altitudes above 1000 meters sea level: Mounting units, sizes A to E Mounting example Dimension drawings, front view, sizes A to E Dimension drawing, side view, sizes A to E Mounting drive units with forced air cooling with internal liquid circuit, sizes G and H(cooling type F) Dimension drawing, cooling type F, size G Dimension drawing, cooling type F, size H Mounting liquid-cooled drive units, sizes G and H with external heat exchanger General mounting instructions Supplementary fan transformer Dimension drawing, drive converter and line filter without heat exchanger, size G Dimension drawing, drive converter and line filter without heat exchanger, size H Dimension drawing, external heat exchanger for cabinet mounting Dimension drawings, external heat exchanger for wall mounting Mounting drawings for drive units with external heat exchanger for cabinet mounting Working on the cooling medium circuit Mounting the extension hoses for external heat exchanger Servicing the cooling medium circuit Electrical installation rules for EMC-correct installation of drives Warnings and information Cable cross-sections Power terminals RD52, sizes A-E Terminal layout diagram, sizes A, B Terminal layout diagram, sizes C, D Terminal layout diagram, size E Description of the power terminals Power terminals RD52, sizes G and H Terminal layout diagram, drive converter size G Terminal layout diagram, drive converter size H Terminal layout diagram, inverter size G Terminal layout diagram, inverter size H Description of the power terminals, drive converters GK G and H Description of the power terminals, inverters GK G and H Connection diagram Control terminals Terminal layout diagram SR Description of the control terminals Encoder connection General engineering information Parameterizing the encoder Changing-over the supply voltage Operating Instructions

5 REDUdrive 500 RD52 Inhaltsverzeichnis III HTL and TTL incremental encoders (for operation with induction motors) Sine/cosine encoder 1V PP and magneto resistive transducer (encoder) Sine/cosine encoder 1 V PP with commutation (rotor position sensing), e.g. ERN Resolver (for operation with induction and synchronous motors) First encoder test Service interface Standard interface RS485 (X12) USS protocol Description of the USS protocol Telegram transfer Electrical Installation Parameterizing the drive converter Character frame Net data block Description of the PKW elements Description of the PZD elements Operator control and visualization Possibilities of operator control Operator control using the operator panel Visualization (monitor) using the operator panel Parameterization using the operator field Fast parameterization using key combinations Load standard values Fault messages when parameterizing Copy function Fault acknowledgement Visualization Monitor Operating display Warning display Fault display LED display Parameterization Parameterizing Parameterization structure Overview Password levels Quick Setup Commissioning Preparatory steps for commissioning Procedure when commissioning the drive system for the first time General information/instructions Operating Instructions

6 IV Inhaltsverzeichnis REDUdrive 500 RD52 8 Basic functions Start inhibit for RD 500, sizes A - H Description Mode of operation Application information Optional drive unit functions Supplementary P24V standby function supply General information Technical data: Troubleshooting Self-test routine - fault messages Warnings Faults Fault acknowledgement List of the warning and fault messages Warning and fault messages cause and remedy / comment Kundenbetreuungsstellen - Sales & Service Facilities 11-1 Indramat Refu Index 12-1 Operating Instructions

7 REDUdrive 500 RD52 Safety Instructions for Electric Servo Drives and Controls Safety Instructions for Electric Servo Drives and Controls 1.1 Introduction Read these instructions before the equipment is used and eliminate the risk of personal injury or property damage. Follow these safety instructions at all times. Do not attempt to install, use or service this equipment without first reading all of the documentation provided with the product. Read and understand these safety instructions and all user documentation of the equipment prior to working with the equipment at any time. If you do not have the user documentation for your equipment contact your local Indramat Refu representative to send this documentation immediately to the person or persons responsible for the safe operation of this equipment. If the product is resold, rented, transferred or passed on to others, then these safety instructions must be delivered with the product. WARNING Inappropriate use of this equipment, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in product damage, personal injury, severe electrical shock or death! 1.2 Explanations The safety warnings in this documentation describe individual degrees of hazard seriousness in compliance with ANSI: Warning symbol with text Degree of hazard seriousness The degree of hazard seriousness describes the consequences resulting from noncompliance with the safety guidelines: Bodily harm or product damage will occur. DANGER Death or severe bodily harm may occur. WARNING Death or severe bodily harm may occur. CAUTION Fig. 1-1:Classes of danger according to ANSI

8 1-2 Safety Instructions for Electric Servo Drives and Controls REDUdrive 500 RD Hazards due to inappropriate use DANGER High voltage and high discharge current! Danger to life, risk of severe electrical shock and risk of injury! DANGER Dangerous movements! Danger to life and risk of injury or equipment damage by unintentional motor movements! WARNING High electrical voltage due to wrong connections! Danger to life, severe electrical shock and severe bodily injury! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Surface of machine housing could be extremely hot! Danger of injury! Danger of burns! CAUTION CAUTION Risk of injury due to inappropriate handling! Bodily injury caused by crushing, shearing, cutting and mechanical shock or improper handling of pressurized systems! Risk of injury due to inappropriate handling of batteries! CAUTION

9 REDUdrive 500 RD52 Safety Instructions for Electric Servo Drives and Controls General information Indramat Refu GmbH is not liable for damages resulting from failure to observe the warnings given in these documentation. Read all of the operating, maintenance and safety instructions in your language before starting up the machine. If you find that due to a translation error you can not completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation as well as care in operation and maintenance are prerequisites for optimal and safe operation of this equipment. Trained and qualified personnel in electrical equipment: Only trained and qualified personnel may work on this equipment or in its proximity. Personnel are qualified if they have sufficient knowledge of the assembly, installation and operation of the product as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they should be trained, instructed and qualified to switch electrical circuits and equipment on and off, to ground them and to mark them according to the requirements of safe work practices and common sense. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer. Follow all safety regulations and requirements for the specific application as practiced in the country of use. The equipment is designed for installation on commercial machinery. European countries: see directive 89/392/EC (Machinery Directive) The ambient conditions specified in the product documentation must be observed. Use only safety features that are clearly and explicitly approved in the Project Planning manual. For example, the following areas of use are not allowed: Cranes and hoisting equipment, elevators used for people or freight, devices and vehicles to transport people, medical applications, refinery plants, the transport of hazardous goods, radioactive or nuclear applications, applications sensitive to high frequency, mining, control of protection equipment (also in a machine). Start-up is only permitted once it is ensured that the machine, in which the product is installed, complies with the requirements of national safety regulations and safety specifications of the application. Operation is only permitted if the national EMC regulations for the application are met. The machine builder is responsible for compliance with the limiting values as prescribed in the national regulations and specific EMC regulations for the application.

10 1-4 Safety Instructions for Electric Servo Drives and Controls REDUdrive 500 RD52 European countries: see Directive 89/336/EC (EMC Directive). US.: Refer to the National Electrical Code (NEC), National Electrical Manufacturers Association (NEMA), and local building codes. The user of this equipment must observe the above noted items at all times. Technical data, connections and operational conditions are specified in the product documentation and must be followed at all times. 1.5 Protection against contact with electrical parts Note: This section refers to equipment with voltages above 50 Volts. Making contact with parts at voltages above 50 Volts could be dangerous to personnel and cause an electrical shock. When operating electrical equipment, it is unavoidable that some parts of the unit conduct dangerous voltages. DANGER High electrical voltage! Danger to life, severe electrical shock and severe bodily injury! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain or repair this equipment. Follow general construction and safety regulations when working on electrical installations. Before powering-up, the productive conductor must be permanently connected to all electrical units according to the connection diagram. Do not operate electrical equipment at any time if the protective conductor is not permanently connected, even for brief measurements or tests. Before working with electrical parts with voltage potentials higher than 50 V, the equipment must be disconnected from the line supply or power supply. The following should be observed with electrical drives, power supplies, and filter components: Wait five (5) minutes after switching off power to allow capacitors to discharge before beginning work. Measure the voltage at the capacitors before beginning work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Install the covers and guards provided with the equipment properly before switching the equipment on. Prevent contact with live parts at any time. A residual-current-operated protective device (r.c.d.) must not be used on an electric drive! Indirect contact may be prevented by other means, for example, by an overcurrent protective device. Equipment that is built into machines must be se-

11 REDUdrive 500 RD52 Safety Instructions for Electric Servo Drives and Controls 1-5 cured against direct contact. Use appropriate housings, for example a control cabinet. European countries: according to EN 50178/1998, section US: Refer to the National Electrical Code (NEC), National Electrical Manufacturers Association (NEMA) and local building codes. The user of this equipment must observe the above noted instructions at all times. To be observed for electric drives and filter components: DANGER High voltage! High leakage current! Danger to life, danger of injury and bodily harm from electrical shock! Before powering-up all housings and motors must be permanently grounded according to the connection diagram. This applies even for brief tests. The protective conductor of the electrical equipment must be permanently connected to the line supply. The leakage current is greater than 3.5 ma. Use a copper conductor with at least 10 mm² cross section over its entire course for this protective connection! Prior to startups, even for brief tests, always connect the protective conductor or connect with ground wire. High voltage levels can occur on the housing that could lead to severe electrical shock and personal injury. European countries: EN / 1998, Section US: Refer to the National Electrical Code (NEC), National Electrical Manufacturers Association (NEMA), and local building codes. The user of this equipment must observe the above noted instructions at all times.

12 1-6 Safety Instructions for Electric Servo Drives and Controls REDUdrive 500 RD Protection against electrical shock by protective low voltage (PELV) All connections and terminals with voltages between 5 and 50 Volts on Indramat Refu products are protective low voltages designed in accordance with the following Standards: International: IEC EU countries: Refer to EN 50178/1998, Section WARNING High voltage due to wrong connections! Danger to life, severe electrical shock and severe bodily injury! Only equipment, electrical components and cables of the protective low voltage type (PELV = Protective Extra Low Voltage) may be connected to all terminals and connections with 0 to 50 Volts. Only safely isolated voltages and electrical circuits may be connected. Safe isolation is achieved, for example, with an isolating transformer, a safe optoelectronic coupler or when battery-operated. 1.7 Protection against dangerous movements Dangerous movements can be caused by faulty control or the connected motors. There are various causes: unclean or wrong wiring of cable connections inappropriate or wrong operation of equipment malfunction of sensors, encoders and monitoring circuits defective components software errors Dangerous movements can occur immediately after equipment has been powered-up or even after an unspecified time of trouble-free operation. The monitors in the drive components make faulty operation almost impossible. Regarding personnel safety, especially the danger of bodily harm and property damage, this alone should not be relied upon to ensure complete safety. Until the built-in monitors become active and effective, it must be assumed in any case that some faulty drive movements will occur. The extent of these faulty drive movements depends on the type of control and the state of operation.

13 REDUdrive 500 RD52 Safety Instructions for Electric Servo Drives and Controls 1-7 DANGER Dangerous movements! Danger to life and risk of injury or equipment damage! Personnel protection must be secured for the above listed reason by means of superordinate monitors or measures. These are implemented in accordance with the specific situation of the plant/system and a danger and fault analysis conducted by the manufacturer of the plant/system. All the safety regulations that apply to this plant/system are included. By switching off, circumventing or if safety devices have simply not been activated, then random machine movements or other types of faults can occur. Avoiding accidents, injury or property damage: Keep free and clear of the machine s range of motion and moving parts. Prevent people from accidentally entering the machine s range of movement: - use protective fences - use protective railings - install protective coverings - install light curtains or light barriers Fences must be strong enough to withstand maximum possible momentum. Mount the emergency stop switch (E-stop) in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the machine if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a start-inhibit system to prevent unintentional start-up. Make sure that the drives are brought to standstill before accessing or entering the danger zone. Secure vertical axes against falling or slipping after switching off the motor power by, for example: - Mechanically securing the vertical axes - Adding an external brake / clamping mechanism - Balancing and thus compensating for the vertical axes weight and the gravitational force The standard equipment motor brake or an external brake controlled directly by the servo drive are not sufficient to guarantee the safety of personnel! Disconnect electrical power to the equipment using a master switch and lock-out the switch against reclosure: - for maintenance and repair work - for cleaning of equipment - if the equipment is not used for long periods of time

14 1-8 Safety Instructions for Electric Servo Drives and Controls REDUdrive 500 RD52 Avoid operating high-frequency, remote control and radio equipment near electronic circuits and feeder cables. If use of such equipment cannot be avoided, verify the system and the plant for possible malfunctions at all possible positions of normal use before the first start-up. If necessary, perform a special electromagnetic compatibility (EMC) test on the plant. 1.8 Protection against magnetic and electromagnetic fields during operations and mounting Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious health hazard to persons with heart pacemakers, metal implants and hearing aids. WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with pacemakers, metal implants and hearing aids are not permitted to enter following areas: - Areas in which electrical equipment and parts are mounted, being operated or started up. - Areas in which parts of motors with permanent magnets are being stored, operated, repaired or mounted. If it is necessary for a person with a pacemaker to enter such an area, then a physician must be consulted prior to doing so. Pacemakers, that are already implanted or will be implanted in the future, have a considerable deviation in their immunity to interference. Due to the unpredictable behavior there are no generally valid rules. Persons with hearing aids, metal implants or metal pieces must consult a doctor before they enter the areas described above. Otherwise health hazards will occur.

15 REDUdrive 500 RD52 Safety Instructions for Electric Servo Drives and Controls Protection against contact with hot parts CAUTION Housing surfaces could be extremely hot! Danger of injury! Danger of burns! Do not touch surfaces near the source of heat! Danger of burns! Wait ten (10) minutes before you access any hot unit. Allow the unit to cool down. Do not touch hot parts of the equipment, such as housings, heatsinks or resistors. Danger of burns!

16 1-10 Safety Instructions for Electric Servo Drives and Controls REDUdrive 500 RD Protection during handling and installation Under certain conditions inappropriate handling and installation of parts and components may cause injuries. CAUTION Risk of injury through incorrect handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock! Observe general instructions and safety regulations during handling installation. Use only appropriate lifting or moving equipment. Take precautions to avoid pinching and crushing. Use only appropriate tools. If specified by the product documentation, special tools must be used. Use lifting devices and tools correctly and safely. Wear appropriate protective clothing, e.g. safety glasses, safety shoes and safety gloves. Never stay under suspended loads. Clean up liquids from the floor immediately to prevent personnel from slipping Battery safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or equipment damage. CAUTION Risk of injury through incorrect handling! Do not attempt to re-activate discharged batteries by heating or other methods (danger of explosion and corrosion). Never charge batteries (danger from leakage and explosion). Never throw batteries into a fire. Do not dismantle batteries. Handle with care. Incorrect withdrawal or installation of a battery can damage equipment. Note: Environmental protection and disposal! The batteries contained in the product should be considered as hazardous material for land, air and sea transport in the sense of the legal requirements (danger of explosion). Dispose of batteries separately from other refuse. Observe the legal requirements given in the country of installation.

17 REDUdrive 500 RD52 Safety Instructions for Electric Servo Drives and Controls Protection against pressurized systems Certain Motors (ADS, ADM, 1MB etc.) and drives, corresponding to the information in the Project Planning manual, must be provided with various media at a high pressure such as compressed air, hydraulic oil, cooling fluid or coolant. In these cases, improper handling of the supply of the pressurized systems or connections of the fluid or air under pressure can lead to injuries or accidents. CAUTION Danger of injury when pressurized systems are handled by untrained personnel! Do not attempt to disassemble, to open or to cut a pressurized system. Observe the operation restrictions of the respective manufacturer. Before the disassembly of pressurized systems, lower pressure and drain off the fluid or gas. Use suitable protective clothing (for example protective eyewear, safety shoes and gloves) Remove any fluid that has leaked out onto the floor immediately. Note: Environmental protection and disposal! The fluids used in the operation of the pressurized system equipment is not environmentally compatible. Fluid that is damaging to the environment must be disposed of separately from normal waste. Observe the national specifications of the country of installation Precautionary measures when handling components which can be destroyed by electrostatic discharge (ESDS) The drive units contain components and parts which can be destroyed by electrostatic discharge. Please observe the following when working with electronic modules and boards: Electronic modules and boards should only be touched if absolutely necessary. Before touching an electronic module/board, the human body must first be electrically discharged. Electronic modules/boards may not come into contact with highlyinsulating materials (e.g. plastic foils, insulating work surfaces, articles of clothing manufactured from man-made fiber). Electronic modules/boards may only be placed on conductive surfaces. The soldering iron tip must be grounded when carrying-out soldering work on electronic modules/boards.

18 1-12 Safety Instructions for Electric Servo Drives and Controls REDUdrive 500 RD52 Electronic modules/boards and components may only be stored and shipped in conductive packaging (e.g. metalized plastic or metal containers). If the packaging is not conductive, electronic modules/boards must be wrapped in a conductive material. In this case, e.g. conductive foam rubber or household aluminum foil can be used. The necessary ESDS protective measures are clearly shown in the following diagram: b e d d b e d f f f f f a c a c a When seated When standing When sitting/standing a: Conductive floor b: ESDS table c: ESDS shoes d: ESDS overall e: ESDS bracelet f: Grounding connection of the cabinets Fig. 1-2: ESDS protective measures

19 REDUdrive 500 RD52 Description Description 2.1 The REFUdrive 500 drive series REFUdrive 500 is a state-of-the-art, universal three-phase drive system for various synchronous and induction motors. The modular hardware and software design allows the drive system to be flexibly adapted to the particular drive application. The system includes various AC drive converters (with/without braking chopper, line contactor etc.), inverter for DC supply as well as rectifier and supply modules which are capable of regenerative feedback into the line supply. The modules can be individually purchased, or as a system, completely wired-up in the cabinet. The power sections are designed for cooling at the rear. This means that forced cooling, also outside the cabinet can be implemented with an associated higher degree of protection (where the heatsink extends outside the cabinet or using a conductive plate). In addition, versions are available with liquid cooling with either integrated or external heat exchangers. Handling Special significance was placed on simple handling. For instance, automatic motor adaptation with parameter identification. The drive system is commissioned, prompted using the operator panel with graphics display or with the highest level of user-friendliness, using a PC with the high-performance REFUwin software package. Electromagnetic compatibility Technical features In order to reduce the harmonics fed back into the line supply, radio interference suppression filters and line reactor are integrated into the AC drive converters. REFUdrive 500 are in full compliance with the EMC Directives regarding noise immunity and noise emission according to the EMC Product Standard for electric drives EN , EN Class A (IEC ). REFUdrive 500 is immune to noise in conformance with EN AC or DC supply Either forced air cooling, heat conducting plate or liquid cooling Removable operator panel with parameter copy function 4-line graphics display Various interfaces, which can be used to control, monitor and parameterize the drive system ( download parameterization): Profibus DP Interbus S CAN-Bus RS 232 / RS 485 Peer-to-peer coupling or Synchrolink for fast communications between several drives

20 2-2 Description REDUdrive 500 RD Rating plate Expanded, freely-combinable technology functions PID, PI controller, AND, OR, XOR, RS flipflop and D latch mathematical function elements timers, counters, comparitors, ramp-function generators freely-assignable characteristic Additional signal processor (32-bit floating point) for high-dynamic performance applications, including servo applications torque rise times of 0.3 ms current cycle times of 0.1 ms 200% overload capability for 0.5 sec (not for drive units 132 kw) 170% overload capability for 1 sec Indramat Refu Typ: RD52.1-4U-004-L-C1xx abcdefghijklmnopqrst FWA-RD VRS-MS-RD52 Serialnr.: B V A Hz Input 3AC /60 Output 3AC / ; max 1400 CE Made in Germany Fig. 2-1: Rating plate 2.3 Important information for use Correct use Introduction Indramat Refu products are developed and manufactured in-line with state-of-the-art technology. They are checked to ensure that they are fully operational before they are shipped. The product may only be used in a way for which it was originally designed. If it is not correctly used, then situations can arise, which can result in bodily injury or material damage. Note: Indramat Refu, as manufacturer, assumes no warranty, liability or claims for damage caused by incorrect use of their products; the risks, resulting from incorrect use of the products lie entirely with the user. Before you use products from Indramat Refu, the following prerequisites must be fulfilled in order to ensure that the products are correctly used:

21 REDUdrive 500 RD52 Description 2-3 Everybody, who uses our products in one form or another, must read and understand the appropriate safety regulations and the instructions for correct use. When hardware products are involved, they must be kept in their original condition; i. e. they may not be modified in any form. It is not permissible to de-compile software products and it is not permissible to change their source codes. Damaged products or products with errors/faults may not be installed and may not be commissioned. It must be guaranteed that the products are installed in full compliance with the regulations specified in the documentation. Applications Indramat Refu drive control units are designed to control (closed-loop) electric motors and to monitor their operation. It may be necessary to connect additional sensors and actuators to control (closed-loop) and monitor motors. Note: The drive control units may only be operated with the accessories and mounted components specified in the REFUdrive 500 documentation. Components, which are not expressly specified, may neither be mounted nor connected. This also applies to cables and conductors. Operation is only permissible in the specified configuration and combination of components and with the software and firmware, specified in the relevant function description. Every drive control unit must be programmed before it is commissioned, so that the motor is controlled corresponding to the specific functions for the application. Equipment types with various drive outputs and different interfaces are available for application-specific use. Typical applications include: Chemical and process technology, Machine tools, Conveyor technology, Handling and assembly systems, and Packing and foodstuff machines. The drive control unit may only be operated under the specified mounting and installation conditions, in the specified mounting position and under the specified ambient conditions (temperature, degree of protection, humidity, EMC etc.). These are all specified in this documentation.

22 2-4 Description REDUdrive 500 RD52 Non-correct use The use of the drive control units in other applications than those specified, or described in the documentation and technical data are considered as "incorrect". Drive control units may not be used, if They are exposed/subject to operating conditions which do not fulfill the specified ambient conditions. For example, the following are not permitted: Operation under water, under extreme temperature fluctuations or extreme maximum temperatures. Furthermore, the drive control units may not be used for applications which have not been clearly released by Indramat Refu. Please refer to the statements which have been made in the general safety information and instructions!

23 REDUdrive 500 RD52 Description Technical data Technical data for pulse frequencies f p = 4 khz RD Rated motor output 1 [kw] Supply voltage, 3-ph V AC (±10%) 2 Output frequency [Hz] Hz Rated current [A] Peak current for t=60 s [A] t=1 s [A] t=0.5 s [A] Rated output S N [kva] Peak output for t=60s [kva] Supply voltage 3-ph. 500 V AC (±10%) Output frequency [Hz] Hz Rated current [A] Peak current for t=60 s [A] t=1 s [A] t=0.5 s [A] Rated output S N [kva] Peak output for t=60s [kva] Ambient conditions, radio interference suppression level, noise immunity Environmental Class 3K3 acc. to DIN IEC (ambient temperature 0-40 C) Cooling air requirement [m³/s] Radio int. sup. level/noise immunity A 1 acc. to EN / EN Mechanical design Sizes A A A A A B B B C C C Degree of protection IP 20 acc. to EN IP 20 acc. to EN (without terminals) Weight of the drive converter, for the various cooling types Forced air cooling [kg] Liquid cooling [kg] Conductive heat plate [kg] Brake resistor RZW01.1 Peak power for t=1s [kw] Continuous brak. power 3 [kw] Resistance value [Ohm] Cont. power of the chopper [kw] : Max. permissible motor power referred to a 4-pole standard induction motor 2: The rated current is linearly reduced from output voltages Va > 400 V from 100 % to 83 % for Va = 480 V. 3: When mounting the standard brake resistors RZW01.1 in the airflow of the drive converter.

24 2-6 Description REDUdrive 500 RD52 Technical data for pulse frequencies f p = 4 khz RD Rated motor output 1 [kw] Supply voltage, 3-ph V AC (±10%) 2 Output frequency [Hz] Rated current [A] Peak current for t=60 s [A] t=1 s [A] t=0.5 s [A] Rated output S N [kva] Peak output for t=60s [kva] Supply voltage, 3-ph. 500 V AC (±10%) Output frequency [Hz] Rated current [A] Peak current for t=60 s [A] t=1 s [A] t=0.5 s [A] Rated output S N [kva] Peak output for t=60s [kva] Ambient conditions, radio interference suppression level, noise immunity Environmental Class 3K3 acc. to DIN IEC (ambient temperature 0-40 C) Cooling air requirement [m³/s] Radio int. sup. level/noise immunity A 1 acc. to EN / EN Mechanical design Sizes C D D E E G G G H H Degree of protection Weight of the drive converter, for the various cooling types IP 20 acc. to EN (without terminals) Forced air cooling [kg] Liquid cooling [kg] Conductive heat plate [kg] Brake resistor RZW01.1 Peak power for t=1s [kw] x270 2x370 Continuous brak. power 3 [kw] Resistance value [Ohm] x2.2 2x2.2 Cont. power of the chopper [kw] : Max. permissible motor power referred to a 4-pole standard induction motor 2: The rated current is linearly reduced from output voltages Va > 400 V from 100 % to 83 % for Va = 480 V. 3: When mounting the standard brake resistors RZW01.1 in the airflow of the drive converter.

25 REDUdrive 500 RD52 Description 2-7 Technical data for pulse frequencies f p = 8 khz RD Rated motor output 1 [kw] Supply voltage, 3-ph V AC (±10%) 2 Output frequency [Hz] Rated current [A] Peak current for t=60 s [A] t=1 s [A] t=0.5 s [A] Rated output S N [kva] Peak output for t=60s [kva] Supply voltage, 3-ph. 500 V AC (+10%) Output frequency [Hz] Rated current [A] Peak current for t=60 s [A] t=1 s [A] t=0.5 s [A] Rated output S N [kva] Peak output for t=60s [kva] Ambient conditions, radio interference suppression level, noise immunity Environmental Class 3K3 acc. to DIN IEC (ambient temperature 0-40 C) Cooling air requirement [m³/s] Radio int. sup. level/noise immunity A 1 acc. to EN / EN Mechanical design Sizes A A A A A B B B C C C Degree of protection IP 20 acc. to EN IP 20 acc. to EN (without terminals) Weight of the drive converter, for the various cooling types Forced air cooling [kg] Liquid cooling [kg] Conductive heat plate [kg] Brake resistor RZW01.1 Peak power for t=1s [kw] Continuous brak. power 3 [kw] Resistance value [Ohm] Cont. power of the chopper [kw] : Max. permissible motor power referred to a 4-pole standard induction motor 2: The rated current is linearly reduced from output voltages Va > 400 V from 100 % to 83 % for Va = 480 V. 3: When mounting the standard brake resistors RZW01.1 in the airflow of the drive converter.

26 2-8 Description REDUdrive 500 RD52 Technical data for pulse frequencies f p = 8 khz (* for 110 kw f p = 6 khz) RD * Rated motor output 1 [kw] Supply voltage, 3-ph V AC (±10%) 2 Output frequency [Hz] Rated current [A] Peak current for t=60 s [A] t=1 s [A] t=0.5 s [A] Rated output S N [kva] Peak output for t=60s [kva] Supply voltage, 3-ph. 500 V AC (+10%) Output frequency [Hz] Rated current [A] Peak current for t=60 s [A] t=1 s [A] t=0.5 s [A] Rated output S N [kva] Peak output for t=60s [kva] Ambient conditions, radio interference suppression level, noise immunity Environmental Class 3K3 acc. to DIN IEC (ambient temperature 0-40 C) Cooling air requirement [m³/s] Radio int. sup. level/noise immunity A 1 acc. to EN / EN Mechanical design Sizes C D D E E G G G H H Degree of protection Weight of the drive converter, for the various cooling types IP 20 acc. to EN (without terminals) Forced air cooling [kg] Liquid cooling [kg] Conductive heat plate [kg] Brake resistor RZW01.1 Peak power for t=1s [kw] x270 2x370 Continuous brak. power 3 [kw] Resistance value [Ohm] x2.2 2x1.6 Cont. power of the chopper [kw] : Max. permissible motor power referred to a 4-pole standard induction motor 2: The rated current is linearly reduced from output voltages Va > 400 V from 100 % to 83 % for Va = 480 V. 3: When mounting the standard brake resistors RZW01.1 in the airflow of the drive converter.

27 REDUdrive 500 RD52 Description 2-9 Technical data for pulse frequencies f p = 12 khz RD Supply voltage, 3-ph V AC (±10%) 1 Output frequency [Hz] Rated current [A] Peak current for t=60 s [A] t=1 s [A] t=0.5 s [A] Rated output S N [kva] Peak output for t=60s [kva] Ambient conditions, radio interference suppression level, noise immunity Environmental Class 3K3 acc. to DIN IEC (ambient temperature 0-40 C) Cooling air requirement [m³/s] Radio int. sup. level/noise immunity A 1 acc. to EN / EN Mechanical design Sizes A A A A A B B B C C C Degree of protection IP 20 acc. to EN IP 20 acc. to EN (without terminals) Weight of the drive converter, for the various cooling types Forced air cooling [kg] Liquid cooling [kg] Conductive heat plate [kg] Brake resistor RZW01.1 Peak power for =1s [kw] Continuous brak. power 2 [kw] Resistance value [Ohm] Cont. power of the chopper [kw] : The rated current is linearly reduced from output voltages Va > 400 V from 100 % to 83 % for Va = 480 V. 2: When mounting the standard brake resistors RZW01.1 in the airflow of the drive converter.

28 2-10 Description REDUdrive 500 RD52 Technical data for pulse frequencies f p = 12 khz RD * Supply voltage, 3-ph V AC (±10%) 1 Output frequency [Hz] Rated current [A] Peak current for t=60 s [A] t=1 s [A] t=0.5 s [A] Rated output S N [kva] Peak output for t=60s [kva] Ambient conditions, radio interference suppression level, noise immunity Environmental Class 3K3 acc. to DIN IEC (ambient temperature 0-40 C) Cooling air requirement [m³/s] Radio int. sup. level/noise immunity A 1 acc. to EN / EN Mechanical design Sizes C D D E E G G G H H Degree of protection Weight of the drive converter, for the various cooling types IP 20 acc. to EN (without terminals) Forced air cooling [kg] Liquid cooling [kg] Conductive heat plate [kg] Brake resistor RZW01.1 Peak power for t=1s [kw] x270 2x370 Continuous brak. power 2 [kw] Resistance value [Ohm] x2.2 2x1.6 Cont. power of the chopper [kw] : The rated current is linearly reduced from output voltages Va > 400 V from 100 % to 83 % for Va = 480 V. 2: When mounting the standard brake resistors RZW01.1 in the airflow of the drive converter.

29 REDUdrive 500 RD52 Description Circuit principle Operator panel, REFUwin REFUwin REFU X11 Interface (RS232) Control board SR Bus termination Serial communication via USS protocol (RS485) From control computer To the next bus note X12 RS485 interface Auxiliary supply Output +24 V X14 Standard terminal strip Bidirectional digital inputs and outputs Dig.input/output 1 Dig.input/output 2 Dig.input/output 3 Output Input Digital inputs Analog output / reference Analog input Dig. input 4 Dig. input 5 Dig. GND An. output / ref. An. input + An. input - An. output Microprocessor Ref. GND X16 Relay output Relay output Process data interface Alternative encoder: Resolver, IGR, ERN, Sin/Cos Resolver excitation voltage IGR supply voltage IGR Sensor cables Sin Resolver signals IGR Encoder track A X18 Rotary encoder Res. excitation voltage Option slot 1 Cos Resolver signals IGR Encoder track B Option slot 2 IGR Encoder track C IGR Encoder track D IGR Zero plus track R Temperature sensor PTC / KTY 84 X15 Temperarure sensor Temperature monitoring Fig. 2-2: Circuit principle, electronics sections

30 2-12 Description REDUdrive 500 RD52 3 phase power supply Optional braking resistor Ext. line contactor Ext. fuses DC link EW GL K1 K2 NF SE SNT VL WS WR X80 BC Ground fault transducer Rectifier Main contactor Pre-charging relay Line filter Current sensing Switch-mode power supply Pre-charging, from 22 kw onwards 3 phase Inverter control Inverter Start inhibit Equipment version Converter with integrated Braking chopper Inverter control BW MF Accessories Braking resistor Motor filter Start inhibit X83 Additional function Electronic stand-by power supply +24 V Ground Electronic stand-by power supply Accessories motor filter Rotary encoder Fig. 2-3: Circuit principle, power section GK A-E

31 REDUdrive 500 RD52 Description phase power supply Ext. fuses Heat exchanger Line filter Inverter control BC BW E1 EW GL K1 K2 P1 SE SNT WS Braking chopper Braking resistor Fan Ground fault transducer Rectifier Main contactor Pre-charging contactor Cooling circuit pump Current sensing Switched-mode power supply Inverter control MF Accessories Motor filter Converter Start inhibit Accessories motor filter Encoder Fig. 2-4: Circuit principle, power section GK G-H forced air cooling with integrated liquid circuit

32 2-14 Description REDUdrive 500 RD52 FF 4 A/660 V Supply SNT DC 600V ± 20% + - ext. fuse DC-link L+ L- PE C1 D1 X1 C D PE EW SE SNT WS WR X80 Ground fault transducer Current sensing Switched-mode puwer supply Inverter control Inverter Start inhibit Optionen MF Motor filter X83 Electronic stand-by power supply DC-link Accessories BW Brakeing resistor MF Motor filter SNT X155 WS Inverter control J 3 WR Stand-by 15 V 24 V Start inhibit +24V å SE EW X X80 X2 U2 V2 W2 PE +24 V Masse Electronic stand by power supply U1 V1 W1 MF U2 V2 W2 PE Accessories motor filter J M 3~ Encoder Fig. 2-5: Circuit principal, power section inverter GK A-E

33 REDUdrive 500 RD52 Description 2-15 DC-link L+ L- PE ext. fuse X1 C D PE X V1 2U1 EW Ground fault transducer SE Current sensing SNT Switched-mode power supply * not available with electronic stand-by power supply WS Inverter control WR Inverter X80 Start inhibit Optionen MF Motor filter X83 Electronic stand-by power supply SNT* DC-link Accessoiries BW Braking resistor MF Motor filter X155 WS Inverter control J 3 WR Stand-by 24 V Start inhibit +24V å SE EW X X80 X2 U2 V2 W2 PE +24 V Masse Electronic stand-by power supply U1 V1 W1 MF U2 V2 W2 PE Accessories motor filter J M 3~ Encoder Fig. 2-6: Circuit principal, power section inverter GK G-H

34 2-16 Description REDUdrive 500 RD Type code Type code, basic drive unit Kurztext- Spalte Beispiel: R D N L - V 1 - F W Product group 1.1 RD = RD 2. Line 2.1 field oriented regulation = Design = Unit type / Nominal connecting voltage 4.1 Converter 3 x AC 380 to 480 V, ±10 % = Converter x AC 500 V, ±10 % = Inverter DC 530 to 670 V, ±10 % = Inverter.... DC 700 V, ±10 % = 8 5. Brake chopper for converter 5.1 Converter with built-in brake chopper = B kw: without brake chopper possible = N 5.2 Inverter without brake chopper = N 2 6. Rated power data (kw) 1, ,5 7, , e.g. 1,5 kw = 001 e.g. 18,5 kw = Cooling mode 7.1 plug-through cooler ( 110 kw)= D 7.2 forced air cooling with integrated liquid circulation (³ 132 kw) = F 7.3 forced air cooling ( 110 kw) = L 7.4 heat dissipation panel ( 18,5 kw)= P 7.5 liquid cooling (³ 132 kw) = R 8. 3 Additional functions 8.1 Feedback of curren filter (U6, V6, W6) = F1 8.2 Feedbach of cable damping (C3, D3) = L1 8.3 Frequency converter > 150 Hz, without output chokes (³ 132 kw) = M V stand-by power, external = V mm² terminals "C" and "F" (³ 132 kw) = W mm² terminals "C" and "D" (³ 132 kw) = Z1 9. Firmware 9.1 Denotes that firmware must be ordered as separate subposition = FW Bemerkung: All converters are equipped with mains filter These three codes supply information about typical rated power of a 4-pole standard AC motor with a relevant connecting voltage. permissble combinationes of additional functions Fig. 2-7: Type code, basic drive unit, Order code

35 REDUdrive 500 RD52 Description 2-17 Type code, configuration Modulslot 1 2 Abbrev. Column Example: C F G - R D N N - N N Object group 1.1 Configuration... = CFG 2. Product group 2.1 RD = RD Module slot 1 and RD51.1 / RR B1-B1 B1-L2 B1-NN B1-T C1-C1 C1-L2 C1-NN C1-T K1-L2 K1-NN K1-T L2-NN L2-T NN-NN NN-T P1-P1 P1-L2 P1-NN P1-T1 3.2 RD52.1 / RR B1-B1 B1-G1 B1-G2 B1-G3 B1-L1 B1-L2 B1-NN B1-T C1-C1 C1-G1 C1-G2 C1-G3 C1-L1 C1-L2 C1-NN C1-T G1-L1 G1-L2 G1-NN G1-T G2-L1 G2-L2 G2-NN G2-T G3-L1 G3-L2 G3-NN G3-T K1-G1 K1-G2 K1-G3 K1-L1 K1-L2 K1-NN K1-T L1-NN L1-T L2-NN L2-T NN-NN NN-T P1-P1 P1-G1 P1-G2 P1-G3 P1-L1 P1-L2 P1-NN P1-T1 3.3 RS B1-L2 B1-NN B1-T C1-L2 C1-NN C1-T L2-NN L2-T NN-NN NN-T P1-L2 P1-NN P1-T1 = only available for RD5X.1 = only available for RR5X.1 = available for RD5X.1 and RR5X.1 Note: B1 = INTERBUS-S slave, remote bus interface C1 = CANopen interface (with galvanic isolation) G1 = Incremental encoder emulation with resolver evaluation G2 = Input for toothed wheel encoder 1 Vpp, TTL, sin/cos and incremental encoder emulation G3 = Incremental encoder emulation K1 = CAN interface (without galvanic isolation) L1 = SynchroLink (fiber optic cable) L2 = Peer-to-Peer coupling via fiber optic cable NN = not equipped P1 = PROFIBUS-DP slave interface T1 = expanded control terminal strip Fig. 2-8: Type code, configuration Note: Your local sales organization will provide you with information about the versions which are presently available.

36 2-18 Description REDUdrive 500 RD52

37 REDUdrive 500 RD52 Mounting Mounting 3.1 Storage and mounting Storage The drive units must be stored in dry, clean areas. The storage temperature must be between -25 C and +70 C. Temperature fluctuations exceeding 20 K per hour are not permissible. Note: AC drive converters and supply modules have AL Elkos as DC link capacitors. They can be stored for a maximum of 2 years in a no-voltage condition at a storage temperature of 40 C Minimum requirements at the installation location The mounting location where the drives are operated, must be dustfree. Dust-laden air must be filtered (3K3 acc. to DIN IEC ). The ambient temperature must lie between C. The relative air humidity may not exceed 90 %; moisture condensation is not permissible. The air drawn-into the unit may not contain aggressive or electrically conductive gases/vapors which could have a negative impact on the function of the equipment. The airflow of the fans may not be impeded. The minimum clearances for air intake and air discharge, specified for the particular drive unit size may not be reduced by additional mounted components. The drive unit has a power loss and heats up its environment. Sufficient clearance must be maintained to heat-sensitive equipment. Installation altitudes above 1000 meters sea level: The utilization of the drive converter or inverter must be reduced (derated) corresponding to the diagram below for installation altitudes above 1000 meters above sea level. Utilization 100 % 90 % 83 % 80 % 70 % Installation altitude in m above sea level Fig. 3-1: Derating as a function of the installation altitude

38 3-2 Mounting REDUdrive 500 RD Mounting units, sizes A to E The REFUdrive 500 units, sizes A to E are modular and are designed for mounting in cabinets. The units have a 22.5 mm mechanical grid pattern. Several drive units can be mounted next to one another without any intermediate space when using mounting rails with tapped holes (also refer to the mounting example). The drive units must be mounted perpendicular to a flat mounting surface. A minimum clearance of 100 mm above and below the unit must be maintained to ensure that the cooling air can flow unrestricted. When the drive units are mounted in a cabinet, the cooling air requirement of the installed units must be calculated (refer to Technical data, Section 1), and the cabinet ventilation appropriately dimensioned. The required mounting bolts are specified in the drilling templates of the dimension drawings. Mounting example Four inverters with forced air-cooling, sizes A, B, C and D are shown mounted next to one another in the drawing below. Warm discharged air 100 mm Min. clearance for cooling Cooling air 100 mm Min. clearance for cooling Fig. 3-2: Mounting example, inverter

39 ESC START MON STOP + - High electrical Voltage. shock. Danger Donot oftouch electricalconnectionsfor 5 minutes power off. after switching Read and follow "Safety Instructions Drives "manual,dok-gene- for Electrical RL-DRIVE******-SVS... before operating PROG DANGER ALARM READY ON ENTER drive 500 ESC START MON STOP + - High electrical Voltage. shock. Danger Donot oftouch electricalconnectionsfor 5 minutes power off. after switching Read and follow "Safety Instructions Drives "manual,dok-gene- for Electrical RL-DRIVE******-SVS... before operating PROG DANGER ALARM READY ON ENTER drive 500 ESC START MON STOP + - High electrical Voltage. shock. Danger Do not oftouch electricalconnectionsfor 5 minutes power off. after switching Read and follow "Safety Instructions Drives "manual,dok-gene- for Electrical RL-DRIVE******-SVS... before operating PROG DANGER ALARM READY ON ENTER drive 500 ESC START MON STOP + - High electrical Voltage. shock. Danger Donot oftouch electricalconnectionsfor 5 minutes power off. after switching Read and follow "Safety Instructions Drives "manual,dok-gene- for Electrical RL-DRIVE******-SVS... before operating PROG DANGER ALARM READY ON ENTER drive 500 ESC START MON STOP + - High Voltage. Danger of electrical shock. Donot touch electricalconnectionsfor minutes after switching 5 power off. Read Instructions and follow for Electrical "Safety Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating PROG DANGER ALARM READY ON ENTER drive 500 REDUdrive 500 RD52 Mounting 3-3 Dimension drawings, front view, sizes A to E Dimension mm Size A B C D E Housing demensions REFU REFU REFU REFU REFU Drilling templates 3 x M M6 M6 2 x M6 2 x M M6 M6 2 x M6 2 x M6 3 x M Grid pattern (22,5 mm = 1 unit) Fig. 3-3: Dimension drawing, drive converters GK A to E

40 3-4 Mounting REDUdrive 500 RD52 Dimension drawing, side view, sizes A to E Dimension in mm Drive converters with forced air-cooling, sizes A and B to E have different depths. Clearance brackets are available for size A drive converters. These allow the depth to be compensated when mounted with other drive converters having different sizes. Refer to the drawing below. Size Forced air cooling A Warm discharged air Forced air cooling B to E Warm discharged air * Mounting bracket Cooling air Cooling air 320 * Accessories RZT01.1 only for size A Size Trough-connection cooler A to E Heat discharge plate A and B Fig. 3-4: Dimension drawing, side view GK A to E with various cooling types

41 REDUdrive 500 RD52 Mounting Mounting drive units with forced air cooling with internal liquid circuit, sizes G and H(cooling type F) Drive units, sizes G and H comprise the following elements: Line filter, drive converter and heat exchanger. The drive converter and heat exchanger are mounted on a common mounting plate and are connectedup. The line filter has its own mounting plate as a result of its weight. The drive unit must be mounted perpendicular to a flat mounting surface. A minimum clearance of 200 mm above the drive units must be maintained to ensure that the hot discharged air is unrestricted. When the drive units are mounted in a cabinet, the cooling air requirement of the units must be calculated (refer to Technical data, Section 1.2) and the cabinet ventilation appropriately dimensioned. The mounting bolts required are specified in the drilling templates of the dimension drawings. Two hoisting support points are provided to mount the units using a crane. These are introduced at the top at the mounting plate at both sides and secured using a bolt (refer to Fig. 3-5). First mount the line filter then above, the mounting plate with drive converter and heat exchanger. The two mounting plates must be mounted, as shown in the dimension drawing, without any clearance between so that the cooling airflow is not impeded. The busbars to connect the line filter and drive converter are supplied with the equipment.

42 DANGER ALARM READY ON ES C MON PROG ENTER START STOP - + REFU 3-6 Mounting REDUdrive 500 RD52 Dimension drawing, cooling type F, size G Dimenisions in mm Drilling Template 400 Front view Side view 520 * 380 Warm discharged air 3 x M x M High Voltage. Danger of electrical shock. Donot touch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating Mounting devices with lugs Cooling air Cooling air 2 x M * The heat exchanger is 520 mm for a typical motor output of 200 kw. Fig. 3-5: Dimension drawing, drive converter GK G

43 ESC START MO N STOP + - PROG DANGER ALARM READY ON EN TER REFU REDUdrive 500 RD52 Mounting 3-7 Dimension drawing, cooling type F, size H Dimension in mm Drilling Template Front view Side view 520 * 380 Warm discharged air 6 x M x M High Voltage. Danger of electrical shock. Donottouch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives"manual,DOK-GENE- RL-DRIVE******-SVS... beforeoperating Mounting devices with lugs Cooling air Cooling air 4 x M * The heat exchanger is 520 mm for a typical motor output of 200 kw. Fig. 3-6: Dimension drawing, AC drive converter GK H 3.4 Mounting liquid-cooled drive units, sizes G and H with external heat exchanger General mounting instructions Drive units, sizes G and H comprise the following elements: Line filter, drive converter and heat exchanger. The drive converter, line filter and heat exchanger are mounted on a separate mounting plate. If the heat exchanger is externally mounted, the drive converter is no longer cooled by the heat exchanger airflow. This means that additional fans are provided on the drive converter. The drive unit must be mounted perpendicular to a flat mounting surface. A minimum clearance of 200 mm above the drive units must be maintained to ensure that the hot discharged air is unrestricted. When the drive units are mounted in a cabinet, the cooling air requirement of the mounted units must be calculated and the cabinet ventilation appropriately dimensioned. The mounting bolts required are specified in the drilling templates of the dimension drawings. Two hoisting support points are provided to mount the units using a crane. These are introduced at the top at the mounting plate at both sides and secured using a bolt (refer to the dimension drawings).

44 3-8 Mounting REDUdrive 500 RD52 Supplementary fan transformer First mount the line filter then above, the mounting plate with drive converter and heat exchanger. The two mounting plates must be mounted, as shown in the dimension drawing, without any clearance between so that the cooling airflow is not impeded. The busbars to connect the line filter and drive converter are supplied with the equipment. Mount the external heat exchanger at the required location. Connect the cooling circuit of the drive converter to the heat exchanger using the heat exchanger hoses; for additional information, refer to 3.6 Working on the cooling medium circuit. The heat exchanger hoses, depending on the requirements, must be ordered together with the drive converter. Refer to the REFUdrive 500 product program for additional information on heat exchanger hoses, hose clamps, couplings, angled connectors etc. For 200 kw and 400 kw units, the size of the internal power supply is not adequate for these additional fans. An external fan transformer is supplied. The fan transformer to connect the drive converter fans must be mounted at a suitable location in the cabinet. Connection for Vsupply 380 V / 400 V Fan supply 220 V / 230 V Connection to the converter (the terminals are on the converter beside the fans, refer to dimension drawing) Connection for Vsupply 415 V Connection for V supply 340 V / 460 V Connection for V supply 500 V Fig. 3-7: Separate fan transformer for 200 kw and 400 kw drive units

45 DANGER ALARM READY ON ESC MON PROG ENTER START STOP + - REFU drive 500 REDUdrive 500 RD52 Mounting 3-9 Separate control-power transformer for electronic fan High Voltage. Danger of electrical shock. Donot touch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual, DOK-GENE- RL-DRIVE******-SVS... before operating 2A L1 L2 Supply connection 3 phases Fig. 3-8: Connection diagram, separate fan transformer for 200 kw and 400 kw drive units

46 ESC START MON STOP - + PROG DANGER AL ARM RE ADY ON ENTER REFU ESC START MON STOP + - PROG DANGER AL ARM READY ON ENTER REFU 3-10 Mounting REDUdrive 500 RD52 Dimension drawing, drive converter and line filter without heat exchanger, size G Dimension in mm (inch) Drilling template 400 Front view 2 fans 230 V ±10%, 50/60 Hz each 25 VA Side view Connections, cooling ciruit Connection for the separate control-power transformer 3 x M x M High Voltage. Danger of electrical shock. Donot touch electricalconnectionsfor5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating Mounting devices with lugs Cooling air 2 x M Fig. 3-9: AC drive converter GK G without heat exchanger Dimension drawing, drive converter and line filter without heat exchanger, size H Dimension in mm (inch) Drilling template 900 (35.4) 500 (19.7) 100 (3.9) Front view 4 fans 230 V ±10%, 50/60 Hz each 25 VA Side view Connections, cooling ciruit Connection for the separate control-power transformer 6 x M8 420 (16.5) 895 (44.1) 10 x M8 4 x M (50.0) High Voltage. Danger of electrical shock. Donot touch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating 390 (15.4) 850 (33.5) Mounting devices with lugs Cooling air 12 (0.5) 300 (11.8) 700 (27.5) 980 (38.6) 380 (15.0) Fig. 3-10: AC drive converter GK H without heat exchanger

47 REDUdrive 500 RD52 Mounting 3-11 Dimension drawing, external heat exchanger for cabinet mounting Dimension in mm View from the top Drilling template Front view Side view Mounting panel 350 Connections, cooling air Cooling air * The heat exchanger is 520 mm for a typical motor output of 200 kw Fig. 3-11: Heat exchanger for cabinet mounting Dimension drawings, external heat exchanger for wall mounting Dimension in mm Drilling template Front view Side view 200 Mounting panel 520 * x M x M8 480 Connections, cooling air Cooling air * The heat exchanger is 520 mm for a typical motor output of 200 kw Fig. 3-12: Heat exchanger for wall mounting

48 ESC START MON STOP + - High Voltage. Danger of electrical shock. Donot touch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating PROG DANGER ALARM READY ON ENTER REFU 3-12 Mounting REDUdrive 500 RD Mounting drawings for drive units with external heat exchanger for cabinet mounting Front view Side view Warm discharged air 100 Cooling air Plug with hose sleeve Cabinet top Support for cabinet top Coupling with hose sleeve Dimension drawing support for cabinet top 3,5 (4x) Fig. 3-13: Mounting drawing, heat exchanger for external cabinet mounting

49 REDUdrive 500 RD52 Mounting Working on the cooling medium circuit Both versions of the liquid-cooled drive units, with integrated and external heat exchanger, are supplied filled with liquid. The cooling liquid comprises tap water and heat exchanger antifreeze, type Antifrogen N (Clariant). It is mixed in the ratio 1.5:1 (Indramat Refu, Order No.: ). This guarantees frost protection down to 30 C. CAUTION Antifreeze is hazardous to the health! If antifreeze is swallowed, immediately consult a doctor and keep the packaging or label for reference. Mounting the extension hoses for external heat exchanger Servicing the cooling medium circuit For drive units with external heat exchangers, all of the parts required for the hose extensions (hoses, connectors, couplings, clamps, heat exchanger liquid etc.) are supplied according to the customer s specification when ordering. Customers must assemble the extension hoses themselves, as described below: 1. Shorten the heat exchanger hose to the required length. 2. Mount the connector with hose liner at one end of the heat exchanger hose using a clamp. 3. Fill the hose with the heat exchanger liquid provided, using a funnel. Connector and coupling have self-closing valves. 4. Connect the coupling with hose liner at the other end of the heat exchanger hose using a clamp. Connect the drive converter to the heat exchanger using the filled heat exchanger hoses. When the heat exchanger hoses are connected or disconnected, cooling liquid does not escape as a result of the self-closing valves of the connector and couplings. The drive converter should be powered-up so that the pump circulates the cooling medium and vents the cooling system. Smaller air bubbles in the cooling medium circuit, which can occur when connecting the extension hoses, then collect in the expansion reservoir. After the air has been vented it should be checked whether the cooling liquid level is at the center of the reservoir. If this is not the case, cooling liquid must be added to the equalization reservoir. To add cooling liquid, remove the sheet metal cover of the heat exchanger. If the heat exchanger was connected in the way described above, it will not be necessary to add any heat exchanger liquid to the expansion reservoir. The cooling medium circuit is a closed cooling system and neither has to be serviced nor checked. If the Drive converter overtemperature fault occurs in operation, then it should be checked whether the cooling liquid level is at the center of the expansion reservoir.

50 3-14 Mounting REDUdrive 500 RD52 WARNING Mixing with other antifreezes can result in flocculation and coat and destroy the cooling system! Do not mix the cooling liquid with other antifreezes. Only use the above specified antifreeze, if cooling liquid must be added to installed drive units.

51 REDUdrive 500 RD52 Electrical installation Electrical installation rules for EMC-correct installation of drives Rule 1 Rule 2 Rule 3 Rule 4 Rule 5 Rule 6 Rule 7 Rule 8 The following 10 rules are the basics for designing drive systems in compliance with EMC. Rules 1 to 7 are generally valid. Rules 8 to 10 are especially important to limit noise emission. All metal parts of the cabinet should be connected with one another through the largest possible surface area so that the best electrical connection is established (not paint on paint!). If required, use serrated washers which cut through the paint surface. The cabinet door should be connected to the cabinet using the shortest possible grounding straps. Signal, line supply, motor and power cables should be routed away from another (this eliminates mutual interference!). The minimum clearance is: 20 cm. Barriers should be provided between power- and signal cables. These barriers should be grounded at several locations. Contactors, relays, solenoid valves, electromechanical operating hour counters etc. in the cabinet must be provided with noise suppression devices, e.g. using RC elements, diodes, varistors. These devices must be connected directly at the coil. Non-shielded cables belonging to the same circuit (feeder and return cables) should be twisted with the smallest possible distance between them. Cores which are not used must be grounded at both ends. Generally, noise which is coupled-in can be reduced by routing cables as close as possible to grounded sheet steel panels. For this reason, cables and wires should not be routed freely in the cabinet, but as close as possible to the cabinet itself and the mounting panels. This is also true for reserve cables. Incremental encoders must be connected using shielded cables. The shield must be connected at the incremental encoder and at the AC drive converter through the largest possible surface area. The shield may not be interrupted, e.g. using intermediate terminals. The shields of signal cables must be connected to ground at both ends through the largest possible surface area to establish a good electrical connection (transmitter and receiver). If the potential bonding between the screen connections is poor, to reduce the shield current, an additional potential bonding conductor with a cross-section of at least 10 mm² should be connected in parallel with the shield. The shield can be connected to ground (=cabinet housing) at several locations. This is also true outside the cabinet. Foil shields are not recommended. Braided screens provide a better shielding effect (factor of 5). If the potential bonding is poor, analog signal cables may only be grounded at one end to the drive converter in order to prevent lowfrequency noise being injected into the screen (50 Hz). Always locate a radio interference suppression filter close to the noise source. The filter should be connected through the largest possible surface area with the cabinet housing, mounting panel etc. The best solution is a bare metal mounting panel (e.g. manufactured from stainless steel, galvanized steel), as the complete mounting surface can be used to establish good electrical contact. The incoming and outgoing cables of the radio interference suppression filter should be separated.

52 4-2 Electrical installation REDUdrive 500 RD52 Rule 9 Rule 10 All variable-speed motors should be connected using shielded cables, whereby the shield is connected at both ends to the housings through the largest possible surface area to minimize the inductance. The motor feeder cables should also be shielded outside the cabinet, or at least screened using barriers. Cables with steel shield are not suitable. To connect the shield at the motor, a suitable PG gland with shield connection can be used (e.g. SKINDICHT SHV/SRE/E from the Lapp Company, Stuttgart). It should be ensured that the connection between the motor terminal box and the motor housing has a low impedance. Otherwise, use an additional grounding strap between them. Never use plastic motor terminal boxes! The shield between the motor and AC drive converter may not be interrupted by installing components such as output reactors, sinusoidal filters, motor filters, fuses, contactors. The components must be mounted on mounting panels which also simultaneously serve as shield connection for the incoming and outgoing motor cables. If required, metal barriers may be required to shield the components.

53 REDUdrive 500 RD52 Electrical installation Warnings and information DANGER Lethal shock as a result of live components at voltage levels exceeding 50V! REFUdrive 500 drive units are operated at high voltage levels. Any work must always be carried-out with the drive converter powered-down (the drive converter must be in a no-voltage condition) and lockedout against accidental re-closure! Only qualified, trained personnel may carry-out any work! If this warning information is not observed, this can result in death, severe bodily injury or significant material damage. The drive unit has hazardous voltage levels up to 5 minutes after it has been powered-down as a result of the DC link capacitors. This means that it is only permissible to work on the unit or the DC link terminals after the appropriate time and after a careful check has been made to ensure that the equipment really is in a no-voltage condition. The power and control terminals can be live (at a dangerous voltage level), even when the motor is stationary. If the DC link voltage is centrally supplied, it must be ensured that the inverter is reliably isolated from the DC link voltage! When working on drive units which are open, it should be noted that personnel could come into contact with live components (components at a dangerous voltage level). The user is responsible in ensuring that all of the units are installed, mounted and connected in compliance with the recognized regulations in the particular country as well as all other regional regulations which may apply. Especially important are cable dimensioning, fusing, grounding, disconnection, isolation and overcurrent protection. CAUTION Damage to the drive units as a result of an incorrect supply voltage! The REFUdrive 500 units are designed for various supply voltages! This is the reason that supply voltages are not specified in the drawings and tables for the terminal strips. When connecting-up the drive converter always observe the rating plate and the line supply voltage, specified in Technical data.

54 4-4 Electrical installation REDUdrive 500 RD52 Information on protective grounding:the cross-section of the protective conductor to the cabinet must be at least 10mm 2 Cu or a second protective conductor must be routed in parallel (VDE 0160, Section 6.5.2) in accordance with DIN VDE This is due to the discharge currents of the drive units (>3.5 ma) through the protective conductor (PE). The discharge current of the drive converter can be up to 100 ma. For higher connected powers, the minimum cross-section of the protective conductor must be in an appropriate ratio to the cross-section of the main phase conductor. Refer to DIN VDE , Fig. 8). An e.l.c.b. device (residual current-operated device) may not be used as protective measure. 4.3 Cable cross-sections The cable cross-sections refer to the rated drive converter current. The associated protective conductor cross-section must be a minimum of 10 mm 2 (if power cables, with cable cross-sections >10 mm 2 are used, then the protective conductor must have the same cross-section). The following is assumed for the line supply feeder cables / DC feeder cables: The cross-sections are valid for one phase for multi-stranded conductors, and were defined in accordance with VDE0298. Up to 35 mm², individual conductors in a cable duct. Above 50 mm², freely routed in the cabinet without any contact to other cables The following is assumed for motor feeder cables: The cross-sections are valid for shielded 4-core cables and were defined in accordance with VDE0298. Up to 35 mm², routed in the cable duct, without any cable bundling. Above 50 mm², freely routed in the cabinet without any contact to other cables.

55 REDUdrive 500 RD52 Electrical installation 4-5 Drive unit output for 400/480 V Power supply connection Recommended minimum cross-section Converter Inverter Cable crosssection which can be connected 1) Maximum fusing, type gl Motor connection Recommended minimum cross-section Cable crosssection which can be connected 1) [kw] [mm 2 ] [mm 2 ] [mm 2 ] [A] [mm 2 ] [mm 2 ] x x x 50 2 x x x 70 3 x x x 70 4 x 95 Stud connection M x 95 4 x 95 Stud connection M16 Converter: x 70 Stud connection M x 95 Stud connection M16 AC drive converter; cables connected to U1, V1, W1 Inverter: Inverter; cables connected to C, D 1): As a result of the terminal size Fig. 4-1: Cable cross-sections for line supply, DC link and motor feeder cables Note: Studs are used for inverters from 132 kw. Terminals are always used for drive converters.

56 Hig Voltag Dang o electric shoc Dono touch he ectri e. a connerti nsfor f 5 al minute afte k. switchin t lpowe c off l c o srea anr follog "Safet Instruction r. fo Electric Drive d d"manu w DOK- y RL-DRIVE******- s r al befor s operatin al, GENE- SVS... e g 4-6 Electrical installation REDUdrive 500 RD Power terminals RD52, sizes A-E Terminal layout diagram, sizes A, B Note: The supplementary function P24V, electronics standby supply (terminal X83) is only mounted if it was actually ordered. It can only be retrofitted by extremely well-trained personnel. Front view Side view U1 V1 W1 X1 DC link connection Brake resistor connection (accessory) Designation from the left: C, D, F X1 Supply connection PE ALARM READY ON ESC MON PROG ENTER START STOP + - REF Udrive 500 DANGER U2 V2 W2 X2 Motor connection X83 Additional function P24V Electronic stand-by power supply X80 Start inhibit Control- and signal cables Fig. 4-2: Terminal layout diagram, GK A, B

57 Hig Voltag Dang o electric shoc Dono touch he ectri e. a conneerti nsfor f 5 minute al afte k. switchin t powe l c off l c o Rea s anr follog "Safet rinstruction. fo Electric ddrived "manu w DOK- y srl-drive******- r al sbefor al, operatingene- SVS... e g REDUdrive 500 RD52 Electrical installation 4-7 Terminal layout diagram, sizes C, D A drive converter, size C (270 mm wide) is illustrated in the terminal layout diagram. The position of the terminals is essentially the same for the narrower or wider drive units. The line supply, DC link and brake resistor terminals are always at the top and the motor connection at the bottom of the enclosure. Note: The supplementary function P24V, electronics standby supply (terminal X83) is only mounted if it was actually ordered. It can only be retrofitted by extremely well-trained personnel. X1 Supply connection DC link connection Brake resistor connection (accessory) PE C1D1U1 V1 W1 CDF ALARM READY ON ESC MON PROG ENTER START STOP + - REFU DANGER C3D3 U2 V2 W2 U6V6 W6 X2 Motor connection Control- and Signal cables X80 Start inhibit X83 Additional function P24V Electronic stand-by power supply Fig. 4-3: Terminal layout diagram GK C, D

58 Hig Voltag Dang o electric shoc Dono touch eh ectri e. a conne erti nsfor f 5 minute al afte k. switchin t powe l c off l c o Rea s anr follog "Safet rinstruction. fo Electric ddrived "manu w DOK- y srl-drive******- r al sbefor al, operatingene- SVS... e g 4-8 Electrical installation REDUdrive 500 RD52 Terminal layout diagram, size E Note: The supplementary function P24V, electronics standby supply (terminal X83) is only mounted if it was actually ordered. It can only be retrofitted by extremely well-trained personnel. X1 Supply connection, DC link connection, Brake resistor connection (option) PE U1 V1 W1 C1D1 CDF ALARM READY ON ESC MON PROG ENTER START STOP + - REFU DANGER C3D3 U2 V2 W2 U6V6 W6 X2 Motor connection Control- and signal cables X80 Start inhibit X83 Option P24V electronic stand-by Fig. 4-4: Terminal layout diagram GK E

59 REDUdrive 500 RD52 Electrical installation 4-9 Description of the power terminals Terminal X1 PE L1 / U1 L2 / V1 L3 / W1 Comment Line supply, DC link connection Protective conductor connection; steel plate lug on the housing with captive nut, for sizes A and B = M5, for sizes C to E = M6 Line supply connection 3 phases L1, L2, L3 permissible line supply voltage, refer to the rating plate on the upper side of the drive unit C DC link connection L+ D DC link connection L - F Option: Connection, external brake resistor between C and F From GK C C1 SNT supply + for connected inverter D1 SNT supply for connected inverter External fusing required X2 U2 V2 W2 PE Motor connection Motor connection U, V, W Protective conductor connection, motor and shield connection for the motor feeder cable; sheet steel lug on the housing with captive nut, sizes A and B = M5, for sizes C and D = M6 X83 Supplementary function P24V, standby supply for the electronics (the terminal is only mounted for drive units with integrated supplementary function) 1 P24V 24VDC 15/+20%, ripple, max 5%, power drain ~40 W, corresponding to VDE0411/500 2 Ground X2, option L1, motor filter feedback C3 DC link L+ D3 DC link L- X2, option F1, filter current feedback for the sinusoidal filter U6 V6 Operation only possible with the original Refu filter W6

60 ESC START MON STOP + - High Voltage. Danger of electrical shock. Do nottouch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating PROG DANGER ALARM READY ON ENTER REFU 4-10 Electrical installation REDUdrive 500 RD Power terminals RD52, sizes G and H After the drive unit has been mounted, it is only necessary to establish the electrical connections between the line filter and drive converter: Bolt the busbars provided between the main contactor of the line filter and the drive converter. Insert the assembled cable with connector (coming from the line filter) into terminal strip X5 in the drive converter. Terminal layout diagram, drive converter size G Heat exchanger Converter X80 X5 X2 Start inhibit Connection to the line filter DC link control voltage U2 V2 W2 X2 Motor connection Terminals for accessorys (L1, F1, W2, Z1) Busbars between teh line contactor and drive converter K1 Main contactor Line filter U 1 V W 1 1 X1 Line connection PE Protective conductor clamping rail Screen connection for motor cable Rail for strain relief X1 Checkback signal, main contactor Fig. 4-5: Terminal layout diagram, inverter GK G

61 ESC START MON STOP PROG High Voltage. Danger of DANGER electrical shock. Donot touch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating ALARM READY ON ENTER REDUdrive 500 RD52 Electrical installation 4-11 Terminal layout diagram, drive converter size H Drive converters connected in parallel Slave Master Heat Exchanger + - Converter REF U X80 Start inhibit X5 X2 Connection to the line filter DC link control voltage Busbars between the line contactor and drive converter Terminals for the accessorys (L1, F1, W1, Z1) K1 Main contactor U1 V1 W1 U2 V2 W2 X2 Motor connection Line filter PE Protective conductor clamping rail Screen connection for motor cable Rail for strain relief X1 Line connection X1 Checkback signal, main contactor Fig. 4-6: Terminal layout diagram GK H

62 ESC START MON STOP PROG High Voltage. Danger of DANGER electrical shock. Do nottouch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating ALARM READY ON ENTER 4-12 Electrical installation REDUdrive 500 RD52 Terminal layout diagram, inverter size G Heat exchanger Inverter + - REFU X80 X5 X2 Start inhibit Connection 2U1 / 2V1 DC link control voltage CD U2 V2 W2 X2 Motor connection Terminals for accessorys (L1, F1, W2, Z1) Fig. 4-7: Terminal layout diagram, inverter GK G

63 ESC START MON STOP PROG ALARM READY ON ENTER REDUdrive 500 RD52 Electrical installation 4-13 Terminal layout diagram, inverter size H Drive inverters connected in parallel Slave Master Heat exchanger High Voltage. Danger of DANGER electrical shock. Donot touch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating Inverter Frequenzumrichter in preparation + - REFU Fig. 4-8: Terminal layout diagram, inverter GK H

64 4-14 Electrical installation REDUdrive 500 RD52 Description of the power terminals, drive converters GK G and H Terminal X1 PE U1 V1 W Comment Line supply connection Protective conductor connection; for size G = terminal rail with cable clamp for size H = terminal rail with M16 and M12 screws Line supply connection, 3 phases L1, L2, L3 Permissible line supply voltage, refer to the rating plate for size G = terminal rail with cable clamp for size H = terminal rail with M16 screws Feedback (checkback) signal contact (NC contact) from the main contactor X2 Motor connection, DC link, line supply isolation C DC link terminal L + D DC link terminal L - F 1 (L/P) 2 (0V AC) U2 V2 W Internal brake resistor connected in the heat exchanger between C and F Connection for the heat exchanger fan Motor connection U, V, W for size G = cable terminal for size H = M16 and M12 screws Function: Isolation from the line supply In operation, terminals and must be closed; the drive converter is isolated from the line supply when these terminals are opened When the drive converter is to be isolated from the line supply, both terminals must be opened in order to prevent erroneous functions when a ground fault occurs. When the terminals are open circuit, the auxiliary circuits are in a no-voltage condition; the open-loop and closed-loop control are disabled. Function: Isolation from the line supply In operation, terminals and must be closed; the drive converter is isolated from the line supply when these terminals are opened When the drive converter is to be isolated from the line supply, both terminals must be opened in order to prevent erroneous functions when a ground fault occurs. When the terminals are opened, the auxiliary circuit are still energized and the open-loop and closedloop control remains enabled. X5 Control voltage for the line filter 1 Connection, 3 x AC control voltage Control for pre-charging and main contactor with checkback signal (NO contact) for the main contactor The customer must establish the connection from the line filter to the drive converter after mounting. The assembled cable with connector (coming from the line filter) is inserted in X5. X83 Supplementary function P24V standby supply for the electronics (the terminal is only mounted for drive units with integrated supplementary function) 1 P24V 24VDC 15/+20%, ripple, max 5%, current drain, approx. 80W (GK G) or 160W (GK H), corresponding to VDE0411/500 2 Ground

65 REDUdrive 500 RD52 Electrical installation 4-15 Description of the power terminals, inverters GK G and H Terminal X1 PE Comment Line supply connection Protective conductor connection; for size G = terminal rail with cable clamp for size H = terminal rail with M16 studs C DC link terminal L+ D DC link terminal L - X2 U2 V2 W2 Motor connection, DC link Motor connection U, V, W for size G = cable terminal for size H = M16 studs X5 Control voltage, 2 x AC 1 2U1 3 2V1 X83 Supplementary function P24V standby supply for the electronics (the terminal is only mounted for units with integrated supplementary function) 1 P24V 24VDC 15/+20%, ripple, max 5%, power drain, approx. 80W (GK G) or 160W (GK H), corresponding to VDE0411/500 2 Ground

66 4-16 Electrical installation REDUdrive 500 RD Connection diagram Line supply 3 phases L1 L2 L3 PE Accessory ext. brake restistor PE X1 U1 V1 W1 C D F Operating panel, REFUwin Ser. communication via USS protocol Commands, setpoints, actual values 5 kw SR X11 Service interface X12 RS485 interface X14 Standard terminal 8 Reference voltage 9 Analog input+ 10 Analog input - dynamic static 11 Analog ground 1 Output +24 V 'On' 5 Dig. input. 4; 6 Dig. input 5; 'Enable operation' X16 Relay output X15 Temperature sensor REFUdrive 500 X18 Speed encoder X2 U2 V2 W2 PE PE X V Ground Additional function P24V Electronic stand-by power supply 1) J M 3~ G Speed encoder 1: Depending on the encoder used, the conductors for the temperature sensor are routed in the encoder cable or are connected-up using a separate cable at connector X15 Fig. 4-9: Connection diagram for an AC drive converter

67 REDUdrive 500 RD52 Electrical installation 4-17 DC link L + L - PE PE X1 C D Operating panel REFUwin SR X11 Service interface Ser. communication via USS protocol X12RS485 interface Commands, setpoints, actual values X14Standard terminal 8 Reference voltage 5 kw 9 Analog input + 10 Analog input - dynamic static 11 Analog ground 1 Output +24 V 5 Dig. input 4; ON 6 Dig. input 5; 'Enable operation' X16Relay output X15Temperature sensor REFUdrive 500 X18Speed encoder X2 U2 V2 W2 PE PE X V Ground P24V Electronic stand-by supply 1) J M 3~ G Speed encoder 1: Depending on the encoder used, the conductors for the temperature sensor are routed in the encoder cable or are connected-up using a separate cable at connector X15 Fig. 4-10:Connection diagram for inverter

68 Electrical installation REDUdrive 500 RD Control terminals Terminal layout diagram SR17002 Bus termination OFF ALARM READY ON LEDs Red = alarm Green = ready Yellow = on 1 ON X11 RS232, operator panel, REFUwin, service interface 1 S9 Puschbutton fault panel Bus termination RS485 X12 RS485 X14 Digital inputs Digital outputs Analog input Reference voltage / Analog output High Voltage. Danger of electrical shock. Donottouch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual, DOK-GENE- RL-DRIVE******-SVS... before operating REFU DANGER X16 X15 Motortemperature sensor X18 Relay output Speed encoder input and motortemperature sensor Break-out the cover to insert additional option card Screen Cable tie Control- and signal cables Sheet steel lugs to connected the screen Fig. 4-11: Control terminals on the SR17002 control board

69 REDUdrive 500 RD52 Electrical installation 4-19 Description of the control terminals Terminal Designation Comment X11 Service interface 3 R x D RS232 service interface; 2 T x D To plug-in the operator panel 5 Ground To connect a PC with the REFUwin operator interface X12 RS485 interface 1 R x D+ / T x D + 2 R x D- / T x D - X13 CANpur 1 CAN high 2 CAN low 3 Ground RS485 interface; communications with USS protocol Point-to-point connection between RD52 and RD52 with internal bus termination. The conductors from X13.1 of the first RD52 to X13.1 of the second RD52 and X13.2 of the first and X13.2 of the second RD52 must be twisted. The maximum cable length is 5 m. X14 Standard terminal strip 1 P24V output Load capability, max. 50 ma 2 Dig. input 1 Dig. output 1 3 Dig. input 2 Dig. output 2 4 Dig. input 3 Dig. output 3 5 Dig. input 4 6 Dig. input 5 Digital inputs without electrical isolation (non floating): Input current at 24 V: 8.6 ma H signal: +13 V V L signal: 3 V... +5V or open-circuit terminal Digital outputs H signal: +21 V, max. 20 ma L signal: 0 V 7 Digital ground Reference ground, P24V (X14.1) 8 Reference ±10 V Analog output 9 Analog input+ 10 Analog input - Optional function, can be selected using P0436 (5 ma load capability, short-circuit proof): Reference voltage +10 V Reference voltage 10 V Analog output 0... ±10 V Differential input can be optionally set: (P0201) Optional input/output; function can be selected using P0471 Optional input/output; function can be selected using P0473 Optional input/output; function can be selected using P0475 ±10 V; A/D converter, 11 bit; resolution 20 mv, R e = 40 kω ma; A/D converter 11 bit; resolution 0.02 ma, R e = 150 Ω ma; A/D converter 11 bit; resolution 0.02 ma, R e = 150 Ω 11 Analog ground Reference ground of the reference voltage or the analog output (X14.8) X15 Motor temperature sensor 1 PTC / KTY+ Connecting a motor temperature sensor (PTC or KTY84). When connecting a 2 PTC / KTY - KTY84, observe the correct polarity! (selected using P P0389)

70 4-20 Electrical installation REDUdrive 500 RD52 X16 Relay output 1 NO contact 2 Common contact 3 NC contact Relay output Load capability: 250 V AC, 7 A 30 V DC, 7 A Terminal Designation Comment X18 The terminal assignment depends on the particular encoder type, refer to Section: 4.8 Encoder connection Fig. 4-12: Description of the control terminals on the SR Encoder connection General engineering information The following encoder types can be connected at the REFUdrive 500 RD52 units: TTL incremental encoders, V B = 5 V, with inverted tracks in accordance with RS422 TTL incremental encoders (type R), V B = 9 to 30 V, with inverted tracks in accordance with RS422 HTL incremental encoders, V B = 9 to 30 V, with / without inverted tracks Sine/cosine encoders, V B = 5 V, signal voltage 1 V PP Sine/cosine encoders, V B = 5 V, with rotor position sensing, e.g. ERN 1387 Resolver Magneto resistive transducer (encoder) The encoder is connected to the control card at X18 (sub-d socket/26 pin) (refer to Section 3.7.1, Terminal diagram SR17002). The sub-d connector/26 pin to connect the encoder is included with the RD52 units. Preassembled encoder cables are available for all encoder types. All of the above specified encoders can be used with induction motors. ERN1387 or a resolver can be used as encoders for synchronous motors. The maximum encoder length essentially depends on the signal frequency, the cable capacitance and the signal voltage and is specified by the encoder manufacturer. Typical values lie between approx. 100 to 300 m. Unused cores of the encoder cable should be connected to the enclosure ground at the encoder and drive converter side. The motor temperature sensor conductors can either be routed in the encoder cable or using a separate cable to connector X15 of the control card (refer to Section 3.7.1, Terminal diagram SR17002).

71 REDUdrive 500 RD52 Electrical installation 4-21 Parameterizing the encoder Parameter No.: Name Description / explanation selectable options 0130 Encoder selection 0 = resolver 1 = incremental encoder 2 = sin/cos&commutation 3 = sine/cosine encoder 4 = without encoder 0131 Resolver pole number The pole number can be freely set between 2 and 64 poles Encoder pulse number The pulse number can be freely set between 64 and pulses. Factory setting min... max values Resolver delta-phi Electrical encoder adjustment Fig. 4-13: Parameterizing the incremental encoder Password

72 4-22 Electrical installation REDUdrive 500 RD52 Changing-over the supply voltage The supply voltage is changed-over using jumper S5 on the control card. When the drive unit is supplied, the jumper is set for 5 V. Proceed as follows to changeover the jumper: Note: Observe the warnings and information/instructions in Section 1 Power-down the drive unit so that it is in a no-voltage condition. Remove the front cover of the unit. To connect encoders with a 15 V power supply voltage, carefully changeover the jumper from the + 5 V setting (factory setting) to +15 V using a pair of tweezers. CAUTION Damage to the units caused by an incorrect supply voltage! Please observe the documentation of the encoder manufacturer ALARM READY ON X15 Motortemperature sensor REFU X18 S5 Speed encoder input and Motortemperature sensor Jumper to change the power supply voltage from +5 V or +15 V High Voltage. Danger of electrical shock. Donottouch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual, DOK-GENE- RL-DRIVE******-SVS... before operating DANGER S5 +5 V +15V Fig. 4-14: Setting the encoder power supply voltage

73 REDUdrive 500 RD52 Electrical installation 4-23 HTL and TTL incremental encoders (for operation with induction motors) Signal display for a clockwise direction of rotation when viewing the motor drive shaft end Track A A Track B B Track N N L: The zero pulse is only evaluated for TTL encoders For applications with positioning functionality, it is therefore not possible to use HTL encoders. Fig. 4-15: Signal display, HTL and TTL incremental encoders Connecting an HTL encoder X18 Speed encoder 8 M 0V (ground) 9 P 15V Insert the + 15V power supply (set jumper S5 to the 15V setting), (refer to Fig. 4-14: ) 10 B Pulse track B 11 B Pulse track B inverted 19 A Pulse track A 20 A Pulse track A inverted Fig. 4-16: Connecting an HTL encoder

74 4-24 Electrical installation REDUdrive 500 RD52 Converter X ,14 mm² HTL-encoder A A B B ,5 mm² 0,5 mm² P 15V M Fig. 4-17: Connecting an HTL encoder with inverted tracks Converter X ,14 mm² HTL-encoder A B ,5 mm² 0,5 mm² P 15V M Fig. 4-18:Connecting an HTL encoder without inverted tracks Power supply voltage V B (DC) Max. output current Limiting frequency Parameterization Technical data of the HTL encoder evaluation 15 V (jumper S5, refer to Fig. 4-14: Setting the encoder power supply voltage) I max = 175 ma 150 khz without inverted tracks 300 khz with inverted tracks P0130: Incremental encoder P0132: Pulse number

75 REDUdrive 500 RD52 Electrical installation 4-25 Connecting a TTL encoder X18 Speed encoder 7 M sense Sensor line 0 V 8 M 0 V (ground) 9 P 5V +5V power supply voltage, refer to Fig. 4-14: Setting the encoder power supply voltage 12 A Pulse track A inverted 13 A Pulse track A 14 B Pulse track B 15 B Pulse track B inverted 16 N Zero pulse N 17 N Zero pulse N inverted 18 P sense Sensor line +5V Fig. 4-19: Connection assignment at X18 for TTL encoders Converter X18 TTL-encoder ,14 mm A 12 A 14 B B 16 N 17 N 18 P sense ,14 mm 2 0,5 mm 2 0,5 mm 2 M sense P 5V M Fig. 4-20: Connection circuit diagram, TTL encoder Power supply voltage V B (DC) Max. output current Limiting frequency Input resistance Parameterization Technical data of the TTL encoder evaluation 5 V ± 2.5% (jumper S5, refer to Fig. 4-14: Setting the encoder power supply voltage) I max = 200 ma 300 khz 120 Ω P0130: Incremental encoder P0132: Pulse number

76 4-26 Electrical installation REDUdrive 500 RD52 Sine/cosine encoder 1V PP and magneto resistive transducer (encoder) For operation with induction motors. Signal display for a clockwise direction of rotation when viewing the motor drive shaft end 360 el. A 0 V 1 V ss Incremental signal tracks A and B, e.g periods per revolution 90 el. B 0 V R 0,5 V 0 V Reference signal, 1 signal per revolution Fig. 4-21: Signal display for a clockwise direction of rotation when viewing the motor drive shaft end Sine/cosine encoder connection X18 Speed encoder and temperature sensor 7 M sense Sensor line 0 V 8 M 0 V (ground) 9 P 5V +5 V power supply voltage (jumper S5, refer to Fig. 4-14: Setting the encoder power supply voltage) 12 A- Incremental signal A 13 A+ 14 B+ Incremental signal B 15 B- 16 R+ Incremental signal R 17 R- 18 P sense Sensor line +5 V 25 Motor temp.+ 26 Motor temp. - Connecting a motor temperature sensor (PTC or KTY84) When connecting a KTY84, please observe the polarity! Fig. 4-22: Connections, sine/cosine and magneto resistive transducer (encoder) We recommend using encoder cable No from Heidenhain to connect this encoder to the drive converter. The following diagram only applies when using this cable.

77 REDUdrive 500 RD52 Electrical installation 4-27 Converter X18 Sine/Cosineencoder 13 green/black 0,14 mm 2 A+ 12 yellow/black A blue/black red/black red black green brown 0,14 mm² B+ B- R+ R- Motor temp+ Motor temp- 9 8 brown/green white/green 0,5 mm² P 5V M 18 7 blue white 0,5 mm² P sense M sense Fig. 4-23: Connection diagram, sine/cosine and magneto resistive transducer (encoder) Power supply voltage V B (DC) Max. output current Limiting frequency Terminating resistor, input Parameterization Technical data of the sine/cosine encoder evaluation 5 V ± 2.5% (jumper S5, refer to Fig. 4-14: Setting the encoder power supply voltage) I max =200 ma 300 khz 120 Ω P0130: Sine/cosine encoder P0132: Pulse number

78 4-28 Electrical installation REDUdrive 500 RD52 Sine/cosine encoder 1 V PP with commutation (rotor position sensing), e.g. ERN 1387 For operation with induction and synchronous motors. Signal display for a clockwise direction of rotation when viewing the motor drive shaft end 360 el. A 0 V 1 V ss 90 el. Incremental signal tracks A and B, e.g perids per resolution B 0 V R 0,5 V 0 V Reference signal, 1 signal per resolution 360 mech. C 0 V 1 V ss Rotor position signal 90 el. Tracks C and D, 1 period per resolution D 0 V Fig. 4-24: Signal display, sine/cosine encoders with rotor position sensing

79 REDUdrive 500 RD52 Electrical installation 4-29 Connection assignment for sine/cosine encoders 1 V PP with commutation X18 3 C+ 4 C- 5 D+ 6 D- Speed encoder and temperature sensor Signal track C, rotor position Signal track D, rotor position 7 M sense Sensor line 0V 8 M 0V (ground) 9 P 5V + 5V power supply voltage, refer to Fig. 4-14: Setting the encoder power supply voltage 12 A+ 13 A- 14 B+ 15 B- 16 R+ 17 R- Incremental signal A Incremental signal B Incremental signal R 18 P sense Sensor line + 5V 25 Motor temp Motor temp. - Connecting a motor temperature sensor (PTC or KTY84) When connecting a KTY84, observe the polarity! Fig. 4-25: Connection, sine/cosine encoder 1 V PP with commutation We recommend using encoder cable No from Heidenhain to connect this encoder to the drive converter. The following diagram only applies when using this cable.

80 4-30 Electrical installation REDUdrive 500 RD52 Converter X18 ERN-encoder green/black 0,14 mm 2 A+ 13 yellow/black A blue/black red/black B+ B- 16 red R+ 17 black R- 3 gray C+ 4 pink C- 5 6 yellow violet D+ D green brown 0,14 mm² Motor temp+ Motor temp- 9 8 brown/green white/green 0,5 mm² P 5V M 18 7 blue white 0,5 mm² P sense M sense Fig. 4-26: Connection diagram for sine/cosine encoder 1 V PP with commutation Technical data for sine/cosine encoder 1 V PP with commutation Power supply voltage V B (DC) Max. output current Limiting frequency Terminating resistance, input Parameterization 5 V ± 2.5% (jumper S5, refer to Fig. 4-14: Setting the encoder power supply voltage) I max = 200 ma 300 khz 120 Ω P0130: Sin/cos&commutation P0132: Pulse number P0130: Sin/cos&commutation P0132: Pulse number P0133: Encoder delta pi (if the encoder is mechanically mis-adjusted), it can be corrected using this parameter. This is only required when using synchronous motors. Also refer to [Fig. 7-2: Flowdiagram, commissioning synchronous motors]. When using a Siemens encoder or an encoder with a round connector having a Siemens-compatible pin assignment, a pre-assembled cable can be purchased from REFU.

81 REDUdrive 500 RD52 Electrical installation 4-31 Resolver (for operation with induction and synchronous motors) Signal display for a clockwise direction of rotation when viewing the motor drive shaft end cos sin mech. angel cos sin mech. angel a a 2-pole resolver 4-pole resolver Fig. 4-27: Signal display, resolver The signals can be displayed using the REFUwin oscilloscope function. Sine: D1086 Cosine: D1087 Mechanical angle: D1890 Resolver connection X18 Speed encoder and temperature sensor 1 R1 Excitation voltage + 2 R2 (R3) Excitation voltage - 10 S1 cos + 11 S3 cos - 19 S2 sin + 20 S4 sin - 25 Motor temp.+ 26 Motor temp. - Fig. 4-28: Connection assignment, resolver Connecting a motor temperature sensor (PTC or KTY84) When connecting a KTY84, observe the polarity!

82 4-32 Electrical installation REDUdrive 500 RD52 Converter X18 Resolver 0,25 mm 2 1 R1 2 R2 / R S1 11 S3 19 S2 20 S4 25 Temp+ 26 0,25 mm 2 Temp- Fig. 4-29: Connection diagram, resolver We recommend that an 8-core, twisted pair cable with additional outer shield is used to connect the resolver to the drive converter. The cable cross-section should be a minimum of 0.25 mm 2 (e.g. LIYCY-CY 4 x 2 x 0.25 or DUE4504-4P ). The resolver cable should be kept as short as possible, and should not exceed 150 m. Power supply voltage V B (AC) Max. output current Parameterization Technical data of the resolver evaluation 7 V RMS, f exc (excitation frequency) I max = 100 ma P0130: Resolver P0131: Pole number f p f exc L: f p = pulse frequency (P0026) Fig. 4-30:Frequency selection P0133: Encoder delta pi (a possible mechanical mis-adjustment of the encoder can be corrected using this parameter. This is only required for synchronous motors. Also refer to [Fig. 7-2: Flowdiagram, commissioning synchronous motors]. Transformation ratio Max. phase shift Max. electrical error Max. output impedance Z PP Zero voltage Recommended resolver parameters ±15 ±10 angular minutes ( ) Ω < 30 mv

83 REDUdrive 500 RD52 Electrical installation 4-33 Center offset between the rotor and stator Axial offset between the rotor and stator Resolver mounting max mm max. ±0.25 mm Assignment, motor pole number resolver pole number The ratio between the pole number of the motor and the resolver must always be an integer number! Pole number = pole pair number 2. Pole No., resolver Pole number, motor Manufacturer Siemens Tamagawa 2 X X X X V23401-H2009-B202 TS2018 N 431 E41 4 X X V23401-H2012-B201 TS2018 N 532 E41 6 X V23401-H2002-B209 TS2018 N 543 E41 8 X V23401-H2003-B209 Fig. 4-31: Assignment, motor pole number - resolver pole number When using a Siemens encoder or an encoder with a round connector (20 coded) having a Siemens-compatible pin assignment, a preassembled cable can be purchased from REFU. First encoder test Connect the motor with mounted encoder to the drive converter. With the drive converter not enabled, manually rotate the motor shaft clockwise (when viewing the drive end, i.e. outdrive side). A positive speed must be displayed on the operator panel. A negative speed must be displayed when rotating the motor shaft in the counter-clockwise direction.

84 4-34 Electrical installation REDUdrive 500 RD Service interface This interface is used to connect the operator panel or a PC with REFUwin. A pre-assembled standard extension cable can be obtained from Indramat Refu to connect the devices (Order No.: , length 5m). ALARM READY ON X11 Service-interface ESC MON PROG ENTER START STOP + - REFU drive 500 High Voltage. Danger of electrical shock. Donot touch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating DANGER Extension cable Sub-D 9 pole Fig. 4-32: Possibilities of connecting to the service interface Connecting the operator panel The operator panel can either be directly connected at connector X11 or connected using the above specified cable. Connecting a PC The cable to connect a PC must have the following configuration: Converter X11 PC RxD 3 3 TxD TxD 2 2 RxD GND 5 5 GND Shield connection Fig. 4-33: Connecting cable for PC Alternatively, the operator panel cable can also be used.

85 REDUdrive 500 RD52 Electrical installation 4-35 Baud rate: Data bits: Parity: Stop bits: Protocol type: The following settings should be observed: Can be set using P0499: 1200, 2400, 4800, 9600 (factory setting), 19200, 38400, 57600, baud 8 Even 1 USS protocol, 4/6 words 4.10 Standard interface RS485 (X12) The RS485 interface supports the USS protocol, which is used to control the drive converter from a PLC. The USS protocol (German: Universal- Serial interface protocol) defines an access technique according to the master-slave principle for communications via a serial bus. Converter X12 TxD+ /RxD+ TxD- / RxD- 1 2 Open-loop control TxD+ /RxD+ TxD- / RxD- To the next slave Shield connection Fig. 4-34: Connection, standard interface Exception: When using this interface, it should be ensured that the same interface configuration is set for each of the bus nodes. "SS1 slave address", in this case, each bus node (station) has its own address. The interface parameterization is in the function description: Firmware 04VRS for REFUdrive 500 RD52 Bus termination The bus must be terminated at the first and last node of a bus system to protect it against the influence of noise. The bus terminator is switched-in using a switch on the control card (refer to Fig. 4-39:Terminal diagram SR17002 ) USS protocol Description of the USS protocol The USS protocol (German: Universal-Serial interface protocol) defines an access technique according to the master-slave principle for communications via a serial bus. When using the RS232, in addition to the master, only one slave is permissible. When using RS485, one master and a max. of 32 slaves can be connected to the bus. The individual slaves (REFUdrive 500) are selected by the master (higher-level computer) using an address character in the telegram.

86 ESC START MON STOP PROG ENTER High Voltage. Danger of electrical shock. Donottouch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating ALARM READY ON ESC START MON STOP High Voltage. Danger of electrical shock. Donottouch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating PROG ALARM READY ON ENTER ESC START MON STOP High Voltage. Danger of electrical shock. Donottouch electricalconnectionsfor 5 minutes after switching power off. Read and follow "Safety Instructions for Electrical Drives "manual,dok-gene- RL-DRIVE******-SVS... before operating PROG ALARM READY ON ENTER 4-36 Electrical installation REDUdrive 500 RD52 A slave can never initiate a data send operation. Direct data transfer between the individual slaves is not possible. Communications are realized in the half-duplex mode. The master function cannot be transferred (single-master system). RS232 parametrization over the bus REFU drive 500 REFU drive 500 REFU drive 500 or DANGER DANGER DANGER RS485 RS232 higher-level computer: Master Fig. 4-35:USS communications Telegram transfer The master sends telegrams (task telegrams) to the slaves and expects a response telegram from each of the addressed slaves. A slave must send a response telegram: If it received a task telegram, error-free, and It was addressed in this task telegram. A slave may not send if these conditions are not fulfilled, the slave was addressed in the broadcast mode (refer to Page 4-43, Broadcast), or the special bit is set (refer to Page 4-42 Special telegrams ). For the master, a connection is established to the associated slave, if it receives a response telegram from the slave in a defined processing time (response delay time, refer to Fig. 4-36:USS). Also refer to 4-46, Task and response ID (AK).