invertek IP66(NEMA 4X)AC Variable Speed Drive User Guide

invertek IP66(NEMA 4X)AC Variable Speed Drive

WARNING!

• The Optidrive should ONLY be installed by a qualified electrician.
• In a residential environment, this product may cause radio interference in which case supplementary mitigation measures may be required.

NOTE
This guide does not provide detailed installation, safety or operational instructions. See the Optidrive E3 IP66 Outdoor User Manual for complete information. Unpack and check the drive. Notify the supplier and shipper immediately of any damage.

CHECK

Identifying the Drive by Model Number
Each drive can be identified by its model number, as shown in the table below.

• When installing the drive on any power supply where the phase-ground voltage may exceed the phase-phase voltage (typically IT supply networks or Marine vessels) it is essential that the internal EMC filter ground and surge protection varistor ground (where fitted) are disconnected. If in doubt, refer to your Sales Partner for further information.
• This manual is intended as a guide for proper installation. Invertek Drives Ltd cannot assume responsibility for the compliance or the non-compliance to any code, national, local or otherwise, for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.
• This Optidrive contains high voltage capacitors that take time to discharge after removal of the main supply. Before working on the drive, ensure isolation of the main supply from line inputs. Wait ten (10) minutes for the capacitors to discharge to safe voltage levels. Failure to observe this precaution could result in severe bodily injury or loss of life.

NOTE
If the drive has been in storage for a period longer than 2 years, the DC link capacitors must be reformed. Refer to online documentation for further information.

PREPARE

Prepare the Mounting Location

• The Optidrive must be mounted in a vertical position only.
• Installation should be on a suitable flat, flame-resistant surface. Do not mount flammable material close to the drive.
• Refer to Technical Data and ensure the chosen mounting location is within the drive specification.
• The mounting location should be free from vibration.
• Do not mount the drive in any area with excessive humidity, corrosive airborne chemicals or potentially dangerous dust particles.
• Avoid mounting close to high heat sources.
• The drive must not be mounted in direct sunlight. If necessary, install a suitable shade cover.
• The mounting location must be free from frost.
• Do not restrict the flow of air through the drive heatsink. The drive generates heat which must be naturally allowed to dissipate. Correct air clearance around the drive must be observed.
• If the location is subject to wide ambient temperature and air pressure variation, install a suitable pressure compensation valve in the drive gland plate.

MOUNT

Mechanical Dimensions

Dimensions

Mounting Clearance

Drive Size

| X Above & Below| Y Either Side
---|---|---
mm| in| mm| in
All Frame Sizes| 200| 7.87| 10| 0.39

NOTE

| Typical drive heat losses are approximately 3% of operating load conditions.

Above are guidelines only and the operating ambient temperature of the drive MUST be maintained below the maximum limit at all times.

Mounting Bolts & Tightening Torques

Mounting Bolts

Frame Size|
All Frame Sizes| 4 x M4 (#8)
Tightening Torques

Frame Size| Control Terminals| Power Terminals
1, 2, 3| 0.5 Nm (4.4 lb-in)| 0.8 Nm (7 lb-in)
4| 0.5 Nm (4.4 lb-in)| 2 Nm (19 lb-in)

CONNECT

Cable Selection

• For 1 phase supply (Sizes 1-3 only), the mains power cables should be connected to L1/L, L2/N.
  For 3-phase supplies, the main power cables should be connected to L1, L2, and L3. Phase sequence is not important.

• For compliance with CE and C Tick EMC requirements, refer to online documentation.

• A fixed installation is required according to IEC61800-5-1 with a suitable disconnecting device installed between the Optidrive and the AC Power Source. The disconnecting device must conform to the local safety code/regulations (e.g. within Europe, EN60204-1, Safety of machinery).

• The cables should be dimensioned according to any local codes or regulations. Maximum dimensions are given in the Rating Tables section of this Quick Start Guide.

Install the Power Wiring

For drives with Ethernet, 4 hole plate is fitted.

Motor Terminal Box Connections
Most general-purpose motors are wound for operation on dual voltage supplies. This is indicated on the nameplate of the motor. This operational voltage is normally selected when installing the motor by selecting either STAR or DELTA connection. STAR always gives the higher of the two voltage ratings .

Information for UL Compliance
Optidrive E3 is designed to meet the UL requirements. For an up-to-date list of UL-compliant products, please refer to UL listing NMMS.E226333. In order to ensure full compliance, the following must be fully observed.

Input Power Supply Requirements

Supply Voltage| 200 – 240 RMS Volts for 230 Volt rated units, + /- 10% variation allowed. 240 Volt RMS Maximum.
380 – 480 Volts for 400 Volt rated units, + / – 10% variation allowed, Maximum 500 Volts RMS.
Frequency| 50 – 60Hz + / – 5% Variation
Short Circuit Capacity| All drives are suitable for use on a circuit capable of delivering not more than indicated in the table below, maximum short- circuit Amperes symmetrical with the specified maximum supply voltage when protected by Class J fuses.
Mechanical Installation Requirements
All Optidrive E3 units are intended for installation within controlled environments which meet the condition limits shown in the Environment section of this Quick Start Guide.
The drive can be operated within an ambient temperature range as stated in the Environment section of this Quick Start Guide.
Electrical Installation Requirements
Incoming power supply connection must be according to the Install the Wiring section of this Quick Start Guide.
Suitable power and motor cables should be selected according to the data shown in Rating Tables section of this Quick Start Guide and the National Electrical Code or other applicable local codes.
Motor Cable| 75°C Copper must be used.
Power cable connections and tightening torques are shown in the Mechanical Dimensions section of this Quick Start Guide.
Integral Solid Sate short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the national electrical code and any additional local codes. Ratings are shown in the Rating Tables section of this Quick Start Guide.
For installations in Canada transient surge suppression must be installed on the line side of this equipment and shall be rated 480Volt (phase to ground), 480 Volt (phase to phase), suitable for over voltage category iii and shall provide protection for a rated impulse withstand voltage peak of 2.5kV.
UL Listed ring terminals/lugs must be used for all bus bar and grounding connections.
General Requirements
Optidrive E3 provides motor overload protection, set at 150% of full load, in accordance with the National Electrical Code (US). Where a motor thermistor is not fitted, or not utilised, Thermal Overload Memory Retention must be enabled by setting P-60 = 1.

Where a motor thermistor is fitted and connected to the drive, connection must be carried out according to the information shown in the Motor Thermistor Connection section of the Quick Start Guide.

UL rated ingress protection (“Type” ) is only met when cables are installed using a UL-recognized bushing or fitting for a flexible conduit system which meets the required level of protection (“Type”).
For conduit installations the conduit entry holes require standard opening to the required sizes specified per the NEC.
Not intended for installation using rigid conduit system.
WARNING: The opening of the branch-circuit protective device may be an indication that a fault has been interrupted. To reduce the risk of fire or electric shock, current-carrying parts and other components of the controller should be examined and replaced if damaged. If burnout of the current element of an overload relay occurs, the complete overload relay must be replaced.

Input Power Supply Requirements

Supply Voltage| 200 – 240 RMS Volts for 230 Volt rated units, + /- 10% variation allowed.
---|---
380 – 480 Volts for 400 Volt rated units, + / – 10% variation allowed.
Imbalance| Maximum 3% voltage variation between phase – phase voltages allowed.
All Optidrive E3 units have phase imbalance monitoring. A phase imbalance of > 3% will result in the drive tripping. For input supplies which have supply imbalance greater than 3% (typically the Indian sub-continent & parts of Asia Pacific including China) Invertek Drives recommends the installation of input line reactors. Alternatively, the drives can

be operated as a single phase supply drive with 50% derating.

Frequency| 50 – 60Hz + / – 5% Variation.
Maximum Supply Short-Circuit Current Capacity| The maximum permissible short circuit current at the Optidrive Power terminals as defined in IEC60439-1 is:| 230V single-phase input drives| 5kA
---|---
230V three-phase input drives| 100kA
400V three-phase input drives| 100kA

Default functions of the control switches

Switch Configuration

Control Connections

Control Terminal Wiring

• All analog signal cables should be suitably shielded. Twisted pair cables are recommended.
• Power and Control Signal cables should be routed separately where possible, and must not be routed parallel to each other.
• Signal levels of different voltages e.g. 24 Volt DC and 110 Volt AC, should not be routed in the same cable.
• The maximum control terminal tightening torque is 0.5Nm.
• Control Cable entry conductor size: 0.05 – 2.5mm2 / 30 – 12 AWG.

Control Terminal Connections
Control Switched Units: May use the built-in control switch and potentiometer, or external control signals connected to the control terminals.

Non-Switched Units:
Require external control signals to be connected to the control terminals.

Using the Control Terminals

|
---|---

+24

VDC

| DI1| DI2| DI3 AI2| +10

VDC

| DI4 AI1| 0V| A0| 0V| RL1| RL2
No.| Purpose|  | Function
1

2

3

4

5

| +24VDC 100mA Output DI1 Digital Input 1

DI2 Digital Input 2

DI3 Digital Input 3/AI2 Analog Input 2

+10VDC 10mA Output

| 24 VDC Output
Function defined by P-12 & P-15.

See below for further info

|
10 VDC Output for external potentiometer
6| DI4 Digital Input 4/AI1 Analog Input 1| Function defined by P-12 & P-15. Signal format selected by P-16
7| 0VDC Common|
8| AO Analog Output/Digital Output| Function selected by P-25. See Parameter List
9

10

11

| 0VDC Common

RL1A Output Relay RL1B Output Relay

|

Function defined by P-18. See Parameter List

Factory Default Functions

No.| Description|
---|---|---
DI1| 0/1| Open: Stop| Closed: Run
DI2| P/Q| Open: Forward Rotation| Closed: Reverse Rotation
DI3| Analog Speed Reference / Preset Speed| Open: Speed Reference set by Analog Speed Reference Closed: Speed Reference set by Preset Speed 1 (P-20)
AI1| Analog Speed Reference Input| Sets the Speed Reference

NOTE For Switched units, the internal pot is selected by default in P-16.

For Non-switched units, an external pot or 0 – 10 V reference may be connected. Other signal types may also be used, set P-16 to the correct format.

NOTE| Additional functions are possible, refer to the online documentation for further information.

Analog and Digital Input Macro Configurations

Overview
Optidrive E3 uses a Macro approach to simplify the configuration of the Analog and Digital Inputs. There are two key parameters that determine the input functions and drive behavior:

• P-12 Selects the main drive control source and determines how the output frequency of the drive is primarily controlled.
• P-15 Assigns the Macro function to the analog and digital inputs.

Additional parameters can then be used to further adapt the settings, e.g.

• P-16 is Used to select the format of the analog signal to be connected to analog input 1, e.g. 0 – 10 Volt, 4 – 20mA.
• P-30 Determines whether the drive should automatically start following a power on if the Enable Input is present.
• P-31 When Keypad Mode is selected, determine at what output frequency/speed the drive should start following the enable command, and also whether the keypad start key must be pressed or if the Enable input alone should start the drive.
• P-47 Used to select the format of the analog signal to be connected to analog input 2, e.g. 0 – 10 Volt, 4 – 20mA. Example Connection Diagrams
• The diagrams below provide an overview of the functions of each terminal macro function and a simplified connection diagram for each.

Macro Functions Guide Key

The table below should be used as a key on the following pages.

Macro Functions – Terminal Mode (P-12 = 0)

Macro Functions – Keypad Mode (P-12 = 1 or 2)

Macro Functions – Fieldbus Control Mode (P-12 = 3, 4, 7, 8 or 9)

^—-START (P-12 = 3 or 4 Only)—- ^
6| STOP| ENABLE| FB REF| AI1 REF| E-TRIP| OK| Analog Input AI1| 3
^—-START (P-12 = 3 or 4 Only)—- ^
7| STOP| ENABLE| FB REF| KPD REF| E-TRIP| OK| Analog Input AI1| 3
^—-START (P-12 = 3 or 4 Only)—- ^
14| STOP| ENABLE| –| –| E-TRIP| OK| Analog Input AI1| 16
15| STOP| ENABLE| PR REF| FB REF| Fire Mode| P-23| P-21| 2
16| STOP| ENABLE| P-23 REF| FB REF| Fire Mode| Analog Input AI1| 1
17| STOP| ENABLE| FB REF| P-23 REF| Fire Mode| Analog Input AI1| 1
18| STOP| ENABLE| AI1 REF| FB REF| Fire Mode| Analog Input AI1| 1
2, 4, 8, 9, 10, 11, 12, 13, 19 = Behavior as per setting 0

Macro Functions – User PI Control Mode (P-12 = 5 or 6)

2, 9, 10, 11, 12, 13, 19 = Behavior as per setting 0
NOTE| P1 Setpoint source is selected by P-44 (default is fixed value in P-45, AI 1 may also be selected). P1 Feedback source is selected by P-46 (default is AI 2, other options may be selected).

Motor Thermistor Connection
Where a motor thermistor is to be used, it should be connected as follows :

COMMISSION

Operation

Managing the Keypad
The drive is configured and its operation is monitored via the keypad and display.

START
When in keypad mode, used to Start a stopped drive or to reverse the direction of rotation if bi-directional keypad mode is enabled.

UP
Used to increase speed in real-time mode or to increase parameter values in parameter edit mode.

DOWN
Used to decrease speed in real-time mode or to decrease parameter values in parameter edit mode.

NAVIGATE
Used to display real-time information, to access and exit parameter edit mode and to store parameter changes.

RESET/STOP
Used to reset a tripped drive. When in Keypad mode is used to Stop a running drive.

Operating Displays

Changing Parameters Read Only Parameter Access

Resetting Parameters

OPERATE

Parameters

Standard Parameters

Hz/RPM
P-03| Acceleration Ramp Time| 0.00| 600.0| 5.0| s
P-04| Deceleration Ramp Time| 0.00| 600.0| 5.0| s
P-05| Stopping Mode/Mains Loss Response| 0| 4| 0| –
 | Setting| On Disable| On Mains Loss
0| Ramp to Stop (P-04)| Ride Through (Recover energy from load to maintain operation)
1| Coast| Coast
2| Ramp to Stop (P-04)| Fast Ramp to Stop (P-24), Coast if P-24 = 0
3| Ramp to Stop (P-04) with AC Flux Braking| Fast Ramp to Stop (P-24), Coast if P-24 = 0
4| Ramp to Stop (P-04)| No action
P-06| Energy Optimiser| 0| 3| 0| –

P-07| Motor Rated Voltage/Back EMF at rated speed (PM/BLDC)| 0| 250/ 500| 230/400| V
P-08| Motor Rated Current| Drive Rating Dependent| A
P-09| Motor Rated Frequency| 10| 500| 50 (60)| Hz
P-10| Motor Rated Speed| 0| 30000| 0| RPM
Optidrive E3 normally uses frequency for all speed-related parameters, e.g. Minimum and Maximum Output Frequency. It is also possible to work directly in RPM, by setting P-10 to the rated speed from the motor nameplate.

When set to the default value of zero, all speed-related parameters are displayed in Hz.

Entering the value from the motor nameplate enables the slip compensation function, and the Optidrive display will also now show motor speed in RPM. All speed-related parameters, such as Minimum and Maximum Speed, Preset Speeds etc. will also be displayed in RPM.

NOTE If P-09 value is changed, P-10 value is reset to 0.

P-11| Low-Frequency Torque Boost| 0.0| Drive Dependent| %
P-12| Primary Command Source| 0| 9| 0| –
0: Terminal Control 5: PI Control

1: Uni-directional Keypad Control                                         6: PI Analog Summation Control

2: Bi-directional Keypad Control                                          7: CAN Control

3: Fieldbus Network Control                                               8: CAN Control

4: Fieldbus Network Control                                               9: Slave Mode

NOTE When P-12 = 1, 2, 3, 4, 7, 8 or 9, an enable signal must still be provided at the control terminals, digital input 1.

P-13| Operating Mode Select| 0| 2| 0| –
0: Industrial Mode  1: Pump Mode  2: Fan Mode| Setting| Appli- cation| Current Limit (P-54)| Torque Characteristic| Spin Start (P-33)| Thermal Overload Limit Reaction (P-60 Index 2)
---|---|---|---|---|---
0| General| 150%| Constant| 0: Off| 0: Trip
1| Pump| 110%| Variable| 0: Off| 1: Current Limit Reduction
2| Fan| 110%| Variable| 2: On| 1: Current Limit Reduction
P-14| Extended Menu Access code| 0| 65535| 0| –
Enables access to Extended and Advanced Parameter Groups. This parameter must be set to the value programmed in P-37 (default: 101) to view and adjust Extended Parameters and value of P-37 + 100 to view and adjust Advanced Parameters. The code may be changed by the user in P-37 if desired.

Extended Parameters

Advanced Parameters

0: Vector speed control mode 1: V/f mode

2: PM motor vector speed control

| 3: BLDC motor vector speed control

4: Synchronous Reluctance motor vector speed control 5: LSPM motor vector speed control

P-52| Motor Parameter Autotune| 0| 1| 0| –
0: Disabled| 1: Enabled
P-54| Maximum Current Limit| 0| 175| 150| %
Defines the max current limit in vector control modes
P-61| Ethernet Service Option| 0| 1| 0| –
0: Disabled| 1: Enabled
P-62| Ethernet Service Timeout| 0| 60| 0| Mins
0: Disabled| >0: Timeout in minutes
P-63| Modbus Mode Selection| 0| 1| 0| –
0: Standard1| 1: Advanced2
Par.| Description| Min| Max| Default| Units
---|---|---|---|---|---
P-64| IP66 DI1 Source| 0| 4| 0| –
Visible only on IP66 Switched Drives

0: Terminal 2 OR Switch Forward OR Switch Reverse           3: Terminal 2 AND (S-Forward OR Switch Reverse) 1: Terminal 2 Only 4: Terminal 2 AND Switch Forward

2: Terminal 2 OR Switch Forward

P-65| IP66 DI2 Source| 0| 2| 0| –
Visible only on IP66 Switched Drive

0: Terminal 3 OR Switch Reverse

1: Terminal 3 Only

2: Terminal 3 AND Switch Reverse

Asynchronous Induction Motors (IM) Vector Control
Optidrive E3 factory default parameters are intended for use with IM motors where the power rating of the motor is approximately the same or slightly less than the indicated power rating of the drive. In this case, it should be possible to operate the motor without any parameter adjustment at all for initial testing.
For optimum performance, the drive parameters should be adjusted to match the motor ratings. This will also ensure correct protection of the motor from damage due to overload.

The basic parameters that should be adjusted are:

• P-07: Motor Rated Voltage (V)

• P-08: Motor Rated Current (A)

• P-09: Motor Rated Frequency (Hz)
  In addition, it is also possible to set:

• P-10: Motor Rated Speed (RPM)
  When this parameter is adjusted, slip compensation is activated. Slip compensation attempts to compensate the motor speed relative to the load applied, such that when operating at a constant speed with different loads, the motor shaft speed should remain approximately the same.
  To further improve the performance of the motor, the following additional steps can be followed:

• Carry out an Autotune.

  • This requires Advanced Parameter Access, P-14 = P-37 + 100 (Default : 201).
  • After the correct nameplate information is entered from the motor, the drive can additionally measure some electrical characteristics of the motor to further optimize the motor control to suit the connected motor.
  • This is achieved by setting P-52 = 1. The autotune will begin IMMEDIATELY following the setting of this parameter!
  • The drive output will be enabled, and the motor shaft may move. It is important to ensure this is safe before carrying out the autotune.
  • For IM motors, the autotune takes only a few seconds and measures only the motor stator resistance. Parameter P-55 will be updated with the new value.

• Adjust the Low-Frequency Torque Boost

  • IM motors require some additional voltage at low frequency to improve the low-speed operation and torque.
  • By adjusting P-11, it is possible to optimize the low-speed operation.
  • If P-11 is increased too far, excessive motor heating or over-current trips may result.

• Speed regulation and response to load changes may be improved by adjusting P-11 Vector Gain to suit the motor and connected load.

  • Higher values will provide a more dynamic behavior at the risk of instability.

NOTE For other motor types refer to online document.

Technical Data

Environment

Operational ambient temperature range

• Enclosed Drives: -20 … 40°C (frost and condensation free)
• Storage ambient temperature range: -40 … 60°C
• Maximum altitude: 2000m. Derate above 1000m: 1% / 100m
• Maximum humidity: 95%, non-condensing

Rating Tables

Frame Size| kW| HP| Input Current| Fuse/MCB (Type B)| Maximum Cable Size| Output Current| Recommended Brake Resistance
---|---|---|---|---|---|---|---
Non UL| UL| mm 2| AWG| A| Ω
110 – 115 (+ / – 10%) V 1 Phase Input, 230V 3 Phase Output (Voltage Doubler)
1| 0.37| 0.5| 7.8| 10| 10| 8| 8| 2.3| –
1| 0.75| 1| 15.8| 25| 20| 8| 8| 4.3| –
2| 1.1| 1.5| 21.9| 32| 30| 8| 8| 5.8| 100
200 – 240 (+ / – 10%) V 1 Phase Input, 3 Phase Output
1| 0.37| 0.5| 3.7| 10| 6| 8| 8| 2.3| –
1| 0.75| 1| 7.5| 10| 10| 8| 8| 4.3| –
1| 1.5| 2| 12.9| 16| 17.5| 8| 8| 7| –
2| 1.5| 2| 12.9| 16| 17.5| 8| 8| 7| 100
2| 2.2| 3| 19.2| 25| 25| 8| 8| 10.5| 50
3| 4| 5| 29.2| 40| 40| 8| 8| 15.3| 25
4| 5.5| 7.5| 55| 80| 70| 35| 2| 24| 15
4| 7.5| 10| 66| 80| 80| 35| 2| 30| 15
200 – 240 (+ / – 10%) V 3 Phase Input, 3 Phase Output
1| 0.37| 0.5| 3.4| 6| 6| 8| 8| 2.3| –
1| 0.75| 1| 5.6| 10| 10| 8| 8| 4.3| –
1| 1.5| 2| 8.9| 16| 15| 8| 8| 7| –
2| 1.5| 2| 8.9| 16| 15| 8| 8| 7| 100
2| 2.2| 3| 12.1| 16| 17.5| 8| 8| 10.5| 50
3| 4| 5| 20.9| 32| 30| 8| 8| 18| 25
3| 5.5| 7.5| 26.4| 40| 35| 8| 8| 24| 20
4| 7.5| 10| 33.3| 40| 45| 16| 5| 30| 15
4| 11| 15| 50.1| 63| 70| 16| 5| 46| 10
380 – 480 (+ / – 10%)V 3 Phase Input, 3 Phase Output
1| 0.75| 1| 3.5| 6| 6| 8| 8| 2.2| –
1| 1.5| 2| 5.6| 10| 10| 8| 8| 4.1| –
2| 1.5| 2| 5.6| 10| 10| 8| 8| 4.1| 250
2| 2.2| 3| 7.5| 16| 10| 8| 8| 5.8| 200
2| 4| 5| 11.5| 16| 15| 8| 8| 9.5| 120
3| 5.5| 7.5| 17.2| 25| 25| 8| 8| 14| 100
3| 7.5| 10| 21.2| 32| 30| 8| 8| 18| 80
3| 11| 15| 27.5| 40| 35| 8| 8| 24| 50
4| 15| 20| 34.2| 40| 45| 16| 5| 30| 30
4| 18.5| 25| 44.1| 50| 60| 16| 5| 39| 22
4| 22| 30| 51.9| 63| 70| 16| 5| 46| 22

NOTE
Cable sizes shown are the maximum possible that may be connected to the drive. Cables should be selected according to local wiring codes or regulations at the point of installation.

Troubleshooting

Fault Code Messages

NOTE
Following an over-current or overload trip (1, 3, 4, 15), the drive may not be reset until the reset time delay has elapsed to prevent damage to the drive.

Invertek Drives Ltd.
Offa’s Dyke Business Park, Welshpool, Powys SY21 8JF the United Kingdom Tel: +44 (0)1938 556868 Fax: +44 (0)1938 556869 www.invertekdrives.com.

References

• Documentation For Optidrive E3 Variable Frequency Drive | Variable Speed Drive | AC Drive | Invertek Drives
• Variable Frequency Drive Manufacturer | Variable Speed Drives | AC Drives | Invertek Drives

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