vtr g1000 user manual

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K I R L OS K AR E L E CT R I C

TABLE OF CONTENTS VICTOR G1000

KIRLOSKAR ELECTRIC 1

1. INTRODUCTION 3 2. GLOSSARY 4 3. INSPECTION AND CONSTRUCTION 5 3.1 Identification of rating 5

3.2 Transit damage 5

3.3 Construction 5 4. TECHNICAL SPECIFICATIONS 6 5. DIMENSIONS 8 5.1 Inverter unit outline dimensions 8

5.2 External braking resistor unit dimensions 9 6. INSTALLATION 10 6.1 Installation recommendations 10

6.2 Mounting directions 10 7. WIRING PRECAUTIONS 11 7.1 Main circuit wiring 11

7.2 Control circuit wiring 11

7.3 Dynamic braking wiring 12

7.4 Connection diagram 13

7.5 Inspection before operation 14

7.6 Preliminary run check 14

7.7 Precautions for noise control 14

7.8 Selection of distribution and control equipments 15 8. TERMINAL BLOCK DESCRIPTION 16 8.1 Power terminals 16

8.2 Control terminals 16

TABLE OF CONTENTS VICTOR G1000


9. DISPLAY UNIT 18 9.1 Description 18

9.2 Operation modes 19

9.3 Display indications in different modes 20

9.4 Data setting 22 10. FUNCTIONS 23 10.1 Function table 23

10.2 Function description 28

11. MAINTENANCE 40 11.1 Preventive maintenance 40

11.2 Maintenance tests 40

11.3 Periodic part replacement 41

11.4 Measuring recommendations 41

12. TROUBLE SHOOTING 42 12.1 Protecting functions 42

12.2 Recovering from faults 44

1. INTRODUCTION VICTOR G1000


Kirloskar Electric Company Ltd., established in 1946, is one of the leading manufacturer of Industrial Electrical and Electronic Equipment in the country. We thank you for procuring our quality product VICTOR AC Drive. We request you to read thoroughly this manual before using the inverter for the best use. Victor G1000 is a Micro computer controlled General Purpose AC Variable Speed (Inverter) Drive catering to all various types of constant and variable torque applications in different Industries such as Sugar, Textile, Paper, Steel, Cement, Chemical, Pharmaceutical, Plastic, Process, Tyre & Rubber, Machine Tool. Victor G1000 AC Drive is based on state-of-the-art electronics and incorporates the latest semiconductor power device - Insulated Gate Bipolar Transistor (IGBT) and unique display unit consisting of Seven segment LED’s and 16x2 character LCD’s. The control circuitry is centered around a 16 bit microcontroller and the control method used is Space Vector Modulation, which optimizes utilization of input voltage and facilitates smooth rotation of the Motor at low speed. This User Manual, furnish the details on selection, operation, installation, maintenance, trouble shooting etc. of Victor G1000 Inverters. The same can be used to configure the AC drive according to the application requirements easily. The VICTOR AC Drives are warranted against any inherent manufacturing defects or faulty workmanship for a period of 12months from the date of commissioning or 15months from the date of dispatch, whichever is earlier. In case, you require any more information or clarification, please contact Kirloskar Electric .

2. GLOSSARY VICTOR G1000


The special terms used in this manual are defined here : 2.1 FUNCTION : This refers to the parameter to be programmed.

Ex.: COMMAND LOCATION. 2.2 DATA : This refers to the settable data within a given function.

Ex.: Command Location has data like 00. DISPLAY UNIT, 01. TERMINAL BLOCK, etc.

2.3 QUALIFIED : This refers to a person : PERSONNEL a. Trained in and authorized to energize and ground circuits and

equipment in accordance with established safety procedures. b. Trained in proper care and use of protective equipment, in

accordance with established safety procedures. c. Trained in rendering first aid. 2.4 DANGER : This word refers to procedures / operation, if violated could cause

severe personal injury, damage to life and property, besides the Inverter.

2.5 CAUTION : This indicates information / instructions if violated will cause minor

personal injury and / or loss of property. 2.6 ATTENTION : This merely draws attention to certain important instructions /

procedures.

3. INSPECTION AND CONSTRUCTION VICTOR G1000


Ensure the following inspection are carried-out on receipt of material from Kirloskar Electric.

3.1 IDENTIFICATION

OF RATING : Ensure the rating written on the name plate is the one ordered. A

sample of rating plate is shown below

MYSORE - INDIAKIRLOSKAR ELECTRIC CO., LTD.

SERIAL No.

INPUT 50 Hz.415 V,3Ph.-

TYPE VTR-

OUTPUT P code : 530- A

` X '

` Y '

3.2 TRANSIT DAMAGE : Inspect the Inverter for any mechanical damage that might have occurred during transit. If any problems are noticed, please contact Kirloskar Electric.

3.3 CONSTRUCTION :

VICT OR

4. TECHNICAL SPECIFICATION VICTOR G1000


RATING CHART

VTR _ _ _ G1 Inverter type

022 037 055 075 110 150 185 220 Applicable Motor rating (kW)

04~2.2 3.7 5.5 7.5 11 15 18.5 22

Inverter Output at 415V (kVA)

4.0 6.5 9.3 13.0 17.3 21.6 28.0 32.3

Output Current (A) 5.5 9.0 13.0 18.0 24.0 30.0 39.0 45.0

INPUT RATINGS

Power supply 3 Phase 415V, 50 Hz Allowable variations Voltage +10% to -15%, Frequency ±5%, Imbalance less than 3%.

OUTPUT RATINGS

Output voltage 3 Phase, 415V ( output voltage cannot exceed input voltage ) Output frequency 0.5 Hz – 440Hz Frequency stability Digital setting : ± 0.01% of maximum frequency (-10°C to +50°C)

Analog setting : ± 0.2% of maximum frequency (at 25°C ± 10°C) Overload capacity 150% for one minute(Inverse time characteristics)

CONTROL SPECIFICATIONS

Control system Space Vector Modulation Frequency control range

0.5 to 440 Hz

Adjustable current limit

30 to 180% of rated current

Maximum frequency 40Hz – 440Hz. Base frequency 40Hz – 440Hz. Carrier frequency 2kHz. Fixed Frequency setting Key operation : UP or Down key, Potentiometer 1k ohm (2W).

Analog input : 0 to 10V, 0 to –10V, 4 to 20mA , +10V to -10V (polarity based speed reversal), Raise / Lower switch, 8 Preset frequencies with X1, X2 and X3 terminals

Frequency resolution Digital : 0.01 Hz (at Fmax. 50 Hz.): Analog : 0.05 Hz (at Fmax. 50Hz.) Jump frequency Jump frequency control ( 3 points) with adjustable jump range Accel. / decel time 0.01 to 3600 sec (4 independently adjustable acceleration & deceleration)

4. TECHNICAL SPECIFICATION VICTOR G1000


CONTROL SPECIFICATIONS CONTD..

Braking Torque DC injection braking ( frequency : 0.5 to 10Hz, Time : 0 to 30seconds, Voltage : 0 to 15%). Dynamic braking ( 20 to 150%)

Slip compensation Load current dependent slip compensation Max./ Min frequency Frequency low limit / Frequency upper limit ( Fstart to Fmax.) Fault history display Present fault and upto 19 previous faults Starting frequency 0.5Hz to 10Hz Torque boost 32 selectable modes with automatic torque boost

PROTECTION, INVERTER TRIP AND ERROR MESSAGES

Stall prevention, Auto restart during instantaneous power failure for 15ms duration, Under voltage, Over voltage, Over current during deceleration, Over current during steady state condition, Over current during acceleration, THR fault, Heat sink overheating, Inverter overload, Short circuit, Electronic thermal overload trip ,Setting error and EEPROM error

INDICATION AND CONTROL

Analog / Digital output

Proportional to output frequency

External output 3 programmable open collector outputs. Fault alarm relay output Display unit having 16 x 2 character LCD with back-lit, 4 seven segment LED and 8key touch pad

Output frequency, Load current, RPM, DC bus Voltage.

ENVIRONMENTAL CONDITIONS

Installation location Indoor not more than 1000m above sea level. Do not install in a dirty location or expose to corrosive gases or direct sun rays

Ambient temperature (-10°C) to (+ 40°C)

(-10°C to + 50°C when mounted inside the switch board)

Humidity 90% RH or less ( non – condensing ) Cooling system Forced air cooling

OPTIONAL FACILITIES

RS 232C / RS 485 (serial communication facility), Dynamic Braking facility &/ or Resistor Unit, Input AC Reactor.

5. DIMENSIONS VICTOR G1000


5.1 INVERTER UNIT OUTLINE DIMENSIONS

FRONT VIEW

VICT OR

BOTTOM VIEW SIDE VIEW

5. DIMENSIONS VICTOR G1000


5.2 EXTERNAL BRAKING RESISTOR UNIT DIMENSIONS DB --- -4 Type

022 037 055 075 150 18.5 22.0 Capacity

(kW) 0.4 0.4 0.8 1.2 2.0 2.4 2.8

Resistor Resistance (Ohms) 200 160 100 66.7 40 33 28.6

VTR --- G1DB Applicable Inverter 022 037 055 075 110,150 185 220 Outline drawing A A B B C C C Motor output(kW) 0.4 0.75 1.5 2.2 3.7 5.5 7.5 11 15 18.5 22 Average breaking

torque( %) 150 150 150 100 100 100 100 100 100 100 100

Allowable braking freq.(%) 50 30 15 15 10 10 10 10 10 10 10

Continuous allowable braking time (sec) 120 120 60 30 30 20 20 20 20 20 20

Inverter (kVA) 4 6.5 9.3 13 17.3 21.6 28 32.3

6. INSTALLATION VICTOR G1000


6.1 INSTALLATION RECOMMENDATIONS Install / store the Inverter in a location that meets the following requirements : a. The ambient temperature should be between (-10) °C to (+50) °C. The top cover (3) and

TB cover (5) is to be removed for temperature above +40 °C.

b. The humidity should be between 20 and 90 % RH. Avoid any location subjected to dew condensation, freezing or where the inverter would come in contact with water

c. The Inverter should be installed at an elevation not more than 1000 Mts. above sea level and vibration should be less than 0.6G.

d. Do not install the Inverter in any place subjected to the following : Direct sunlight, dust, corrosive gas, inflammable gas or oil mist.

6.2 MOUNTING DIRECTIONS a. Mount the Module vertically so that KIRLOSKAR ELECTRIC can be seen in its front.

b. The Inverter generates heat during operation. Hence, Provide sufficient cooling air to pass through heat sink and allow sufficient space around the module as shown below :

VI CT OR

7. WIRING PRECAUTIONS VICTOR G1000


7.1 MAIN CIRCUIT WIRING a. Input power supply connections (R,S,T) can be made regardless of phase sequence.

b. Motor wiring ( U, V, W ), when connected normally the motor will rotate counter clockwise when viewed from load side. If the motor rotates in reverse, interchange any 2 of the U, V or W terminal connections.

c. Ground terminal connections (E) : For safety reasons, do not operate without the unit being grounded.

CAUTION * Never connect the power supply to output terminals ( U, V, W ). It should only be

connected to ( R, S, T ) terminals

* Input power supply should never exceed the tolerances specified in the specification sheet.

* Never connect a capacitor at the output of the Inverter in an attempt to improve power factor.

* Do not use a contactor on the output side of the Inverter for ON / OFF operation. 7.2 CONTROL CIRCUIT WIRING

a. Factory wiring at the time of shipment is as shown below. It is not necessary to modify the wiring for Display Unit Operation.



b. For external ( TB ) operation please wire as shown below. For description of terminals,

please refer Terminal block description.

CAUTION * Never connect power supply to control terminals (except for 30A, 30B, 30C terminals). * For RUN and STOP, use FWD - CM (forward) or REV - CM (reverse) terminals. Avoid

using a contactor ( ON / OFF ) installed on the line side of the Inverter for RUN and STOP.

* Never conduct megger test at the Inverter control terminals or on the control circuits. 7.3 DYNAMIC BRAKING (DB) WIRING – OPTIONAL a. When frequent braking or high torque braking is required connect the optional DB resistor

has shown in the figure. Remove the factory installed jumper from CM – THR terminals.



CAUTION * If by any chance DB1 and DB2 are short circuited the Inverter will be damaged.

* Standard Inverters are not equipped with Dynamic Braking (DB) Transistor and hence Dynamic Braking Resistor Unit cannot be made use of.

7.4 CONNECTION DIAGRAM: a. Main Circuit diagram of the Inverter is as shown below :

b. The following connection diagram shows the Inverter as seen by the external world.



CAUTION

* A minimum of 10cm separation is recommended between control and power circuit wiring

* Never use the same cable duct for routing both the control and power wiring.

* Always use twisted or shielded wires for routing control wiring. Wire should be as short as possible (< 20 mts.). Connect outer end of the shielded wires to CM and leave other end open.

* Install a snubber across any magnetic switches, coils etc. which are closer to the Inverter

* Check for any stray wires touching unintended points.

* If an Inverter trip occurs, strictly follow the Trouble shooting procedures.

* DANGER : Never operate the Inverter without earthing it.

7.5 INSPECTION BEFORE OPERATION : a. Check for correctness of the wiring .

b. Ensure no stray metal pieces, wires etc. are inside the Inverter.

c. Ensure all screws and terminal connections are tight.

d. Ensure all PCB’s connectors are properly fitted. 7.6 PRELIMINARY RUN CHECK Run the motor at low frequency(about 5Hz). Check the following points : a. Smooth rotation.

b. Correct direction.

c. No abnormal noise or vibration.

d. Smooth speed increase and decrease.

7.7 PRECAUTIONS FOR NOISE SOURCE Connect a RC filter (for AC circuit) or a diode (for DC circuit) in parallel with the coil of the

magnetic contactors or relays as detailed below so as to prevent noise interference :



7.7 PRECAUTIONS FOR NOISE SOURCE Magnetic Contactor (Main circuit) AC : RC Filter DC : Diode Auxiliary relay AC : RC Filter DC : Diode Solenoid brake clutch AC : RC Filter DC : Diode Fluorescent lamp RC Filter

7.8 SELECTION OF DISTRIBUTION AND CONTROL EQUIPMENTS Inverter Type VTR _ _ _ G1

022 037 055 075 110 150 185 220 Motor output (kW) 0.4 0.75 1.5 2.2 3.7 5.5 7.5 11 15 18.5 22 Inverter output (kVA) 4 6.5 9.3 13 17.3 21.6 28 32.3 Applicable wire for

Main circuit(sq.mm) 1.5 2.5 4 4 10 10 16 16

Applicable wire for Control circuit (sq.mm)

0.50

MCB rating ( A ) 16 16 32 32 32 40 63 63 Fuse rating ( A ) 10 20 30 30 30 40 60 60 Contactor rating ( A) 9 9 16 16 16 32 40 40 Thermal overload

relay 0.8~ 1.2

1.4~ 2.2

2.8~ 4.2

4 ~ 6 7~10 10~ 13

13~ 18

18~ 25

23~ 32

28~ 40

38~ 50

8. TERMINAL BLOCK DESCRIPTION VICTOR G1000


8.1 POWER TERMINALS SYMBOL TERMINAL NAME DESCRIPTION

R, S, T Inverter input terminals Connection for commercial power 415V AC

U, V, W Inverter output terminals Connection for 3∅ AC Motor

DB1, DB2

External braking resistor unit terminals

Connection for external DB Resistor *(Option)

E Earth terminal Connection for Earthing 8.2 CONTROL TERMINALS SYMBOL TERMINAL NAME DESCRIPTION

CM Control circuit common terminal Common terminal for control input / output signal.

10V Frequency setting reference DC +10V (accuracy of +/- 5%) is available for frequency setting (Potentiometer of 1kΩ, 2 W).

Vin Voltage input Voltage setting input point (Input impedance of 22kΩ) 0V ◊ 0Hz and ±10 V ◊ Maximum frequency.

Iin Frequency setting input Current input Current setting input point (input

impedance of 250Ω) 4mA◊ 0Hz and 20mA ◊ Maximum frequency. FWD - CM is closed:

Forward FWD Forward command input

terminal FWD - CM is open:

Stop REV - CM is closed:

reverse REV Reverse command input

terminal REV - CM is open:

stop

When FWD and REV both are open or closed the Inverter will come to stop.

BX Motor coast-to-stop input terminal With BX-CM closed, the inverter output is stopped immediately.

Multi step frequency setting Frequency setting up to maximum of eight kinds can be made in combination of ON and OFF of each terminal.

X1/X2/ X3

Raise lower control X1 – CM is closed : frequency raise function X2 – CM is closed : frequency lower function X1,X2 multistep frequency operation will not function with this setting.

8. TERMINAL BLOCK DESCRIPTION VICTOR G1000


SYMBOL TERMINAL NAME DESCRIPTION RST Reset signal input terminal With RST - CM closed, the inverter will

come out of fault mode provided the, fault has been cleared.

FM Frequency meter terminal a)When programmed for analog, provides an output DC (0-10 V), 10V is the output when maximum frequency is reached and is in proportion until zero frequency is reached. b)When programmed for digital, outputs a pulse signal corresponding to the ouput frequency

HLD 3- wire operation command This feature allows to control RUN/STOP by means of one shot command eliminating additional external relay circuit.

AC1 3 types of acceleration / deceleration times possible with the following combination. AC1 – CM Accel / decel. - time1 AC2 - CM Accel/ decel - time2

AC2 Multi - step acceleration/ Deceleration, input terminals

AC1, AC2 - CM Accel/ decel - time3 THR External thermal overload relay,

external breaking resistor overload thermal switch terminal

With THR –CM ( open ) motor will coast to stop. When no external thermal relay / switch, the THR - CM terminal must be shorted.

30A 30B 30C

Inverter faults signal output terminal

Output is made from one change over contact to indicate inverter protective function operates. (Contact capacity for resistance load 230V AC, 2A, 30V DC, 2A).Normal contact : 30C – 30B.

OC1 OC2 OC3

Programmable open collector outputs.

13 programmable outputs possible.

9. DISPLAY UNIT VICTOR G1000


9.1 DESCRIPTION The display unit is an accessory that can be used as a convenient tool for

programming, monitoring , controlling the Inverter and displaying real time parameters such as load current, output frequency etc.

The display unit consists of Digital Monitor, Unit Display, LCD display and Operation

Keys.

a. DIGITAL MONITOR : During program mode, the function code is indicated by the two digits on the left and the data code corresponding to the function code is indicated by the two digits on the right. During run mode, it displays the set frequency / current / voltage / rpm. During fault mode, ST01 will be displayed.

b. UNIT DISPLAY : The LED displays the unit information (Eg. : Speed, RPM,

DC bus voltage and frequency). c. LCD DISPLAY : During program mode, the appropriate function data

information is displayed in plain English text. During fault mode, the fault information is displayed.

d. OPERATING KEYS : Resets fault, after the fault has been corrected.

Saves the data of a particular function during program mode. SET

RESET



Used to enter and exit the program mode.

Toggles between function and data in the LCD display during

data setting. Steps through the drive function and to increase / decrease

the numeric value of data. Stops the drive when the function command location has

data– display unit. Runs the drive when the function command location has

data – display unit. 9.2 OPERATION MODES The basic operating modes are Ready to Run, Program, Run and Fault Modes.

Operations like configuring the drive is done only in PROGRAM MODE. Upon power on the drive automatically enters the READY TO RUN MODE. The operation keys are programmed for different function in different modes. The complete set of key operations in different modes are as follows :

a. READY TO RUN MODE

In this mode the Inverter is ready to run the motor. The following keys are active

PRG : This key is used to enter the programming mode of the Inverter. The key lights up when in program mode.

RUN : This is used to run the Inverter, when the Inverter is configured to have the function command location with data – display unit. The key lights up during operation. RUN key does not function when the command location is having data – Terminal Block.

STOP : This is used to stop the Inverter, if the Inverter is configured to have the function command location with data – display unit. The key lights up during operation when in STOP mode. This key does not function when the command location is having data – Terminal Block.

5 / 6 : These are used for increasing or decreasing the frequency of the Inverter, if the function – Speed reference is configured to have data – Digital.

RUN

PRG

SHIFT

5 /6

STOP



b. RUN MODE

This mode is active when the Inverter is driving the motor. The following keys are active when the function command location is set for display unit.

STOP : This is used to stop the Inverter and bring it to READY TO RUN MODE.

RUN : If the STOP command is given accidentally during run mode and the Inverter output is not yet zero, this command restores the Inverter output to the set frequency.

5 / 6 These keys are active when the type of frequency reference is DIGITAL. These keys are used to increase or decrease the set value of frequency.

SET : This key is used to store the frequency, currently set.

SHIFT : This key is used to scroll through a range of displays on LCD.

RESET : This key is used when type of frequency reference is digital to enter and exit the frequency meter calibration mode.

c. PROGRAM MODE

In this mode drive parameters are configured according to the requirements.

SHIFT : On every press, the key definition toggles between data and function.

5 / 6 : Using this key the function or data can be scrolled in either direction.

SET : Stores the data for a particular function during programming mode.

PRG. : Use to enter and exit the programming mode. d. FAULT MODE

RESET : This key is used to reset the Inverter from the fault that has occurred

SHIFT : This key is used to enter and exit the previous fault screen

5 / 6 : These keys are used to scroll through previous faults 9.3 DISPLAY INDICATIONS IN DIFFERENT MODES:

a. READY TO RUN MODE F set XXX . XX Hz READY – TO RUN

Here the seven segment display keeps blinking. The set frequency / speed / DC bus volts is indicated in this seven segment display .The stop LED above the stop key glows. The LCD displays the following :



b. PROGRAM MODE The LCD displays the function in the first line and data in the second line. In the seven

segment LED display the first two digits from left indicates – function code and the next two digits indicates – data code.

c. RUN MODE During run mode four user configurable screen are displayed. Successive screens may

be reached by pressing the SHIFT key. The seven segment display shows by default value of the parameter that is programmed.

F set XXX . XX Hz I out XXX . XX A XX %

SCREEN. 1 The seven segment display shows frequency being output to first decimal place accuracy. At this time the LCD screen is as shown

F set XXX . XX Hz F out XXX . XX Hz

SCREEN. 2 The seven segment display shows frequency being output to third decimal place accuracy. At this time the LCD screen is as shown

F set XXX . XX Hz Speed XXX .XX RPM

SCREEN. 3 The seven segment display shows the frequency being output to first decimal place accuracy. At this time the LCD display is as shown

F set XXX .XX Hz DC Bus XXX .XX Volts

SCREEN.4 The seven segment display shows the frequency being output to first decimal place accuracy. At this time the LCD display is as shown

d. FAULT MODE

FAULT DETECTED UNDER VOLTAGE

The seven segment LED indicates “Sto 1”. The LCD displays the following. The second line indicates the nature of fault.



9.4 DATE SETTING METHOD

10. FUNCTIONS VICTOR G1000


The Victor G1000 AC Drive has 61 functions that can be programmed using the display unit. The factory preset settings will usually suit a wide range of application. To configure the controller as needed for an application, each of the following listed functions can be set with appropriate data.

10.1 FUNCTION TABLE

FUNCTION ( LED ) DATA ( LCD ) FACTORY REMARKS CODE DESCRIPTION CODE DESCRIPTION SETTING

00

LED Parameters

00 01 02 03

Hz RPM DC Bus Voltage I out

00

Default display in LCD

01

Command Location

00 01 02

Display unit Terminal block Serial link

00

Location from which RUN and ST0P are given

02

Speed – Ref.1

00 01 02 03 04 05 06 07

Digital Analog (0 to 10V) Analog (0 to –10V) Analog (-10 to 10V) Analog (4 to 20 mA) Serial – Link Raise – Lower Raise - Lower Sto

00

Reference for speed Variations

03 Max. Frequency -- XXX Hz 50Hz 40 ~ 440Hz

(1Hz resolution)

04 Base Frequency -- XXX Hz 50 Hz 40 ~ 440Hz (1Hz resolution)

O5 Accel. Time -- XXX . XX S 11 sec 0.01 ~ 3600 sec

06 Decel. Time -- XXX . XX S 11 sec 0.01 ~ 3600 sec

07 Torque Boost Level -- XXX th – CURVE 8th Curve 0 to 31 curves possible

08 RPM Multiplier -- XXX 30 Multiplier for RPM display ( 0.01 to 99.99 )

09 Current Limit -- XXX % 150% 30 to 185% possible

10 Data Protection 00 01

Disable Enable

00 Protects data from being changed, when enabled




11 Speed.2 – Ref. 00 01

Disable Enable

00

12 Speed – Ref.2 00 01

Analog (4 – 20mA) Analog (0 – 10V) 00

Enabling this function and shorting X3 – CM, speed reference will be taken from the data set in the Speed – Ref.2

13 Elect. Thermal Overload -- XXX % 0 % 0 ~ 100%

0% means Disable 14 Bias Frequency -- XXX % 0 % 0 ~ 100%

15 Freq. Lower limit -- XXX % of max. Hz 0 % 0 ~ 100%

16 Freq. Upper limit -- XXX % of max. Hz 100 % 0 ~ 100%

17 Brake Type 00 01

Normal torque High torque

00 Selection depends on the load

18 DC Injection Brake

00 01

Disable Enable

00 For Dc braking

19 DC Brake Frequency -- XXX Hz 1Hz

0 ~ 10Hz (1Hz resolution)

20 DC Braking Time -- XXX .XX s

0.01 sec 0.01 ~ 60sec (0.1sec resolution)

21 DC Braking Voltage -- XXX % 10% 0 ~ 100 %

22 Auto Restart 00 01

Disable Enable

00 Does not work when UV latch is enabled

23 Auto Torque Boost

00 01

Disable Enable

00 Automatic voltage adjustment based on load.

24 FM – Output 00 01

Digital Analog

01 Selects the type of frequency signal

25 Wire Operation 00 01

2-Wire 3-Wire

00 For 3- wire operation,HLD-CM is closed

26 Start Frequency -- XXXHz 00 0.5~ 10Hz (1Hz resolution)

27 Slip Compensation -- XXX % 0 % 0 ~ 100%

28 Accel. – Time.1 -- XXX .XX S 2 sec 0 ~ 3600 sec can be selected through AC1 and CM




29 Accel. – Time.2 -- XXX .XX S 6 sec 0 ~ 3600 sec can be selected through AC2 and CM

30 Accel. – Time.3 -- XXX .XX S 20 sec 0 ~ 3600 sec can be selected through AC1, AC2 and CM

31 Decel. – Time.1 -- XXX .XX S 2 sec 0 ~ 3600 sec can be selected through AC1 and CM

32 Decel. – Time.2 -- XXX .XX S 6 sec 0 ~ 3600 sec can be selected through AC2 and CM

33 Decel. – Time.3 -- XXX .XX S 20 sec 0 ~ 3600 sec can be selected through AC1, AC2 and CM

34 Speed.1 -- XXX Hz 10Hz 0 Hz to Fmax







41 Jump Hz. range -- XXX Hz 0HZ 0 ~ 5Hz (1Hz resolution)

42 Jump Hz. 1 -- XXX Hz 0HZ 0 ~ Fmax (1Hz resolution)



45 UV Latch 00 01

Disable Enable

01 Under voltage latch feature

46 Over Load early warning -- XXX % 150 % Control TB output 30%

to 150% (1% resolution)

47 Frequency Equi. Hyst. -- XXX Hz 005Hz 0 ~ 5Hz




48 Stop Hz Signal -- XXX Hz 10Hz 0 ~ 440Hz (1Hz resolution)

49 Open Collector.1 01 Frequency Equivalence 00

50 Open Collector.2 00 Stop Hz Signal 01

51

Open Collector.3

02 03 04 05 06 07 08 09 10 11 12

UV signal OL early warning Run indication F max. reached Speed.1 reached Speed.2 reached Speed.3 reached Speed.4 reached Speed.5 reached Speed.6 reached Speed.7 reached

04 13 programmable open

collector outputs possible. Rating : 27V, 50mA Max.

52 Past Fault Memory No. 01-19 -- -- 1 - 19 Previous faults

can be stored.

53 Baud Rate 00 XXX Baud 9600 Five different baud rates can be set

54 Link Control 00 01

Disable Enable

00 --

55 Link Address 0 ~ 29 XX 01 Sets the address of the Drive

56 Frequency Resolution

00 01

Fine Coarse

01 Frequency resolution can be set in coarse or fine mode

57 Wobbulation 00 01

Disable Enable

00 Wobbulation selection

58 Wobble Width -- XXX .XX Hz -- 0.01 ~ Fmax in steps of 0.01Hz

59 Kick Width -- X .XX Hz 5Hz 0 – 9.9Hz

60 Ramp Up Time -- XXX .X S 10sec 0.1 – 99.9 sec

61 Ramp Down Time -- XXX .X S 10sec 0.1 – 99.9 sec



10.2 FUNCTION DESCRIPTION

FUNCTION DATA DESCRIPTION

FUNCTION : 00 LED PARAMETERS

Frequency Frequency in Hz is displayed RPM Speed of the rotating motor in RPM is displayed DC Bus Voltage Voltage at the DC Bus in volts is displayed Iout Output current in Amps. is displayed

FUNCTION 01 COMMAND LOCATION

Display Unit With this option the command location becomes display unit. The run/stop command should be given through Run / stop key. However, the terminal Fwd / Rev needs to be connected to CM to enable the drive to run

Terminal Block With this command location Run command can be given only through Fwd / Rev terminals

Serial Link Run command is given through serial link

FUNCTION 02 SPEED REFERENCE

Digital Frequency reference to be given from key pad of display unit. It can be set using Up / Down keys in Ready-to-Run and Run modes and should be stored with Set key.

Analog ( 0 – 10V ) The frequency reference can be varied from 0 to 100% of maximum frequency setting by applying between VIN and CM, a voltage from 0 to 10V.

Analog ( 0 to - 10V ) The frequency reference can be varied from 0 to 100% of maximum frequency setting by applying between VIN and CM, a voltage from 0 to –10V

Analog ( -10V to +10V )

The frequency can be varied from 0 to 100% of maximum frequency setting by applying between VIN and CM, a voltage from (-10V) to (+10V).

Analog ( 4 ~ 20mA ) A current input of 4 to 20mA varies the frequency reference from 0 to 100% of maximum frequency linearly.

Serial – Link The frequency reference can be varied through a serial link Raise – Lower With this selection the multi speed operation is disabled. With X1-CM

closed, the frequency starts increasing in steps of 0.01Hz , when X2 – CM is shorted ,the frequency starts decreasing from Fset . When the inverter is stopped by operation command the initial value at restart is the previous Fset.




Raise – Lower sto Functions similar to raise-lower but when the inverter is stopped by operation command ,the restart value will be zero.

FUNCTION 03 MAXIMUM FREQUENCY

XXX Hz This is the maximum frequency that can be applied to the motor in order to run the machine at its maximum speed. Range : 40 to 440 Hz with resolution of 1Hz

FUNCTION 04 BASE FREQUENCY

XXX Hz This is the rated frequency of the motor. At this frequency inverter applies rated voltage to the motor. This point signifies end of the constant - torque region. Above this frequency and up to maximum frequency motor voltage will be constant equal to its rated value. Range : 40 to 440Hz

FUNCTION 05 ACCELERATION TIME

XXXX XX S This is the time taken by the Inverter to reach maximum frequency. If the time is too short current limit function of the Inverter operates and this setting will be overridden. Range: 0.01 to 3600s. The resolution is as follows

Setting (sec) Setting Time Resolution (sec)


0.01 to 9.99 0.01 100 to 999 1.0

10 to 99.9 0.1 1000 to 3600 10.0




FUNCTION 06 DECELERATION TIME

XXXX XX S

This time taken by the Inverter to stop from maximum frequency without tripping. If the time is too short then DC voltage limiting function of the Inverter operates and this setting will be overridden. Range : 0.01s to 3600s. The resolution of deceleration time is :



0.01 to 9.99 0.01 100 to 999 1.0

10 to 99.9 0.1 1000 to 3600 10.0 Acceleration Time Deceleration Time

FUNCTION 07 TORQUE BOOST LEVEL

XXX th – Curve To increase the torque develop at low frequencies, this parameter is used. It can be set in 32 steps ( 0 to 31).

FUNCTION 08 RPM MULTIPLIER

XXX This can be selected based on the motor, used to indicate synchronous RPM (00 to 99.99 ). RPM multiplier = Maximum speed Maximum frequency




FUNCTION 09 CURRENT LIMIT

XXX % When the output current reaches the current limit level ,output frequency is automatically lowered to avoid over current trip. It operates during acceleration and steady state condition. Range: 30% to 185% of rated current

FUNCTION 10 DATA PROTECTION

Disable / Enable When enabled, does not allow function setting / change.

FUNCTION 11 SPEED.2 – REF.

Disable / Enable When enabled and X3 - CM are shorted speed reference will be taken from data set in Speed Ref.2

FUNCTION 12 SPEED – REF.2

Analog (4~20mA) / Analog ( 0~ 10V)

With Speed Ref.2 is enabled speed reference signal corresponds to this data

FUNCTION 13 ELECTRONIC THERMAL OVER LOAD

XXX % This function enables the Inverter to protect a standard motor from over load. The setting current value is obtained by the equation

Setting Current value K (%) = Motor rated current x 100 Inverter rated current

K is 1.0, when base frequency is 50Hz.




FUNCTION 14 BIAS FREQUENCY

XXX % of Fmax This function provides a speed control, the adjustable range is from 0 to 100 % of Fmax. This is used when linearity between the setting frequency and motor speed is required.

FUNCTION 15 FREQUENCY LOWER LIMIT

XXX % of max Hz This function is used to limit the output frequency to a certain width, so as to prevent motor under speed

FUNCTION 16 FREQUENCY UPPER LIMIT

XXX % of max Hz This function is used to limit the output frequency to a certain width, so as to prevent motor over speed

FUNCTION 17 BRAKE TYPE

Normal Brake / High Torque Brake

Braking selection depending on the load

FUNCTION 18 DC INJECTION BRAKE

Disable / Enable This function is used to decrease stop time and improve stop position accuracy




FUNCTION 19 DC BRAKE FREQUENCY

XXX Hz Sets the frequency at which DC brake is applied. The DC brake frequency should be higher than the start frequency of the Inverter. Range : 0 to 10Hz

FUNCTION 20 DC BRAKE TIME

XXXX . XX S Sets the time for which DC brake is applied. Range : 0.01 to 60 sec

FUNCTION 21 DC BRAKE VOLTAGE

XXX % If 0% DC Injection is disabled

FUNCTION 22 AUTO RESTART

Enable / Disable Automatically restarts the Inverter and synchronizes a running motor after a brief power failure. This works only, when UV Latch is disabled.

FUNCTION 23 AUTO TORQUE BOOST

Enable / Disable This function is used to adjust the boost value automatically depending on load fluctuations, thus ensuring an efficient operation.

FUNCTION 24 FM OUTPUT

Digital / Analog Frequency meter output can be selected to drive an analog or digital meter. In case of analog, the output average voltage at FM terminal with respect to CM varies as a function of output frequency of the Inverter. In case of digital the frequency, waveform varies as a function of output frequency of the Inverter.




FUNCTION 25 WIRE OPERATION

2 Wire Operation * When FWD - CM / REV - CM is selected the motor runs according to the FWD / REV direction

* When both FWD – CM and REV - CM are on at the same time, deceleration occurs. HLD terminal input is ignored

3 Wire Operation * When HLD - CM is ON and FWD – CM is ON for over 20ms : Forward command enables. HLD - CM is OFF : Stop

* HLD - CM is ON and REV - CM is ON for over 20ms : Reverse command enables. HLD-CM is OFF : Stop

* During the period when HLD - CM is ON, either FWD / REV signal whichever is inputted first, takes precedence

* When HLD - CM is OFF, if FWD / REV signal are input, 2 wire operation will result.

2 Wire Operation 3 Wire Operation

FUNCTION 26 START FREQUENCY

XXX .XX Hz Minimum frequency of system ( 0.5 to 10 Hz)




FUNCTION 27 SLIP COMPENSATION

XXX % Automatically judges the relative size of the output current fluctuations and regulates the inverter frequency for consistent rpm operation. Operates only during constant speed operation.

FUNCTION 28 ~ 30 ACCELERATION TIME.1 ~ 3

XXX .XX S Setting between the 0.01s to 3600s range is possible. Selection of acceleration time 1 through 3 is made via AC1 and AC2 terminal combination

Accel –Time AC1 - CM AC2 - CM

Accel –Time1 CLOSE OPEN

Accel –Time2 OPEN CLOSE

Accel –Time3 CLOSE CLOSE

FUNCTION 31 ~ 33 DECELERATION TIME.1 ~ 3

XXX .XX S Setting between the 0.01s to 3600s range is possible. Selection of acceleration time 1 through 3 is made via AC1 and AC2 terminal combination

Decel –Time AC1 – CM AC2 - CM Decel –Time1 CLOSE OPEN Decel –Time2 OPEN CLOSE Decel –Time3 CLOSE CLOSE




FUNCTION 34 ~ 40 SPEED.1 ~ 7

The selection of Speed.1 ~ Speed.7 ( 0.00Hz to Fmax ) for multi-step speed is as given below

Speed X1 – CM X2 – CM X3 – CM Speed 1 CLOSE OPEN OPEN Speed 2 OPEN CLOSE OPEN Speed 3 CLOSE CLOSE OPEN Speed 4 OPEN OPEN CLOSE Speed 5 CLOSE OPEN CLOSE Speed 6 OPEN CLOSE CLOSE

XXX .XX Hz

Speed 7 CLOSE CLOSE CLOSE

FUNCTION 41 JUMP- Hz-RANGE

XXX Hz The frequency range of jump around the jump frequency set. Range : 0 to 5 Hz with 1Hz resolution




FUNCTION 42 ~ 44 JUMP FREQUENCY

XXX Hz This function allows the Inverter to jump (+/- 5) Hz of a selected frequency, so as to prevent the resonance of machine or structure. The jump frequency can be set at three positions. Jump - Hz 1 ~ 3 Range : 0 to Fmax with 1Hz resolution

FUNCTION 45 UV LATCH

Disable / Enable When the DC voltage drops below the under voltage level the Inverter stops immediately

FUNCTION 46 OVERLOAD EARLY WARNING SIGNAL

XXX % When the Inverter output current exceeds the set overload level, the open collector output is high. Rang : 30 to 150% of the rated current




FUNCTION 47 FREQ. – EQUI. – HYST.

XXX Hz Open collector programmable output, sets the hysterisis width of frequency equivalence signal. Range : 0 to 5Hz.

FUNCTION 48 STP – Hz - FREQUENCY

XXX Hz Open collector programmable output. When the Inverter output frequency reaches the set stop Hz during deceleration, the open collector output goes high ( 0 to Fmax).

FUNCTION 49 ~ 51 OPEN COLLECTOR .1 ~ 3

00 to 12 Open collector 1 ~ 3 are programmable outputs. Any of the function data can be selected to output different condition of Inverter for external indication . The output transistor conducts when the selected function data for that channel reaches / exceeds the value set. There are totally 13Nos. conditions as detailed below :

* Frequency Equivalence * Speed.2 Reached * Stop Hz Signal * Speed.3 Reached * UV signal * Speed.4 Reached * OL Early Warning Signal * Speed.5 Reached * Run Indication * Speed.6 Reached * Fmax Reached * Speed.7 Reached * Speed.1 Reached




FUNCTION 49 ~ 51 OPEN COLLECTOR .1 ~ 3

00 to 12

FUNCTION 52 PAST FAULT MEMORY

Past fault 1 ~ 19 Up to 19Nos. previous faults are stored in first in first out order

FUNCTION 53 BAUD RATE

00 to 05 Baud rate of 300, 600, 1200, 2400, 4800 and 9600 can be programmed

FUNCTION 54 LINK CONTROL

Disable / Enable Link control can be enabled or disabled using this function

FUNCTION 55 LINK ADDRESS

XX Address 00 to 29 are available to program the drive address

FUNCTION 56 FREQUENCY RESOLUTION

Fine / Coarse Frequency resolution can be set in COARSE / FINE mode. Coarse resolution is 0.05Hz and Fine resolution is 0.006Hz

FUNCTION 57 WOBBULATION

Disable / Enable When this function is enabled the output frequency varies periodically between two known limits as required.

FUNCTION 58 WOBBULATION WIDTH

XXX .XX Hz Wobbulation width can be programmed from 0.01Hz to 50Hz (Fmax) with 0.01Hz resolution.




FUNCTION 59 KICK WIDTH

XXX .XX Hz Kick width can be programmed from 0 to 9.99Hz

FUNCTION 60 RAMP UP TIME

XXX .X S Programmable from 0.1 to 99.9 s

FUNCTION 61 RAMP DOWN TIME

XXX .X S Programmable from 0.1 to 99.9 s

11. MAINTENANCE VICTOR G1000


11.1 PREVENTIVE MAINTENANCE: Routine maintenance and inspection are essential for reliable operation of the

inverter.During inspections, the following precautions shall be taken WARNING

* When carrying out inspection ensure that the power supply is removed and red LED in power supply and gate drive PCB is not glowing.

* While plugging in or removing a connector ensure that the housing of the connector is held and not the wires.

11.2 MAINTENANCE TESTS a. MEGGER TEST

* When conducting an external circuit megger test, disconnect all Inverter terminals making sure to never apply test voltage to the inverter. Remove the noise capacitor earthing at R, S, T Terminals )

* When conducting a megger test on the Inverter itself, perform the test only on the main circuit as shown in the diagram below. Do not conduct a megger test on the control circuits by removing all PCB connectors.

* When conducting a continuity test on the control circuits, use a tester ( high resistance range type ) and not a megger or a buzzer.

b. INSPECTION ITEMS

Inspection item Object of inspection Correction Power source

voltage and frequency

Within permissible range : voltage of 415V (+10%,15% ) and frequency of 50 Hz ( ± 5%)

Adjust the power supply voltage and frequency.

Ambient temperature

Within permissible range of (-10)°C to (+50)°C

After investigating the cause, correct to within specified limits.

Vibration Within permissible limit : 0.6G or less Contact Kirloskar Electric Noise / Smell Noise from cooling fans etc. Contact Kirloskar Electric Dust On cooling fins/ fans, PCB’s etc. Cleaning Connectors/ Loose connectors / screws Tighten the connectors / screws

11. MAINTENANCE VICTOR G1000


11.3 PERIODIC PART REPLACEMENT

The life of the Inverter will vary according to the installation environment and the amount

of running time. However, if continuous operation is within the allowable limits, the life of the ordinary electrolytic capacitor is approx. 5 years with the life of the cooling fan being approx. 3 years. It is recommended that, capacitors are to be replaced after then 4 th year and fans are to be replaced after the 2 nd year of installation.

11.4 MEASURING RECOMMENDATIONS

Since the Inverter input current and output voltage are of non-sinusoidal type, selection

of the wrong measuring device can lead to gross miscalculations. When using a CT (current transformer) to measure the current, if the frequency is low, the amount of error will be large. For this reason always use a CT with large capacity as much as possible.

a. MEASUREMENT ITEMS AND TYPES OF DEVICES

ITEM SINGLE MEASUREMENT PRECISION MEASUREMENT Input voltage Tester Moving – iron type voltmeter Input current Clamp meter Moving – iron type ammeter Input power --- Electro - dynamometer type watt meter Output voltage Tester Rectifier type voltmeter Output current Clamp meter moving - iron type ammeter Output power --- Electro - dynamometer type watt meter b. LAYOUT OF MEASURING LOCATION AND DEVICES

12. TROUBLE SHOOTING VICTOR G1000


12.1 PROTECTIVE FUNCTIONS NOTE : For any trip LED indication is “ St01 ” a. OVER CURRENT PROTECTION

Protects Inverter when the current flow momentarily reaches the specified protection level

FUNCTION EXPLANATION LCD DISPLAY PROTECTIVE OPERATION During acceleration FAULT DETECTED

OC DURING ACCEL During deceleration FAULT DETECTED

OC DURING DECEL During constant speed FAULT DETECTED

OVER CURRENT

* Inverter output cut off. * Motor - coast- to - stop. * Alarm signal is internally

held until the alarm command is reset. Fault alarm output.

* Fault alarm output. b. EXTERNAL THERMAL FAULT

FUNCTION EXPLANATION LCD DISPLAY PROTECTIVE OPERATION Detects when the Link between

THR - CM is opened, the Link could be OLR, NC contact or Thermal switch or external interlock

FAULT DETECTED OVERHEAT THR

Same as above

c. INVERTER OVER HEATING

FUNCTION EXPLANATION LCD DISPLAY PROTECTIVE OPERATION Detects Inverter over heating

caused by over load operation, cooling fan failure, abnormal high temperature

FAULT DETECTED HEATSINK HOT

Same as above

d. INVERTER OVER LOAD

FUNCTION EXPLANATION LCD DISPLAY PROTECTIVE OPERATION 150% overload for one minute

allowed. FAULT DETECTED INV – OVER LOAD

Same as above

e. OVER VOLTAGE

FUNCTION EXPLANATION LCD DISPLAY PROTECTIVE OPERATION Protects the Inverter when the DC

Bus voltage exceeds the over voltage protection level (760V DC).

FAULT DETECTED OVER VOLTAGE

Same as above



f. UNDER VOLTAGE

FUNCTION EXPLANATION LCD DISPLAY PROTECTIVE OPERATION Protects the inverter when the DC

Bus voltage falls below the under voltage protection level (410V DC). For momentary power failure or under voltage less than 15msec; operation is intermittent. For a period exceeding 15msec. the Inverter is stopped. If the Inverter restart after instantaneous power failure mode is selected, operation will resume automatically after the power is restored

FAULT DETECTED UNDER VOLTAGE

Same as above

g. ELECTRONIC THERMAL OVERLOAD

FUNCTION EXPLANATION LCD DISPLAY PROTECTIVE OPERATION Motor current can be set as a

percentage of rated inverter current. As the motor speed reduces, electronic thermal overload if enabled, the trip will occur as per motor current and frequency

FAULT DETECTED EL THERM OV LOAD

Same as above

h. SETTING ERROR

FUNCTION EXPLANATION LCD DISPLAY PROTECTIVE OPERATION Displayed when incompatible

function codes are selected. Also gets displayed when the EPROM error is detected

FAULT DETECTED SETTING ERROR

If incompatible function codes are set during programming system does not allows user to exit from program mode



12.2 RECOVERING FROM FAULTS

LCD DISPLAY CHECK POINT CORRECTIVE MEASURE Power supply voltage within permissible limits

Adjust power supply voltage

Proper torque boost Adjust to proper value Proper acceleration time Lengthen acceleration time

a. OC – DURING ACCELERATION

Other than the above Contact Kirloskar Electric Power supply voltage within permissible limits


Proper Deceleration time Lengthen Deceleration time connect braking unit (option)

b. OC – DURING DECELERATION

Other than the above Contact Kirloskar Electric Power supply voltage within permissible limits.


Sudden change in load Eliminate sudden load change

c. OVER CURRENT

Other than the above Investigate for noise intrusion Power supply voltage within permissible limits.

Adjust power supply

Proper Deceleration time Increase deceleration time

d. OVER VOLTAGE

Other than above Connect DB unit (option) Inverter ambient temp. within permissible limits.

Maintain the temperature within range

Cooling fan not operating. Replace cooling fan

e. HEAT SINK HOT

Load is over permissible limits. Reduce load Proper wiring between THR – CM Rewire Thermal over load relay activated Reduce load, Correct ambient

temp. / lower braking frequency

f. OVER HEAT THR

Continuity check between THR-CM Correct the wiring Power supply voltage within permissible limits


MCCB is closed Close MCCB

g. UNDER VOLTAGE

Other than the above Investigate power supply capacity Electronic thermal overload set correctly

Change thermal relay h. OVER LOAD

Load is over permissible limits Reduce load

NOTES VICTOR G1000

KIRLOSKAR ELECTRIC

K I R L OS K AR E L E CT R I C COMPANY L I MI T E D, UNIT.IV, BELAVADI INDUSTRIAL AREA, MYSORE – 570 018, INDIA

PHONE : 0091-821-2402522 - 26, FAX : 0091-821-2402266 Email : [email protected] Web : www.kec4.com

vtr g1000 user manual

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