Lenze 8230 Series User manual

EDB9300UES

00402016

Operating Instructions

Global Drive

Frequency inverters

8230 series

Power range 110 ... 250 kW

23(1

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Contents

Contents i1

Comments i4

1 Brief description 1

1.1 General 1

1.2 Basic operation 2

1.3 Main features 3

2 Technical Data 5

2.1 Key to types, rating plate 5

2.2 Series of types 6

2.2.1 Technical data at rated current 7

2.2.2 Technical data at basic load current 8

2.2.3 Power loss and cooling air volume 9

2.3 System data 10

2.3.1 Standards, operating conditions and certificates 15

2.3.1.1 Standards applicable 15

2.3.1.2 Certificate 16

2.3.1.3 CE Certificate 16

2.3.2 CE mark 17

2.4 Supply components 19

2.4.1 Components for 3AC supply 19

2.4.1.1 Fuses for 3AC mains connection 19

2.4.1.2 Mains chokes (3-phase chokes) 21

2.4.1.3 Line fuses for operation class gL and cable cross-sections 23

2.4.1.4 Fuse circuit breakers 23

2.4.1.5 Mains contactor 23

2.5 Options 24

2.5.1 Control unit (BDE) 24

2.5.2 Brake chopper and braking resistors 26

2.5.2.1 Brake chopper 27

2.5.2.2 Braking resistors 28

2.5.3 RFI filters 30

2.5.4 Motor filters and output chokes 31

2.5.4.1 Motor filters 31

2.5.4.2 Motor choke 34

2.5.6 Option boards for Alspa MD2000 36

2.5.6.1 Encoder interface 37

2.5.6.2 Operation on a mains supply with no earth 43

2.6 Summary circuit diagrams 44

2.6.1 Summary circuit diagram, 8230 frequency inverter 44

2.7 Connection, terminal wiring 45

2.7.1 Power stack 45

2.7.1.1 3AC supply 45

2.7.2 Electronics section, A10 control board 48

2.7.2.1 Terminal strip wiring :X15 and signal functions 49

2.7.2.2 Description of terminal strip inputs / outputs 54

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Contents

2.8 Dimensions, Installation drawing, weights 58

2.8.1 8230 frequency inverter build-in units 58

2.8.2 Mains chokes for 8230 frequency inverter 60

2.8.3 Installation drawing for control unit 61

2.8.4 Dimensions and installation dimensions Base for semiconductor fuses

of operating class gR with 110 mm length 63

2.8.7 Dimensions and installation dimensions Braking resistor 64

2.8.8 Dimensions and weights motor filters 65

2.8.9 Motor choke 66

2.8.10 Dimensions and weights 67

3 Transport, Installation and Connection 68

3.1 Safety instructions 68

3.2 Storage 69

3.3 Transport 69

3.4 Installation 69

3.5 Connection and wiring 70

3.5.1 Potential separation 77

3.6 Installation and connection instructions for EMC 79

3.7 Specific measures for ensuring electromagnetic compatibility (EMC) 88

4 Operation and Software 90

4.1 Unit operation 90

4.1.1 Control philosophy 92

4.2 Parameter adjustment 93

4.3 Menu 95

4.4 Description of parameters and displays 100

4.4.1 Display 100

4.4.2 Application parameter 101

4.4.3 Configuration parameters 105

4.4.4 Parameters for analog I/O 113

4.4.5 Parameters for digital I/O’s 119

4.4.6 Ratings 123

4.4.7 Control parameters 128

4.4.8 Diagnosis 131

4.4.9 Password 131

4.4.10 Language 133

5 Commissioning 134

5.1 Safety instructions for commissioning 134

5.2 Commissioning sequence diagram, 8230 frequency inverter build-in unit 136

5.3 General 140

5.4 Mains and motor connection 140

5.5 Commissioning Report 141

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Contents

5.6 First commissioning with the 8230 frequency inverter BDE control unit 148

5.6.1 Language Select 148

5.6.2 Ratings 149

5.6.3 Control structure 152

5.6.4 Speed adjustment/speed limit 152

5.6.5 Field weakening 152

5.6.6 Multiple motor operation/Group supply 153

5.6.7 Motor potentiometer function 154

5.7 Terminal strip wiring 154

5.8 Configuring the drive 156

5.9 Demand selection 157

5.10 Control structure 158

5.10.1 Frequency control 158

5.10.2 Control without encoder 158

5.10.3 Control with encoder 159

6 Help in the event of errors 160

6.1 First value log for error messages 160

6.2 Switching sequence on errors 160

6.3 Event log 160

6.4 Events 160

6.5 Error log 163

6.6 Errors 163

7 Maintenance 167

7.1 Battery for RAM and clock 167

7.1.1 Battery change 167

7.1.2 Technical data of battery 167

7.2 Fans 167

7.3 Power connections 167

7.4 Reforming the link capacitors 168

Declaration of Conformity AAS-KE 001/9.95 170

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Comments

Expressions used Note:

A note shows important or additional information separately from the text.

Important!

Important means that the instructions given must be followed precisely in order to

prevent any loss of data or damage.

Warning!

Warning means that the operator may be injured if the relevant instructions are

not followed.

Limitation of liability Unless agreed elsewhere the latest issue of the “General Supply Conditions for

Products and Services of the Electrical Industry” applies accordingly.

We are not obliged to make software updates or upgrades available to users.

Modifications to improve handling and updates for new types of equipment can only

be offered to registered users at preferential prices.

Data, illustrations, amendments Data and illustrations are approximate only and subject to modification without notice.

Please advise if you have any suggestions for improving or otherwise amending the

documentation. A printed form is provided on the last few pages of this document.

Training Lenze GmbH & Co KG offers training seminars to provide additional system

knowledge.

Without prior permission this document may not be duplicated or otherwise made available to third parties. It may not be misused in

any way by the recipient or third parties. Translation into a foreign language is not permitted. All data, dimensions, weights,

illustrations and other technical details may be subject to modification without notice, in particular for further development of our

equipment. The information agreed in an order is final and binding.

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1 Brief description

BA8230 1

1.1 General 8230 frequency inverter are processor-controlled pulse inverters with a field-orientated

control concept for continuous low-loss speed adjustment of AC motors.

The power stack consists of a diode rectifier in a 3-phase bridge circuit on the mains

side and an IGBT inverter on the motor side.

The basic inverter models are designed for standard applications. Through suitable

options (eg. bus couplers, encoder interface) the units can be integrated into

automation systems and can also fulfil highly dynamic requirements.

Operation of all units is identical throughout the entire type range. Easy familiarisation

and operation as well as maximum flexibility were the prime objectives during

development.

The inverters are operated and parameters adjusted by means of a control unit

(BDE).

Connection to automation systems is possible through conventional bus systems (see

field bus coupler options).

With a mains voltage range from 380 to 480 V build-in units cover the power range

from 144 kVA to 330 kVA.

In conjunction with standard asynchronous motors the drive capacities provided are

therefore as follows:

- At unit rated current

110 kW to 200 kW, 400 V

- At unit 1.5 x rated current

132 kW to 250 kW, 400 V

Note:

This operating manual applies to the following units:

8230 frequency inverter

Software version:

V2.0

Important!

8230 frequency inverter are designed as standard for operating on earthed networks.

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Brief description

2BA8230

1.2 Basic operation The link voltage is generated from the mains supply through the mains rectifier. A 3-

phase choke connected to the mains supply reduces harmonic currents and serves to

decouple the unit from other converters (consumers) on the same supply network.

8230 frequency inverter are connected as standard to an earthed network.

The link voltage is smoothed by high quality electrolytic capacitors. With the motor

converter these provide the magnetising reactive power required by the motor and

decouple the converter on the mains side from the inverter on the motor side.

Through optimised pulse width modulation the motor converter generates from the

link voltage a sinusoidal 3-phase system with variable frequency and voltage.

A power dump (option) in conjunction with a braking resistor allows braking energy to

be used in regenerative operation.

Control and regulation of the 8230 frequency inverter are fully digital. Different control

structures such as, frequency control, speed control with or without encoder and

torque control with or without encoder can be selected, depending on the application

requirements. The field-orientated control concept provides control dynamics directly

comparable to those of a DC drive.

In addition, various inputs and outputs can be connected individually according to the

task involved. Thus the drive system can very easily be customised for the

requirements of the specific application.

Fig. 1: Summary circuit diagram, basic layout, operation

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Brief description

BA8230 3

1.3 Main features •Consistent range of Types for drives from 110 kW to 250 kW with

IGBT inverters

•Supply voltage ranges:

- 3AC 380 V ... 460 V +10 %/ -15 % ... 480 V +6 %/ -15 %

•Standard design for connection to earthed networks

•Output frequency range: 0 ... 300 Hz

•120% overload capacity for 60 s related to 1.2 rated controller current

(Applications with medium overload)

•150% overload capacity for 60 s related to 1.5 rated controller current

(Applications with high overload)

•Standard asynchronous motors can be used without power reduction

•High dynamics: Torque rise time: tan = 2 to 8 ms

•8230 frequency inverter units are resistant to idling, short circuit and earth fault

•DC system bus supply for several 8230 frequency inverter through

DC link connection (option)

•4Q operation (option) through power dump with braking resistor

•Mains supply power connections at top and motor connections at foot

•Motor temperature monitoring by thermistor processing electronics (PTC)

•Easy, user-friendly system structure

•Consistent and easily learned operation via control unit (option) with plain

text display (various languages available)

•Extensive additional operating facilities via PC, for example menu control,

user-controlled commissioning, oscilloscope function

•Control structures available:

- Frequency control

- Speed control with or without incremental rotation encoder

- Torque control with or without incremental rotation encoder

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Brief description

4BA8230

•Kinetic back-up on mains failure

Back-up operation of the control electronics using the kinetic energy in the drive

systems at speeds close to zero, also suitable for flow machines

•Capture without torque surge

(the inverter is applied to the de-excited motor while the motor is running)

•Automatic restart facility after mains failure

(Parameter-adjustable up to 15 s as standard)

•Conventional drive through standard terminal strip

- 12 digital potential-separated inputs for control signals (eg. Start, Stop etc.),

of which 3 inputs are parameter-adjustable through selection list

- 4 digital potential-free outputs for messages (On, Ready, Error, free

output parameter-adjustable through selection list, 1 output

"Ready” can be re-assigned via technology)

- 2 free adjustable and scaleable analog outputs

- 2 scaleable analog demand inputs

- 2 parameter sets switchable via control unit or terminal strip

•Expansion of standard terminal strip (I/O interface option)

- 20 configurable digital inputs with separate potential

- 8 configurable digital outputs with separate potential

- 2 configurable analog demand inputs

- 2 configurable analog outputs

•Comprehensive testing and diagnostics facilities:

- Self-test on control electronics and hardware

- Event memory with timings of all binary events with first

value error message and documentation

- Error log with timing details

- Protocol log for documenting all parameter changes

•Comprehensive protection and monitoring facilities.

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2 Technical Data

BA8230 5

2.1 Key to types, The type data includes the following information. An example:

rating plate

Fig. 2: 8230 frequency inverter rating plate

The following details are required for identifying the unit:

- Type No :

-Serial No :



Hans-Lenze-Strasse 1 D-31855 Aerzen

Made in Germany

Global Drive 8230

Type EVF8234BE

029. 206879

00001

00395613

3/PEAC 400/460V 360/430A 50/60Hz

3/PEAC 0-460V 400/483A 200/250kW 0-300Hz

600A / 60s (400V) 520A / 60s (460V)

Id.-No.

Input

Sach.-No.

Ser.-No.

Output

Overload

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