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Safety engineering
Functional test
Monitoring the safety function with a PLC
14
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EDS82EV903   EN   3.0
Example: Parameterising a digital output 
In the following we will show you a possibility of parameterising a digital output, so that
a conclusion with regard to the motor current is provided.
Sequence
Parameter
Comment
1. Configure the input signal of digital
output A1:
Link DIGOUT to internal status signal
DCTRL1−IMOT<ILIM
C0415/2 = 20
2.
Set current threshold I
lim
:
I
motor
< I
lim
 A1 = HIGH
I
motor
I
lim
A1 = LOW
Set the current threshold to 2 %
C0156 = 2
Functional test within the inspection interval
For the functional test, check both disconnecting paths separately.
1st disconnecting path: pulse inhibit via safety relay K
SR
The individual tests are passed if the correct states given in the table result.
Individual test
Specification
Correct status
Relay control input (X3.1/34)
Feedback output (X3.1/K31)
Pulse inhibit
LOW
HIGH
Pulse enable
HIGH
LOW
2nd disconnecting path: controller inihibit
Requirement for the test:
ƒ
"Automatic DC injection brake" function deactivated (C0019 = 0.00)
ƒ
"Quick stop" function (QSP) deactivated
ƒ
Pulses enabled by safety relay K
SR
(X3.1/34 = HIGH)
The individual tests are passed if the correct states given in the table result.
Individual test
Specification
Correct status
Controller inhibit (28)
Setpoint
Digital output (Ax)
Controller inhibit
LOW
nset
I
lim
HIGH
Controller enable
HIGH
LOW
Functional test not passed
If an individual test results in an impermissible status, the functional test is not passed.
ƒ
The drive or machine has to be shut down immediately.
ƒ
Commissioning is not permitted until the safety function operates correctly.
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Application examples
Pressure control
15
502
EDS82EV903  EN  3.0
15
Application examples
15.1
Pressure control
The following examples show a simple pressure control with the 8200 vector frequency
inverter or 8200 motec using the internal process controller.
The setpoint can either be defined in a fixed way via the code C0181 (example 1) or variably
with the motor potentiometer function (example 2).
Application example
A centrifugal pump (quadratic load characteristic) is to maintain constant pressure in a
pipeline system (e.g. water supply for private households or industrial plants).
Note!
ƒ
For this example, the controller must be equipped with a standard I/O since
an analog input for the actual pressure value is required.
ƒ
If you want to select the pressure setpoint via an analog source, you need an
application I/O since two analog inputs are required. This variant will not be
considered in the following.
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Application examples
Pressure control
Example 1: Simple pressure control with fixed setpoint selection
15
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EDS82EV903   EN   3.0
15.1.1
Example 1: Simple pressure control with fixed setpoint selection
The actual value is supplied via the analog input of the standard I/O  and linked to the
controller input (PCTRL−ACT). The setpoint is defined via code C0181 .
PCTRL1
DCTRL1-QSP
DCTRL1-CINH
C0412/3
PCTRL1-NADD
C0105
C0220
C0221
+
C0181
PCTRL1-SET2
C0049
PCTRL1-RFG1
2
0
C0412/5
PCTRL1-ACT
C0412/4
PCTRL1-SET1
1
PCTRL1-SET3
C0145
C0071
C0070
C0072
>1
C0410/18
PCTRL1-I-OFF
C0410/21
PCTRL1-STOP
C0410/19
PCTRL1-OFF
STOP
Imax,
Auto-DCB,
LU,OU
>1
0
1
CINH,DCB
C0074
C0184
RESET
+
0
2
1
C0238
C0011
-C0011
PCTRL1-NOUT
PCTRL1-OUT
PCTRL1-QMIN
PCTRL1-NMIN
C0010
PCTRL1-ACT
C0017
PCTRL1-SET=ACT
PCTRL1-SET
NSET1-NOUT
C0138
C0239
2
0,1
C0238
C0051
+
2
1
PCTRL1-SET3
AIN1
+
AIN1-GAIN
+
AIN1-OFFSET
C0414/1
C0413/1
C0010
C0034
A
D
X3
AIN1-OUT
8
7
8200vec543
Fig. 15−1
Signal flow − overview
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Application examples
Pressure control
Example 1: Simple pressure control with fixed setpoint selection
15
504
EDS82EV903  EN  3.0
Application−specific configuration
Code
Settings
IMPORTANT
No.
Name
Value
Meaning
C0014 Operating mode
3
V/f characteristic control V f2
square−law characteristic with
constant V
min
boost
C0019
Operating
threshold −
automatic DC
injection brake
(auto DCB)
0
Automatic DC injection brake is deactivated
If the lower frequency limitation is
activated (C0239) or if C0181 is used
as controller setpoint (C0145), the
automatic DC injection brake must
be deactivated!
C0106
Hold time −
automatic DC
injection brake
(auto DCB)
0
Automatic DC injection brake is deactivated
C0070
Process
controller gain
1.00
Lenze default
setting
Adapt to process, if required.
Further information:   318 ff.
C0071
Process
controller reset
time
100
Lenze default
setting
C0074
Influence of the
process
controller
100.0
0.0
{0.1 %}
100.0
C0145
Source of
process
controller
setpoint
1
Setpoint from C0181 (PCTRL1−SET2)
Automatic DC injection brake (auto
DCB) must be deactivated with
C0019 = 0 or C0106 = 0
C0181
Process
controller
setpoint 2
(PCTRL1−SET2)
−650.00
{0.02
Hz}
650.0
C0238
Frequency
precontrol
0
No feedforward control (only process controller)
Process controller has full influence.
C0239
Lower frequency
limitation
 0
Prevent reversed rotation
The value does not fall below the
limit independently of the setpoint.
Automatic DC injection brake (auto
DCB) must be deactivated with
C0019 = 0 or C0106 = 0
C0412
Linking analog signal sources to internal analog
signals
1
Setpoint 1
(NSET1-N1)
255
fixed free (disconnect from analog input)
The analog input of the standard I/O
(AIN1) is linked factory−set to the
speed feedforward control. This
connection must be separated so
that the input can be used for the
analog actual value (C0412/5).
2
Setpoint 2
(NSET1-N2)
255
5
Actual process
controller value
(PCTRL1−ACT)
1
Analog input X3/8 of the standard I/O
Actual pressure value
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Application examples
Pressure control
Example 2: Simple pressure control with changeable setpoint selection
15
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EDS82EV903   EN   3.0
15.1.2
Example 2: Simple pressure control with changeable setpoint selection
The actual value is supplied via the analog input of the standard I/O  and linked to the
controller input (PCTRL−ACT).
The setpoint is defined with the motor potentiometer function  and supplied to the
process controller via the controller input (PCTRL1−NADD). This value is added to the value
from  the speed feedforward  control (NSET1).  This requires  the output  of the speed
feedforward control (NSET1−NOUT) to be zero.
PCTRL1
DCTRL1-QSP
DCTRL1-CINH
C0412/3
PCTRL1-NADD
C0105
C0220
C0221
+
C0181
PCTRL1-SET2
C0049
PCTRL1-RFG1
2
0
C0412/5
PCTRL1-ACT
C0412/4
PCTRL1-SET1
1
PCTRL1-SET3
C0145
C0071
C0070
C0072
>1
C0410/18
PCTRL1-I-OFF
C0410/21
PCTRL1-STOP
C0410/19
PCTRL1-OFF
DFIN1
STOP
Imax,
Auto-DCB,
LU,OU
>1
0
1
CINH,DCB
C0074
C0184
RESET
+
0
2
1
C0238
C0011
-C0011
PCTRL1-NOUT
PCTRL1-OUT
PCTRL1-QMIN
PCTRL1-NMIN
C0010
PCTRL1-ACT
C0017
PCTRL1-SET=ACT
PCTRL1-SET
NSET1-NOUT
C0138
C0239
DCTRL1
2
0,1
C0238
C0051
+
2
1
PCTRL1-SET3
0
AIN1
+
AIN1-GAIN
+
AIN1-OFFSET
C0414/1
C0413/1
C0010
C0034
A
D
X3
AIN1-OUT
8
7
MPOT1
MPOT1-OUT
C0265
C0410/7
MPOT1-UP
C0410/8
MPOT1-DOWN
MPOT1-QSP
C0011
C0010
C0265=3,4,5
MPOT
INIT
DIGIN1
X3
1
1
0
E1
E2
E4
E3
C0411
8200vec544
Fig. 15−2
Signal flow − overview
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Application examples
Pressure control
Example 2: Simple pressure control with changeable setpoint selection
15
506
EDS82EV903  EN  3.0
Application−specific configuration
Code
Settings
IMPORTANT
No.
Name
Value
Meaning
C0014 Operating mode
3
V/f characteristic control V f2
square−law characteristic with
constant V
min
boost
C0019
Operating
threshold −
automatic DC
injection brake
(auto DCB)
0
Automatic DC injection brake is deactivated
If the lower frequency limitation is
activated (C0239) or if C0181 is used
as controller setpoint (C0145), the
automatic DC injection brake must
be deactivated!
C0106
Hold time −
automatic DC
injection brake
(auto DCB)
0
Automatic DC injection brake is deactivated
C0070
Process
controller gain
1.00
Lenze default
setting
Adapt to process, if required.
Further information:   318 ff.
C0071
Process
controller reset
time
100
Lenze default
setting
C0074
Influence of the
process
controller
100.0
0.0
{0.1 %}
100.0
C0145
Source of
process
controller
setpoint
0
Overall setpoint (PCTRL1−SET3)
Setpoint = NSET1−NOUT +
PCTRL1−NADD
(Main setpoint + additional setpoint)
C0181
Process
controller
setpoint 2
(PCTRL1−SET2)
−650.00
{0.02
Hz}
650.0
C0238
Frequency
precontrol
0
No feedforward control (only process controller)
Process controller has full influence.
C0239
Lower frequency
limitation
 0
Prevent reversed rotation
The value does not fall below the
limit independently of the setpoint.
Automatic DC injection brake (auto
DCB) must be deactivated with
C0019 = 0 or C0106 = 0
C0412
Linking analog signal sources to internal analog
signals
1
Setpoint 1
(NSET1-N1)
255
fixed free (disconnect from analog input)
The analog input of the standard I/O
(AIN1) is linked factory−set to the
speed feedforward control. This
connection must be separated so
that the input can be used for the
analog actual value (C0412/5).
2
Setpoint 2
(NSET1-N2)
255
5
Actual process
controller value
(PCTRL1−ACT)
1
Analog input X3/8 of the standard I/O
Actual pressure value
Note!
ƒ
The motor potentiometer in connection with the standard I/O may only be
linked with the signals NSET1−N1, NSET1−N2 or PCTRL1−NADD. The linkage
with other signals would cause a setpoint step−change.
ƒ
When selecting the setpoint via the motor potentiometer, we recommend
the acceleration and deceleration times  5s (C0220, C0221).
Application examples
Operation with mid−frequency motors
15
507
EDS82EV903   EN   3.0
15.2
Operation with mid−frequency motors
Mid−frequency asynchronous motors are used where high and adjustable speeds are
required. Possible  applications are milling  cutters for wood working machines, fans,
vacuum pumps, concrete vibrators, grinding and polishing drives.
Dimensioning notes
ƒ
If the motor is to be braked shortly, and with high moments of inertia, an external
brake resistor must be used. (  484)
ƒ
Set the speed setting range so that motors with integral fan are always cooled
sufficiently (setting range as a function of load)
Application−specific configuration
Code
Name
Setting
Comment
C0011
Max. output frequency
Set to the value given on the motor nameplate, not higher
than 400 Hz.
C0012
Acceleration time −
main setpoint
Set it so that acceleration takes place below the current
limitation.
C0013
Deceleration time −
main setpoint
Set it so that braking is possible with or without external
brake without the "overvoltage (OU)" message being
displayed.
C0014
Operating mode
2
Linear characteristic (best operational performance for
mid−frequency motors)
C0015
V/f rated frequency
  205
C0016
V
min
boost
Setting depends on the load at low frequencies.
Recommendation: 0 %
C0018
Switching frequency
3
16 kHz (good concentricity with only 16 kHz)
Observe power reduction
C0021
Slip compensation
0 %
Normally not required.
C0022
I
max
limit in motor
mode
Set to rated motor current.
At short acceleration times and high moments of inertia to
150 %.
C0023
I
max
limit in generator
mode
150 %
Lenze setting
C0106
Hold time for DCB
0 s
DC injection brake must be deactivated!
C0144
Switching frequency
reduction
0
No reduction.
Application examples
Speed control
15
508
EDS82EV903  EN  3.0
15.3
Speed control
Note!
Lenze three−phase AC motors and Lenze geared motors can be delivered in
conjunction with the ITD21 pulse encoder by Lenze (512/2048 increments, HTL
output signals) which can be used to generate a two−track speed feedback
(tracks A and B):
ƒ
With function module application I/O: 0 ... 102.4 kHz
ƒ
With function module standard I/O: 0 ... 1 kHz
Example
Speed control with inductive single−track three−wire sensor
The speed control is designed to correct the deviation between the actual speed and the
setpoint speed caused by the effect of the load (motive and generative).
In order to detect the motor speed, the inductive sensor scans e.g. a gear, a metallic fan
impeller or cam. Scanning should take place directly on the motor or within the machine.
 
 
           
 
 
 
 
 
  
     
   
 
 
    
  
    
         
Fig. 15−3
Speed control with 3−conductor sensor
Setpoint
Three−wire sensor
8200 8200 motec or 8200 vector
Application examples
Speed control
15
509
EDS82EV903   EN   3.0
Speed sensor requirements
Note!
You can use every speed sensor which meets the level and scanning ratio
requirements.
ƒ
The maximum frequency of inductive sensors generally ranges from 1 ... 6 kHz
depending on the type.
ƒ
At the detection point, the number of attenuation cams per revolution must ensure
an output frequency of the sensor as high as possible.
ƒ
The control dynamics will be sufficient if the output frequency (f
act
) is > 0.5 kHz at
rated speed.
ƒ
If the current consumption of the sensor is not higher than the value permitted at
X3/20, a three−wire sensor can be directly connected to the controller.
Output frequency calculation
f
ist
zn
60
z = number of cams per revolution
n = speed at the detection point [rpm]
f
act
= output frequency of the sensor in [Hz]
Permissible pulse shape at X3/E1
      
 
 
  
 
T
e
= on (HIGH)
T
a
= off (LOW)
Permissible level range:
LOW: 0 ... +3 V
HIGH: +12 ... +30 V
Permissible range of the scanning ratio
T
e
: T
a
= 1 : 1 until T
e
: T
a
= 1 : 5
Application examples
Speed control
15
510
EDS82EV903  EN  3.0
Application−specific configuration
ƒ
Basic settings.
Code
Settings
IMPORTANT
Value
Meaning
C0410 Free
configuration of
digital input
signals
Configuration of frequency input
X3/E1
24
DFIN1−ON
1
C0412
Free
configuration
of analog input
signals
Analog signal source
5
Actual process
controller value
(PCTRL1−ACT)
2
C0011
Maximum
output
frequency
(1
C0074[%]
100
)
p
60
n
max
p = number of pole pairs
n
max
= required maximum speed
[rpm]
C0014
Operating
mode
2
V/f characteristic control
Dynamics in "Vector control" mode
too low
C0019
Operating
threshold auto
DCB
approx. 0.5 Hz
Adaptation to the application
C0021
Slip
compensation
0 %
No slip compensation with controlled
operation
C0035
DCB selection
1
Brake current selection under C0036
C0036
Voltage/current
DCB
50 ... 100 %
Adaptation to the application
C0070
Process
controller gain
1 ... 15
5 = typical
C0071
Process
controller reset
time
50 ... 500 ms
100 ms = typical
C0072
Differential
component −
process
controller
0
Inactive
C0074
Influence of the
process
controller
2 ... 10 %
S
N
n
0
n
N
n
0
Example
S
N
15001400
1500
6.67%
Adaptation to the application
Set 200% rated motor slip (2 *
S
rated
)
C0106
Hold time auto
DCB
1 s
Guide value
Afterwards the controller sets
controller inhibit
C0181
Process
controller
setpoint 2
(PCTRL1−SET2)
Adaptation to the application
Selection with keypad or PC
C0196
Activation auto
DCB
0
DCB active when C0050 < C0019 and
setpoint < C0019
C0196 = −1− is not permissible in this
configuration
C0238
Frequency
precontrol
1
With frequency feedforward control
C0239
Lower
frequency
limitation
0 Hz
Unipolar, no reversal of rotation
direction
C0425
Configuration
of frequency
input X3/E1
(DFIN1)
Set C0425 so that, at maximum
motor speed, the frequency supplied
by the encoder is lower than f
max
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