ALTER PWM3D-000 Manuale utente

Alter ELETTRONICA s.r.l.

15033 Casale Monferrato (AL) – ITALY

PWM3D-000

PWM3D-010

Drive 4 quadrants series PWM Digital

for asynchronous motors with transducer

Instructions

Instructions manual

manual:

: 91/104

91/104 - Version

- Version 9.2

9.2 - Date:

- Date: 26/05/2021

26/05/2021

Compatible wit Firmware V

Compatible wit Firmware V9.x

9.x

Combined wit t e drive:

Type No.: ___ / ___ ___ ___ Serial No.: ___ ___ ___ ___ ___

Instruct on manual 91/104 V9.2

General Index

1 Safety nformat on................................................................................................................................................3

1.1 Danger.........................................................................................................................................................3

1.2 Attent on.....................................................................................................................................................3

1.3 Warn ngs.....................................................................................................................................................4

1.4 D rect ves, trademarks and standards.........................................................................................................4

2 Ident f cat on of the product.................................................................................................................................5

2.1 CE mark ng and dent f cat on plate...........................................................................................................5

2.2 Declarat on of conform ty...........................................................................................................................5

2.3 Manufacturer’s declarat on.........................................................................................................................5

2.4 Model encod ng..........................................................................................................................................6

3 Techn cal character st cs.......................................................................................................................................7

3.1 General ty...................................................................................................................................................7

3.2 Techn cal data.............................................................................................................................................7

4 Installat on..........................................................................................................................................................11

4.1 Prel m nary operat ons..............................................................................................................................12

4.2 Motor w r ng.............................................................................................................................................13

4.3 Power connect ons....................................................................................................................................13

4.4 S gnal connect ons....................................................................................................................................14

4.5 Commands start ng sequence...................................................................................................................20

4.6 Commands shutdown sequence................................................................................................................20

4.7 Restart ng after an alarm...........................................................................................................................20

5 Comm ss on ng...................................................................................................................................................21

5.1 Menu structure..........................................................................................................................................21

5.2 Nav gat on n the menus...........................................................................................................................34

5.3 Descr pt on of funct ons n the menus......................................................................................................35

5.4 Cal brat on and adjustments.....................................................................................................................57

5.5 Opt onal transducers.................................................................................................................................59

5.6 Spec al funct ons.......................................................................................................................................65

6 D agnost cs.........................................................................................................................................................76

6.1 Yellow LEDs – Commands.......................................................................................................................76

6.2 Green LEDs – Internal states and outputs................................................................................................76

6.3 Red LEDs – Alarms..................................................................................................................................77

6.4 Alarm messages........................................................................................................................................77

6.5 Report ng messages..................................................................................................................................81

6.6 D agnost c menu.......................................................................................................................................83

7 Annexes..............................................................................................................................................................84

7.1 Led Summary Table..................................................................................................................................84

8 Mechan cal character st cs..................................................................................................................................85

8.1 S ze 1........................................................................................................................................................85

8.2 S ze 2........................................................................................................................................................86

8.3 S ze 3........................................................................................................................................................87

2 Alter Elettron ca s.r.l.

Instruct on manual 91/104 V9.2 Safety nformat on

1 Safety information

Read th s manual carefully before us ng the dr ves PWM3D-000.

Keep the manual carefully and n a place of easy access n order to consult t later n case of need.

Make sure th s manual s del vered to the end user.

The safety symbols used n th s manual are descr bed below:

DA GER:

Th s symbol nd cates the poss b l ty of even ser ous njur es to people, due to electr cal or mechan cal shocks.

ATTE TIO :

Th s symbol nd cates the poss b l ty of damage to property or to the dr ve tself.

WAR I GS:

Add t onal nformat on for proper use of the dr ve

1.1 Danger

•Never feed the dr ve w thout the l d and never remove the l d wh le the power supply s present.

•Do not perform man pulat ons on the dr ve w th wet hands. There s a danger of electr cal shocks.

•Ma nta n a suff c ent safety d stance from the motor and the mach ne when the network s act vated and never touch the

rotat ng parts of the motor when t s n operat on. There’s a danger of gett ng hurt.

•When resett ng alarms make sure the dr v ng s gnal s d sabled to avo d unexpected motor departures. Set up a separate

emergency stop dev ce. There’s a danger of gett ng hurt.

•Before start ng w r ng make sure that there s no power supply and that the motor s st ll.

•All power sources must be d sconnected before any ma ntenance s carr ed out.

•Before start ng nspect on, please wa t at least 2 m nutes after sw tch ng off voltage, make sure the LEDs and LCD d splay

are sw tched off

•Ma ntenance, nspect on and replacement shall be carr ed out by a des gnated person. Remove all metal accessor es such as

watches, bracelets etc before start ng work.

•Make sure that the power supply voltage of the dr ve matches the l cense plate data.

1.2 Attention

•To comply w th the regulat ons on electr cal safety, make mass connect ons accord ng to the standards of the country where

the dr ve s nstalled.

•The nstallat on must be carr ed out by qual f ed techn cal personnel.

•Always f x the dr ve before w r ng.

•Install a protect ve c rcu t (fuse or magnet c sw tch) on the dr ve power supply.

•Do not connect a power source to term nals A, B, C.

•Make sure that the power supply voltage of the dr ve matches the l cense plate data.

•Attach the clamp screws w th an appropr ate t ghten ng torque.

•Properly connect w res A, B, C. The motor may not start or rotate abnormally and damage the mach ne.

•If there s no power supply to the dr ve, do not connect the motor cable f t s n rotat on. There s a danger of damag ng the

car.

•Do not occlude the dr ve vent lat on slots.

•Ensure the motor’s funct onal ty as a s ngle un t before mechan cally attach ng t to the mach ne and ver fy that the

max mum motor speeds are tolerated by the mach ne. There s a danger of njury and damage to the car.

•Never change the dr ve.

Alter Elettron ca s.r.l. 3

Safety nformat on Instruct on manual 91/104 V9.2

•Clean the dr ve w th a vacuum cleaner. Do not use organ c solvents. There s a danger of damag ng the dr ve.

•It s essent al for your safety that any rev s on of the dr ve s carr ed out by our company.

•In case of d sposal, the dr ve must be cons dered an ndustr al waste, therefore comply w th the rules mposed by the laws n

force n the country n wh ch t s nstalled.

1.3 Warnings

•Ma ntenance shall be carr ed out by qual f ed techn cal personnel.

•The ground connect on and nstallat on of the dr ve must be carr ed out n accordance w th the secur ty rules mposed by the

laws n force n the country where the dr ve s nstalled.

•Appropr ate preparat on must be g ven to operators and mach ne operators.

•The dr ve can cause rad o frequency nterference f t lacks the appropr ate network f lter.

•Follow the spec f cat ons of the dr ve and follow the nstruct ons n th s manual.

•Ensure that adequate vent lat on and clean ng of the dr ve s ma nta ned.

•Avo d penetrat on of water or other flu ds ns de the dr ve.

•For w r ng use appropr ate cables, poss bly sh elded.

1.4 Directives, trademarks and standards

The dr ve PWM3D-000 compl es w th the follow ng ndustr al standards:

Standard/Marking Description

CEI E 60204-1 Low voltage safety d rect ve, 73/23/EEC.

CEI E 61800-3 Product standard related to EMC D rect ve 89/336/EEC.

CEI E 60529 Degree of protect on IP20.

CE CE mark ng.

4 Alter Elettron ca s.r.l.

Instruct on manual 91/104 V9.2 Ident f cat on of the product

2 Identification of t e product

2.1 CE marking and identification plate

The CE mark ng shall attest to the conform ty of the apparatus w th the essent al health and safety requ rements la d down n the

European D rect ves set out n the EC declarat on of conform ty. It cons sts of a s lver polyester adhes ve label w th a black pr nt, of

the follow ng d mens ons: L= 95 mm – H= 50 mm (F gure 1).

It s appl ed externally at the bottom (cons der ng vert cal panel mount ng).

The follow ng data are nd cated n a leg ble and ndel ble way on the plate:

1) Techn cal data supply serv ces.

2) Frequency range three-phase/mono-phase nput voltage.

3) Three-phase/mono-phase nput supply voltage.

4) Max mum current requ red (peak) from the three-phase

nput.

5) Dr ve type.

6) Dr ve model (see encod ng table on page 6).

7) Ser al number (un versal for each type of dr ve).

8) F rmware vers on of the product.

9) Max mum voltage output dr ve.

10) Max mum current (peak) d spensable from the dr ve.

2.2 Declaration of conformity

The ALTER Elettronica S.r.l. declares that, n the cond t ons spec f ed n th s document, the dr ves (CDM) model " PWM3D-000“, are

n conform ty w th the Commun ty d rect ves EMC, nclud ng the latest amendments, w th the relat ve Ital an transpos t on leg slat on

and the Commun ty d rect ves Low Voltage, nclud ng the latest amendments, w th the relevant Ital an transpos t on leg slat on.

Therefore, the CE mark ng, aff xed to dr ves (CDM) model "PWM3D-000“, cert f es compl ance w th both the EMC D rect ve and

the Low Voltage D rect ve.

2.3 Manufacturer’s declaration

The ALTER Elettronica S.r.l. for the purposes of the Mach nery D rect ve (DM) 89/392 and subsequent amendments, w th the relevant

Ital an leg slat on transpos ng D.P.R. 459 of 1996-07-24, declares that the model dr ves "PWM3D-000“ must be nstalled accord ng to

the nstruct ons conta ned n th s manual and shall not be put nto operat on unt l the mach nes n wh ch they are ncorporated have

been declared to comply w th the DM D rect ve ment oned here n.

Alter Elettron ca s.r.l. 5

Figure 1: Identification plate

Ident f cat on of the product Instruct on manual 91/104 V9.2

2.4 Model encoding

The follow ng tables nd cate the encod ng method for order ng a model dr ve: PWM3D-000

Drive model Options Maximum voltage

output

Current service

continuous output

PWM3D- x x x xxx xxx

010= 10Arms

016=16Arms

021= 21Arms

026=26Arms

036= 36Arms

044= 44Arms

056= 56Arms

070= 70Arms

087=87Arms

095= 95Arms

111= 111Arms

130= 130Arms

200 = 200Arms

440 = 440Vac

480 = 480Vac

000 = General asynchronous motor control.

010 = General asynchronous motor control (supply only by DC-BUS nput).

PWM3D = PWM dr ve, 3rd ser es, D g tal

Table 1: model encod ng

NOTE: the maximum output voltage is attaina le as long as you have at least the same input voltage value on the terminals L1,

L2, L3 or the voltage on the DC BUS = 1.41 x output voltage.

6 Alter Elettron ca s.r.l.

Instruct on manual 91/104 V9.2 Techn cal character st cs

3 Tec nical c aracteristics

3.1 Generality

These dr ves are des gned to power and control the operat on of asynchronous motors w th transducer.

The IGBT br dge s nserted ns de the case.

Energy recovery takes place on nternally (or externally) mounted clamp res stance.

All control and control c rcu ts are d g tal and completely nsulated from power.

D g tal nputs and outputs are stat c and opto- solated.

W th an external control t s poss ble to nsert an accelerat on and decelerat on ramp on the speed reference.

Accelerat on and decelerat on t mes are adjustable.

The current l m t s set nternally n a f xed way.

The I/O connectors are mounted on a fully access ble board to fac l tate connect ons.

These dr ves are su table for the control of the motors used n mach ne tools, graph cs, belt movement, etc. and n all those appl ca -

t ons where t needs great flex b l ty of operat on.

3.2 Tec nical data

Use the follow ng table to know the techn cal character st cs of the var ous models identified by the continuous service output cur-

rent; See the encod ng table n Chapter 2.4 on page 6 to match the current w th the order code.

DRIVE ACCESSORIES CO ECTIO S

OUTPUT

CURRE T (Arms)

SIZE

POWER

RESIST.

I TER AL

CLAMP

(W)

CODE

EXTER AL CLAMP

RESISTOR

THREE-PHASE

FILTER

THREE-PHASE

I DUCTA CE

FUSES O

L1-L2-L3 or

DC+ DC-

MAXIMUM SECTIO OF

CABLES

[mm²]

[1] [4]

CO T.

OM.

PEAK

Inom

(A)

Max.

I2tat10ms

(A2s)

L1 L2 L3

A B C

Rest+

R-

X3 X6 X7

X9 X10

X11 X12

[2] [3]

10 6 12 1 150 RES32R1KW5 23/020 17/001 16 684 2,5 2,5 1,5

16 10 20 1 150 RES32R1KW5 23/020 17/001 25 684 4 2,5 1,5

21 13 26 1 150 RES20R900W10 23/003 17/001 32 684 6 2,5 1,5

26 17 34 1 150 RES20R900W10 23/003 17/003 40 2400 6 2,5 1,5

36 22 44 2 300 RES8R4KW5 23/003 17/003 50 8000 10 10 1,5

44 26 52 2 300 RES8R4KW5 23/004 17/003 63 8000 16 10 1,5

56 32 64 2 300 RES8R4KW5 23/004 17/003 100 8000 16 10 1,5

70 43 86 2 300 RES8R4KW5 23/005 17/004 100 18000 25 10 1,5

87 53 106 2 300 RES8R4KW5 23/005 17/005 160 18000 25 10 1,5

95 64 128 2 - RES3R38KW10 23/007 17/007 160 18000 50 10 1,5

111 75 150 2 - RES3R38KW10 23/007 17/007 200 51000 50 10 1,5

130 90 180 2 - RES3R38KW10 23/007 17/008 250 125000 50 10 1,5

200 200 200 3 - RES3R38KW10 23/008 17/008 250 125000 50 10 1,5

Table 2: Data for the s z ng of dr ves

OTES:

[1] W th temperature ns de the panel where the dr ve from 0 to 40 °C s mounted. Current reduct on of 4 % for each °C above

40 °C. Mean ng of the output current:

•Continuous service: The dr ve can d spense th s current w th nf n te t me, but the ava lab l ty of the peak s not

guaranteed, depend ng on the temperature of the heat s nk.

•Rated: The dr ve can d spense th s current w th nf n te t me also hav ng the peak current ava lable n case of need.

•Peak: The dr ve can d spense th s current for a t me that depends on the temperature of the heat s nk, so also the n-

com ng a r, but t s at least 30 seconds.

[2] D mens ons and masses on page 63 and page 68.

[3] The f lter shall be mounted when the PWM3D dr ves are used n F rst Amb ent, to meet the EMC compat b l ty requ re-

ments.

Alter Elettron ca s.r.l. 7

Techn cal character st cs Instruct on manual 91/104 V9.2

[4] Only ultra-fast protect ve fuses (for semiconductor protection) are essential for three -phase or DC BUS nputs. Other

fuses do not prov de a suff c ent degree of protect on and therefore, n case of fa lure, the dr ve can be severely damaged.

3.2.1 Apparent power and absorbed current

To s ze the transformer/self-transformer, nductance and EMC f lter, t s necessary to calculate the apparent power requ red by the

dr ves connected to the supply l ne by follow ng these po nts:

1. Calculate power from motor to load:

Pm=C⋅

Pm= motor power [W]

C = Torque dispensed [Nm]

Ω = Maximum using speed [rad/sec]

If you do not know the usage data, cons der the plate data of the motor.

The follow ng convers on formulas must be used w th other Un ts of measure:

C[Nm]=C[Kgm]⋅9,81

ω[rad /sec]= n[giri /min]

9,55

2. Calculate the power requ red by each dr ve:

Pc=Pm

⋅1,5

Pm= motor power [W]

Pc= Power a sor ed y the drive [VA]

and calculate the total power as the sum of the power absorbed by the nd v dual dr ves:

Pt=Pc1Pc2Pc3....

Pc= Power a sor ed y a drive [VA]

Pt= Total power a sor ed y drives [VA]

3. The apparent power and total current requ red shall be calculated us ng the follow ng formulae:

Pa=Pt⋅1,73



d2

Pa= Apparent power delivered y the transformer/autotransformer [VA].

Pt= Total power drives [VA].

d = Total num er of drives connected to the same power supply.

Iu= Current to e used to size the line inductor and the filter EMC [A].

Va= Power supply voltage of the drives [V].

Iu=Pa

1,73⋅Va

The apparent power and current value thus calculated are val d only f the motors always work under the cond t ons cons dered n the

calculat ons. dur ng normal operat on there are var at ons n torque and speed lead ng to s gn f cant reduct ons n the average values of

apparent power and current. To have more exact values t s necessary to know the actual cond t ons of use of all motors.

Contact the ALTER Techn cal Off ce to exam ne spec al cases.

3.2.2 Current absorbed wit DC-BUS power supply

To s ze the power supply supply supply voltage to the DC-BUS t s necessary to calculate the total current requ red by the dr ves con-

nected to the power supply tself w th the follow ng formula:

It=Pt

Vdc

Pt= Total power drives [VA]

Vdc= DC-BUS power supply voltage [V]

It= Total current required y drives [A]

The total power of the dr ves can be calculated us ng the formulas of paragraph above “Apparent power and absorbed current”. The

power supply voltage on the DC-BUS depends on the power supply used, but when us ng the PSR3 model th s value s 650Vcc.

3.2.3 General tec nical c aracteristics

–Execut on for f x ng on panel. Degree of protect on IP20.

–Amb ent operat ng temperature: from 0 °C to +40 °C.

–Storage temperature: from -10 °C to +70 °C

–Relat ve hum d ty max.: 95 % w thout condensat on.

–Max mum alt tude: 1000 m. a.s.l.

–S ngle-phase serv ce supply: 230Va.c. ±10 % – 500mA max (protect on w th external retarded fuses 250V – 1A).

–Power supply: from a m n mum of 60V to a max mum nd cated on the dr ve plate. (protect w th external fuses as show n

table 7 at page 7.

–Frequency of supply: 50/60Hz.

–Output current: As from table 2 at page 7.

8 Alter Elettron ca s.r.l.

Instruct on manual 91/104 V9.2 Techn cal character st cs

–Max. d ss pated power: 10 x Output Current.

–Thermal t me constant: 15’

–Cont nuous power d ss pated by nternal clamp res stance: As from table 2 at page 7.

–Res stance of nternal or external clamps (ava lable separately).

–Connect ng term nals to the D.C. BUS.

–Galvan c solat on between power and control electron cs.

–Over-voltage protect on on:

–S gnal nputs and outputs.

–Serv ce and power suppl es.

–Frequency of "sw tch ng“: 16KHz.

–M n mum value of the electr c t me constant of the motor: 1 msec. To calculate th s value, see the formula n paragraph

"Motor w r ng“ on page 13.

–Connect ons:

–Power on connectors (S ze 1) or term nal block (S ze 2).

–Serv ce and s gnals on connectors.

–Use w th asynchronous motors equ pped w th one of the follow ng dev ces:

–Incremental encoder (5V l ne dr ver).

–Resolver [opt onal card].

–S nuso dal encoder (S n-Cos outputs l ne dr ver 5V) [opt onal card].

–Phon c wheel [opt onal card].

–EnDat encoder [opt onal card].

–Any other transducers upon request [opt onal card].

–Emulated encoder output.

–Ramp on the speed s gnal adjustable between 0.1Sec and 650 sec ( nsert w th log cal control).

–Opto- solated log cal nputs (command from 15 to 30Vcc – 10mA max):

–Enable dr ve.

–Speed ramp rat ng.

–Alarm reset command.

–4 programmable nputs.

–Opto- solated log c outputs (24Vc. – 100mA max) protected aga nst overload and short c rcu t:

–Report no alarms.

–Converter ready.

–No. 4 programmable outputs.

–Analog nputs (max mum d fferent al voltage and common mode 10V).

–N°1 d fferent al nput w th resolut on of 15 b t + s gn, nput res stance: 10KW, programmable.

–N°3 nputs w th resolut on of 11 b t + s gn, nput res stance: 70KW, programmable.

–Analog outputs (±10V max. – output res stance 1KW):

–No. 4 programmable outputs.

–Power outputs:

–+24V ±20 % – 100mA max.

–+10V ±5 % – 5mA max.

–-10V ±5 % – 5mA max.

–Input for the thermal probe (PTC or N.C. contact) mounted n the motor.

–Input for the thermal probe (PTC or N.C. contact) mounted on the external brak ng res stance group.

–LED d splay of operat on status.

–16-character LCD d splay on 2 l nes for parameter sett ng and d agnost cs.

–Automat c lock ng of the dr ve for:

–Internal power supply s m ss ng or nsuff c ent.

–Insuff c ent or excess ve power supply (three-phase or DC-Bus).

–motor not connected or ncorrectly connected.

–Over-temperature of the dr ve.

–Over-temperature of capac tors on the DC-BUS.

–Over-temperature of the motor.

–Converter overload.

–Over-current n the dr ve.

–Transducer fa lure mounted on the motor.

–Fa lure or overload n the recovery c rcu t on res stance.

–Fa lure n the dr ve.

–Overload or short c rcu t of d g tal outputs.

–Wrong sett ngs.

Alter Elettron ca s.r.l. 9

Techn cal character st cs  Instruct on manual 91/104 V9.2
3.2.4   Power supplies
3.2.4.1   NOTE
Any d fferent al sw tches placed to protect dr ves shall have type B  ntervent on character st cs ( n accordance w th the second amend-
ment to IEC 755).
3.2.4.2   SERVICES
Power supply: s ngle-phase 230Va.c. ±10 % – 500mA max. (term nals: 230V)
M n mum sect on of connect ng cables: 1,5 mm²
Protect the supply w th no.2 delayed fuses w th a rated current 1A.
3.2.4.3   POWER
The power supply of the PWM3D-000 drive can be suppl ed  n the follow ng ways:
•A   three-phase   ground   neutral   network   w th   a   cha ned   voltage   w th n   the   l m ts   nd cated   on   the   dr ve   plate   (see
"Ident f cat on plate on page 5. Insert between the three-phase network and the dr ve a three-phase  nductance of at least 100
uH s zed for the current absorbed by the dr ve and hav ng a saturat on current equal to at least tw ce the rated current (see
Draw ng 1 on page 11.
•From a transformer w th connect ons /  and centre star on the ground or a self-transformer (/) to adapt the ma ns
voltage.
•From a D.C. l ne (see Draw ng 2 to page 12.
•Only for the dr ve S ze 1   : From a s ngle-phase network w th voltage w th n the l m ts  nd cated on the dr ve plate (see
"Ident f cat on plate“ on page  5). Insert between the s ngle-phase network and the dr ve an  nductance of at least 100  uH
s zed for the current absorbed by the dr ve and hav ng a saturat on current of at least tw ce the rated current (see Draw ng 1
on page 11).
The power supply of the PWM3D-010 drive can only be suppl ed  n the follow ng way:
•From a D.C. l ne (see Draw ng 2 to page 12).
Always protect your feed ng w th ultra-fast fuses as shown  n table 2 on page 7.
10  Alter Elettron ca s.r.l.