HV9000 AF Drives Series C Manual

Transcription

1 HV9000 AF Drives Series C Manual User Manual HVStandard Application Manual April 2004 Supersedes May 2003 MN E For more information visit:

2 HOW TO USE THIS MANUAL This manual provides you with the information necessary to install, startup and operate a Cutler-Hammer HV9000 Series C drive. We recommend that you read this manual carefully. At minimum the following 10 steps of the Quick Start Guide must be done during installation and startup. QUICK START GUIDE GUIDE 1. Check the equipment received compared to what you have ordered as shown in section Before performing any startup activities carefully read the safety instructions in section Before mechanical installation, check the minimum clearances around the unit and verify that ambient conditions will meet the requirements listed in section 5.2 and Table Specifications. 4. Check the size of the motor cable, the utility cable and the fuses. Verify the tightness of the cable connections as detailed in Tables to Follow the installation instructions in section Control cable sizes and grounding systems are explained in section 6.2. The signal configuration for the HVStandard application is shown in section 10. Remember to connect the common terminals CMA and CMB of the digital input groups as shown in Figure For instructions on how to use the Multiline Display Control Panel refer to section The HVStandard application has a large number of application related parameters. All of these have default values. To ensure proper operation, verify the nameplate data of the motor and the HV9000 as well as the specific application requirements. Nominal voltage of the motor. Nominal Frequency of the motor. Nominal speed of the motor. Input Amp limit of the drive (drive current rating). Output amp limit of the drive. Input supply voltage and number of phases to the HV Follow the startup instructions provided in section Your Cutler-Hammer HV9000 is now ready for use. Cutler-Hammer is not responsible for the use of the HV9000 differently than noted in these instructions. If any problem occurs, please call the telephone number listed on the back of this manual for assistance.

3 Page 1 CONTENTS HV SAFETY Warnings Safety instructions Grounding & ground fault protection Running the motor initial operation..3 2 EU DIRECTIVE CE label EMC directive General Technical criteria HV9000 EMC levels RECEIVING HV9000 nameplate and catalog number description Storage Warranty TECHNICAL DATA General Power Ratings V Compact NEMA V V V V Specifications INSTALLATION Ambient conditions Cooling Mounting Wiring Power connections Utility cable Motor cable Control cable Installation instructions Cable selection & installation for UL listing Cable & motor insulation checks Control connections Control cables Galvanic isolation barriers Digital input function inversion CONTROL PANEL Introduction Control panel operation Monitoring Menu M Parameter Group Menu M Reference Menu M Buttons Menu M Active Faults Menu M Fault History Menu M Contrast Menu M Operating Menu M Active Warning Display STARTUP Safety Precautions Sequence of operation Fault Tracing Standard Application General Control Connections Control I/O Signal Logic Parameter Menus Motor protection functions in...87

4 Page 2 SAFETY HV SAFETY ONLY A QUALIFIED ELECTRICIAN CAN CARRY OUT THE ELECTRICAL INSTALLATION 1.1 Warnings 1 Internal 2 When 3 The 4 Do 5 Any 6 Only components and circuit boards (except the isolated I/O terminals) are at utility potential when the HV9000 is connected to the line. This voltage is extremely dangerous and may cause death or severe injury if you come in contact with it. the HV9000 is connected to the utility, the motor connections U (T1), V (T2), W (T3) and DC-link/brake resistor connections & + are live even if the motor is not running. control I/O terminals are isolated from the utility potential, but relay outputs and other I/Os (if jumper X4 is in the OFF position refer to Figure ) may have dangerous external voltages connected even if power is disconnected from the HV9000. not open the cover of the HV9000 immediately after disconnecting power to the unit, because components within the drive remain at a dangerous voltage potential for some time. Wait until at least five minutes after the cooling fan has stopped and the keypad or cover indicators are dark before opening the HV9000 cover. upstream disconnect/protection device is to be used as noted in the National Electric Code (NEC). spare parts obtained from a Cutler-Hammer authorized distributor should be used.

5 Page 3 SAFETY HV Safety instructions 1 The 2 Do 3 Disconnect 4 Do 5 Ensure HV9000 is meant only for fixed installations. Do not make any connections or measurements when the HV9000 is connected to the utility. not make any high voltage or megger tests on any part of the HV9000. the motor cables from the HV9000 before meggering the motor cables or the motor. not touch any components on the circuit boards. Static voltage discharge may destroy board components. that the HV9000 cover is closed before connecting utility power to the HV Grounding & ground fault protection The HV9000 must always be grounded with a grounding conductor connected to the grounding terminal. NOTE: Warning Symbols Pay special attention to instructions marked with the following warning symbols HV9000 ground fault protection protects only the HV9000 if a ground fault occurs in the motor or in the motor cable. Due to high HV9000 leakage current, fault current protective devices may not operate correctly with the HV9000. When fault current protection devices are used, they should be tested with the HV9000 under isolated installation conditions = Dangerous Voltage = General Warning 1.4 Running the motor initial operation! 1 Before 2 Confirm 3 The running the motor, ensure that the motor is properly mounted, wired, and grounded. that the motor rotational direction is proper before coupling it to the driven load. maximum motor speed (frequency) should never be set to exceed the motor or load rating.

6 Page 4 EU DIRECTIVE HV EU DIRECTIVE 2.1 CE label The CE label on the product guarantees free movement of the product in the European Union (EU) area. According to EU rules, this guarantees that the product has been manufactured in accordance with the appropriate product directives. Cutler-Hammer HV9000 Series C drives are CE labeled in accordance with the Low Voltage directive (LVD) and the EMC directive. 2.2 EMC directive General The EMC directive (Electro Magnetic Compatibility) states that electrical equipment must not disturb the environment and must be immune to other electromagnetic disturbances in the environment. A Technical Construction File (TCF) exists which demonstrates that HV9000 drives fulfill the requirements of the EMC directive. A TCF has been used as a statement of conformity with the EMC directive as it is not possible to test all installation combinations Technical criteria The design intent of the HV9000 is to develop a family of drives which are user friendly and cost effective while fulfilling customer needs. EMC compliance was a major consideration at design outset. The HV9000 drive is targeted for the world market. To ensure maximum flexibility while meeting EMC needs for different regions, all HV9000 drives meet the highest immunity levels, while leaving emission level choices to the user HV9000 EMC levels The HV9000 drive does not fulfill any EMC emission requirements without an optional RFI filter, either built in or separate. With an RFI filter, the drive fulfills the EMC emission requirements in the heavy industrial environment (standards EN and EN ). All products fulfill all EMC immunity requirements (standards EN , EN , EN ).

7 Page 5 RECEIVING HV RECEIVING Cutler-Hammer HV9000 drives have been subjected to demanding factory tests before shipment. After unpacking, check that the HV9000 does not show any signs of damage and that the unit received is as ordered. The model number description code for HV9000 drives is provided in Figure If there are signs of shipping damage contact the shipping company. If the received equipment is not the same as ordered, please contact your distributor immediately. NOTE: Do not destroy any drive packing material. For most units, a template has been provided on the protective cardboard to mark drive mounting points. 3.1 HV9000 nameplate and catalog number description Figure HV9000 Nameplate and Catalog Number Description

8 Page 6 RECEIVING HV Storage If the HV9000 must be stored before installation and startup, check that the ambient conditions in the storage area will be within these limits: Temperature: 40 C to +60 C 40 F to +140 F Humidity: < 95% Non-Condensing Environment: Clean, dust and dirt free 3.3 Warranty This equipment is covered by the Cutler-Hammer warranty period. Cutler-Hammer distributors may have a different warranty period, which is specified in their terms, conditions, and warranty. Should any questions arise concerning the warranty, please contact your distributor.

9 Page 7 TECHNICAL DATA HV TECHNICAL DATA 4.1 General Figure is a block diagram of the HV9000. The three phase AC choke with the DC link capacitor forms a LC filter which together with the rectifier, produces the DC voltage for the IGBT inverter block. The AC choke smooths the disturbances from the utility into the HV9000, as well as the high frequency disturbances caused by the HV9000 on the utility line. It also improves the input current waveform to the HV9000. The IGBT inverter produces a symmetrical, three-phase, pulse width modulated, AC voltage to the motor. The motor and application control block is microprocessor and software based. The microprocessor controls the motor based on measured signals, parameter settings and commands from the control I/O block and control panel. The motor and application control block commands the motor control ASIC, which calculates the IGBT switching positions. Gate drivers amplify these signals to drive the IGBT inverter. The control panel is a link between the user and the HV9000. With the control panel, the user can set parameter values, read status information and give control commands. The panel is removable and can be mounted externally and connected via cable to the drive. The control I/O block is isolated from line potential, and is connected to ground via a 1M Ohm resistor and 4.7µF capacitor. If needed, the control I/O block can be grounded without a resistor by changing the position of the jumper X4 (GND ON/OFF) on the control board (see Figure ). Input and output EMC filters are not required for the functionality of the HV9000. They are only needed for compliance with the EU EMC Directive as detailed in section 2 or similar requirements. Figure HV9000 Block Diagram

10 Page 8 TECHNICAL DATA HV Power Ratings V Compact NEMA 1 208V, Compact NEMA 1 Rated HP & Output Current Variable Torque Frame Size/ Enclosure Size HP Ivt! M3/Compact NEMA ½ M4B/Compact NEMA 1 M5B/Compact NEMA 1 Dimensions W H D in Inches and (mm) ( ) ( ) ( ) Weight in lbs Catalog Number HV9F10CC-2M0B008 HV9F20CC-2M0B008 HV9F30CC-2M0B008 HV9F50CC-2M0B008 HV9F75CC-2M0B008 HV9010CC-2M0B008 HV9015CC-2M0B008 HV9020CC-2M0B V, Compact NEMA 1 Rated HP & Output Current Frame Size/ Variable Torque Enclosure Size HP Ivt! ½ M3/Compact NEMA 1 M4B/Compact NEMA 1 M5B/Compact NEMA 1 Dimensions W H D in Inches and (mm) ( ) ( ) ( ) Weight in lbs Catalog Number HV9F10CC-2M0B00 HV9F20CC-2M0B00 HV9F30CC-2M0B00 HV9F50CC-2M0B00 HV9F75CC-2M0B00 HV9010CC-2M0B00 HV9015CC-2M0B00 HV9020CC-2M0B00 HV9025CC-2M0B00 480V, Compact NEMA 1 Rated HP & Output Current Frame Size/ Variable Torque Enclosure Size HP Ivt! ½ M3/Compact NEMA 1 M4B/Compact NEMA 1 M5B/Compact NEMA 1 Dimensions W H D in Inches and (mm) ( ) ( ) ( ) Weight in lbs Catalog Number HV9F10CC-5M0B00 HV9F20CC-5M0B00 HV9F30CC-5M0B00 HV9F50CC-5M0B00 HV9F75CC-5M0B00 HV9010CC-5M0B00 HV9015CC-5M0B00 HV9020CC-5M0B00 HV9025CC-5M0B00 HV9030CC-5M0B00 HV9040CC-5M0B00! Ivt = continuous rated output current (variable torque load, maximum 40 C ambient).

11 Page 9 TECHNICAL DATA HV Power Ratings 208 V 208V, NEMA 1 Rated HP & Output Current Variable Torque HP Ivt! ½ Frame Size/ Enclosure Size M4/NEMA 1 M5/NEMA 1 M6/NEMA 1 M7/NEMA M8/NEMA 1 208V, NEMA 12 Rated HP & Output Current Variable Torque HP Ivt! ½ Frame Size/ Enclosure Size M4/NEMA 12 M5/NEMA 12 M6/NEMA 12 M7/NEMA M8/NEMA V, Protected Chassis/Chassis Rated HP & Output Current Variable Torque Frame Size/ Enclosure Size HP Ivt! 2 10 M4/Protected 3 5 7½ M5/Protected M6/Protected M7/Protected Dimensions W H D in Inches and (mm) ( ) ( ) ( ) ( ) ( ) Dimensions W H D in Inches and (mm) ( ) ( ) ( ) ( ) ( ) Dimensions W H D in Inches and (mm) ( ) ( ) ( ) ( ) M8/Chassis " ( )! Ivt = continuous rated output current (variable torque load, maximum 40 C ambient). " Protected enclosure with option. Weight in lbs Catalog Number HV9F20CS-2M0A008 HV9F30CS-2M0A008 HV9F50CS-2M0A008 HV9F75CS-2M0A008 HV9010CS-2M0A008 HV9015CS-2M0A008 HV9020CS-2M0A008 HV9025CS-2M0A008 HV9030CS-2M0A008 HV9040CS-2M0A008 HV9050CS-2M0A008 HV9060CS-2M0A HV9075CS-2M0A008 Weight in lbs Catalog Number HV9F20CJ-2M0A008 HV9F30CJ-2M0A008 HV9F50CJ-2M0A008 HV9F75CJ-2M0A008 HV9010CJ-2M0A008 HV9015CJ-2M0A008 HV9020CJ-2M0A008 HV9025CJ-2M0A008 HV9030CJ-2M0A008 HV9040CJ-2M0A008 HV9050CJ-2M0A008 HV9060CJ-2M0A HV9075CJ-2M0A008 Weight in lbs Catalog Number HV9F20CP-2M0A008 HV9F30CP-2M0A008 HV9F50CP-2M0A008 HV9F75CP-2M0A008 HV9010CP-2M0A008 HV9015CP-2M0A008 HV9020CP-2M0A008 HV9025CP-2M0A008 HV9030CP-2M0A008 HV9040CP-2M0A008 HV9050CP-2M0A008 HV9060CP-2M0A HV9075CN-2M0A008

12 Page 10 TECHNICAL DATA HV Power Ratings 230 V 230V, NEMA 1 Rated HP & Output Current Variable Torque HP Ivt! Frame Size/ Enclosure Size 3 10 M4/NEMA 1 5 7½ M5/NEMA 1 M6/NEMA 1 M7/NEMA M8/NEMA 1 230V, NEMA 12 Rated HP & Output Current Variable Torque HP Ivt! Frame Size/ Enclosure Size 3 10 M4/NEMA 1 5 7½ M5/NEMA 1 M6/NEMA 1 M7/NEMA M8/NEMA 1 Dimensions W H D in Inches and (mm) ( ) ( ) ( ) ( ) ( ) Dimensions W H D in Inches and (mm) ( ) ( ) ( ) ( ) ( ) Weight in lbs. Catalog Number 17.6 HV9F30CS-2M0B HV9F50CS-2M0B00 HV9F75CS-2M0B00 HV9010CS-2M0B00 HV9015CS-2M0B00 HV9020CS-2M0B00 HV9025CS-2M0B00 HV9030CS-2M0B00 HV9040CS-2M0B00 HV9050CS-2M0B00 HV9060CS-2M0B00 HV9075CS-2M0B HV9100CS-2M0B00 Weight in lbs. Catalog Number 17.6 HV9F30CJ -2M0B HV9F50CJ-2M0B00 HV9F75CJ -2M0B00 HV9010CJ -2M0B00 HV9015CJ -2M0B00 HV9020CJ -2M0B00 HV9025CJ-2M0B00 HV9030CJ-2M0B00 HV9040CJ-2M0B00 HV9050CJ-2M0B00 HV9060CJ-2M0B00 HV9075CJ-2M0B HV9100CJ-2M0B00! Ivt = continuous rated output current (variable torque load, maximum 40 C ambient).

13 Page 11 TECHNICAL DATA HV V, Protected Chassis/Chassis Rated HP & Output Current Frame Size/ Variable Torque Enclosure Size HP Ivt! 3 10 M4/Protected 5 7½ M5/Protected M6/Protected M7/Chassis " M8/Chassis " Dimensions W H D in Inches and (mm) ( ) ( ) ( ) (248.9 x x 315.0) ( ) Weight in lbs. Catalog Number 15.4 HV9F30CP-2M0A HV9F50CP-2M0A00 HV9F75CP-2M0A00 HV9010CP-2M0A00 HV9015CP-2M0A00 HV9020CP-2M0A00 HV9025CP-2M0A00 HV9030CP-2M0A00 HV9040CP-2M0A00 HV9050CN-2M0A00 HV9060CN-2M0A00 HV9075CN-2M0A HV9100CN-2M0A00! Ivt = continuous rated output current (variable torque load, maximum 40 C ambient). " Protected enclosure with option.

14 Page 12 TECHNICAL DATA HV Power Ratings 480 V 480V, NEMA 1 Rated HP & Output Current Variable Torque HP Ivt! 5 7½ Frame Size/ Enclosure Size M4/NEMA 1 M5/NEMA 1 M6/NEMA 1 M7/NEMA 1 M8/NEMA 1 M9/NEMA 1 Dimensions W H D in Inches and (mm) ( ) ( ) ( ) ( ) ( ) ( ) Weight in lbs Catalog Number HV9F50CS-5M0A00 HV9F75CS-5M0A00 HV9010CS-5M0A00 HV9015CS-5M0A00 HV9020CS-5M0A00 HV9025CS-5M0A00 HV9030CS-5M0A00 HV9040CS-5M0A00 HV9050CS-5M0A00 HV9060CS-5M0A00 HV9075CS-5M0A00 HV9100CS-5M0A00 HV9125CS-5M0A00 HV9150CS-5M0A00 HV9200CS-5M0A00 HV9250CS-5M0A00 HV9300CS-5M0A00 HV9400CS-5M0A00 480V, NEMA 12 Rated HP & Output Current Variable Torque HP Ivt! 5 7½ Frame Size/ Enclosure Size M4/NEMA 12 M5/NEMA 12 M6/NEMA 12 M7/NEMA 12 M8/NEMA 12 M9/NEMA 12 Dimensions W H D in Inches and (mm) ( ) ( ) ( ) ( ) ( ) ( ) Weight in lbs Catalog Number HV9F50CJ-5M0A00 HV9F75CJ-5M0A00 HV9010CJ-5M0A00 HV9015CJ-5M0A00 HV9020CJ-5M0A00 HV9025CJ-5M0A00 HV9030CJ-5M0A00 HV9040CJ-5M0A00 HV9050CJ-5M0A00 HV9060CJ-5M0A00 HV9075CJ-5M0A00 HV9100CJ-5M0A00 HV9125CJ-5M0A00 HV9150CJ-5M0A00 HV9200CJ-5M0A00 HV9250CJ-5M0A00 HV9300CJ-5M0A00 HV9400CJ-5M0A00! Ivt = continuous rated output current (variable torque, maximum 40 C ambient).

15 Page 13 TECHNICAL DATA HV V, Protected Chassis/Chassis Rated HP & Output Current Frame Size/ Variable Torque Enclosure Size HP Ivt! 5 7½ M4/Protected M5/Protected M6/Protected M7/Chassis " M8/Chassis " M9/Chassis " Dimensions W H D in Inches and (mm) ( ) ( ) ( ) ( ) ( ) ( ) Weight in lbs Catalog Number HV9F50CP-5M0A00 HV9F75CP-5M0A00 HV9010CP-5M0A00 HV9015CP-5M0A00 HV9020CP-5M0A00 HV9025CP-5M0A00 HV9030CP-5M0A00 HV9040CP-5M0A00 HV9050CP-5M0A00 HV9060CP-5M0A00 HV9075CP-5M0A00 HV9100CN-5M0A00 HV9125CN-5M0A00 HV9150CN-5M0A00 HV9200CN-5M0A00 HV9250CN-5M0A00 HV9300CN-5M0A00 HV9400CN-5M0A00! Ivt = continuous rated output current (variable torque, maximum 40 C ambient). " Protected enclosure with option.

16 Page 14 TECHNICAL DATA HV Power Ratings 575 V 575V, NEMA 1/Chassis Rated HP & Output Current Frame Size/ Variable Torque Enclosure Size HP Ivt! 3 5 7½ M5/NEMA 1 M6/NEMA 1 M8/Chassis " M9/Chassis " M10/Chassis " Dimensions W H D in Inches and (mm) ( ) ( ) ( ) ( ) ( ) Weight in lbs Catalog Number HV9F30CS-6M0A00 HV9F50CS-6M0A00 HV9F75CS-6M0A00 HV9010CS-6M0A00 HV9015CS-6M0A00 HV9020CS-6M0A00 HV9025CS-6M0A00 HV9030CS-6M0A00 HV9040CS-6M0A00 HV9050CS-6M0A00 HV9060CS-6M0A00 HV9075CS-6M0A00 HV9100CS-6M0A00 HV9125CN-6M0A00 HV9150CN-6M0A00 HV9200CN-6M0A00 HV9250CN-6M0A00 HV9300CN-6M0A00 HV9400CN-6M0A00! Ivt = continuous rated output current (variable torque, maximum 40 C ambient). " Protected enclosure with option.

17 Page 15 TECHNICAL DATA HV Specifications Utility Input Voltage V in 208V, 230V, 480V, 575V Connection Input Frequency 45 to 66 Hz Output Voltage 0 to V in Continuous Output Current I vt Maximum Ambient +40 C, 1.1 Ivt (1 min/10 min) Motor Starting Torque 200% Connection 1.5 I Starting Current vt 2 sec. Every 20 sec. if Output Frequency < 30 Hz and if Heatsink Temperature < +60 C Output Frequency 0 to 120 Hz Frequency Resolution 0.01 Hz Control Method V/Hz Frequency Control Switching Frequency 1 to 16 khz Depending on HP Rating Analog Input Current/Input Voltage 12 Bit Resolution, Frequency Reference Control ±1% Accuracy Characteristics Field Weakening Point 30 to 120 Hz Acceleration Time 0.1 to Seconds Deceleration Time 0.1 to Seconds Braking Torque DC Brake 30% T N Ambient Operating Temperature 10 to +40 C at I vt Storage Temperature 40 to +60 C Relative Humidity < 95% Non-Condensing Operating Environment Chemical Vapors IEC , Unit in Operation, Class 3C2 Mechanical Particles IEC , Unit in Operation, Class 3S2 Environmental Limits Altitude Maximum Altitude 3000 Meters 1000 Meters at Continuous I vt > 1000 Meters, Reduce I vt by 1% Every 100 Meters Vibration IEC Operation Max. Displacement Amplitude 3mm at 2 to 9 Hz Max. Acceleration Amplitude 0.5G at 9 to 200 Hz Shock IEC Operation Max. 8G for 11mS Storage and Shipping Max. 15G for 11mS in Packing Box Enclosure Open and Protected Chassis IP00 and IP20 Compact NEMA 1 IP20 NEMA 1 IP21 NEMA 12 IP54 Oversized NEMA 1 Oversized NEMA 12 Noise Immunity Fulfills EN ,-2 and EN EMC Fulfills EN and EN when Equipped with an Emissions Optional External RFI-Filter Safety Fulfills EN50178, EN , CE, UL, C-UL, FI, GOST R (Check Unit Nameplate for Unit Approvals) Table Specifications

18 Page 16 TECHNICAL DATA HV9000 Control Connections Protective Functions Analog Voltage Analog Current Digital Inputs (6) Auxiliary Voltage Potentiometer Reference Analog Output Digital Output Relay Outputs Overcurrent Protection Overvoltage Protection Undervoltage Protection Ground Fault Protection Utility Supervision Motor Phase Supervision Unit Overtemperature Protection Motor Overload Protection Stall Protection Motor Underload Protection Short Circuit Protection for +24V and +10V Reference Voltages 0 to +10V, R = 200k Ohm Single Ended (-10V to +10V, Joystick Control) Resolution 12 Bit, ±1% Accuracy 4-20mA, R = 250 Ohm, Differential Positive or Negative Logic +24V ±20%, 100mA Maximum +10V, 0 to +3%, 10mA Maximum 4 to 20mA, R < 500 Ohm, 10 bit Resolution, ±1% Accuracy Open Collector Output, 50mA/48V Maximum Switching Voltage 300VDC, 250VAC Maximum Switching Load 8A/24V 0.4A/250VDC 2kVA/250VAC Maximum Continuous Load 2A rms Trip Limit 4 Ivt Utility Voltage 208V 230V 480V 575V Trip Limit 1.55 V in 1.41 V in 1.41 V in 1.62 V in Trip Limit 0.65 V in Protects the Drive from a Ground Fault in the Motor or Motor Cable Trips On Loss of Any Input Phase Trips On Loss of Any Output Phase Yes Yes Yes Yes Yes Table Specifications (continued)

19 Page 17 INSTALLATION HV INSTALLATION 5.1 Ambient conditions The environmental limits mentioned in Table must not be exceeded. 5.2 Cooling As detailed in Figure and Table 5.2-1, the specified space around the HV9000 ensures proper cooling air circulation. If multiple units are to be installed above each other, the dimensions must be b + c and air from the outlet of the lower unit must be directed away from the inlet of the upper unit. With high switching frequencies and high ambient temperatures, the maximum continuous output current has to be derated according to Table and Figures 5.2-3a 5.2-3d. Frame Size/Enclosure Style Dimensions in Inches a a2! b c M3/Compace NEMA 1 M4/Protected & NEMA M4/NEMA M4B/M5B Compact NEMA 1 M5 Protected & NEMA M5/NEMA M6/Protected & NEMA M6/NEMA M7/Chassis" & NEMA 12 M7/NEMA 1 3 (1.5)# 3 (2.5)# 12 4 M8/Chassis" & NEMA 12 M8/NEMA 1 10$ (3)" M9/Chassis" & NEMA 12 M9/NEMA 1 8$ (3)" M10/Chassis & NEMA 12 M10/NEMA 1 8$ (3)" M11/Chassis & NEMA 12 M11/ NEMA 1 M12/Chassis & NEMA 12 Consult Factory M12/NEMA 1! Distance from inverter to inverter in multiple inverter installations " Protected enclosure with optional cover # Minimum allowable space. No space available for fan change $ Space for fan change on sides of HV9000 Table Installation Space Dimensions HP Figure Installation Space Voltage/Enclosure /Compact NEMA /Protected & NEMA 1/ /Compact NEMA /Protected & NEMA 1/ /Compact NEMA /Protected & NEMA 1/ /Protected & NEMA 1/ /Compact NEMA /Protected & NEMA 1/ /Compact NEMA 1 7½ /Protected & NEMA 1/ /Compact NEMA /Protected & NEMA 1/ /Protected & NEMA /Compact NEMA /Protected & NEMA 1/ /Compact NEMA /Protected & NEMA 1/ /Compact NEMA /Chassis & NEMA 1/ /Protected & NEMA /Protected & NEMA 1/ /Protected & NEMA 1/ /Protected & NEMA 1/ /Protected & NEMA 1/ /Protected & NEMA /Protected & NEMA 1/ /Protected & NEMA 1 Required Airflow (CFM) /Protected & NEMA Table Installation Space Dimensions

20 Page 18 INSTALLATION HV9000 Figure 5.2-2a 3-25HP Figure 5.2-2b HP Figures 5.2-2a 5.2-2c show power dissipation as a function of the switching frequency for 480V variable torque drives in standard enclosures (Types N, P, S and J). Figure 5.2-2c HP Figure 5.2-2d 2-75HP Figure 5.2-2e HP Figures 5.2-2d and 5.2-2e show power dissipation as a function of the switching frequency for 230V standard enclosure variable torque drives (Types N, P, S and J).

21 Page 19 INSTALLATION HV9000 Figure 5.2-2f 1-5HP Figure 5.2-2g 7½-20HP Figures 5.2-2f 5.2-2h show power dissipation as a function of the switching frequency for 480V compact enclosure variable torque drives (Type C). Figure 5.2-2h 25-40HP

22 Page 20 INSTALLATION HV9000 HP Curve 3.6kHz 10kHz 16kHz 1½ - 7½ No Derating No Derating 10 HV9010 HV No Derating 25 No Derating No Derating HV No Derating 40 HV HV HV HV9075 HV HV9100 No Derating 125 HV HV9150 HV No Derating Not Allowed No Derating 200 HV HV9250 HV9250 Figure 5.2-3a 300 No Derating HV HV9400 HV9400 Table Constant Output Current Derating Curves for 480V Ivt Figure 5.2-3a-3d Constant Output Current Ivt Derating Curves as a Function of Ambient Temperature and Switching Frequency Figure 5.2-3b Figure 5.2-3d Figure 5.2-3c

23 Page 21 INSTALLATION HV Mounting The HV9000 should be mounted in a vertical position on the wall or on the back panel of an enclosure. Mounting clearances and cooling requirements are detailed in Figure and Tables & To ensure a safe installation, the mounting surface should be relatively flat. Mounting is accomplished using four screws or bolts. Figure and Table detail unit dimensions. Figures and illustrate HP units which have special lifting eyes that must be used. If further information is needed contact your Cutler-Hammer distributor. Figure Mounting Dimensions Frame Enclosure Voltage Dimensions in Inches W1 W2 H1 H2 H3 H4 D1 R1 R2 M M4B Compact NEMA 1 208/230/ M5B M M M6 208/230/ NEMA 1/12 M M M M /230/480 M M M6 208/230/ M6 Chassis Protected M7 208/230/ M M /575 M Table Dimensions for Open Panel Units

24 Page 22 INSTALLATION HV9000 Figure Lifting HP Units NOTE: Insert a lifting rod through the lifting holes when lifting HP units. Figure Lifting HP Units

25 Page 23 WIRING HV Wiring General wiring diagrams are shown in Figures 6-1 thru 6-3. The following sections have more detailed instructions about wiring and cable connections. If further information is required, contact your Cutler-Hammer distributor. Figure 6-1 General Wiring Diagram for Open/Protected Chassis Units Frame Sizes M4 thru M6

26 Page 24 WIRING HV9000 Figure 6-2 General Wiring Diagram for Open/Protected Chassis Frame Sizes > M7 NEMA 1/12 Units Frame Sizes > M8

27 Page 25 WIRING HV9000 Figure 6-3 General Wiring Diagram for NEMA 1/12 Units Frame Sizes M4 thru M7 Compact NEMA 1 Units

28 Page 26 WIRING HV Power connections Use the appropriate temperature rated cables if operating in an ambient higher than +40 C. The cables and fuses must be sized in accordance with the current rating of the HV9000. Installation of the output cable where one motor is connected with one cable to the HV9000, consistent with UL, is explained in section Installation should follow any local regulations and installation conditions. The minimum copper cable sizes and the corresponding fuses are given in Tables to The fuses have been selected so that they will also function as overload protection for the cables. For maximum protection of the HV9000, consistent with UL requirements, UL recognized type RK fuses should be used. If I 2 t motor temperature protection is used as overload protection for the HV9000, the motor cables may be selected accordingly. On larger units, if three or more cables are used in parallel, each cable must have its own overload protection Utility cable Utility cable classifications for different EU EMC levels are defined in Table Motor cable Motor cable classifications for different EU EMC levels are defined in Table Control cable Control cable classifications for different EU EMC levels are defined in Table Other control cable requirements are specified in section 6.2. Cable Level N Level I Utility Cable 1 1 Motor Cable 2 2 Control Cable 3 3 Where: 1 = The power cable is suitable for the installation, ampacity and voltage. Shielded cable is not required. 2 = The power cable contains a concentric protection wire and is suitable for the ampacity and voltage. For maximum EMC protection, use of shielded cable is required. 3 = The control cable has a compact low impedance shield. Table Cable Types for Different EMC Levels 230V HP Ivt Fuse Copper Cable Utility and Motor (Ground) (16) (14) 7½ (10) (8) (6) (6) (6) (4) (2) (0) MCM (000) Table Utility Cables, Motor Cables and Fuse Recommendations According to Ivt Output Current 230V Range

29 Page 27 WIRING HV V HP Ivt Fuse Copper Cable Utility and Motor (Ground) (16) 7½ (14) (12) (10) (8) (6) (6) (6) (4) (2) (0) MCM (000) [250 MCM (00)] [350 MCM (000)] [550 MCM (250 MCM)] Table Utility Cables, Motor Cables and Fuse Recommendations According to Ivt Output Current 480V Range 575V HP Ivt Fuse 3 5 7½ 10 Copper Cable Utility and Motor (Ground) (14) (12) (10) (8) (6) (6) (4) (2) MCM (00) MCM (000) Table Utility Cables, Motor Cables and Fuse Recommendations According to Ivt Output Current 575V Range Frame HP Voltage Cable (AWG/MCM) M3 All M4 All 230/ M4B All M5 All 230/480/ M5B M Copper 00 Aluminum M MCM M MCM Aluminum M MCM MCM M MCM! MCM! For NEMA 1/12 units, a maximum of 3 parallel connected cables can be used. Table Maximum Cable Sizes for The Power Terminals

30 Page 28 WIRING HV Installation instructions 1 2 All open chassis HV9000 units should always be mounted inside a control cabinet or an enclosure. If a HV9000 open chassis unit is to be installed outside a control cabinet or an enclosure, a protective ÍP20 cover should be installed to cover the cable connections, see figure The protective cover may not be needed if the unit is mounted inside a control cabinet or an enclosure. Locate the motor cable away from other cables. Avoid long parallel runs with other cables. If the motor cable runs in parallel with other cables, the minimum distances between the motor and control cables given below should be used. The minimum distances listed below, also apply between the motor cable and signal cables of other systems. The maximum motor cable length is 600 ft (180 meters) for drives rated 5HP and above. For ratings 2HP and below, the maximum motor cable length is 160 ft (50 meters). For 3HP ratings, the maximum motor cable length is 330 ft (100 meters). Power cables should cross other cables at a 90 angle. For drive ratings of 2HP and below, the output dv/dt filter option is required for motor cable lengths exceeding 33 ft (10 meters). For drive ratings of 3HP and above, the output dv/dt filter option is required when motor cable lengths exceed 100 ft (33 meters). 3 Distance Between Cables in feet and (meters) 1 (0.3) 3.3 (1) Motor Cable Length in feet and (meters) 165 (50) 600 (180) Refer to section for cable insulation check procedures.

31 Page 29 WIRING HV Connecting cables. Motor and utility cables should be stripped as detailed in Figure and Table Open the cover of the HV9000 as shown in Figure To insert the cables, remove the required grommets from the cable cover of open chassis units, or from the bottom of NEMA 1/12 units. Cable installation must be consistent with the instructions in section to maintain the UL listing. Connect the utility, motor and control cables to the correct terminals as shown in Figures thru If the RFI filter option is used, refer to the RFI Filter Instruction Manual. Check that control cables and wires do not make contact with electrical components inside the unit. Ensure that the ground cable is connected to the ground terminals of the HV9000 and motor. For HP open chassis units, connect the isolator plates of the protective cover and terminals as shown in Figure If a shielded power cable is used, connect the shield to the ground terminals of the HV9000, motor and supply panel. Ensure that the control cables and any internal wiring are in place before reinstalling the cable cover or unit cover. NOTE: For frame sizes M7-M10, transformer connections within the unit must be changed if the input supply voltage to the drive is other than the default supply voltage. Voltage Code (VC) Default Supply Voltage 230V 480V 575V

32 Page 30 WIRING HV Cable selection & installation for UL listing For installation and cable connections the following must be noted. Use only copper wire with a temperature rating of at least 60/75 C. Units are suitable for use on a circuit capable of delivering not more than the fault RMS symmetrical amperes shown in Table , 480V maximum. Terminal tightening torques are provided in Table Frame Voltage Maximum RMS Symmetrical Amps on Supply Circuit M3 All 35,000 M4-M12 All 100,000 Table Maximum Supply Symmetrical Fault Current Frame HP Voltage Tightening Torque (in-lbs) M3 All All 7 M4B All All 7 M5B All All 20 M4 All All 7 M5 All All 20 M M M M M M M7 All All 44 M8 All All 610! M9 All All 610!! The isolated standoff of the busbar will not withstand the listed tightening torque. Use a wrench to apply counter torque when tightening. Table Tightening Torque

33 Page 31 WIRING HV9000 Figure Stripping Motor and Utility Cables Frame HP Voltage Stripping Lengths in Inches L1 L2 L3 L4 M3 All M4 All 230/480 M4B All M5 All 230/480/ M5B M M M Contact Factory M Table Stripping Lengths of Cables! Loosen screws (2 places). " Pull cover bottom outwards. # Push cover upwards. Figure Opening the Cover of the HV9000

34 Page 32 WIRING HV9000 M4, M5 Frame Figure Cable Assembly for Standard Open Chassis 3-15HP Voltage Code HP Voltage Code HP Voltage Code 2-8 Show the ground wires show for the motor and utility cables

35 Page 33 WIRING HV9000 M4 FRAME Figure Cable Assembly for Standard NEMA 1 & 12 3HP Voltage Code HP Voltage Code 5 2-3HP Voltage Code 2-8 Show the ground wires show for the motor and utility cables

36 Page 34 WIRING HV9000 M5 Frame Figure Cable Assembly for Standard NEMA HP Voltage Code HP Voltage Code HP Voltage Code 2-8 Show the ground wires show for the motor and utility cables

37 Page 35 WIRING HV9000 M5 Frame Figure Cable Assembly for Standard NEMA HP Voltage Code HP Voltage Code HP Voltage Code 2-8

38 Page 36 WIRING HV9000 M6 Frame Figure Cable Assembly for Open Chassis 20-40HP Voltage Code HP Voltage Code HP Voltage Code 2-8

39 Page 37 WIRING HV9000 M6 Frame Figure Cable Assembly for Standard NEMA 1 & HP Voltage Code HP Voltage Code HP Voltage Code 2-8

40 Page 38 WIRING HV9000 M7 Frame Figure Cable Assembly for Open Chassis 50-75HP Voltage Code HP Voltage Code HP Voltage Code 2-8

41 Page 39 WIRING HV9000 M8, M9, M10 Frames Figure Cable Assembly for Open Chassis 100HP Voltage Code HP Voltage Code HP Voltage Code 6 Cable Assembly for NEMA1 & HP Voltage Code HP Voltage Code 5 75HP Voltage Code 2-8

42 Page 40 WIRING HV9000 M8, M9, M10 Frame After Making the Cable Connections Before Switching on the Utility Supply: 1. Insert all 10 terminal isolator plates A between the terminals as shown below. 2. Insert and fasten the 3 protective plastic covers B, C and D over the terminals. Figure Cable Cover & Terminal Assembly for Open Chassis 100HP Voltage Code HP Voltage Code HP Voltage Code 6 Cable Cover & Terminal Assembly for NEMA 1 & HP Voltage Code HP Voltage Code 5 75HP Voltage Code 2-8

43 Page 41 WIRING HV9000 M5 Frame Figure Cable Assembly for Open Chassis 3-30HP Voltage Code 6

44 Page 42 WIRING HV9000 M6 Frame Figure Cable Assembly for Open Chassis HP Voltage Code 6

45 Page 43 WIRING HV9000 M3 Frame Figure Cable Assembly for Compact NEMA 1 1-3HP Voltage Code 2 1-5HP Voltage Code 5 1-2HP Voltage Code 2-8

46 Page 44 WIRING HV9000 M4B Frame Figure Cable Assembly for Compact NEMA HP Voltage Code 2 7½-20HP Voltage Code 5 3-7½HP Voltage Code 2-8

47 Page 45 WIRING HV9000 M5B Frame Figure Cable Assembly for Compact NEMA HP Voltage Code HP Voltage Code HP Voltage Code 2-8

48 Page 46 WIRING HV Cable & motor insulation checks 1. Motor cable insulation checks. Disconnect the motor cable from terminals U(T1), V(T2) and W(T3) of the HV9000 unit and from the motor. Measure the insulation resistance of the motor cable between each phase conductor, then between each phase conductor and the protective ground conductor. The insulation resistance must be > 1M Ohm. 2. Utility cable insulation checks. Disconnect the utility cable from terminals L1, L2 and L3 of the HV9000 unit and from the utility. Measure the insulation resistance of the utility cable between each phase conductor, and then between each phase conductor and the protective ground conductor. The insulation resistance must be > 1M Ohm. 6.2 Control connections The functionality of the terminals for the HVStandard application is detailed in section Basic connections are shown in Figure Control cables Control wiring should be 20 AWG minimum, shielded multicore cable. The maximum wire size that the control terminal block will accept is 14 AWG Galvanic isolation barriers The control connections are isolated from the utility potential and the I/O ground is connected to the frame of the HV9000 via a 1M Ohm resistor and a 4.7µF capacitor. The control I/O ground can also be connected directly to the frame by changing the position of jumper X4 to the ON-position as shown in Figure Digital inputs and relay outputs are also isolated from I/O ground. 3. Motor insulation checks. Disconnect the motor cable from the motor and open any bridging connections in the motor conduit box. Measure the insulation resistance of each motor winding. The measurement voltage must be at least equal to the utility voltage, but must not exceed 1kV. The insulation resistance must be > 1M Ohm.

49 Page 47 WIRING HV Digital input function inversion Figure Isolation Barriers The active signal level of the digital input logic depends on how the common input (CMA, CMB) of the input group is connected. The connection can be either to +24V or to GND. The +24V or GND source for the digital inputs and common terminals (CMA, CMB) can be either external or internal (terminals 6 & 12). Positive logic (+24V active signal). Input is active when the switch is closed. Negative logic (0V active signal). Input is active when the switch is closed. Figure Positive/Negative Logic

50 Page 48 CONTROL PANEL HV CONTROL PANEL 7.1 Introduction The control panel of the HV9000 Series C drive has a Multiline Display with seven indicators for the Run Status and three indicators for the control source The panel also has three text lines for the menu location, menu/submenu description & the number or value of the selected item. The eight pushbuttons on the control panel are used for controlling the HV9000, setting parameters and monitoring values. The panel is detachable and isolated from the utility line potential. The display examples in this section show only the text and numeric lines of the Multiline Display. The Run Status indicators are not included in the examples.

51 Page 49 CONTROL PANEL HV9000 Figure HV9000 Control Panel

52 Page 50 CONTROL PANEL HV Control panel operation Data displayed on the control panel is arranged in menus and submenus. The menus are used to display and edit measurement & control signals, set parameters & reference values, and display faults. NOTE: For HVStandard operation, a maintained closed contact or jumper must be present at DIA3 and DIB6 to Start the HV9000. Refer to Figure for additional details. The symbol M1 M10 on the left side of the first line of the display stands for one of the Main Menus. A arrow in the lower right corner indicates that a further submenu can be accessed by pressing the RIGHT MENU button. A arrow in the lower right corner prompts you to press the ENTER button until the screen changes. If the Operating Menu was the last menu used (indicated by an O in the upper left side of the first line of the display), P 1.17 Password must first be accessed as detailed in Figure

53 Page 51 CONTROL PANEL HV9000 Figure Control Panel Operation

54 Page 52 CONTROL PANEL HV Monitoring Menu M1 The Monitoring menu can be entered when the symbol M1 is visible on the first line of the Multiline Display. How to view the monitored values is presented in Figure All monitored signals are listed in Table Values are updated once every 0.5 seconds. This menu is meant only for signal viewing. The values cannot be altered using the Monitoring menu. NOTE: The values available in this menu are also directly accessible in the Operating menu Figure Figure Monitoring Menu Number Signal Name Unit Description V1 Motor Speed % Motor Speed in % V2 Output Frequency Hz Frequency to the Motor V3 Motor Speed RPM Calculated Motor Speed V4 Motor Current A Measure Motor Current V5 Motor Torque % Calculated Actual Torque/Nominal Torque of the Unit V6 Motor Power % Calculated Actual Power/Nominal Power of the Unit V7 Motor Voltage V Calculated Motor Voltage V8 DC-Bus Voltage V Measured DC-Link Voltage V9 Unit Temperature C Heat Sink Temperature V10 Op Day Counter DD.dd! Operating Days (max. 32,500 days) V11 Service Days DD Service Days Reset by button B1 V12 Op Hours Counter HH.h " Operating Hours Reset by Button B1 (max hours) V13 MWh Counter MWh Total Megawatt hours V14 Megawatt Hrs MWh Total Megawatt hours Reset by Button B2 V15 Kilowatt Hrs KWh Total KWh Reset by Button B2 V16 Voltage/Analog Input V Voltage of Terminal +Vin (Terminal 2) V17 Current/Analog Input ma Current of Terminals +Iin and Iin (Terminals 4 & 5) V18 Dig Input A Status Digital Input Status Group A See Figure V19 Dig Input B Status Digital Input Status Group B See Figure V20 Digital & Relay Outputs Digital & Relay Output Status See Figure V21 Control Program Displays Control Software Version Number V22 Drive Option SW Displays Software Version on Option Card V23 Unit Nominal Power kw Power Size of the Drive V24 Calc Motor Temp % 100% = Nominal Motor Temp. has been reached! DD = Full Days Table Monitored Signals Table " dd = Decimal Part of Day

55 Page 53 CONTROL PANEL HV9000 Figure Digital Inputs Group A Status Figure Digital Inputs Group B Status Figure Output Signal Status

56 Page 54 CONTROL PANEL HV Parameter Group Menu M2 When the symbol M2 is visible on the first line of the Multiline Display, the Parameter Group Menu has been reached. Parameter values are changed as shown in Figure Push the RIGHT MENU button to move to the submenus under Basic Parameter Group G1, or use the UP/DOWN BROWSER button to go to the other Parameter Groups G2 to G10. Locate the parameter you want to change by using the UP/DOWN BROWSER button. Pressing the RIGHT MENU button again allows you to enter the Edit Mode. Once your are in the Edit Mode, the symbol of the parameter will start to blink. Set your new value with the UP/DOWN BROWSER button, then confirm the change by pressing the ENTER button again. The blinking will stop and the new value will be visible. Several parameters are locked, i.e. uneditable, when the drive is running. If you try to change the value of a locked parameter, the text * locked * will appear on the display. You can return to the Main Menu anytime by pressing the LEFT MENU button for 2-3 seconds. If a password has been set (P1.18), when switching from the operating mode to the editing mode, you must enter your password to change parameters. If you are at the last parameter in a parameter group, you can move directly back to the first parameter in the group by pressing the UP BROWSER button. Figure Parameter Setting on the Control Panel

57 Page 55 CONTROL PANEL HV Reference Menu M3 When the symbol M3 is visible on the first line of the Multiline Panel, the Reference Menu has been reached. If the control panel is the active control source, the % of maximum frequency can be changed by changing the display value with the UP/DOWN BROWSER button. Note: The reference value cannot be changed if a Smoke Purge Signal is present at DIB4 (closed contact at term. 14), when a PM Setback signal is present at DIB5 (closed contact at term. 15), or when the control panel is not the active source. Figure Reference Setting from the Control Panel 7.6 Buttons Menu M4 When the symbol M4 is visible on the first line of the Multiline Panel, the Buttons menu has been reached. Sub-menus B1 and B2 serve as virtual buttons that can reset the drives operating hours and mwh counters respectively. Pressing the ENTER button for 2-3 seconds toggles the counters from On or Off, resetting the counters. Figure Button Menu Setting

58 Page 56 CONTROL PANEL HV Active Faults Menu M5 The Active Faults menu is reached when M5 is visible on the first line of the Multiline Display as shown in Figure When a fault brings the HV9000 to a stop, the fault code F and a description of the fault are automatically displayed. If there are several faults at the same time, the list of active faults can be browsed with the UP/DOWN BROWSER button. The display can be cleared with the STOP/RESET button and the read-out will return to the same display it had before the fault trip. Figure Active Faults Menu 7.8 Fault History Menu M6 The Fault History Menu can be entered from the Main Menu when the symbol M6 is displayed on the first line of the Multiline panel, as shown in Figure The memory of the drive can store up to 9 faults in the order of their appearance. The most recent fault has the number 1, the second latest the number 2, etc. If there are 9 uncleared faults in memory, the next fault will erase the oldest from memory. Pressing the ENTER button for 2-3 seconds will reset fault history. The symbol F will then change to 0. Figure Fault History Menu

59 Page 57 CONTROL PANEL HV Contrast Menu M7 When the symbol M7 is visible on the first line of the Multiline Display the Contrast Menu has been reached, as shown in Figure Use the RIGHT MENU button to enter the editing submenu. When the symbol C starts to blink, you can change the contrast using the UP/DOWN BROWSER button. The change takes effect immediately. Press the LEFT menu button to return to the M7 Contrast Menu. Figure Contrast Setting

60 Page 58 CONTROL PANEL HV Operating Menu M8 When the symbol M8 is visible on the first line of the Multiline Display, the Operating Menu has been reached. The symbol in the lower right hand corner prompts you to press the ENTER button until the Operating Submenu is entered. How to browse through monitored values is presented in Figure Monitored signals are listed in Table Values are updated once every 0.5 seconds. Values can be changed in the operating menu using the UP/DOWN BROWSER button. To exit the submenu, press the ENTER button until P 1.17 Password is displayed, re-enter your password, then press ENTER again. Figure Operating Menu Number Signal Name Unit Description O1 Motor Speed % Motor Speed in % O2 Output Frequency Hz Frequency to the Motor O3 Motor Speed RPM Calculated Motor Speed O4 Motor Current A Measure Motor Current O5 Motor Torque % Calculated Actual Torque/Nominal Torque of the Unit O6 Motor Power % Calculated Actual Power/Nominal Power of the Unit O7 Motor Voltage V Calculated Motor Voltage O8 DC-Bus Voltage V Measured DC-Link Voltage O9 Temperature C Heat Sink Temperature O10 Operating Day Counter DD.dd! Operating Days (max. 32,500 days) O11 Service Days DD Service Days Reset by button B1 O12 Operate Hours HH.h " Operating Hours Reset by Button B1 (max hours) O13 MW Hours Counter MWh Total Megawatt hours O14 Megawatt Hrs MWh Total Megawatt hours Reset by Button B2 O15 Kilowatt Hrs KWh Total KWh Reset by Button B2 O16 Voltage/Analog Input V Voltage of Terminal +Vin (Terminal 2) O17 Current/Analog Input MA Current of Terminals +Iin and Iin (Terminals 4 & 5) O18 Digital Input Status Group A See Figure O19 Digital Input Status Group B See Figure O20 Digital & Relay Output Status See Figure O21 Control Program Displays Control Software Version Number O22 Drive Option SW Displays Software Version on Option Card O23 Unit Nominal Power kw Power Size of the Drive O24 Motor Temperature Rise % 100% = Nominal Motor Temp. has been reached! DD = Full Days Table Monitored Signals Table " dd = Decimal Part of Day

61 Page 59 CONTROL PANEL HV9000 Figure Digital Inputs Group A Status Figure Digital Inputs Group B Status Figure Output Signal Status

62 Page 60 CONTROL PANEL HV Active Warning Display When a warning occurs, text with the symbol A appears on the display. Warning codes are explained in Table The display does not have to be cleared in any special way. The warning on the display does not disable the normal functions of the pushbuttons. Code Warning Check: A15 Motor stalled Motor stall protection. Check motor. A28 The application change has failed. Choose the application again and push the ENTER button. A30 Unbalanced current fault Unbalanced line load. Contact your Cutler-Hammer distributor. A45 HV9000 frequency converter overtemperature warning Temperature >70 C. Check the cooling air flow and the ambient temperature. ALARM Table Warning Codes

63 Page 61 STARTUP HV STARTUP 8.1 Safety Precautions Before startup, observe the following warnings and safety instructions. 1 Internal 2 When 3 Do 4 Do 5 The components and circuit boards (except the isolated I/O terminals) are at utility potential when the HV9000 is connected to the line. This voltage is extremely dangerous and may cause death or severe injury if you come in contact with it. the HV9000 is connected to the utility, the motor connections U (T1), V (T2), W (T3) and DC-link/brake resistor connections & + are live even if the motor is not running. not make any connections when the HV9000 is connected to the utility line. not open the cover of the HV9000 immediately after disconnecting power to the unit, because components within the HV9000 remain at a dangerous voltage potential for some time. Wait until at least five minutes after the cooling fan has stopped and the keypad or cover indicators are dark before opening the HV9000 cover. control I/O terminals are isolated from the utility potential, but relay outputs and other I/Os (if jumper X4 is in the OFF position refer to Figure ) may have dangerous external voltages connected even if power is disconnected from the HV Before connecting to the utility make sure that the cover of the HV9000 is closed. 8.2 Sequence of operation 1 Read and follow all safety precautions. 2 At installation ensure: That the HV9000 and motor are connected to ground. That the utility and motor cables are in accordance with the installation and connection instructions as detailed in section 6.1. That the control cables are located as far as possible from the power cables as detailed in section That control cable shields are connected to protective ground that wires do not make contact with any electrical components in the HV9000. That the common input of digital input groups is connected to +24V or ground of the I/O terminals or external supply as detailed in section That a maintained closed contact or jumper is present at DIA3 and DIB6 to allow the drive to start. Refer to Figure for additional details.

64 Page 62 STARTUP HV Check the quality of the cooling air as detailed in sections 4.3 and Check that moisture has not condensed inside the HV Check that all start/stop switches connected to the I/O terminals or Network run/stop commands are in the stop state. 6 Connect the HV9000 to the utility and switch the power on. 7 Ensure that Group 1 parameters match the application by setting the following parameters to match the motor nameplate: Parameter 1.11 = the nominal voltage or the motor. Parameter 1.12 = the nominal frequency of the motor. Parameter 1.13 = the nominal F.L. speed of the motor. Parameter 1.14 = the motor nominal F.L. current. and the incoming power supply: Parameter 1.15 = the nominal input supply voltage to the drive. Parameter 1.16 = the type of power supply 1ø or 3ø. 8 Perform either Test A or Test B without the motor connected to the HV9000. Test A Control from the Control Panel. Apply input power to the HV9000. Press the ENTER button for (2) seconds, then press ENTER again to acknowledge password. Press the START button. Go to the Monitoring Menu and check that the output frequency follows the reference as detailed in section 7.3. Press the STOP/RESET button. Test B Control from the I/O Terminals. Apply input supply power to the HV9000. Press the ENTER button for (2) seconds, then press ENTER again to acknowledge password. Change control from the keypad to the I/O terminals. Change the frequency reference. Check from the monitoring menu at the control panel that the output frequency follows the frequency reference. Stop the HV9000 by either opening the run enable contact at DIA3 or the interlock contact at DIB6. 9 Disconnect all power to the HV9000. Wait until the cooling fan on the unit stops and the indicators on the panel are not lit. If no keypad is present, check the indicators in the cover. Wait at least 5 more minutes for the DC bus to discharge. Connect the motor to the HV9000 and check for correct motor rotation. If possible, perform a startup test with the motor connected to the HV9000 but not connected to the process. If the HV9000 must be tested with the motor connected to the process, perform initial testing under no-load or light load conditions.

65 Page 63 FAULT TRACING HV Fault Tracing When a fault trip occurs, the fault indicator is illuminated and the fault code and it s description are displayed. The fault can be cleared with the reset button or via an I/O terminal. The faults are sorted in fault history where they can be viewed as detailed in section 7.8. The fault codes are explained in Table 9-1. Fault Fault Possible Cause Check: Codes F1 Overcurrent HV9000 frequency converter has measured too high a current (> 4 In) in the motor output: Sudden heavy load increase. Short circuit in the motor cables. Unsuitable motor. F2 Overvoltage The voltage of the internal DC link of the HV9000 frequency converter has exceeded nominal voltage by 35%: Deceleration time is too fast. High overvoltage spikes at utility. F3 Ground Fault Current measurement detected that the sum of the motor phase current is not zero: Insulation failure in the motor or the cables. F4 Inverter Fault HV9000 frequency converter has detected faulty operation in the gate drivers of the IGBT bridge: Interference fault. Component failure. F5 Charge Switch DC bus charging contact/relay is open while Start command is active: Interference fault. Component failure. F9 Undervoltage DC bus voltage has gone below 65% of nominal voltage: Most common reason is failure of the utility supply. Internal failure of the HV9000 frequency converter can also cause an undervoltage trip. F10 F11 Input Line Supervision Output Phase Supervision Input line phase is missing. Parameter 1.16 is set for the incorrect power type. Current measurement has detected that there is no current in one of the motor phases. Table 9-1 Fault Codes Check loading. Check motor size. Check cables. Adjust the deceleration time. Enable overvoltage supervision. Check the motor cables. Reset the fault and restart the drive. If the fault occurs again contact your Cutler-Hammer distributor. Reset the fault and restart the drive. If the fault occurs again contact your Cutler-Hammer distributor. In case of temporary supply voltage break, reset the fault and restart the drive. Check the utility input. If the utility supply is correct an internal failure has occurred. Contact a Cutler-Hammer distributor. Check the utility connection. Check parameter Check motor cables.

66 Page 64 FAULT TRACING HV9000 Fault Codes F13 F14 Fault Possible Cause Check: HV9000 Undertemperature HV9000 Overtemperature Temperature of heat sink below 10 C. Temperature of heat sink over 75 C. For compact NEMA 1 over 80 C. F15 Motor Stalled The motor stall protection has tripped. F16 Motor The HV9000 motor temperature Overtemperature model has detected motor over heating: Motor is overloaded. F17 Motor Underload The motor underload protection has tripped. F18 Analog Input Component failure on control board. Hardware Fault F20 10V Voltage +10V reference shorted on control Reference board. F21 24V Supply +24V supply shorted on control F22 F23 F25 F26 F55 F56 F57 F59 EEPROM Checksum Fault Microprocessor Watchdog Panel Communication Error Protocol Not Supported (FLN(P1) only) Paraset not OK (FLN only) Communication Loss (FLN only) No/Wrong Option (N2 only) board. Parameter restoring error: Interference fault. Component failure. Check for excessively low cooling air temperature Check the cooling air flow. Check that the heat sink is not dirty. Check ambient temperature. Check that the switching frequency is not too high when compared to ambient temperature and motor load. Check for free rotation of the motor and load. Decrease motor load. Check the temperature model parameters if the motor was not overheated. Check the motor, drive train, load, etc. Contact your Cutler-Hammer distributor. Check the cabling from +10V reference voltage. Check the cabling from +24V reference voltage. On resetting this fault the drive will automatically load the parameter default settings. Check all parameter settings after reset. If the fault occurs again contact your Cutler- Hammer distributor. Reset the fault and restart. If the fault occurs again contact your Cutler-Hammer distributor. Check the panel cable, reset the panel Interference fault. Component failure. The connection between the control panel and the HV9000 drive is not working. Application software is not Upgrade the software or obtain different compatible with the installed communication board. communication board. Application parameters do not match Check that the correct application is loaded with option board parameters the correct option board Communication with network has Troubleshoot network connections and been lost. communication. Option board ID number is invalid or Check that correct option board is installed missing Table 9-1 Fault Codes

67 Page 65 STANDARD APPLICATION HV Standard Application 10.1 General The HVStandard application provides a high degree of flexibility is the use and setup of your HV9000. The features and operating characteristics available are programmable with the various parameters detailed in section Motor thermal protection is detailed in section Control Connections Figure Control I/O Signals

68 Page 66 STANDARD APPLICATION HV Control I/O Signal Logic Drive Stop Figure Control Signal Logic

69 Page 67 STANDARD APPLICATION HV Parameter Menus Parameter Group 1: Basic Parameters 1.1 Minimum Speed Minimum Speed Range: 0.0 P1.2 Units: Percent Defines the minimum output speed limit setting Default: Maximum Speed 1.3 Accel Time 1.4 Decel Time Maximum Speed Default: Range: P Units: Percent Defines the maximum output speed limit setting. 100% corresponds to the motor nominal speed P1.13 Acceleration Time Default: 60.0 Range: Units: Seconds Time required for output frequency to change from the minimum frequency to the maximum frequency set by parameters P1.1 and P1.2. Deceleration Time Default: 60.0 Range: Units: Seconds Time required for output frequency to change from the maximum frequency to the minimum frequency set by parameters P1.2 and P Smokepurge speed Smoke Purge Speed Range: P1.1 P1.2 Units: Percent Defines the speed reference only if DIB4 is closed. Default: PM Setback Speed 1.7 Smoke P Priority PM Setback Speed Default: 20.0 Range: P1.1 P1.2 Units: Percent Defines the speed reference only if DIB5 is closed and the HV9000 is already running Smoke Purge Priority Level Default: 0 = Low Range: = Low 1 = High When set to low, the following signals will prevent a Run command from being executed or will Stop the HV9000 if it is already running. Stop from the HV9000 Control Panel or from an HOA switch DIA3 is open. DIB6 External Interlock active DIB6 is open. The drive will restart automatically if the smoke purge command stays active (DIB4 is closed) and all interlocks are cleared. The HV9000 will display the interlock status messages in the following priority. 1 = External Interlock = DIA6 is open. 2 = Run Enable/Off = DIA3 is open. 3 = Smoke Purge = DIB4 is closed. 4 = PM Setback = DIB5 is closed. When set to high, all interlocks are overridden and the HV9000 will start, then accelerate to Smokepurge Speed. The HV9000 will display the interlock status messages in the following priority. 1 = Smoke Purge = DIB4 is closed. 2 = External Interlock = DIB6 is open. 3 = Run Enable/Off = DIA3 is open. 4 = PM Setback = DIB5 is closed. NOTE: When the smoke purge command is On, all software generated faults are continuously cleared.

70 Page 68 STANDARD APPLICATION HV9000 Figure Smoke P Priority Interaction

71 Page 69 STANDARD APPLICATION HV9000 Parameter Group 1: Basic Parameters (continued) 1.8 Current Limit Current Limit Range: Units: Percent Default: 100 This determines the maximum current allowed as a percentage of the HV9000 nameplate current rating 1.9 V/Hz Ratio Sel. V/Hz Ratio Selection Default: 0 = Linear Range: = Linear 1 = Squared This determines if the voltage varies directly with frequency or follows a squared relationship. With a squared relationship the motor runs under-excited below nominal frequency allowing less torque, but with reduced electromechanical noise. The squared relationship is typically used for applications where the torque requirements vary as the square of speed, e.g. centrifugal fans and pumps. Figure Linear and Squared V/Hz Curves 1.10 V/Hz Optim. V/Hz Optimization Default: 0 = None Range: = None 1 = Auto torque boost This determines if the V/Hz ratio is increased as the frequency is lowered to counteract motor IR drop to increase torque for applications with high starting or friction requirements, e.g. conveyors. At low speed and higher torque loads the motor may overheat. Attention must be paid to suitable motor cooling Motor Voltage 1.12 Motor Nom Freq 1.13 Motor Nom Speed Motor Voltage Range: Units: Volts This corresponds to the motor nominal nameplate voltage Motor Nominal Frequency Range: Units: Hertz This corresponds to the motor nominal nameplate frequency Motor Nominal Speed Range: Units: RPM This corresponds to the motor nominal nameplate speed Default: 460 Default: 60 Default: 1705 This is way too low. Should be 1750 to 1760.

72 Page 70 STANDARD APPLICATION HV9000 Parameter Group 1: Basic Parameters (continued) 1.14 Motor Nominal Current Default: 1.0 x I nhv9 Motor Nom Currnt Range: x I nhv9 Units: Amperes This corresponds to the motor nominal full load nameplate current and is used to calculate motor thermal protection. This parameter cannot be changed when the HV9000 is running Supply Voltage 1.16 Supply Type 1.17 Password 1.18 Set Password Supply Voltage Default: 16 = 480 Range: Units: Volts 11 = = = = = = = 500 This is catalog number dependant and sets the utility line voltage to which the HV9000 is connected. It cannot be changed when the HV9000 is running. Supply Type Default: 0 = 3-Phase Range: = 3-Phase 1 = Single phase Sets the input line supervision for units which can be operated from both 1 and 3 power. If the incorrect supply type is entered, fault F10, Input Line Supervision, will be displayed. This cannot be changed with the HV9000 running. Password Default: 0 Range: When switching from the Operating Mode to parameter editing, the password screen will be displayed to prompt you to enter your password Set Password Default: 0 Range: The value entered here becomes your password. Once set, it cannot be changed without entering the old password first.

73 Page 71 STANDARD APPLICATION HV9000 Parameter Group 1: Basic Parameters (continued) 1.19 HOA Control HOA Control Range: = Keypad 1 = Terminal 2 = Network Default: 0 = Keypad This parameter selects the control location from which the Hand/Off/Auto mode selection will be made. Keypad = Control is from the HV9000 Control Panel Keypad. A maintained closed contact or jumper must be present at DIA3 and DIB6 to Start the drive. DIA3 Closed Contact = Run Enabled, Open Contact = Run Disabled. DIB6 Closed Contact = Ext. Interlock Off, Open Contact = Ext. Interlock On (Coast to Stop). Terminal = Control is from terminals DIA2 and DIA3. DIA2 Closed Contact = Hand, Open Contact = Auto. DIA3 Closed Contact = On, Open Contact = Off. Network = Control is from a network. This selection is only available when a communication or network board is installed in the drive. When the keypad is used to change between Hand, Off and Auto modes, there is a 2 second delay before the change becomes active. When the control terminals or the network is used to change between Hand, Off, and Auto modes, there is no delay. Parameter 1.19 cannot be changed while the HV9000 is running. NOTE: Inputs DIA2 and DIA3 should not be used independently, as toggling DIA2 without opening DIA3 may not stop the HV9000 when expected Hand Off Auto DIA2 X O O DIA3 X O X 1.20 Ref.source hand 1.21 Start src hand Reference Source Hand Default: 0 = Keypad Range: = Keypad UP/DOWN buttons 1 = Current terminals 4 and 5 2 = Voltage terminals 1 and 3 3 = Network This sets the speed reference source for Hand mode operation and cannot be changed while the HV9000 is running. Start Source Hand Default: 0 = Keypad Range: = Keypad 1 = BAS Start DIA1 2 = I/O (3-wire) start with DIA1, stop with DIA3 3= Self Start starts when Hand is selected 4 = Network This parameter cannot be changed while the drive is running. The drive may start automatically when the run enable (DIA3) and external interlock (DIA6) are cleared, and start source is set to BAS, self-start, or network start. Other start sources require a new start command after the external interlock or run enable is opened.

74 Page 72 STANDARD APPLICATION HV9000 Parameter Group 1: Basic Parameters (continued) 1.22 Ref.source auto Reference Source Auto Range: = Keypad 1 = Current 2 = Voltage 3 = Network 4 = PI Network set point 5 = PI Panel set point 6 = Motor potentiometer 7 = Motor potentiometer Res Default: 2 = Voltage This parameter sets the speed reference for Auto mode operation and cannot be changed while the HV9000 is running 1.23 Start src auto Start Source Auto Range: = Keypad START/STOP buttons 1 = BAS Start DIA1 2 = I/O (3-wire) start with DIA1, stop with DIA3 3= Self Start starts when Auto is selected 4 = Network This parameter sets the start source for Auto mode operation Default: 0 = Keypad Figure Speed Reference Selection

75 Page 73 STANDARD APPLICATION HV9000 Parameter Group 2: Input Signals 2.1 DIB4 Function DIB4 Function Range: = Not used 1 = External fault closed 2 = External fault open 3 = Accel/Decel time set 4 = Jog speed selection 5 = Fault reset 6 = Accel/Decel prohibit 7 = Smoke purge 8 = PM setback 9 = I/O control 10 = External interlock 11 = Multi Step 1 This parameter sets the function for digital input DIB4. Default: 7 = Smoke Purge 2.2 DIB5 Function 2.3 DIB6 Function 2.4 Jog Speed Ref DIB5 Function Range: = Not used 1 = External fault closed 2 = External fault open 3 = Accel/Decel time set 4 = Jog speed selection 5 = Fault reset 6 = Accel/Decel prohibit 7 = Smoke purge 8 = PM setback 9 = I/O control 10 = External interlock 11 = Multi Step 2 12 = Reverse 13 = Motor potentiometer UP This parameter sets the function for digital input DIB5. DIB6 Function Range: = Not used 1 = External fault closed 2 = External fault open 3 = Accel/Decel time set 4 = Jog speed selection 5 = Fault reset 6 = Accel/Decel prohibit 7 = Smoke purge 8 = PM setback 9 = I/O control 10 = External interlock 11 = Multi Step 3 12 = Motor potentiometer DOWN This parameter sets the function for digital input DIB6. Jog Speed Reference Range: 0.0 (P1.2 x P1.12) / P1.13 Units: Hertz This parameter sets the speed reference for jogging. Default: 8 = PM Setback Default: 10 = External Interlock Default: 5.0

76 Page 74 STANDARD APPLICATION HV9000 Parameter Group 2: Input Signals (continued) 2.5 Vin Signal Range Analog input Vin Signal range Range: = 0-10V 1 = Custom range Default: 0 = 0-10V This determines the signal range for analog input terminals 2 3. The custom range is set by P2.6 and P Vin Custom Min 2.7 Vin Custom Max Vin Custom Minimum Range: 0.00 P2.7 Units: Percent Defines the minimum value for Vin as a percentage of 10V. Vin Custom Maximum Range: P Units: Percent Defines the maximum value for Vin as a percentage of 10V. Default: 0.00 Default: Vin Invert Vin Signal Inverted Default: 0 = No inversion Range: = No inversion 1 = Inverted Setting this parameter to 1 causes the maximum set output to occur with the minimum reference input and the minimum set output to occur with the maximum reference input. Figure No Signal Inversion Defines the maximum value for Vin as a percentage of 10V. Figure Signal Inverted

77 Page 75 STANDARD APPLICATION HV9000 Parameter Group 2: Input Signals (continued) 2.9 Vin Filter Time Vin Filter Time Range: Units: Seconds Default: 0.10 When this parameter, is given a value greater than 0, it activates the function that filters out disturbances from the Vin signal. A long filtering time makes the signal change slower. Figure Signal Filtering 2.10 Iin Signal Range Analog Input Iin Signal Range Default: 0 = 0-20 ma Range: = 0-20mA 1 = 4-20mA 2 = Custom range This determines the signal range for analog input terminals 4 5. The custom range is set by P2.11 and P Iin Custom Min 2.12 Iin Custom Max Iin Custom Minimum Range: 0.00 P2.12 Units: Percent Defines the minimum value for Iin as a percentage of 20mA. Iin Custom Minimum Range: P Units: Percent Defines the maximum value for Iin as a percentage of 20mA. Default: 0.00 Default: Iin Invert Iin Signal Inverted Default: 0 = No inversion Range: = No inversion 1 = Inverted Setting this parameter to 1, causes the maximum set output to occur with the minimum reference input and the minimum set output to occur with the maximum reference input. NAME RANGE AND DESCRIPTION DEFAULT SETTING

78 Page 76 STANDARD APPLICATION HV9000 Parameter Group 2: Input Signals (continued) 2.14 Iin Filter Time Iin Filter Time Range: Units: Seconds Default: 0.10 When this parameter, is given a value greater than 0, it activates the function that filters out disturbances from the Iin signal. A long filtering time makes the signal change slower Mot pot Ramp Tim Motor Potentiometer Ramp Time Default: 2.0 Range: Units: Seconds Defines the rate of change of the reference from the motor potentiometer. Parameter Group 3: Output Signals P3.1 Iout Content Iout Content Range: = Not used 1 = Motor frequency. (0 fmax) 2 = Motor speed (0 Motor nominal speed) 3 = Motor current (0 InMotor) 4 = Motor torque (0 TnMotor) 5 = Motor power (0 PnMotor) 6 = Motor voltage (0 VnMotor) 7 = DC-Bus voltage (0 1000V) Default: 1 = Motor frequency This parameter selects the desired function for the analog output signal. P3.2 Iout Filter Time P3.3 Iout Invert Iout Filter Time Default: 1.00 Range: Units: Seconds When this parameter is given a value greater than 0, it activates the function that filters out disturbances from the analog output signal. A long filtering time makes the output signal change slower. If you set a value of 0, no filtering takes place. See Figure Iout Invert Default: 0 (No inversion) Range: Not inverted 1. Inverted Setting this parameter to 1, inverts the analog output signal so that the maximum output occurs at the minimum value of the parameter selected in P2.3.1 and the minimum output occurs at the maximum value of the parameter selected in P See Figure P3.4 Iout Minimum Iout Minimum Range: ma minimum 1. 4 ma minimum Sets the signal minimum to either 0 ma or 4 ma. Default: 0

79 Page 77 STANDARD APPLICATION HV9000 Parameter Group 3: Output Signals (continued) P3.5 Iout Scale Iout Scale Range: Units: Percent Default: 100 Signal Max. value of signal Motor frequency 2 x P1.12 Motor speed 2 x P1.13 Motor current 2 x P1.14 Motor voltage P1.11 DC-Bus voltage 1000 V P3.6 DO1 Content P3.7 RO1 Content P3.8 RO2 Content Scaling factor for the analog output signal. Digital Output DO1 Content Range: = Ready 2 = Run 3 = Fault 4 = Fault invert 5 = Auto 6 = Hand 7 = Off 8 = Loss of follower 9 = Overheat warning 10 = Smoke purge 11 = PM setback 12 = External interlock 13 = Speed supervision 14 = I/O control 15 = At speed DO1 sinks current when the selected function occurs. Relay Output RO1 Content Range: 1 15 Same as P3.6, except 9 = Warning active. Relay RO1 activates when the selected function occurs. Relay Output RO2 Content Range: 1 15 Same as P3.6, except 9 = Jog speed selected Relay RO2 activates when the selected function occurs. Figure Iout Scale Default: 1 = Ready Default: 2 = Run Default: 3 = Fault

80 Page 78 STANDARD APPLICATION HV9000 Parameter Group 4: Drive Control 4.1 Accel Time 2 Acceleration Time 2 Range: Units: Seconds Default: 10.0 Time required for the motor speed to change from minimum to maximum as set by parameters P1.1 and P Decel Time 2 Deceleration Time 2 Default: 10.0 Range: Units: Seconds Time required for the motor speed to change from maximum to minimum as set by parameters P1.2 and P Stop Function 4.4 Multi Step Multi Step Multi Step Multi Step Multi Step Multi Step 6 Stop Function Range: = Coasting: The motor coasts to a halt without any control from the HV9000 after the Stop command. 1. Ramping: After the Stop command, the speed of the motor is reduced according to the set deceleration parameters. If the regenerated energy is high, it may be necessary to use a braking chopper and resistor for faster deceleration. This parameter sets the stop mode for the HV9000. Multi Step 1 Speed Range: (P1.1 x P1.12) / P1.13 (P1.2 x P1.12) / P1.13 Units: Hertz Multi step speed 1. See Table Multi Step 2 Speed Range: (P1.1 x P1.12) / P1.13 (P1.2 x P1.12) / P1.13 Units: Hertz Multi step speed 2. See Table Multi Step 3 Speed Range: (P1.1 x P1.12) / P1.13 (P1.2 x P1.12) / P1.13 Units: Hertz Multi step speed 3. See Table Multi Step 4 Speed Range: (P1.1 x P1.12) / P1.13 (P1.2 x P1.12) / P1.13 Units: Hertz Multi step speed 4. See Table Multi Step 5 Speed Range: (P1.1 x P1.12) / P1.13 (P1.2 x P1.12) / P1.13 Units: Hertz Multi step speed 5. See Table Multi Step 6 Speed Range: (P1.1 x P1.12) / P1.13 (P1.2 x P1.12) / P1.13 Units: Hertz Multi step speed 6. See Table Default: 1 = Ramping Default: 5.0 Default: 10.0 Default: 20.0 Default: 30.0 Default: 40.0 Default: 50.0

81 Page 79 STANDARD APPLICATION HV9000 Parameter Group 4: Drive Control (continued) 4.10 Multi Step 7 Speed Multi Step 7 Range: (P1.1 x P1.12) / P1.13 (P1.2 x P1.12) / P1.13 Units: Hertz Multi step speed 7. See Table Default: 60.0 Speed Refere nce Multi Step Speed Select 1 DIB4 11 Multi Step Speed Select 2 DIB5-11 Multi Step Speed Select 3 DIB6-11 P P P P P P P Table Multi Step Speed Selection

82 Page 80 STANDARD APPLICATION HV9000 Parameter Group 5: Prohibit Frequencies 5.1 Skip Speed1 Low Skip Speed 1 Low Range: P1.1 P5.2 Units: Percent Default: 0.0 In some systems it may be necessary to avoid certain speeds because of mechanical resonances. Using P5.1 to P5.6 it is possible to set limits for three "skip speed" regions. See Figure Skip Speed1 High 5.3 Skip Speed2 Low 5.4 Skip Speed2 High 5.5 Skip Speed3 Low 5.6 Skip Speed1 High Skip Speed 1 High Default: 0.0 Range: P5.1 P1.2 Units: Percent 0.0 = No prohibit speed range 1 In some systems it may be necessary to avoid certain speeds because of mechanical resonances. Using P5.1 to P5.6 it is possible to set limits for three "skip speed" regions. See Figure Skip Speed 2 Low Default: 0.0 Range: P1.1 P5.4 Units: Percent In some systems it may be necessary to avoid certain speeds because of mechanical resonances. Using P5.1 to P5.6 it is possible to set limits for three "skip speed" regions. See Figure Skip Speed 2 High Default: 0.0 Range: P5.3 P1.2 Units: Percent 0.0 = No prohibit speed range 2 In some systems it may be necessary to avoid certain speeds because of mechanical resonances. Using P5.1 to P5.6 it is possible to set limits for three "skip speed" regions. See Figure Skip Speed 3 Low Default: 0.0 Range: P1.1 P5.6 Units: Percent In some systems it may be necessary to avoid certain speeds because of mechanical resonances. Using P5.1 to P5.6 it is possible to set limits for three "skip speed" regions. See Figure Skip Speed 3 High Default: 0.0 Range: P5.5 P1.2 Units: Percent 0.0 = No prohibit speed range 3 In some systems it may be necessary to avoid certain speeds because of mechanical resonances. Using P5.1 to P5.6 it is possible to set limits for three "skip speed" regions. See Figure Figure Skip Speeds Selection Example

83 Page 81 STANDARD APPLICATION HV9000 Parameter Group 6: Motor Control 6.1 Switching Freq Switching Frequency Range: Model dependant Units: kilohertz Default: 3.6 Motor noise can be minimized using a high switching frequency. Increasing the switching frequency reduces the power capacity of the HV9000. The range of this parameter and the default value depends on the size of the HV9000. See Figures and and Table for detailed information. 6.2 V/Hz Ratio Sel. 6.3 V/Hz Optim. V/Hz Ratio Selection Default: 0 Range: = Linear: The voltage to the motor changes linearly with frequency from 0 Hz to the motor nominal nameplate frequency where nominal voltage is supplied. Linear V/Hz should be used in constant torque applications. This default setting should be used if there is no special need for another setting. 1 = Squared: The voltage of the motor changes following a squared curve from 0 Hz to the motor nominal nameplate frequency where nominal voltage is supplied. The motor runs under magnetized below nominal frequency producing less torque and electromechanical noise. A squared V/Hz ratio is used in applications where the torque demand of the load is proportional to the square of the speed, e.g. in centrifugal fans and pumps. See Figure This parameter determines the method for the voltage/frequency ratio control of the HV 9000 output. V/Hz Optimization Default: 0 = None Range: = None 1 = Automatic torque boost This parameter determines if automatic torque boost is used. With automatic torque boost the voltage to the motor changes automatically which allows the motor produce sufficient torque to start and run at low frequencies. The voltage increase depends on the motor type and power. Automatic torque boost can be used in applications where the starting torque required due to high starting friction is large, e.g. in conveyors. NOTE: In high torque low speed applications - it is likely that the motor will overheat. If the motor has to run a prolonged time under these conditions, special attention must be paid to cooling the motor. Use external cooling for the motor if the temperature tends to rise too high. Figure Linear and Squared V/Hz Curves

84 Page 82 STANDARD APPLICATION HV9000 Parameter Group 7: PID Control 7.1 PI-Control Gain PID Controller Gain Range: Units: Percent Default: This parameter defines the gain of the PID controller. If the value of the parameter is set to 100%, a change of 10% in the error value causes the controller output to change by 10%. If the parameter value is set to 0, the PID controller operates as an ID-controller. See examples 1, 2, and 3 below. 7.2 PI-Contr I Time 7.3 Derivative Gain 7.4 PID Ref Acc Time 7.5 PID Ref Dec Time 7.6 PID Low Limit 7.7 PID High Limit PID Controller Integral Time Default: Range: Units: Seconds This parameter defines the integration time of the PID controller. If this parameter is set to 1.00 second, a change of 10% in the error value causes the controller output to change by 10.00%/second. If the parameter value is set to 0.00 seconds, the PID controller will operate as a PD controller. See examples 1, 2, and 3 below. PID Controller Derivative Gain Default: 0.0 Range: Units: Percent This parameter defines the derivative gain of the PID controller relating to the response to the change in the error value per second. If the parameter value is set to 0, the PID controller operates as a PIcontroller. See examples 1, 2, and 3 below. PID Reference Acceleration Time Default: 3.0 Range: Units: Seconds This parameter sets the time that the PID reference rises from 0% to 100%. PID Reference Deceleration Time Default: 3.0 Range: Units: Seconds This parameter sets the time that the PID reference falls from 100% to 0%. PID Low Limit Default: 0.00 Range: - fmax P7.7 Units: Hertz This parameter sets the minimum limit for the PID controller output. The limit setting is - fmax < P7.6< P7.7 < fmax, where fmax = (P1.2 x P1.12) / P1.13. These limits are of importance for example when you define the gains, and I-time for the PID controller. PID High Limit Default: Range: P7.6 fmax Units: Hertz This parameter sets the minimum limit for the PID controller output. The limit setting is - fmax < P7.6< P7.7 < fmax, where fmax = (P1.2 x P1.12) / P1.13. These limits are of importance for example when you define the gains, and I-time for the PID controller. 7.8 Act Value Select Actual Value Select Range: = Voltage 2 = Current 3 = Network This parameter selects the source for the actual value 1 signal. Default: 2 = Current

85 Page 83 STANDARD APPLICATION HV9000 Parameter Group 7: PID Control (continued) 7.9 Actual Value 1 Minimum Scale Act 1 Min Scale Range: Units: Percent Default: 0.00 = No minimum scaling This parameter defines the minimum scaling point for actual value 1. See Figure Act 1 Max Scale Actual Value 1 Maximum Scale Range: Units: Percent Default: = No maximum scaling This parameter defines the maximum scaling point for actual value 1. See Figure Figure Example of Actual Value 1 Signal Scaling 7.11 PID Error Invert 7.12 PID Control PID Error Value Inversion Range: = Disabled, not inverted 1 = Enabled, inverted This parameter inverts the error value of the PID controller. PID Control Range: = Disabled 1 = Enabled This parameter enables the PID controller. Default: 1 = Disabled, no inversion Default: 0.0

86 Page 84 STANDARD APPLICATION HV9000 Parameter Group 8: Protections 8.1 External Fault External Fault Range: 0 3 0=No action 1=Warning 2=Fault, stop as set by P4.3 3=Fault, coasting stop Default: 2 = Fault, stop as set by P4.3 This sets the response to an external fault signal programmed into digital input DIB4, DIB5, or DIB Reference Fault Loss of Reference Fault Range: = No action 1 = Warning 2 = Fault, stop as set by P4.3 3 = Fault, coasting stop This sets the response to a loss of reference fault. Default: 1 = Warning 8.3 Switching Freq 8.4 Foll. Loss Speed 8.5 Freq Supv Lim 1 Switching Frequency Set Default: 3.6 (Model dependant) Range: (Model dependant) Units: kilohertz Motor noise can be minimized using a high switching frequency. Increasing the switching frequency reduces the power capacity of the HV9000. The setting of this parameter depends on the size of the HV9000 and the motor load. See Figures and 5.2-3, and Table Follower Loss Speed Default: 0.0 Range: Units: Percent This parameter sets the level being supervised for loss of the speed follower signal. Below this speed, operation of digital output DO1 or relay output RO1 or RO2 will occur, dependant upon the settings of P3.6, P3.7, or P3.8. Frequency Supervision Limit 1 Default: 2 = High limit Range:0 2 0 = Not used 1 = Low limit 2 = High limit If this parameter is set for 1 or 2 and the speed goes under/over the set limit (P8.6) this function causes operation of digital output DO1 or relay output RO1 or RO2, dependant upon the settings of P3.6, P3.7, or P Speed spv Lim. Speed Supervision Limit Range: Units: Percent This parameter sets the speed level being supervised by P8.5 Default: 0.0

87 Page 85 STANDARD APPLICATION HV9000 Parameter Group 9: Auto Restart 9.1 Number of Tries! Number of Auto Restart Tries Range: 0 10 Default: 0 Defines how many times the HV9000 will try to automatically restart during the trial time set in P9.2. If the HV9000 restarts within the trial time, the count is cleared after the trial time has elapsed. If the HV9000 does not restart within the trial time, the count is reset after the HV9000 is restarted. 9.2 Trial Time! Trial Time Default: 30 Range: Units: Seconds The time interval over which the number of restart tries set by P9.1 will take place. The time begins at the first auto restart. 9.3 Start Function! Switching Frequency Set Range: = Ramping 1 = Flying start Defines the type of auto restart ramp start or flying start. Default: 0 = Ramping 9.4 Power-up restart Power-up Restart Default: 0 = Disabled Range: = Disabled 1 = Enabled If P9.4 is enabled, DIA1 is set to BAS or Network Start, and power is removed and restored, on powerup the HV9000 will return to the state that was active when the input power was disconnected. If a start command was active, the HV9000 will restart.! Only the following faults will be cleared by the Auto Restart Function. F1 Overcurrent F2 Overvoltage F9 Undervoltage F13 HV9000 Undertemperature F14 HV9000 Overtemperature

88 Page 86 STANDARD APPLICATION HV9000 Parameter Group 10: Communications 10.1 Communication Network Select Comms Select Range: = HV Basic2 1 = FLN Siemens Specifies the communication network in use. Default: 0 = HV Basic Network Address 10.3 Comms Timeout! Network Address Default: 99 Range: HV Basic 2 =???????? FLN = 0 99 Used for network address assignment when the HV9000 is networked. For FLN information see publication number TD.08H.31.T.E. The default network address for a FLN Network is 99. For HV Basic2 information, see publication number TD.???.??.T.E. The default network address for a HV Basic2 Network is??. Communication TImeout Default: 0 Range: Units: Seconds This parameter specifies the maximum time lapse between successive network communications before a fault will be generated for FLN (P1) network communications only. 0 = Disables the communication timeout - if communication is lost, no fault will be generated. The HV9000 will continue to operate based on the last received command = If communication is lost, a communication loss fault (F57) is generated, and the HV9000 will stop.! This parameter applies to FLN (P1) Network Communications only.

89 Page 87 MOTOR PROTECTION HV Motor protection functions in HVStandard operation Motor thermal protection protects the motor from overheating. In HVStandard operation, motor thermal protection uses a constant setting and will always cause a fault trip if the motor is overheated. Your HV9000 is capable of supplying higher than normal current to the motor. If the load requires this high current there is risk that the motor will be thermally overloaded. This is especially true at low frequency, as the cooling and thermal capacity of the motor are reduced. The motor thermal protection provided by the HV9000 is based on a calculated model which uses the output current of the HV9000 to determine the load on the motor. The thermal current IT shown in Figure shows the load current above which the motor is overloaded. If the motor current is above this curve, the motor s temperature is increasing. Figure Motor Thermal Current IT Curve