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Zener 8000-V Installation Manual

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ZENER VARIDRIVE SOLUTIONS
ZENER 8000-V
Installation Manual
Document:
IM00165
Printed:
27 February 2019

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Summary of Contents for Zener 8000-V

  • Page 1 ZENER VARIDRIVE SOLUTIONS ZENER 8000-V Installation Manual Document: IM00165 Printed: 27 February 2019...
  • Page 2 SAFETY Your ZENER 8000-V must be applied, installed and operated in a safe manner. It is the responsibility of the user to ensure compliance with all regulations and practices covering the installation and wiring of your ZENER 8000- V.

  • Page 3: Table Of Contents

    Software ..................................2 Installation ................................. 3 ZENER 8000-V mounting location ......................... 3 Installation Information ............................3 ZENER 8000-V Mechanical Installation Information ....................4 V1 Module ................................4 V1 Module dimensions ............................4 V1 Module mounting cut-out detail ........................5 V1 Module mounting clearance requirements ....................6 V2 Module ................................
  • Page 4 Terminating resistors ............................25 General ................................25 Shortcuts ................................. 25 Extended Features Option Wiring .......................... 26 ZENER 8000-V Start Up ............................27 Operation Displays & Pushbuttons ........................28 Local Mode Operation Example ........................29 Complete Menu ..............................30 Application Menu ............................... 31 Loading an Application ...........................
  • Page 5 Status Messages ..............................47 Specifications ................................49 Output Current Specifications ..........................51 Troubleshooting guide ............................51 Your ZENER 8000-V Setup Notes ..........................54 Appendix A - Electrical distribution earthing systems ..................... 58 Electrical earthing ..............................58 Protective earthing ............................58 Functional earthing............................
  • Page 6 Contents IM00165...

  • Page 7: Explanation Of Symbols

    8000-V with the door open or any part of the enclosure removed. Do not touch the terminals of the ZENER 8000-V or any associated motor and wiring when it is energised, even if the ZENER 8000-V and motor are stopped. Electric shock may result.

  • Page 8: Receiving

    Inspect the ZENER 8000-V for any shipping damage. If any damage is found, report it to the carrier immediately. Do not attempt to operate the ZENER 8000-V if any obvious damage exists. After the initial inspection, the ZENER 8000-V can be repacked and stored in a clean, dry location until it is required for use.

  • Page 9: Installation

    ZENER 8000-V mounting location The ZENER 8000-V chassis is intended to be mounted in a switchboard style enclosure with the heatsink section protruding through the rear wall of the enclosure. The input and output line reactors provided as part of the ZENER 8000-V should be mounted within the switchboard, adjacent to, or on the enclosure floor, below the ZENER 8000-V module chassis.

  • Page 10: Zener 8000-V Mechanical Installation Information

    ZENER 8000-V Mechanical Installation Information Each ZENER 8000-V system consists of one module or a number of modules for connection in parallel. There are two physical sizes of module, V1 and V2, with a number of different electrical ratings available in each physical module size.

  • Page 11: V1 Module Mounting Cut-Out Detail

    ZENER 8000-V Installation Manual M6 TAPPED HOLE M6 TAPPED HOLE for mounting clamp for mounting clamp M6 TAPPED HOLE M6 TAPPED HOLE for mounting clamp for mounting clamp CUTOUT M6 TAPPED HOLE for mounting clamp M6 TAPPED HOLE for mounting clamp...

  • Page 12: V1 Module Mounting Clearance Requirements

    ZENER 8000-V Installation Manual CUSTOMER'S PANEL CUSTOMER'S PANEL AIR EXHAUST This area must be kept clear INVERTER HEATSINK This area must be kept clear MOUNTING CUTOUT As shown on Sheet 2 1018 1018 AIR INTAKE This area must be kept clear...

  • Page 13: V2 Module

    ZENER 8000-V Installation Manual V2 Module The inverter modules for ratings of 84A and above are of V2 dimensions. COOLING FAN ASSEMBLY TOP GLAND PLATE Allow access for removal Opening 94mm x 54mm 403 mm 651 mm 19 mm 224.8 mm 36.5 mm...

  • Page 14: V2 Module Mounting Cut-Out Detail

    ZENER 8000-V Installation Manual 651 mm 20 mm 611 mm 50.5 mm M6 TAPPED HOLE M6 TAPPED HOLE for mounting clamp for mounting clamp 328.5 mm M6 TAPPED HOLE M6 TAPPED HOLE for mounting clamp for mounting clamp 718 mm...

  • Page 15: V2 Module Mounting Clearance Requirements

    ZENER 8000-V Installation Manual 751 mm 277 mm 494 mm 758 mm 150 mm 50 mm 50 mm CUSTOMER'S PANEL 50 mm 50 mm CUSTOMER'S PANEL AIRFLOW 277 mm 125 mm 150 mm For installations with inverter modules mounted side by side, the minimum mounting pitch horizontally is 751mm.

  • Page 16: Remote Console Mounting

    An Earth termination is available if the user would like to earth all exposed metal components including the front panel. The console only uses extra low voltage so earthing is not required. With power removed from the ZENER 8000, connect the CAT-5 cable supplied to the console & the ZENER Drive. IM00165...

  • Page 17: Zener 8000-V Power Wiring

    Note that the protection offered by this device on the AC line side of the ZENER 8000-V does not extend to the output (motor) side because the AC line side current may be considerably less than the ZENER 8000-V output current when operating at less than full speed.

  • Page 18: Electrical Isolation

    Electrical Isolation A suitable means of isolating the ZENER 8000-V from the electrical supply must be provided in accordance with your local electrical code. In the event that a second supply is connected to the relay contacts on the control...

  • Page 19: Power Wiring For Single Units

    ZENER 8000-V Installation Manual Power Wiring for Single Units 3 Phase AC supply AC line overcurrent protection (see text for details) Input line reactor Important notes: Input and output line reactor terminals should INVERTER MODULE not be used to terminate...

  • Page 20: Power Wiring For Parallel Units

    ZENER 8000-V Installation Manual Power Wiring for Parallel Units 3 Phase AC supply AC line overcurrent protection (see text for details) Input line reactors 2, 3 or 4 parallel modules may be INVERTER INVERTER INVERTER INVERTER used, for various MODULE...

  • Page 21: Control Interconnection For Parallel Units

    ZENER 8000-V Installation Manual Control Interconnection for Parallel Units 1,2 or 3 slave units may be used ZENER.8000 ZENER.8000 ZENER.8000 ZENER.8000 All control wiring SLAVE SLAVE SLAVE MASTER communications Module 4 Module 3 Module 2 Module 1 connects to master module...

  • Page 22: Earth Leakage Currents In It Supply System Environments

    A general explanation of “IT” and “TN” electrical distribution earthing systems is provided as an appendix. Basic VSD power circuit The ZENER 8000-V rectifies the incoming AC line to produce a DC voltage that feeds and inverter stage consisting of 6 IGBT switches. The switches are operated to create a pulse width modulated (PWM) output voltage between the M1/M2/M3 output terminals.

  • Page 23: Common Mode Voltage And Capacitive Currents

    ZENER 8000-V Installation Manual Common mode voltage and capacitive currents A side effect of the PWM process is that there is also a voltage generated between an imaginary star point on the 3 phases feeding the motor (M1/M2/M3) and the star point of the incoming AC supply.

  • Page 24: Magnitude Of Capacitive Leakage Currents

    ZENER 8000-V Installation Manual Note that all of the capacitors in this diagram are just “stray” capacitances incidental to cables, motors etc. There are no intentionally installed capacitors here. Single line diagram showing potential paths for capacitive leakage currents Magnitude of capacitive leakage currents The magnitude of an AC current can be evaluated according to several different concepts.

  • Page 25: Earth Leakage Monitoring Instruments / Devices

    ZENER 8000-V Installation Manual characteristic in a general sense rather than a formal specification. Please consult the manufacturer of the particular device regarding expected behaviour and suitability for your application. The expected value of capacitive leakage current by the RMS(300Hz LP) method can be estimated as: 1.5mA RMS for each 1nF of total stray capacitance...

  • Page 26: Q&A

    ZENER 8000-V Installation Manual Q&A This seems very different to 415V VFDs installations. Why? The basic mechanism producing capacitive leakage currents is the same in both types of VFD. In a 415V VFD intended for a TN supply network the path for the capacitive leakage current is managed by using a screened power cable between the VFD and motor together with substantial capacitors (integral to the VSD) connected between the AC input and ground.

  • Page 27: Can I Add An Emc Filter On The Ac Line To The Drive

    ZENER 8000-V Installation Manual Can I add an EMC filter on the AC line to the drive? There is no issue from a drive point of view; however the majority of packaged EMC filters available in the market have substantial capacitors connected between the phase conductors and earth which is acceptable in a TN supply system, but likely to be problematic in an IT supply system.

  • Page 28: Electromagnetic Compatibility (Emc)

    Clause 6.6 Engineering practice provides a methodology for dealing with C4 category equipment such as ZENER 8000-V systems as well useful information on problems associated with applying the more usual kind of AC line filter employed in low voltage appliances to power systems with isolated or impedance grounded neutrals (IT‑network).

  • Page 29: Screened Power Cables And Alternative Materials

    ZENER 8000-V Installation Manual Screened power cables and alternative materials There is a wide variety of materials available as well as a degree of misunderstanding concerning the benefits of material without explicit EMC related specification. The following table seeks to summarise the situation.

  • Page 30: Eia/Rs-485 Communications Wiring

    EIA/RS-485 interface circuit. The third conductor is used to keep the common connection (marked as terminal “C” in ZENER 8000-V) in all the communications interfaces at the same potential, that is, keep the common mode voltage at each interface within the limits specified by the standard.

  • Page 31: Terminating Resistors

    Serial Communications Serial Communications Serial Communications Only 3 slave devices shown. More slave devices (ZENER 8000 and other) may be added up to the loading limit of 32 units. Communications Each ZENER 8000 interface is 0.5 load units. cable screen...

  • Page 32: Extended Features Option Wiring

    ZENER 8000-V Installation Manual Extended Features Option Wiring IM00165...

  • Page 33: Zener 8000-V Start Up

    Select the terminal configuration you require. Connect the control wiring according to the appropriate Control Wiring Diagram or follow a quick setup. The ZENER 8000-V is now ready to run. Before applying power ensure that rotation of the motor shaft will not cause injury or damage.

  • Page 34: Operation Displays & Pushbuttons

    ZENER 8000-V Installation Manual Operation Displays & Pushbuttons The operational displays show the operating state of the ZENER 8000-V. The six operational displays are: Speed  / Reference Display, Meter Display, PID Display, PID / Meter Display and kWhr / Hours Run Display. Press (ENTER) to reveal each display.

  • Page 35: Local Mode Operation Example

    IMPORTANT! If the motor shaft rotates in the wrong direction remove the input power, wait for the ZENER 8000-V to discharge and swap any two motor phase wires. Re-apply input power and select a direction by pressing ▲ FWD or ▼ REV.

  • Page 36: Complete Menu

    G00 INPUT/OUTPUT menus to set up the ZENER 8000-V before running the motor to prevent any unexpected motor operation. The ZENER 8000-V is supplied with a link between the EN terminal and the +5V terminal. This link must always be made for the motor to run.

  • Page 37: Application Menu

    An “application” groups parameters together in one location creating a short menu to summarise all the relevant parameters necessary for your application. The ZENER 8000-V has several applications on offer ready for your selection and convenience. Some of the more common and simplest of applications will be described in the following sections. More sophisticated applications will have extra documentation detailing wiring and commissioning information.

  • Page 38: Loading An Application

    ZENER 8000-V Installation Manual Loading an Application 4 Speed Sel. -00 Follow the diagram below to load an application. E.g. Loading the “ ” application. Begin at a 0.0Hz 0.0kW 0.0A run display  EXIT A00 DEFAULTS   ENTER Load Factory ...

  • Page 39: Application User Menu

    ZENER 8000-V Installation Manual Application user menu Once an application is loaded, parameters that a user/operator may change are available in the Application user 4 Speed Sel. -00 menu. Continuing with the “ ” application example, the diagram below shows how to access the Application user menu.

  • Page 40: Control Connections And Configuration

    Assignment of particular control functions to terminals (inputs) and relays (status outputs). These can be selected individually. The ZENER 8000-V control terminals can be configured, on an individual terminal basis, to suit a wide variety of applications. This provides enormous flexibility.

  • Page 41: Control Inputs

    ZENER 8000-V Installation Manual Control Inputs The ZENER 8000-V is operated by a set of digital input functions designed to work with logical signals that originate external to the drive. The extensiveness of this set of functions is testament to variety of applications the ZENER 8000-V can operate with.
  • Page 42 ZENER 8000-V Installation Manual The G01 DI config menu permits the selection of all standard and custom configurations. The available choices are: For each configuration the digital sources are: G01 DI config Function I00 FWD&LATCH D3(4) D2(3) EN(6) D2(3) D2(3) D2(3) I01 REV&...

  • Page 43: Standard Industrial Terminals

    This section shows the typical configurations applicable to a wide range of industrial applications. The motor speed may be controlled from the local console on the ZENER 8000-V or a remote signal source. Switching between local and remote operation is controlled by a contact closure. This terminal configuration is the factory default.

  • Page 44: Setup Guide

    ZENER 8000-V Installation Manual Setup Guide Features Single direction operation, Select between local (console) and Remote (wiring to terminal strip) control Procedure STEP 1. Complete the power wiring according to the instructions on pages 11 to 23 STEP 2. Choose your own control method from one of the following. Connect your control wiring as shown.
  • Page 45 ZENER 8000-V Installation Manual STEP 3. Choose your speed reference and connect it as shown. Speed control from an external potentiometer Control Board Terminals Vref This is typically used for simple manual speed control. See also Console Reference below. 1k to 10k Ohm...
  • Page 46 ZENER 8000-V Installation Manual STEP 4. Follow the instructions on page 27 for ZENER 8000-V start up, setting the parameters according to the table below. Alternative values may be used to suit the application. Menu Menu Item Suggested Setting G01 Inpt fxn CFG I00 FWD &...

  • Page 47: Application: Machine Drive, Start/Stop, Jog Forward & Reverse

    Individual jog forward and jog reverse speed references.  Remote potentiometer normal operating speed reference.  Relays configured for RUN and TRIP operation.  The full range of ZENER 8000-V features and functions remain available. Expected Wiring Control Board Terminals COM SCN Vref Stop/reset Start Jog Forward 1kΩ...

  • Page 48: Application: Water Pumping With Automatic Pressure Control

    4 to 20mA analogue input for pressure feedback with loop supply.  Factory Default RUN/LOCAL-REMOTE logic  Dual Ramp Logic  The full range of ZENER 8000-V features and functions remain available. Expected Wiring Control Board Terminals COM SCN Vref Extended Features Card (Left option slot) Stop/...

  • Page 49: Application Parameters

    ZENER 8000-V Installation Manual To change the required pressure:  Press the ESC push button on the console to reveal Pressure Ctl-00 application menu. user menu  Press ENTER to view the first application parameter. Reqd Pressure  500.0 kPa Press UP or DOWN to view other parameters.

  • Page 50: Pressure Control Performance

    ZENER 8000-V Installation Manual Pressure Control Performance Observation Corrective Actions  Verify the analogue input reading matches the transducer output signal.  A steady state error may be present. Go to H00 PID In closed loop the pressure does not Control ...

  • Page 51: Additional Detailed Information

    Contact ZENER for recommendations. Packing for transport Drive components for shipment to Zener need to be suitably packed for the chosen mode of transport to avoid damage. Shipping equipment on open pallets or otherwise without appropriate physical protection generally results in significant transport damage and we strongly recommend against this arrangement.

  • Page 52: Display Messages

    The ZENER 8000-V will protect itself against a variety of fault conditions. When one or more of these conditions occur, the ZENER 8000-V will trip, shut down the motor and display one or more fault messages on the top line of the console display.

  • Page 53: Status Messages

    NO AC detected no AC input voltage supply The ZENER 8000-V is waiting for the DC bus capacitors to be fully charged before running the motor CHARGING The ZENER 8000-V is on but has no enable signal so it is unable to turn a motor...
  • Page 54 FILLING The pipe fill function is activated and pipe filling is underway The PID-A block is operating and the ZENER 8000-V is part of a closed loop feedback system PID-A The PID-B block is operating and the ZENER 8000-V is part of a closed loop feedback system...

  • Page 55: Specifications

    ZENER 8000-V Installation Manual Specifications Input Supply Digital Inputs +5V and COM 5Vdc Supply Voltage 950 to 1100Vac, 3Ø 40mA max current -15% to +10% D1 to D4 and EN Frequency 48 to 62 Hz Digital Inputs Logic High 3 to 5Vdc...
  • Page 56 ZENER 8000-V Installation Manual Deceleration time 0.5 to 600s S time 0.01 to 40s Flux Plus 0 to 200% Slip Comp 0 to 150% of slip speed Audible Frequency 2 to 16kHz Current Limit 18 to 100% of overload current rating...

  • Page 57: Output Current Specifications

    +5V. Check that the ENABLED message is displayed. Motor does not rotate when UP Check that if you have a remote ZENER 8000-V is in REMOTE button on the Console is pressed. terminal it is not at +5V with respect to COM.
  • Page 58 This is a normal operating mode for the ZENER 8000-V. When the load is being accelerated too fast, the ZENER 8000-V limits current drawn by the motor by Current limit circuit is operating. extending the acceleration ramp time.
  • Page 59 ZENER 8000-V Installation Manual Symptom Cause Remedy ZENER 8000-V’s maximum current. ratings. See general specification and check Input voltage has exceeded the input is within ratings. Check maximum ratings. input supply for voltage transients. OVER VOLTAGE message appears. Fix the external source.

  • Page 60: Your Zener 8000-V Setup Notes

    ZENER 8000-V Installation Manual Your ZENER 8000-V Setup Notes Copy this page or complete in pencil Date: …………………………………… Site designator: …………………………………………….. Serial No: ………………..…………… Parameter User Default Parameter User Default A06 Application: E078 SFC time <none> 1 sec B01 MOTOR VOLTS...
  • Page 61 ZENER 8000-V Installation Manual Parameter User Default Parameter User Default F100 PRESET1 G0750 T2 Input 1 10.00% F1001 PRESET2 units G0751 T2 Input 2 F101 PRESET2 G0752 T2 Reset 20.00% F1011 PRESET3 units G0753 T1 Logic Standard F102 PRESET3 T2 IN1,2,3 m0:7 IN: 30.00%...
  • Page 62 ZENER 8000-V Installation Manual Parameter User Default Parameter User Default G156 AO config G270 Warn mode 0 to 5V ALWAYS G160 Protocol G271 Warn input none G161 bits/sec G272 Warn text 19200 -<UW1>- G162 Parity G280 Warn mode Even parity...
  • Page 63 ZENER 8000-V Installation Manual Parameter User Default Parameter User Default H22 Integ. time J05 LOCAL RUN EN 2.00 sec H23 Diff time S04 FAN OVERRIDE 0.00 sec DISABLED H24 +Opt clamp S05 PF & UV MASK DISABLED H25 –Opt clamp...

  • Page 64: Appendix A - Electrical Distribution Earthing Systems

    ZENER 8000-V Installation Manual Appendix A - Electrical distribution earthing systems Electrical earthing "Earthing" is the connection of the exposed-conductive parts of an electrical installation by means of protective conductors to an electrode in contact with the earth's surface. Earthing is provided for both safety (protective) and functional purposes...
  • Page 65 ZENER 8000-V Installation Manual (b) To take advantage of the limited fault current available in the event of an earth fault in an IT system with impedance earthed neutral. This arrangement is widely used in the mining industry on the basis...

  • Page 66: Glossary

    ZENER 8000-V Installation Manual Glossary ~STOP The logical inverse of STOP. This circuit must be closed for the ZENER 8000-V to run. 2-wire control Control of the stop / start function by a simple contact closure (eg a start / run switch contact).
  • Page 67 AC input current measured in a way that reflects the true heating value of the current. The terminal on the ZENER 8000-V for the connection of the screen of all cabled associated with analogue and digital control functions. Underwriters Laboratories Inc. An American organization involved in product safety standards and certification.
  • Page 68 ZENER 8000-V Installation Manual IM00165...
  • Page 69 ZENER 8000-V Installation Manual IM00165...
  • Page 70 ZENER ELECTRIC PTY LIMITED ACN 001 595 428 366 Horsley Rd PO Box 347 T: +61 2 97953600 Milperra NSW 2214 Milperra NSW 2144 sales@zener.net Australia Australia http://www.zener.com.au © Zener Electric Pty Ltd 2019 IM00165 February 2019...

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