VECTOR CONTROL

INVERTERS SERIES 8V

User's Manual
General Part
 Document No. MPE1 8VIIIIII
Floppy Disk No. 4
Revision 0
Date 22/09/1997
Page 2 of 48

VECTOR CONTROL
INVERTER SERIES 8V

User's Manual
General Part

Name Signature Date

Prepared by I. CERA 22/09/1997

Approved by A. FORNASA 22/09/1997

E.E.I. S.r.l. Vicenza 22/09/1997 MPE1 8VIIIIII

SAFETY WARNINGS

WARNINGS

• ONLY SKILLED (EN60204-1, 3.58) OR INSTRUCTED (EN60204-

1, 3.31) PERSONS ARE ENTRUSTED TO INSTALL, SET UP,
USE, AND SERVICE THIS INVERTER.
• E.E.I. S.r.l. DOES NOT ACCEPT ANY RESPONSIBILITY BY
INADEQUATE OR WRONG INSTALLATION, SET UP, USE, OR
SERVICE OF THIS INVERTER.
• THE VOLTAGES ON BARE PARTS OF THE INVERTER MAY
CAUSE LETHAL SHOCK.
• THE INVERTER MAY HAVE ROTATING PARTS (FAN).

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This document, together with its attachments, is property of E.E.I. S.r.l. All rights are
reserved. Full or partial reproduction is forbidden.

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TABLE OF CONTENTS

SAFETY WARNINGS.................................................................................................. IV

Chapter 1 GENERAL DESCRIPTION

1.1 GENERAL ......................................................................................................... 1-2
1.2 MAIN FEATURES ............................................................................................. 1-2
1.3 APPLICATIONS ................................................................................................ 1-3
1.4 GENERALITIES ABOUT VECTOR CONTROL ................................................. 1-4

Chapter 2 TECHNICAL SPECIFICATIONS

2.1 TECHNICAL SPECIFICATIONS OF INVERTERS SERIES 8V ......................... 2-2
TABLE 2.1: INVERTERS SERIES 8V.......................................... 2-2
2.2 EMPLOYMENT LIMITS ..................................................................................... 2-3
TABLE 2.2: EMPLOYMENT LIMITS ............................................ 2-3
2.3 MECHANICAL DETAILS ................................................................................... 2-4
TABLE 2.3: SHAPES AND DIMENSIONS ................................... 2-5
2.4 CONTROL BOARD LAYOUT ............................................................................ 2-7

Chapter 3 POWER CONNECTIONS

3.1 SAFETY WARNINGS........................................................................................ 3-2
3.2 POWER CONNECTIONS FOR INVERTERS SERIES 8V ................................ 3-3
TABLE 3.1: FUSES AND POWER CABLE CROSS-SECTIONS. 3-4

Chapter 4 MAN-MACHINE INTERFACES

4.1 GENERAL ......................................................................................................... 4-2
4.2 PORTABLE PROGRAMMING UNIT ................................................................. 4-3
4.3 PC-COMPATIBLE PROGRAMMING SOFTWARE ........................................... 4-3
4.4 E.E.I. VIDEOKEYBOARD ................................................................................. 4-4
4.5 LOCAL SUPERVISOR WITH PC ...................................................................... 4-4
4.6 REMOTE SUPERVISOR WITH PC................................................................... 4-5

Chapter 5 PROTECTIONS
5.1 PROGRAMMABLE PROTECTIONS ................................................................. 5-2
5.2 NON-PROGRAMMABLE PROTECTIONS ........................................................ 5-3

Chapter 6 SERVICING
6.1 INSTALLATION OF NEW APPLICATIONS....................................................... 6-2
6.2 CONTROL CARD REPLACEMENT .................................................................. 6-3
6.3 MAINTENANCE ................................................................................................ 6-4

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App. A CONNECTION AND WIRING SCHEMES

FIG. A1: EXTERNAL WIRING AND BLOCK DIAGRAM .................................. A-2
FIG. A2: INTERNAL CONNECTIONS MOD. 8V003021.................................. A-3
FIG. A3: INTERNAL CONNECTIONS MOD. 8V003051.................................. A-4
FIG. A4: INTERNAL CONNECTIONS MOD. 8V203360-8V203500................. A-5
FIG. A5: INTERNAL CONNECTIONS MOD. 8V313750-8V313100................. A-6
FIG. A6: INTERNAL CONNECTIONS MOD. 8V403120-8V513150-8V513200A-7
FIG. A7: INTERNAL CONNECTIONS MOD. 8V613300 .................................. A-8
FIG. A8: INTERNAL CONNECTIONS MOD. 8V703600 .................................. A-9

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chapter 1

GENERAL DESCRIPTION

1.1 GENERAL .........................................................................................................1-2

1.2 MAIN FEATURES..............................................................................................1-2
1.3 APPLICATIONS.................................................................................................1-3
1.4 GENERALITIES ABOUT VECTOR CONTROL .................................................1-4

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1.1 GENERAL

The EEI inverters series 8V allow an efficient employment of three-phase motors (1

÷ 450 kW, 2 ÷ 8 poles) for four-quadrant drives, with a good uniformity of motor rotation
and low noise.

According to choice, two control techniques are available:

• Sensorless frequency/voltage control: open loop cotrol of asynchronous motors
without encoder or rotor position sensors.
• Field oriented control with position & speed feedback from incremental encoder. The
performance of these AC drives becomes comparable to that of DC drives: high
static precision and dynamic response of speed and torque (also at zero speed and
at strong load variations), use of AC motors at constant torque or at constant
torque/power.

A 16 bit microcontroller manages the main controls through numeric processings of

analog and digital signals. Specific programs are available for several applications
(others are made on request). A high number and variety of internal functions,
parameters and auxiliary inputs/outputs characterises all program versions.
Their flexibility allows to program and control many functions and control types, self-
diagnosis, running and working. Power and versatility of the internal functions make
unnecessary hardware variants and external circuitries allowing either single or multiple
motor machine control.
Serial communication RS 485 allows data storage and parameters adjustment from
external units even during running, and a complete visualization and a fast setting from
operator.
Connection with a bus CAN (Controller Area Network) allows to realise multi-drive
configurable architectures, with high-speed digital transmission of references, signals,
commands, etc.

1.2 MAIN FEATURES

• Power circuit with IGBTs (insulated gate bipolar transistors), electrolytic capacitors
with life-time longer than 50000 hours, low inductance connections.
• PWM modulation with 5 kHz frequency.
• Field oriented control with position and speed feedback from encoder, employment
of Hall effect current sensors, Gate Arrays and hybrid circuits.
• 16 bit microcontroller for general management of drive controls, alarms, diagnostic,
digital and analog I/O signals.
• Several auxiliary configurable digital I/Os, all with optical isolation.
• Several auxiliary configurable analog I/Os, some differential, others in frequency for
position control.
• Application program resident in Flash memory programmable via serial line. Either
standard or specific programs for several applications are available. Dedicated
programs may be developed on request.
• Auxiliary serial multiplexed output for alarm or data transmission.
• Local signalling with two 7-segment displays and 16 LEDs.
• Serial line RS485 for communication with host PC or EEI videokeyboard that allow:

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- Displaying accurate diagnostic information

- Setting parameters and their immediate reading, tuning, restoring after control
card replacement
- As option, communication with a plant Host Computer provided with Modem for
telediagnosis and teleservice.
• CAN bus (Controller Area Network) for digital high-speed transmission of
references, signals, commands, etc.
• Optional interface unit for serial communication based on PROFIBUS standard.
• Single DC link for multi-inverter feeding. At this purpose, a large range of AC/DC
converters for 380-415V AC line are available:
- Non-regenerative with braking resistor
- Regenerative with braking energy recovered into mains and sinusoidal current
absorption (reactive power and harmonic currents nearly zero).
• 24 Vdc independent auxiliary supply.
• Control circuits isolated from power circuits and auxiliary 24 Vdc supply (internal
switching power supply).

1.3 APPLICATIONS

The inverters series 8V are dedicated for industrial applications requiring good static
and dynamic performances and independent or combined controls of speed,
acceleration, torque, space, and eventual. They allow:

• Auxiliary transducers management (encoders, dancer arms, force sensors)

• Choice of several control and running modes (jog, slow and fast run, etc.)
• Production parameters and data storage.

Typical application areas are:

• Single drives, with PID speed regulation, several internal or external speed
references, rounded programmable ramps of acceleration, deceleration, normal and
quick stop.
• Multi-drive machines, with internal management of functions as:
− Diameter or pull controls for pay-off/take-up
− Pull and/or stretching controls
− Space controls: positioners and trackings
− Controls with absolute electric shaft or with programmable numeric ratio,
changeable via serial line.

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1.4 GENERALITIES ABOUT VECTOR CONTROL

The solidity and reliability of the asynchronous motor, its low cost and no
maintenance need, surely account for the success and broad diffusion of this motor in
industrial applications. But we do not forgive that all this it has made possible by the
technological development reached in static conversion field, and in particular by the
vector control inverter.
In industrial automation applications, either realised with DC motors or AC motors,
the regulation system of the converter carries out the comparison between a speed
reference and the actual motor speed detected by suitable transducer. The result of this
comparison is then corrected by a cascade of a speed regulator and a torque regulator.
The latter gives out a torque demand so to make zero the difference between the wanted
speed and the actual speed.
From those simple and short considerations, it is easy understanding that the faster
a regulation system gives out a torque demand as a consequence of an input speed
error, the better is such a regulation system.
In a DC motor the torque is proportional to the armature current and thus it can be
rapidly varied, when thyristor drives are employed, by increasing or decreasing the firing
delay angle of thyristors. Consequently, the dynamic features of these drives are very
good.
Instead, in an asynchronous motor, the torque is not connected with a directly
controllable quantity; in fact, it depends on the slip frequency (difference between the
stator voltage frequency and the rotor rotational frequency).
By means of traditional inverters it is possible varying amplitude and frequency of
the AC voltage output.
But acting on the voltage frequency in order to vary the slip frequency, and thus
indirectly the torque, surely implies electrical transients on the motor that force not very
quick variations of frequency. This explains the poor dynamic performances of the
inverters with this type of control.
On the contrary, by means of vector control inverters it is possible to act on
quantities that directly affect the delivered torque.
The stator currents may be decomposed in two vectorial components: one called Id
(direct component) displaced according to the direction of the rotor magnetic flux, the
other one called Iq (component in quadrature) perpendicular to Id. The component Id is
proportional to the magnetic field, Iq is proportional to the torque.
The control of an asynchronous motor becomes then similar to that of a DC motor:
Id corresponds to the field current and Iq to the armature current.
The EEI vector control inverter gains advantage from this method by adopting an
indirect control (the amount of slip is forced) with impressed voltage.
The dynamic performances obtained reach and overcome the performances given
by a DC drive.


The EEI vector control inverters Series 8V are designed to be fed by an external DC
line, instead of to be provided with an internal rectifier.
Such a solution allows to supply with a single apparatus several inverters or
choppers (DC/DC converters), to install a centralised system for braking energy
dissipation, and the exchange of energy between braking and accelerating drives, with
consequent saving of energy absorbed from mains.

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DC feeding is thus supplied by a suitable converter that rectifies the mains voltage.
Different converters may be employed, according to the power required and other
particular requirements.
For instance, EEI produce special converters and automatic systems for filtering and
compensation of reactive power, in applications in which it is necessary to improve the
power factor and/or limit the harmonic distortion produced by the conversion systems.
The standard solution is a half-controlled non-regenerative AC/DC converter: it
gradually charges the filtering capacitors of the inverters during starting phase and
becomes a simple rectifier, thus with a high power factor, in steady state operation.

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chapter 2

TECHNICAL SPECIFICATIONS

2.1 TECHNICAL SPECIFICATIONS OF INVERTERS SERIES 8V..........................2-2

TABLE 2.1: INVERTERS SERIES 8V ..........................................2-2
2.2 EMPLOYMENT LIMITS .....................................................................................2-3
TABLE 2.2: EMPLOYMENT LIMITS ............................................2-3
2.3 MECHANICAL DETAILS ...................................................................................2-4
TABLE 2.3: SHAPES AND DIMENSIONS ...................................2-5
2.4 CONTROL BOARD LAYOUT ............................................................................2-7

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2.1 TECHNICAL SPECIFICATIONS OF INVERTERS SERIES 8V

TABLE 2.1: INVERTERS SERIES 8V

CODE kW kVA Ica [A] Icc [A] W diss Modulo LxHxP (mm)
(1) (2) (3) (4) (5) (6) (7)
8V0nu02l 1 1.5 2.5 2.4 35 M0 225x340x255
8V0nu05l 2 3 5 4.8 68 M0 225x340x255
8V0nu07l 3 4.5 7.5 7.3 100 M0 225x340x255
8V0nu12l 5 7.5 12.5 12 140 M0 225x340x255
8V1nu25l 10 15 25 25 260 M1 225x340x255
8V2nu36l 16 22.5 37.5 37 410 M2 225x450x255
8V2nu50l 22 30 50 49 650 M2 225x450x255
8V3nu75l 35 45 75 76 850 M3 225x560x255
8V3nu10l 48 60 100 102 950 M3 225x560x255
8V4nu12l 60 75 125 128 990 M4 225x660x255
8V5nu15l 75 90 150 156 1230 M5 225x750x285
8V5nu20l 100 120 200 208 1650 M5 225x750x285
8V6nu30l 150 180 300 311 2540 M6 305x775x285
8V7nu60l 300 360 600 641 5000 M7 605x850x285
8V8nu75l 400 500 750 866 6850 M8 605x1025x285
n Inverter version code
u Input voltage code
l Regulation card code

NOTES
• The converters are designed for a continuous use with an unity utilisation
factor, in the conditions indicated in table 2.1 and 2.2. Other conditions are
indicated in IEC EN 60204-1.
• The values shown in columns 1 (mechanical power at motor shaft), 2 (motor
total input power), 4 (DC current absorbed by the inverter) are indicatives
and they refer to the following rated conditions:
- Supply voltage: 500 Vdc (from 380 Vac line)
- Output three-phase voltage: 350 Vac - 50 Hz
- 4-pole three-phase asynchronous motor, with typical efficiency and power
factor, running at rated speed, with Iac current indicated in column 3.
• Column 3 (Iac) shows the rms rated output current of the inverter, in
Amperes; column 4 (W diss) indicates the power dissipated by the inverter,
in Watts, at current Iac and Vac = 350 V - 50 Hz.
• Columns 6 and 7 indicate shape and dimensions, in mm, shown in details on
tables 2.3.
• For altitudes above 1000 m up to a maximum 4000 m derate current Iac
indicated by 1% per 100 m.
• The EEI are at Customer's disposal for advising the choice of inverter-motor
configurations and control techniques tailored on the specific application.

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2.2 EMPLOYMENT LIMITS

TABLE 2.2: EMPLOYMENT LIMITS

Quantity Unit MIN MAX

DC supply voltage (Vdc) Vdc 650
DC line current ripple (1) % 30
AC output voltage (2) Vac 0 455
Output frequency Hz 0 150
Capacitors life (3) h 50000
Transient overload % 125
Auxiliaries 24 Vdc voltage Vdc 20 28
Operating temperature °C 0 +50
Storage temperature °C -25 +70
Altitude m 1000
Relative humidity (non-condensing) % 95
Vibrations g 0.2

NOTES

• The DC line power supply must produce a rms ripple small than 30% of Idc current
indicated in table 2.1.

• The maximum output voltage (Vac max) depends on the available DC voltage Vdc:
Vacmax = 0.7 x Vdc

• The life-time of uncharged capacitors is at least 10 years at 40 °C ambient

temperature. It is recommended to replace capacitors before the indicated terms.

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2.3 MECHANICAL DETAILS

• Constructive shapes and dimensions of the inverters series 8V are indicated in table
2.1 and, with more details, in table 2.3.

• Assembly on onboard panel with screws M6.

• Plate 20/10 enclosure epoxy painted; anodized aluminium external heat-sinks.

• Models with natural ventilation, with radial or axial fans (see table 2.3).

• Easy accessibility and maintenance: complete front-door opening for access to

interface and power internal circuitries, external control circuitries.

• Connections by connectors for a rapid replacement of control and interface circuitries.

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TABLE 2.3: SHAPES AND DIMENSIONS

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NOTES

• All dimensions are indicated in mm

• Symbol * indicates interaxial clamp, with screw M6
• Power terminals are indicated with letters/symbols R, S, T, +, -
• Ground terminal is indicated with the proper symbol
• Control terminals and serial line socket are respectively indicated with letters
F and L
• Fans power supply:
- Module M1: 24 Vdc, 2.5 W (internal supply)
- Module M2: 24 Vdc, 4.5 W (internal supply)
- Modules M3 and M4: 24 Vdc, 12 W (auxiliary supply line)
- Modules M5 and M6: 380Vac, 350W (external supply line)
- Module M7: 380Vac, 2x350W (external supply line).

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2.4 CONTROL BOARD LAYOUT

The following figures show the layout of the mains components on the control board
R03 and R06, respectively.

figure 2.1

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figure 2.2

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chapter 3

POWER CONNECTIONS

3.1 SAFETY WARNINGS ........................................................................................3-2

3.2 POWER CONNECTIONS FOR INVERTERS SERIES 8V.................................3-3
TABLE 3.1: FUSES AND POWER CABLE CROSS-SECTIONS .3-4

NOTE

In the present manual, only power wiring of inverter is described.

Control wiring, since dependent on kind of application installed
onboard, is treated in the manual of application.

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3.1 SAFETY WARNINGS

CAUTION
ELECTRIC SHOCK HAZARD
• THE VOLTAGES ON BARE PARTS OF THE INVERTER MAY
CAUSE LETHAL SHOCK.

WARNING

IN ORDER TO WARRANT THE SAFETY OF PEOPLE, THE

INVERTER ENCLOSURE AND THE APPARATUS IN WHICH IT IS
INSTALLED MUST BE GROUNDED.
IN SUCH A WAY, CURRENT A FAULT MAY GENERATE WILL BE
EASILY SCATTERED AND TOUCH VOLTAGES WILL BE
REDUCED AT NON-DANGEROUS LEVELS.

CAUTION
ELECTRIC SHOCK HAZARD
• WHENEVER THE DRIVE HAS BEEN ENERGISED, IT MUST BE
ISOLATED (DISCONNECTED FROM THE POWER SUPPLY) IF
ANY INTERNAL ADJUSTMENTS ARE TO BE MADE. A PERIOD
OF 15-20 MINUTES MUST ELAPSE AFTER ISOLATION TO
ALLOW THE INTERNAL CAPACITORS TO DISCHARGE FULLY.
UNTIL THE DISCHARGE PERIOD HAS PASSED, DANGEROUS
VOLTAGES MAY BE PRESENT AT THE TERMINALS AND
WITHIN THE MODULE.
SUCH A RECOMMENDATION FAILS IF A SINGLE DC LINK IS
USED, AS WRITTEN IN IEC EN 60204-1: IN THIS CASE AN
APPROPRIATE BLEEDER RESISTOR IS ABLE TO BRING DC
VOLTAGE UNDER 60V WITHIN 5 SECONDS.

WARNING
IN ORDER TO ENSURE A GOOD COOLING OF THE INVERTER,
IT IS NECESSARY TO LET ABOUT 100 mm FREE SPACE OVER
AND UNDER THE DRIVE.
LACK OF OBSERVANCE OF THIS NOTICE MAY CAUSE
DANGEROUS OVERHEATING OF THE DRIVE.

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WARNINGS

• INVERTER INSTALLATION IS A RESPONSIBILITY OF THE

USER AND IT MUST BE DONE ACCORDING TO THE SAFETY
PROVISION IN FORCE.
• POWER CABLES AND RELATIVE SHORT CIRCUIT
PROTECTION MUST BE CORRECTLY DIMENSIONED, IN
ORDER TO GUARANTEE THE SAFETY DURING WORKING.
• A WRONG CONNECTION MAY DESTROY OR DAMAGE THE
DRIVE.
• ONLY QUALIFIED PERSONNEL CAN PERFORM SETUP OR
MAINTENANCE OF THE DRIVE.
• A CORRECT OPERATION OF THE DRIVE ASSUMES SUITABLE
CARRIAGE, INSTALLATION, SET UP, AND MAINTENANCE.
• KEEP THE DROP-FRONT CLOSED DURING DRIVE
OPERATION.

3.2 POWER CONNECTIONS FOR INVERTERS SERIES 8V

Terminals Function Clamping Screws

+ DC supply input M8
-
R, S, T AC three-phase output M8
Ground terminal M8

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TABLE 3.1: FUSES AND POWER CABLE CROSS-SECTIONS (*)

TYPE kW kVA Iac nom Iac Idc nom Fuse Fuse Carrier DC side AC side
Fuse (code) (code) Power Cable Power Cable
(**) (**) Cross-section Cross-section
[A] [A] [A] [mm²] [mm²]

8V003021 1 1.5 2.5 3 10 170M0158 89090014 1 1

8V003051 2 3 5.0 6 10 170M0158 89090014 1.5 1.5

8V003071 3 4.5 7.5 9 16 170M0159 89090014 2.5 2.5

8V003121 5 7.5 12.5 15 25 170M0161 89090014 4 4

8V103251 10 15 25 30 40 170M0163 89090014 10 6

8V203360 16 22.5 37.5 47 63 170M0165 89090014 16 16

8V203500 22 30 50 63 80 170M0166 89090014 25 16

8V313750 35 45 75 94 125 170M1368 89090014 35 25

8V313100 48 60 100 125 160 170M1369 89090014 70 50

8V403120 60 75 125 150 200 170M2617 89090015 70 70

(***)

8V513150 75 90 150 188 250 170M1371 89090014 120 70

(***)

8V513200 100 120 200 250 350 170M2620 89090015 20 x 5 120

(***)

8V613300 150 180 300 375 500 170M4414 2 x 89090011 30 x 5 25 x 5

8V703600 300 360 600 640 800 170M6462 2 x 89090022 50 x 5 30 x 5

900

(*) Data referred to the drive rated current.

(**) External components. BUSSMAN fuse codes are shown.
(***) With additional bars for cables with cross-section greater than 90 mm².

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chapter 4

MAN-MACHINE INTERFACES

4.1 GENERAL .........................................................................................................4-2

4.2 PORTABLE PROGRAMMING UNIT..................................................................4-3
4.3 PC-COMPATIBLE PROGRAMMING SOFTWARE............................................4-3
4.4 E.E.I. VIDEOKEYBOARD..................................................................................4-4
4.5 LOCAL SUPERVISOR WITH PC.......................................................................4-4
4.6 REMOTE SUPERVISOR WITH PC ...................................................................4-5

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4.1 GENERAL

A programming and supervision unit can talk to several converters through a single
serial line RS 485 that connect the unit with all the drives and the other microprocessor
cards optionally connected.
The communication is bidirectional (from unit to drives and vice-versa) with the
programming unit as 'master' and the drives and other microprocessor cards as 'slaves'.
The programming unit can:

- receive and display a large number of data about drive operation (memorised
parameters, measurements, operating states, alarms, diagnostic information)
- ask cyclically to the slaves for data to display
- transmit to the slaves the parameter values programmed by operator through the
keypad of the programming unit (in case of inverter, the values will be stored into the
EEPROM memory of the control card R03.0).
In particular it is thus possible to setup a drive during commissioning, to change
some parameters when necessary, to make effective the different operating modes
foreseen by the drive, to restore the old parameter values in case of replacement of
a fault control card.

It has to underline that presence and working of a programming unit are not
necessary for the drive running but just to it setting.
Optionally, a programming unit can be connected to a Host Computer for plant
control, by means of another serial line RS 485 and proper interface and software. Host
Computer allows for example to collect production and efficiency data from several
machines, statistical processing of production data and failure events, report printing, etc.
To a Host Computer is then possible to connect a MODEM for telediagnosis and
teleservice.

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4.2 PORTABLE PROGRAMMING UNIT

The portable programming unit designed by EEI is contained in a very small

enclosure (96x96x29 mm) provided with a 5-digit + sign display for numerical values
displaying, a 1-digit display for operating mode visualization, and a 4-key touch-pad.
Thanking to it compactness and essentiality, the portable programming unit is an
economical and useful mean to set parameters in a drive. After setup, it may become
also a convenient measuring instrument, on-panel mountable, for main operating
quantities visualization.
The communication with an EEI converter is possible by directly connecting the
programming unit with the serial line socket present on the converter control card.

figure 4.1

4.3 PC-COMPATIBLE PROGRAMMING SOFTWARE

For each application, EEI offer at request a program runable on an AT-compatible

PC for setup and communication with a single converter.
The communication between computer and drive is realised by a RS-232/RS-485
interface supplied with the kit.
This solution is suggested in case of drives which do not require, after
commissioning, a programming unit permanently connected, except for servicing or
inspection.

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4.4 EEI VIDEOKEYBOARD

The EEI videokeyboard is a microprocessor system especially dedicated to multi-

drive machine programming and monitoring.
It allows to setup the drives connected and to report actual data and alarms from
drives and machine.
The videokeyboard, contained into a self-extinguishing plastic enclosure and
designed for panel mounting, is mainly composed by:
• a LCD graphic display (240x128 pixels), back-lighted and provided with cursor for
lighting setting.
• a 20-key touch-pad, including key 'Enter', 2 function keys, 6 cursor movement keys,
and number keys. Key pression is signalised by LED and buzzer.
• a 16 bit microcontroller card, with a RAM memory completed of buffer battery for
data conservation when unit is off, an EPROM memory containing application
software, an EEPROM memory for storage of the parameter values of all the drives
connected.

figure 4.2

Figure 4.2 shows the videokeyboard front (265x132.5 mm).

4.5 LOCAL SUPERVISOR WITH PC

The same functions of a videokeyboard can be carried out by a Personal Computer

with colour monitor, equipped with proper EEI software. The PC should be connected to
serial line with a RS232/RS485 interface (EEI card C06.0).
The advantage of a PC as regards a videokeyboard lies in a more powerful and
clear visualization of the various pages.

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4.6 REMOTE SUPERVISOR WITH PC

A remote PC equipped with EEI special software, may become a remote supervisor
(Host Computer) for a plant composed by several machines. The remote supervisor
should be connected to the machine supervisors through a RS232/RS485 interface (EEI
card C06.0) and an external RS 485 serial line. The machine supervisors
(videokeyboards or PCs) should be connected to the external serial line through EEI
interfaces (cards type 450.0 or C06.0, respectively).

With the special software supplied by EEI, a remote supervisor carries out the
following functions:
− collection, storage, statistical analysis, and visualization of operating and
production data
− product quality certification by monitorship of the main features of the product
− automatic programming of operating modes of the machines
− real time displaying of data from the machines.
A remote supervisor is user friendly since equipped with graphic man-machine
interface and on-line guide.
It may be also provided with optional accessories as printer (for quality, production,
operating data printing), modem (for telediagnosis and teleservices), etc.

MACHINE 1 MACHINE 2 MACHINE N

DRIVE DRIVE DRIVE

DRIVE DRIVE DRIVE

DRIVE DRIVE DRIVE

RS485 RS485 RS485

DRIVE DRIVE DRIVE

450.C C06.0 450.C

RS485

External Serial Line

MODEM Phone Line

C06.0

figure 4.3

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chapter 5

PROTECTIONS

5.1 PROGRAMMABLE PROTECTIONS .................................................................5-2

5.2 NON-PROGRAMMABLE PROTECTIONS ........................................................5-3

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In the following paragraphs they are explained the general protections foreseen in
an inverter series 8V, by distinguishing those programmable by the user through
software parameters from those non-programmable.
Intervention of each of the protections described causes a converter consent output
commutation. The protection occurred is signalised by the display DG0 of the control
card, by means of a hexadecimal code. A table with the alarm codes is reported in the
manual of application in use.

5.1 PROGRAMMABLE PROTECTIONS

1 Motor thermal When motor rated current is exceeded, the control system
overload starts to calculate the integral of the squared overcurrent.
Protection trips if the calculated value reaches the
maximum programmed threshold
2 Minimum DC Protection trips when the DC link voltage becomes lower
link voltage than the value programmed in Volts.
3 Maximum DC Protection trips when the DC link voltage exceeds the
link voltage value programmed in Volts.
4 Speed Speed transducer integrity is checked by two different
feedback protections.
failure Alarm trips when one or both the following conditions
happens:
1) the motor speed detected by encoder exceeds the set
NOTE: Protection value or the frequency exceeds the set value + 5%
valid only for (slip margin). Such protection is always enabled.
drive with 2) the speed error, that is the difference between
vector control. reference and feedback, exceeds the set value. Such
protection is enabled by a configuration bit.

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5.2 NON-PROGRAMMABLE PROTECTIONS

1 Tests at switching-on At a control card switching-on, after a reset command (key

'CPU Reset'), or at a 'watch-dog' alarm trip, the
microcontroller performs an internal functionality test, a
CRC test of data stored into EEPROM, a RAM read-write
test, and a test of control card supply voltages.
2 Microcontroller 'watch- The microcontroller checks the correct execution of the
dog' protection program loaded inside.
'Watch-dog' test lies in zero setting, at every program
cycle, of a hardware counter inside the microcontroller.
Protection trips if such a zero setting does not occur within
a fixed time. Trip causes an automatic reset of the control
system of the converter.
3 EEPROM failure Protection trips if, during setting of a parameter, the value
is not correctly stored into EEPROM.
4 EEPROM error Protection trips if the microcontroller, with a CRC test,
detects corruption of data stores into EEPROM. The test is
made at every switching on or reset of the control card.
5 RAM error Protection trips if the microcontroller is not able to read or
write the RAM memory. RAM read-write test is done at a
control card switching-on and after a reset command (key
'CPU Reset').
6 Supply voltages out of Protection trips if values of control card supply voltages
tolerance +12V (VDD) and -12V (VEE) are out of tolerance range.
7 IGBT module Protection trips if a failure is detected in the IGBT power
protection modules (overload, minimum driver supply voltage,
overtemperature).
8 Inverter Protection trips if the thermal sensor (klixon) placed on the
overtemperature heat-sink of the inverter signals 'maximum temperature
reached'.
9 External motor Protection trips on input Z6 turning off. This optoinsulated
protections input receives consent signal from the external motor
protections (overtemperature, fan failure, etc.)
10 DC link overvoltage Protection trips if the DC link voltage exceeds a maximum
(HardWare) threshold fixed by an analog circuitry.

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chapter 6

SERVICING

6.1 INSTALLATION OF NEW APPLICATIONS .......................................................6-2

6.2 CONTROL CARD REPLACEMENT...................................................................6-4
6.3 MAINTENANCE.................................................................................................6-5

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6.1 INSTALLATION OF NEW APPLICATIONS

As already mentioned in this manual, the most important feature of EEI converters is
the possibility to obtain customised software versions.
Therefore it may occur that a customer needs to install a new application software
version.
The software is installed into a memory of the control board. The kind of memory
employed depends on the control card mounted: in the traditional card R03 the memory
is and EPROM, while in the new card R06 it is a FLASH.
The EPROM memory is marked with a lable reporting the number of the application,
checksum number, and date. The FLASH memory reports only the number of the
application.
In case of EPROM, the updating of the program requires the substitution of the
component, while, in case of FLASH it is possible re-programming the memory via serial
line RS485 connected with a PC with proper software.
Here they are listed in detail the instructions to follow:

EPROM (card R03):

− De-energise the control card R03 by disconnecting the wire from faston terminal
+24 or removing the fuse present on the card
− Remove with the aid of a screwdriver the pre-existent EPROM (component no.
22) by keeping attention to not damage the pins.
− Install the new EPROM in the socket by respecting the correct displacement of the
component and checking that all pins are inserted
− Energise again the control card.

ATTENTION

EPROM memory replacement may cause partial or total reset of

parameter values previously memorised.
Moreover, a new software version may contain new parameters,
therefore a general verify of the parameter values is recommended.

FLASH (card R06):

− Energise the control card (+24 Vdc between the terminals +24 and 0P).
- Connect the PC to terminal RS485 of the control card through a serial cable and
the proper RS232/RS485 interface.
- Push at the same time the push-buttons CPU-RESET and PRO located on the
right center of the control card.
- Release only the CPU-RESET push-button and check that the display DG0 show
digit '1' and the red Led PRG is on. Then release also the push-button PRO.
- Start the proper program in the PC (e.g. C:\LOADER.EXE). On the screen it will
appear a menu bar.
- Chose the function 'LOAD' of the menu 'UTILITY' and answer to the questions as
they will be put, by confirming the answers with the key Enter (e.g.: serial port
used, baud-rate of serial transmission between master and slave, name of the
program *.HEX to load into FLASH).

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- When answered to all the questions, chek that the display DG0 show before the
digit '2' (FLASH data deleting) an then the digit '3' (FLASH data writing). In this
phase, on the screen of the PC they will scroll numbers indicating the percentage
of data transferring into FLASH memory.
- At the end, exit from the program and disconnect the computer from the control
card of the inverter.

NOTE:
If you have available a new FLASH memory in which is already installed the new
application program, it is possible to replace the old FLASH by the new one by
following the same instructions given for an EPROM replacement. The only
differences are that in this case the component is the no. 19 instead of no. 22 and
the replacement requires a proper extractor instead of a simple screwdriver.

ATTENTION

EPROM memory replacement may cause partial or total reset of

parameter values previously memorised.
Moreover, a new software version may contain new parameters,
therefore a general verify of the parameter values is recommended.

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6.2 CONTROL CARD REPLACEMENT

In order to replace a damaged control card R03 or R06 with a new one, make sure
that the drive is de-energised and follow strictly these instructions:

• Disconnect the connections of the card

• Unscrew the four clamping screws on the angles and take out the card, paying
attention to the connector on the bottom

• With the aid of a screwdriver, remove from the damaged card the EEPROM memory
(component no. 28 mounted on socket, on the centre) and install it on the new card.

• In the new card, set the same address of the damaged card by acting on the proper
dip-switches. With card R03, they are on the center (on the left of the EEPROM
memory) and are marked as SW0, SW1, SW2, SW3, SW4. With card R06, they are
on the right (below the two displays) and are marked as SW1, SW2, SW3, SW4,
SW5.

• In case of card R03, check that the EPROM memory of the new card has the same
application number, checksum number, and date of the old card (refer to the lable
on the component no. 22).
In case of card R06, check that the FLASH memory of the new card has the same
numebr of the old one (refere to the lable on the component no. 19).

• Check that the trimmers 'I MAX ECC' and 'I MAX COPPIA' (on card R03) or 'I MAX'
(on card R06) placed on the top right are completely clockwise rotated (trimmer at
maximum).

• Clamp the new card on the module by screwing the four screws on the angles

• Reconnect the wires to the card

• Energise the drive

• Check on the programming unit that 'master' and 'slave' values of the parameters
related with the drive are equal. If not, copy the value 'master' into the value 'slave'.

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6.3 MAINTENANCE

ATTENTION

DE-ENERGISE THE DRIVE BEFORE DOING ANY REPAIR OR

MAINTENANCE ACTIONS

In order to keep the electric equipment in the best conditions and to preserve its
performance, we recommend to do an inspection every 6 months, by following these
instructions:

• Remove dust and dirt from the inverter unit

• Check for any colour changes or deformations of cable sheaths and components

• Check for loosening of termination screws and slack between connectors and wires.

• Check for loosening of screws clamping different parts of the module.

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Appendix A

CONNECTION AND WIRING SCHEMES

FIG. A1: EXTERNAL WIRING AND BLOCK DIAGRAM .................................. A-2

FIG. A2: INTERNAL CONNECTIONS MOD. 8V003021.................................. A-3
FIG. A3: INTERNAL CONNECTIONS MOD. 8V003051.................................. A-4
FIG. A4: INTERNAL CONNECTIONS MOD. 8V203360-8V203500................. A-5
FIG. A5: INTERNAL CONNECTIONS MOD. 8V313750-8V313100................. A-6
FIG. A6: INTERNAL CONNECTIONS MOD. 8V403120-8V513150-8V513200A-7
FIG. A7: INTERNAL CONNECTIONS MOD. 8V613300 .................................. A-8
FIG. A8: INTERNAL CONNECTIONS MOD. 8V703600 .................................. A-9

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A-9