Training Manual

Frequency converter

Manufacturer:

KAESER KOMPRESSOREN GmbH

96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
/KKW/SSFC 1.00 en SCHULUNGSHANDBUCH

20100827 120114
 Contents

1 Regarding this document

1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 2
1.5 Validity .............................................................................................................................. 3
2 Technical Specification
2.1 Getting familiar with control ranges .................................................................................. 4
2.2 Frequency converter types used ...................................................................................... 4
3 Safety and responsibility
3.1 Basic instructions ............................................................................................................. 6
3.2 Dangers ............................................................................................................................ 6
3.2.1 Safely dealing with sources of danger ................................................................ 6
3.2.2 Safe machine operation ...................................................................................... 7
3.3 Safety devices .................................................................................................................. 7
3.4 Safety signs ...................................................................................................................... 7
3.5 Warranty ........................................................................................................................... 7
4 Design and function
4.1 Understanding the PI control ............................................................................................ 9
4.1.1 Amplification P .................................................................................................... 9
4.1.2 Attenuation I ........................................................................................................ 10
4.2 Control behaviour in dependency to the delivery ............................................................. 10
4.2.1 Control behaviour of a compressor with frequency converter ............................ 11
4.2.2 Control behaviour in two compressors ............................................................... 11
4.2.3 Effectiveness ...................................................................................................... 13
4.3 Frequency converters – operation .................................................................................... 14
4.3.1 Understanding the parameter structure .............................................................. 17
4.3.2 Signal exchange between the SIGMA CONTROL and the frequency 17
converter .............................................................................................................
4.3.3 Signal exchange between the SIGMA CONTROL and the frequency converter 19
via USS protocol .................................................................................................
4.4 Comparison of control types ........................................................................................... 20
5 Installation and operating conditions
5.1 Installation conditions ....................................................................................................... 21
5.2 Installing drives according to EMC requirements ............................................................. 22
5.2.1 Basic principles of EMC ...................................................................................... 22
5.2.2 Electro-magnetic compatibility of the frequency converter ................................. 22
5.2.3 Understanding filters and couplers ..................................................................... 25
5.2.4 Basic principles of electro-magnetic compatibility .............................................. 26
6 Assembly
6.1 Safety ............................................................................................................................... 30
6.2 Power supply requirements .............................................................................................. 30
6.2.1 Power supply structures ..................................................................................... 30
6.2.2 Power supply tolerance ...................................................................................... 31
6.2.3 Faults in the power supply .................................................................................. 31
7 Commissioning
7.1 Safety ............................................................................................................................... 33
7.2 Commissioning the frequency converter with imported parameter set ............................ 33

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 Contents

7.2.1 Forming the frequency converter ........................................................................ 34

7.3 Commissioning the frequency converter .......................................................................... 35
7.3.1 Connecting the frequency converter to SIGMA CONTROL ............................... 36
7.3.2 Loading and saving parameters with “DriveMonitor” .......................................... 43
7.3.3 Connection to the SIGMA AIR MANAGER ........................................................ 54
8 Operation
8.1 Operating the parameterization unit (PMU) ..................................................................... 56
8.1.1 Run-up ................................................................................................................ 57
8.1.2 «Parameter access» key ............................................................................... 57
8.1.3 Fault and alarm display ....................................................................................... 58
8.2 Changing parameters in the SIMOVERT MASTERDRIVES ........................................... 58
8.2.1 Password protection of the SIMOVERT MASTERDRIVES ............................... 58
8.2.2 RESET to SIEMENS factory setting ................................................................... 59
8.3 Setting the PI regulation ................................................................................................... 60
8.3.1 Testing the PI regulation ..................................................................................... 60
8.4 Changing the pressure ..................................................................................................... 61
9 Fault-finding and rectification
9.1 Faults in the SIMOVERT MASTERDRIVES ................................................................... 62
9.2 Warnings in the SIMOVERT MASTERDRIVES .............................................................. 72
9.3 Fatal errors ....................................................................................................................... 75
10 Annex
10.1 Freely accessible parameters in SIMOVERT MASTERDRIVES .................................... 77
10.2 Parameters for the operational state of the frequency converter ..................................... 80
10.3 Electrical wiring diagrams ................................................................................................ 81
10.3.1 CSD82/102/122-SFC .......................................................................................... 81
10.3.2 CSD82/102/122-SFC with USS interface protocol ............................................. 119

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 List of Illustrations

Fig. 1 Compressed air deliveries ......................................................................................................... 4

Fig. 2 Amplification P too large ............................................................................................................. 9
Fig. 3 Amplification P too small ............................................................................................................ 10
Fig. 4 Optimum PI control ..................................................................................................................... 10
Fig. 5 Control range of a compressor with frequency converter ........................................................... 11
Fig. 6 LOAD/IDLE switching points ...................................................................................................... 12
Fig. 7 Correct sizing ............................................................................................................................. 12
Fig. 8 Incorrect sizing ........................................................................................................................... 13
Fig. 9 Efficiency curve of a compressor ............................................................................................... 13
Fig. 10 Efficiency curve – motor and frequency converter ..................................................................... 14
Fig. 11 Efficiency curve of a compressor with frequency converter ....................................................... 14
Fig. 12 Basic wiring diagram of a frequency converter .......................................................................... 14
Fig. 13 Wiring diagram of a frequency converter ................................................................................... 15
Fig. 14 SIMOVERT MASTERDRIVES – Operational Diagram .............................................................. 16
Fig. 15 Signal exchange between the SIGMA CONTROL and the frequency converter ....................... 17
Fig. 16 Signal Exchange between SIGMA CONTROL and the FC with USS protocol .......................... 19
Fig. 17 Interference source / interference sink ....................................................................................... 22
Fig. 18 Schematic diagram of the output voltage and motor current of a frequency converter .............. 23
Fig. 19 Path of the interference current in a screened motor conductor ................................................ 24
Fig. 20 Arrangement of the radio interference filter components ........................................................... 24
Fig. 21 Measures to increase the interference immunity ........................................................................ 25
Fig. 22 Screening connection of the motor cable ................................................................................... 26
Fig. 23 Screening connection at the motor ............................................................................................. 27
Fig. 24 Screen connection of signal conductors at the SIMOVERT MASTERDRIVES ......................... 27
Fig. 25 Screen connection of signal conductors in the switching cabinet .............................................. 28
Fig. 26 Incorrect cable laying ................................................................................................................. 28
Fig. 27 Forming circuit ............................................................................................................................ 34
Fig. 28 Forming time chart ..................................................................................................................... 35
Fig. 29 CUVC PCB ................................................................................................................................. 41
Fig. 30 Interface cable ............................................................................................................................ 44
Fig. 31 "DriveMonitor" ............................................................................................................................ 44
Fig. 32 Online settings tabs .................................................................................................................... 45
Fig. 33 Creating a new drive .................................................................................................................. 45
Fig. 34 Drive properties .......................................................................................................................... 46
Fig. 35 Parameter list OFFLINE mode ................................................................................................... 47
Fig. 36 Parameter list ONLINE mode ..................................................................................................... 48
Fig. 37 Parameter menu ......................................................................................................................... 50
Fig. 38 Free parameterization ................................................................................................................ 51
Fig. 39 Parameter list ............................................................................................................................. 51
Fig. 40 Upload/Download ....................................................................................................................... 53
Fig. 41 Diagnosis .................................................................................................................................... 54
Fig. 42 PMU Keys and Displays ............................................................................................................. 56
Fig. 43 Toggle sequence ........................................................................................................................ 57

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 List of Illustrations

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 List of Tables

Tab. 1 Danger levels and their definition ............................................................................................... 2

Tab. 2 Frequency converter types ......................................................................................................... 4
Tab. 3 Type overview – SIMOVERT MASTERDRIVES ........................................................................ 4
Tab. 4 Safety signs ................................................................................................................................ 7
Tab. 5 Abbreviations .............................................................................................................................. 10
Tab. 6 Control behaviour at correct design ........................................................................................... 12
Tab. 7 Control behaviour at incorrect design ......................................................................................... 13
Tab. 8 Messages to SIGMA CONTROL ............................................................................................... 18
Tab. 9 Description of USS parameters .................................................................................................. 19
Tab. 10 Interface parameters .................................................................................................................. 20
Tab. 11 Components for the forming circuit ............................................................................................ 35
Tab. 12 Legend for the SFC Contact display .......................................................................................... 38
Tab. 13 Parameter settings in SIGMA CONTROL from software version 72.32 ..................................... 40
Tab. 14 Selecting the signal type for the SIMOVERT MASTERDRIVES analogue input ....................... 41
Tab. 15 Assignment setpoint pressure – current – parameter value ....................................................... 42
Tab. 16 Trouble-shooting parameters ..................................................................................................... 43
Tab. 17 Motor rated frequency and parameterization ............................................................................. 43
Tab. 18 Drive properties .......................................................................................................................... 46
Tab. 19 Status of the connection with the frequency converter ............................................................... 49
Tab. 20 Parameter menu ......................................................................................................................... 50
Tab. 21 Structure of the parameter list .................................................................................................... 52
Tab. 22 PMU Keys and Displays ............................................................................................................. 56
Tab. 23 Functions of the «Parameter access» key ............................................................................ 58
Tab. 24 Password .................................................................................................................................... 59
Tab. 25 PI values for SIMOVERT MASTERDRIVES ............................................................................. 60
Tab. 26 Parameter r947 (fault number) ................................................................................................... 62
Tab. 27 Parameter r782 (time of fault) .................................................................................................... 63
Tab. 28 Fault messages, fault descriptions and remedies ...................................................................... 63
Tab. 29 Warning messages, fault descriptions and remedies ................................................................. 72
Tab. 30 Fatal errors ................................................................................................................................. 76
Tab. 31 Freely accessible parameters .................................................................................................... 77
Tab. 32 Parameters for the operational state of the frequency converter ............................................... 80

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 List of Tables

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 1 Regarding this document
1.1 Using this document

1 Regarding this document

1.1 Using this document
■ This document is for the exclusive use of KAESER Service personnel or the trained personnel
of authorised sales partners.
■ This document does not supersede or invalidate any existing Work Instructions.
■ The document explains the function of certain products and gives instructions on operating,
maintenance and repair.

➤ This document should be made accessible to authorised personnel only.

1.2 Further documents

This document does not claim to be complete or up-to-date and further information may be found,
for instance, in the following documents:

■ Work Instructions
■ Safety data sheets
■ Technical Information issues
■ Electrical diagrams
■ P&I diagrams
■ etc.

If necessary, contact the Service Manager of your subsidiary or KAESER Service Support.

1.3 Copyright
This document is protected by copyright. Passing on this document or any excerpts from it is not
permitted. Please refer any queries regarding application or duplicating to KAESER Service Sup‐
port. We would be pleased to help you in using the information to meet your unique requirements.

1.4 Symbols and labels

1.4.1 Warnings
Warning notices indicate three levels of danger signified by the signal word.
■ DANGER
■ WARNING
■ CAUTION

1. DANGER!
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
The signal word "DANGER" indicates that death or severe injury can result from ignoring the
warning.
➤ The measures required to protect yourself from danger are shown here.

Training Manual Frequency converter

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 1 Regarding this document
1.4 Symbols and labels

2. Always read and comply with warning instructions.

Signal term Meaning Consequences of non-compliance

DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent May result in death or severe injury
danger
CAUTION Warns of a potentially dangerous May result in moderate physical injury or damage
situation to objects

Tab. 1 Danger levels and their definition

1.4.2 Potential damage warnings

Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.

Damage warnings have only one danger level identified with this signal term:
■ NOTE

1. NOTICE!
The type and source of the imminent danger is shown here!
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
2. Carefully read and fully comply with warnings against damages.

1.4.3 Other alerts and their symbols

This symbol indicates particular important information.

Material Here you will find details on special tools, operating materials or spare parts.

Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.

Option H1 ➤ This symbol denotes operating instructions consisting of only a single operating step.
In lists of actions with several stages, the sequence of actions is numbered.
Information related to just one option is marked with a symbol (e.g., H1 indicates that this sec‐
tion applies only to machines with screw-in machine feet).
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protec‐
tion.

Further information Further subjects are introduced here.

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 1 Regarding this document
1.5 Validity

1.5 Validity
This document may apply to different versions. Please refer to the instructions in the appropriate
chapter.

Training Manual Frequency converter

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 2 Technical Specification
2.1 Getting familiar with control ranges

2 Technical Specification
2.1 Getting familiar with control ranges
The diagram displays the control rages of frequency-controlled compressors manufactured by
KAESER. The individual compressor can maintain the mains pressure within these limits.

Compressed air deliveries at 10 bar / 400V / 50Hz

Fig. 1 Compressed air deliveries

2.2 Frequency converter types used

Series Frequency converter type
SM–ASK MICROMASTER
ASD–HSD SIMOVERT MASTERDRIVES

Tab. 2 Frequency converter types

The assignment of compressor type to a specific frequency converter is not mandatory. More pow‐
erful frequency converters may be used in order have reserves available, if necessary.
Model (number) PN [kW] IN [A] UN [V]
6SE7023-8ED61 18 37,5 380–480
6SE7024-7ED61 22 47 380–480
6SE7026-0ED61 30 59 380–480

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 2 Technical Specification
2.2 Frequency converter types used

Model (number) PN [kW] IN [A] UN [V]

6SE7027-2ED61 37 72 380–480
6SE7031-0EE60 45 92 380–480
6SE7031-2EF60 55 124 380–480
6SE7031-5EF60 75 146 380–480
6SE7031-8EF60 90 186 380–480
6SE7131-0EB61-3BA0 45 92 380–480
6SE7131-2EC61-3BA0 55 124 380–480
6SE7131-5EC61-3BA0 75 146 380–480
6SE7131-8EC61-3BA0 90 186 380–480
6SE7132-1ED61-3BA0 110 210 380–480
6SE7132-6ED61-3BA0 132 260 380–480
6SE7133-2ED61-3BA0 160 315 380–480
6SE7133-7ED61-3BA0 200 370 380–480
6SE7135-1EE62-3BA0 250 510 380–480
6SE7136-0EE62-3BA0 315 590 380–480
6SE7137-0EE62-3BA0 400 690 380–480
6SE7138-6EG62-3BA0 500 860 380–480

Tab. 3 Type overview – SIMOVERT MASTERDRIVES

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 3 Safety and responsibility
3.1 Basic instructions

3 Safety and responsibility

3.1 Basic instructions
The machine is manufactured to the latest engineering standards and acknowledged safety regula‐
tions. Nevertheless, dangers can arise through its operation:
■ danger to life and limb of the operator or third parties,
■ damages to the machine and other material assets.

DANGER
Disregard of these instructions can result in serious injury.
➤ Read the service manual carefully and take note of the contents for safe machine opera‐
tion.

➤ Use this machine only if it is in a technically perfect condition and only for the purpose for
which it is intended; observe all safety measures and the instructions in the service manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety!

3.2 Dangers
Basic instructions

The following describes the various forms of danger that can occur during machine operation.
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.

3.2.1 Safely dealing with sources of danger

The following describes the various forms of danger that can occur during machine operation.

Electricity

➤ Allow only qualified and authorised electricians or trained personnel under the supervision of a
qualified and authorised electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations.
➤ Before commissioning or re-commissioning the machine, the user must ensure adequate pro‐
tection against electric shock from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply isolator and verify the absence of any voltage.
➤ Switch off any external power sources.
These could be connections to floating contacts or electrical machine heating, for example.
➤ Use fuses corresponding to machine power.
➤ Check regularly that all electrical connections are tight and in proper condition.

Conversion or modification of the machine

➤ Do not permit conversion or modification of the machine as this can compromise function and
safe working.

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 3 Safety and responsibility
3.3 Safety devices

3.2.2 Safe machine operation

The following is information supporting you in the safe handling of the machine during individual
product life phases.

Positioning

➤ Install the machine in a suitable compressor room.

➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
splashing water.
➤ Ensure adequate ventilation.
➤ Keep the ambient temperature within specified limits.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.

3.3 Safety devices

Various safety devices ensure safe working with the machine.
➤ Do not change, bypass or disable safety devices.
➤ Regularly check safety devices for their correct function.
➤ Do not remove or obliterate labels and notices.
➤ Ensure that labels and notices are clearly legible.

3.4 Safety signs

Safety signs are to be found on all machines. The table lists the various safety signs used and their
meanings.

Symbol Meaning
Danger of fatal injury from electric shock!
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and verify the absence
of any voltage.
Risk of injury caused by an automatic machine start!
➤ Switch off and lock out the mains isolating devices and verify the absence of any volt‐
age before opening any machine enclosure or guard.

Tab. 4 Safety signs

3.5 Warranty
This document does not contain any independent warranty commitment. Our general terms and
conditions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is intended un‐
der the conditions specified.
Due to the multitude of applications for which the machine is suitable, the user is obliged to deter‐
mine its suitability for his specific application.

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 3 Safety and responsibility
3.5 Warranty

Furthermore, we do not assume any warranty obligation for damages caused by:
■ the use of unsuitable parts or operating materials,
■ unauthorised modifications,
■ incorrect maintenance,
■ incorrect repair.

Correct maintenance and repair includes the use of genuine KAESER spare parts and operating
materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.

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 4 Design and function
4.1 Understanding the PI control

4 Design and function

Compressors with frequency converter are used to constantly maintain the mains pressure at
±0.1 bar when the compressed air consumption fluctuates between 40 % and 90 % of the maxi‐
mum delivery.

4.1 Understanding the PI control

The SIGMA CONTROL controller compares the specified setpoint pressure with the actual pres‐
sure of the compressed air network.
If the actual pressure differs from the setpoint pressure, the PI control will determine a correcting
variable for the amplification P and the attenuation I. This correcting variable makes the motor ro‐
tate faster or slower, depending on the deviation, until the actual pressure is equal the setpoint
pressure. Thus, the PI control adjusts the actual pressure to the setpoint pressure when the con‐
sumption fluctuates.
If the setpoint pressure is modified at the SIGMA CONTROL controller, the PI control will adjust the
motor speed in order for the actual pressure to be equal the setpoint pressure.
The ideal parameter values for the PI control cannot be calculated. KAESER presets parameter
values which have been determined in practice and which are known to quickly react without
swinging to normally occurring pressure changes.

4.1.1 Amplification P
The amplification P defines how strongly the system will weight the difference between actual pres‐
sure and setpoint pressure. It is predefined as a parameter value.
The following reaction can occur if the amplification P is selected incorrectly:

Reaction to an excessive amplification P

If the amplification P is selected too large, the controller will respond quickly but the actual pressure
will also quickly exceed the setpoint pressure. The PI control will respond and reduce the actual
pressure which then will again fall below the setpoint pressure.
The control is now again in its initial state and will again respond with overmodulation.
This means that the actual pressure will continuously swing around the setpoint pressure without
ever meeting it.

Fig. 2 Amplification P too large

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 4 Design and function
4.2 Control behaviour in dependency to the delivery

Reaction to a too small amplification P

If the amplifiation P is selected too small, the controller will respond too slow. Much time will pass
until the setpoint pressure is attained. In this case as well, the setpoint pressure is not met but ex‐
ceeded. The PI control will respond and reduce the actual pressure which then will again fall below
the setpoint pressure.
The control is now again in its initial state and will respond with overmodulation.
This means that the actual pressure will continuously swing around the setpoint pressure without
ever meeting it.

Fig. 3 Amplification P too small

4.1.2 Attenuation I
The attenuation I is used as second parameter for the PI control. It prevents the swinging of the
actual pressure around the setpoint pressure by attenuating the swings.

Fig. 4 Optimum PI control

Further information If swings are still observed during operation, change the parameter values of the PI control as
specified in chapter 8.3.

4.2 Control behaviour in dependency to the delivery

Abbreviation Meaning
p1 Pressure setpoint
dpFC Increasing pressure (factory setting: 0.2 bar)
p1SD Switching differential between LOAD and IDLE (factory setting: 0.5 bar)

Tab. 5 Abbreviations

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 4 Design and function
4.2 Control behaviour in dependency to the delivery

The setpoint pressure of compressors with frequency converters must approach the maxi‐
mum permissible pressure only by up to 0.4 bar in order to maintain a control reserve.

4.2.1 Control behaviour of a compressor with frequency converter

Fig. 5 Control range of a compressor with frequency converter

Compressed air requirement larger than 40 %

The compressor with frequency converter operates within its control range if the compressed air
requirement is higher than 40 % of the maximum compressed air delivery D2 .
The compressor can constantly maintain the actual pressure at the setpoint pressure ±0.1 bar!

Compressed air requirement lower than 40 %

The motor will reach its lower speed limit at a current frequency of approximately 25 Hz, if the com‐
pressed air requirement is less than 40 % of the maximum compressed air delivery D1 . Since from
this point on, the compressed air delivery and the motor speed are constant, the actual pressure
will exceed the setpoint pressure at reduced compressed air requirement.
If the mains pressure exceeds the value p1 + dpFC, the compressor will switch to IDLE, i.e, the
inlet valve closes and the motor continues to run with minimum speed.
If the mains pressure falls below the value p1 + dpFC − p1SD, the compressor will switch to LOAD.
The compressor cannot constantly maintain the actual pressure at the setpoint pressure ±0.1 bar!

4.2.2 Control behaviour in two compressors

The following conditions must be complied with in order to prevent control gaps if a DUAL control‐
led compressor and a compressor with frequency converters work in the same compressed air net‐
work:
■ FAD DUAL compressor ≤ control range FC compressor
■ IDLE switching point DUAL compressor < IDLE switching point FC compressor (p1 + dpFC)
■ LOAD switching point DUAL compressor < LOAD switching point FC compressor (p1 + dpFC − p1SD)

The compressor with frequency converter is activated first and deactivated last!!!

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 4 Design and function
4.2 Control behaviour in dependency to the delivery

Fig. 6 LOAD/IDLE switching points

I Compressor with DUAL control 1 LOAD switching point
II Compressor with frequency converter 2 IDLE switching point
p1 Pressure setpoint

Example for correct sizing

■ FAD DUAL compressor = 40 %

■ FAD FC compressor = 60 %

Fig. 7 Correct sizing

DUAL controlled compressor Compressor with frequency con‐

verter
D1 Standstill LOAD/IDLE
D2 Standstill Control range
D3 LOAD Control range

Tab. 6 Control behaviour at correct design

The limit of the delivery by the compressor with frequency converter is attained if the compressed
air requirement is more than 60 % of the maximum compressed air delivery. The mains pressure
drops and the DUAL controlled compressor is activated.
Because the DUAL controlled compressor provides 40 % of the total delivery at LOAD, the com‐
pressor with frequency converter supplies more than 20 % of the total delivery. Thus, its control
range is met.
If the compressed air demand falls again to less than 60 % of the maximum delivery, the actual
pressure rises in the compressed air network beyond the cut-out point of the DUAL controlled com‐
pressor. This compressor now switches to IDLE and the compressor with frequency converter in‐
creases its output.

Example for incorrect sizing

■ FAD DUAL compressor = 60 %

■ FAD FC compressor = 40 %

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 4 Design and function
4.2 Control behaviour in dependency to the delivery

Fig. 8 Incorrect sizing

DUAL controlled compressor Compressor with frequency con‐

verter
D1 Standstill LOAD/IDLE
D2 Standstill Control range
D3 instable state

Tab. 7 Control behaviour at incorrect design

The limit of the delivery by the compressor with frequency converter is attained if the compressed
air requirement is more than 40 % of the maximum compressed air delivery. The mains pressure
drops and the DUAL controlled compressor is activated.
Because the DUAL controlled compressor provides 60 % of the total delivery at LOAD, the com‐
pressor with frequency converter switches to IDLE.
However, the delivery is still too high in the range between 40 % and 60 % of the total delivery and
the DUAL controlled compressor also switches to IDLE and neither compressor supplies com‐
pressed air.
The compressor with frequency converter switches back on and supplies 40 % of the total delivery.
The initial state is again attained.

4.2.3 Effectiveness

Fig. 9 Efficiency curve of a compressor

P optimum operating point
A increased back expansion
B Flow-in behaviour at the inlet valve

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 4 Design and function
4.3 Frequency converters – operation

Fig. 10 Efficiency curve – motor and frequency converter

D1 Motor
D2 Frequency converter

The effectiveness of motor and frequency converter drops at low speeds. In addition, the self-cool‐
ing of the motor is lower at a low speed. In order to be able to work continuously, a limitation of the
power consumption is required for the maximum speed range as well.
At identical motor size, the maximum delivery of a compressor with frequency converter is
some percents smaller than the one of a compressor with DUAL control.
In order to keep the capacity reduction of the BS, CS and ES models within limits, the differ‐
ential pressure of the oil separator cartridge is set to 0.8 bar instead of 1.0 bar.

Fig. 11 Efficiency curve of a compressor with frequency converter

Compared to compressors with DUAL control, energy savings are realised only in the median con‐
trol range.

4.3 Frequency converters – operation

Basic wiring diagram of a frequency converter

Fig. 12 Basic wiring diagram of a frequency converter

1 Input (AC current) 4 Power switching
2 Rectifier 5 Motor (AC current, variable)
3 Intermediate circuit voltage (DC current)

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 4 Design and function
4.3 Frequency converters – operation

Wiring diagram of a frequency converter

Fig. 13 Wiring diagram of a frequency converter

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 4 Design and function
4.3 Frequency converters – operation

SIMOVERT MASTERDRIVES – Operational Diagram

Fig. 14 SIMOVERT MASTERDRIVES – Operational Diagram

Further information Further information is provided on the "SIMOVERT MASTERDRIVES compendium" CD.

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 4 Design and function
4.3 Frequency converters – operation

4.3.1 Understanding the parameter structure

The SIMOVERT MASTERDRIVES frequency converter has approximately 3,000 parameters.

The following parameter types are used:

■ Display parameters
─ display operational values (having the prefixes "r" or "n")
e.g., parameter r003 (starting frequency)
■ User-defined parameters
─ for the configuration of the frequency converter (with prefixes "P" or "U”)
e.g., parameter P050 (language setting)

Many parameters can be only modified when the frequency converter is switched off.

4.3.2 Signal exchange between the SIGMA CONTROL and the frequency converter

Fig. 15 Signal exchange between the SIGMA CONTROL and the frequency converter
*1 Setpoint pressure from the compressor, extern as variant
*2 Power supply for fan motor separately or looped-through
*3 Screening to 30 m maximum

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 4 Design and function
4.3 Frequency converters – operation

The following messages may be displayed, if SIGMA CONTROL does not have a signal from the
frequency converter:
Input Message/display Type Note
I2.1 FC mains compr. Maintenance Enables an immediate restart after voltage has
message been restored.
I2.3 Frequency-controlled Alarm mes‐ Must be acknowledged at both, the frequency
compressor sage converter and the SIGMA CONTROL, except
when only the signal conductor was interrupted.
I0.0 EMERGENCY STOP Alarm mes‐ The system does not differentiate between the
sage two EMERGENCY-OFF devices (frequency con‐
verter or compressor).
I0.6 The contact is open in normal operation with motor in standstill and will close at the attain‐
ment of the minimum speed (10 to 20Hz).
Load Contact closed:
SIGMA CONTROL opens the inlet valve, com‐
pressor switches to LOAD
Idle Contact open:
SIGMA CONTROL closes the inlet valve, com‐
pressor switches via IDLE to standstill.

Tab. 8 Messages to SIGMA CONTROL

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 4 Design and function
4.3 Frequency converters – operation

4.3.3 Signal exchange between the SIGMA CONTROL and the frequency converter
via USS protocol

Fig. 16 Signal Exchange between SIGMA CONTROL and the FC with USS protocol
*2 Power supply for fan motor separately or looped-through
*3 Screening to 30 m maximum

Beginning with the DSD series, PT100 sensors are used for temperature monitoring. They
are connected to the SIGMA CONTROL.

USS = universal serial interface

Data such as actual pressure, setpoint pressure, speed, ON/OFF, alarm, "minimum speed at‐
tained" are digitally transferred via the RS485 interface from the SIGMA CONTROL to the
SIMOVERT MASTERDRIVES.

Parameter number Parameter value Parameter description

P030.001 B6100 Start/stop command for the frequency converter
P030.002 B6107 Alarm acknowledged at frequency converter
(flank from 0 to 1 corresponds to an acknowledgement)

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 4 Design and function
4.4 Comparison of control types

Parameter number Parameter value Parameter description

P030.003 B6110 Guidance required
1 = conditions for transfer of the data via SST2
P030.004 B6500 Message from the controller
1 = idling mode active
P031.001 K0588 Drive controller output in %
P031.002 K6003 Actual pressure in % of maximum pressure
P031.003 K0467 Actual pressure [bar]
"DriveMonitor" incorrectly displays the unit %.
P031.004 K6002 Setpoint pressure in % of maximum pressure
P031.005 K0468 Actual pressure [bar]
"DriveMonitor" incorrectly displays the unit %.
r014 Setpoint speed [1/min]
r015 Actual speed [1/min]
r004 Motor current [A]
r006 Intermediate circuit voltage [V] = 1.35 x Umains

Tab. 9 Description of USS parameters

The interface parameters in the frequency converter was must be assigned as follows for the USS
communication between controller and frequency converter:
Parameter number Parameter value Parameter description
P700.002 0 Bus address SST 2 = 0
P701.002 7 Baud rate SST 2 = 19200
P702.002 4 Number of PKW for SST 2 = 4
P703.002 16 Number of PZD for SST 2 = 16
P704.002 1000 Tig. Ausz. for SST 2 = 1000
P781.012 101 Alarm delay for SST 2
switched off

Tab. 10 Interface parameters

In addition to these parameter settings, the bus terminating resistor for the SST2 on the con‐
verter CUVC card must be closed.

On the SIGMA CONTROL, a bridge in the SUB-D plug is installed to activate the
SIGMA CONTROL internal terminating resistance, thereby avoiding the need for a bus plug with
integrated terminating resistance.

4.4 Comparison of control types

Controlling with a proportional controller also permits a pressure constancy of ±0.1 bar at a FAD
range between 20 % and 80 % percent of the maximum delivery.
However, heavy losses are experienced as, at a reduction of the delivery to 50 %, approximately
80 % of the motor capacity are still picked up.
The effectiveness in this range is higher for compressors with frequency converter.

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 5 Installation and operating conditions
5.1 Installation conditions

5 Installation and operating conditions

5.1 Installation conditions
The following ambient conditions must be taken into account in order to avoid damage or destruc‐
tion of the frequency converter:

Temperature

➤ Install the frequency converter in an area with an ambient temperature between 0 °C and
45 °C (MDV).

Altitude

➤ Decrease of performance must be taken into account when installing the frequency converters
in heights above 1,000 m.

Impact

➤ Do not drop frequency converters or subject to severe mechanical impact.

Shocks

➤ Do not install frequency converters in areas with shock hazards.

Electro-magnetic radiation

➤ Do not install frequency converters in the vicinity of electro-magnetic radiation sources.

Air pollution

➤ Do not install frequency converters in environments with polluted air (from, e.g., dust or ag‐
gressive gases).

Water

➤ Do not install frequency converters in the vicinity of potential water hazard sources causing
condensation or dripping water (e.g., beneath water pipes).

Superheating

➤ Ensure that the ventilation slots of the frequency converter is not covered.
➤ Ensure that clearance of at least 100 mm is available for the unimpeded entry and exit of cool‐
ing air above and beneath the frequency converter.
➤ Ensure that the enclosure has sufficient air flow.

Foundation

➤ Install frequency converters vertically on an even, non-combustible surface.

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 5 Installation and operating conditions
5.2 Installing drives according to EMC requirements

5.2 Installing drives according to EMC requirements

5.2.1 Basic principles of EMC
As per the definition in the German EMC Act, EMC stands for "electro-magnetic compatibility".
EMC is given when devices do not electro-magnetically interfere with each other.

5.2.2 Electro-magnetic compatibility of the frequency converter

The electro-magnetic compatibility depends on two properties of the concerned devices:
■ Interference emission
■ Interference immunity

Electrical devices may be interference sources (senders) and interference sinks (receiver).

Fig. 17 Interference source / interference sink

1 Interference source (sender)
2 Interference sink (receiver)

A device may be both, interference source and interference sink, at the same time. Thus, in the
case of the frequency converter, the power component is an interference source and the control
component is an interference sink.
Electro-magnetic compatibility is achieved when the interference sources do not impact the func‐
tion of the interference sinks.
Specifications and evaluation criteria for the device behaviour are governed by the European
standard EN 61800-3.

5.2.2.1 Frequency converters as interference sources

In order to lose as little performance as possible, the frequency converter switches the intermediate
circuit voltage as voltage blocks on the motor winding. Thus, a nearly sine-shaped current flows in
the motor.

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 5 Installation and operating conditions
5.2 Installing drives according to EMC requirements

Fig. 18 Schematic diagram of the output voltage and motor current of a frequency converter
U Output voltage
I Motor current

The disadvantage of the used semi-conductor switches is that during every switching flank, an im‐
pulse-shaped high-frequency interference current flows via parasitic capacities CP to earth. Parasit‐
ic capacities exist between the motor conductor and the earth but also within the motor.
Furthermore, low-frequency mains feedbacks must be taken into account. By rectifying the mains
voltage, a non-sine mains current is removed distorting the mains voltage.

Measures for the reduction of the interference emission

Line reactors reduce low-frequency mains feedback.

The high-frequency portions of the interference current may cause interfering voltage drops in
unscreened motor conductors, because the interference current flows undefinedly back to the fre‐
quency converter (via, e.g., foundation earth, cable trays, cabinet rails). In order to reduce the high-
frequency interference emission, you must direct the interference current into a harmless, defined
direction.
For the high-frequency portions of the interference current to definedly flow back to the fre‐
quency converter, a screened motor conductor is mandatory. This must be connected across
a large area with the enclosures of the frequency converter and the motor, in order for the
screen to be the most favourable path of the interference current back to the frequency con‐
verter.

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 5 Installation and operating conditions
5.2 Installing drives according to EMC requirements

Fig. 19 Path of the interference current in a screened motor conductor

1 Mains filter
2 Frequency converter
3 Screened motor conductor

A screened motor conductor with a screen connected on both sides ensures that the interference
current IS will flow back to the frequency converter on the screen. Although (nearly) no voltage drop
occurs at the impedance ZE with a screened motor conductor, the voltage drop at the impedance
ZN may affect other devices.
This can be prevented with a radio interference filter installed in the mains conductor to the fre‐
quency converter.
Radio interference filters and frequency converters must be connected to each other at low resist‐
ance for high-frequency interference currents, ideally by mounting on a common mounting plate.
In order to limit the radio interference radiation, frequency converters must be installed in an en‐
closed switching cabinet. The radio interference radiation originates in the micro-processor of the
control component, similar to the interference emission of a PC.

Fig. 20 Arrangement of the radio interference filter components

1 TN net or TT net 4 Frequency converter
2 Radio interference filter 5 Screened motor conductor
3 Line reactor

5.2.2.2 The frequency converter as interference sink

Measures to increase the interference immunity

Consequent separation of power and signal conductors is the most efficient measure to avoid inter‐
ference.

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 5 Installation and operating conditions
5.2 Installing drives according to EMC requirements

Increasing the interference immunity with screened signal conductors

Fig. 21 Measures to increase the interference immunity

1 Interference source 3 Component
2 Screened signal conductor 4 Filter

The inputs and outputs of the control component of the frequency converter are equipped with fil‐
ters. They isolate the interference currents IS from the electronics and smooth the useful signal.
This smoothing interferes in signal conductors with very high-frequency useful signals (such as dig‐
ital speedometers). As smoothing is not possible to maintain the functionality, screened signal con‐
ductors must be used. The interference current now flows across the screen and the enclosure
back to the interference source.
Screens for digital signal conductors must always be connected at both ends, the sender and
the receiver!
Screens for analogue signal conductors must be connected at one end only, in order to pre‐
vent low-frequency interference (ground hum)! Earth the other side of the screen over a ca‐
pacitor and the screen for high-frequency is thus still connected at both ends.

5.2.3 Understanding filters and couplers

Radio interference filters

Radio interference filters reduce the conductor-related radio interference voltage at the mains con‐
nection and serve in maintaining limit values for the "primary environment" or "secondary environ‐
ment".
This applies independently of the application of a dv/dt or sine filter at the output of the frequency
converter.

dv/dt filters

dv/dt filters mainly protect the motor winding by reducing the maximum occurring voltage stresses.
The reduced voltage rise then effects a smaller interference current.

Sine filters

Sine filters are low-pass filters creating a nearly sinusoidal voltage from the voltage blocks switch‐
ed to the output terminals by the frequency converter. Voltage rises and maximum voltage peaks
are limited even more effective than with a dv/dt filter.

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 5 Installation and operating conditions
5.2 Installing drives according to EMC requirements

Couplers

Date conductor filters and/or coupling elements may be additionally required at the interface be‐
tween the zones. Couplers with galvanic isolation (e.g., buffer amplifiers) prevent a spreading of
the interference from one zone to the next zone. Buffer amplifiers are to be installed for analogue
signals in particular.

5.2.4 Basic principles of electro-magnetic compatibility

Disregard of the basic principles of electro-magnetic compatibility will inevitably result in temporary
malfunctions. These faults then appear to be irreparable.
The earthing of machines is mostly a protective measure. In the case of drives, however, they
affect interference and resistance. A system may be earthed via a star-point connection or
with a large contact area to the device. The large contact area earthing method is preferred
for drives, i.e., all components of the machine to be earthed are connected over a large area
or a mesh.

Further information The entire basic rules set may be requested from KAESER Service Support.

5.2.4.1 Examples to the basic principles

Screening connection of the motor cable at the entry point to the switching cabinet

Fig. 22 Screening connection of the motor cable

1 Screening rail
2 Cable clamp rail

➤ Connect the screening rail on both sides with a high degree of conductivity and over a large
area with the switching cabinet enclosure.

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 5 Installation and operating conditions
5.2 Installing drives according to EMC requirements

Screening connection at the motor

Fig. 23 Screening connection at the motor

1 Motor terminal box
2 Cable screw connection with screen contacts (EMC cable screw connection)

➤ Up to degree of protection IP 20, use a screw connection (nickel-plated brass) with strain relief
clamp.
➤ Use special PG screw connections with screen support for higher degrees of protection (up to
IP 68).
➤ Install additional earthing braids if the motor terminal box is manufactured from synthetic mate‐
rial.

Screen connection of signal conductors at the SIMOVERT MASTERDRIVES

Fig. 24 Screen connection of signal conductors at the SIMOVERT MASTERDRIVES

1 Screen clip
2 Cable tie

➤ Use the supplied screen clips to connect the signal conductor screens with the
SIMOVERT MASTERDRIVES.

Screen connection of signal conductors in the switching cabinet

For built-in devices, the screens may be also attached on comb-shaped screen rails using cable
ties.

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 5 Installation and operating conditions
5.2 Installing drives according to EMC requirements

Fig. 25 Screen connection of signal conductors in the switching cabinet

1 Comb rail
2 Cable tie
3 Intermediate terminals

➤ Connect the comb rails on both sides with a high degree of conductivity and over a large area
with the switching cabinet enclosure.
If possible, do not use intermediate terminals as they will diminish the screening effects.

5.2.4.2 Example for INCORRECT cable laying

Fig. 26 Incorrect cable laying

From a purely visual point of view, this wiring layout looks good. However, in view of electro-mag‐
netic compatibility, this installation is completely useless!
This wiring provides optimum conditions for the spread and launching of interferences!
The individual mistakes:
■ The device has been installed on a coated mounting plate.

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5 Installation and operating conditions
5.2 Installing drives according to EMC requirements

■ All conductors are unscreened.

■ The installation was executed using cable ducts.
─ Motor and signal conducts are installed in parallel in the lower cable duct.
─ Mains conductors and external power supplies are installed in parallel in the upper cable
duct.
─ All conductors are combined in the vertical cable duct.

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 6 Assembly
6.1 Safety

6 Assembly
6.1 Safety
The safety instructions in this section must be followed to ensure a save working environment for
the assembly work.
Warning instructions are located before a potentially dangerous task.

Basic safety instructions

➤ Follow the instructions in chapter 3 "Safety and Responsibility".

➤ Installation work may only be carried out by authorised personnel.
➤ Before activating ensure that:
■ No personnel are working on the machine
■ All access doors and panels are closed and secure.

Working on live components

➤ Work on electrical equipment may only be carried out by authorised electricians.

The general and regional installation and safety instructions for the work on high-voltage in‐
stallations (e.g., German VDE) in particular must be observed as well as the regulations con‐
cerning the appropriate use of tools and deployment of personal protective equipment.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of any
voltage.
Verify the absence of voltage on floating relay contacts.

➤ As dangerous voltages may be present, use only isolated screwdrivers when working on the
mains inlet and the motor connecting terminals, even if the frequency converter itself is deacti‐
vated.
➤ Wait for at least 5 minutes before working on the frequency converter or the intermediate cir‐
cuit terminals.

6.2 Power supply requirements

To ensure reliable operation, the voltage and current supply must be suitable for the frequency
converter system and provide the specified capacity. The following circumstances must be consid‐
ered:

6.2.1 Power supply structures

Earthed networks

The SIMOVERT MASTERDRIVES frequency converter is suited for the connection to networks
with earthed star point (TN networks and TT networks as per product standard EN 60364-3).

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 6 Assembly
6.2 Power supply requirements

Unearthed networks

Several industrial sectors use networks with unearthed star point (IT networks) to increase the ma‐
chine availability.
In the event of an earth fault, no fault current will flow and the machine can continue to operate.
For the connection to IT networks or networks with earthed phase conductor, the
SIMOVERT MASTERDRIVES frequency converters must be equipped with Option L20.

NOTICE
Fault current in an earth fault in combination with radio interference filters!
Switch off the drives or the radio interference filter will be destroyed.
➤ Install radio interference filters either on the earthed primary side or, using a single spe‐
cial filter, on the secondary side of the feeding transformer.

This special filter as well generates leakage current towards earth. An earth leakage monitor
as it is usually used in an unearthed network must be adjusted for the special filter.

6.2.2 Power supply tolerance

The SIMOVERT MASTERDRIVES frequency converter is designed for the operation at a specific
area of the supply voltage.
■ 3 AC 380 (−15%) – 480 V (+10%) = 323 – 528 V
■ 3 AC 500 (−15%) – 600 V (+10%) = 425 – 660 V
■ 3 AC 660 (−15%) – 690 V (+10%) = 561 – 759 V

These are maximum tolerances. The drive motors are not designed for these tolerances.
The permissible network frequency of the supply voltage is 50/60 Hz for all frequency converters.
The rule:
Voltage input at capacitymax ≤ voltage output

On initial start-up, the parameterization and existing control transformers must be precisely
adjusted to the input voltage.

NOTICE
Supply voltage exceeds required limit values!
The frequency converter may be damaged.
➤ Ensure that the defined limit values are met.

The supply voltage may exceed the limit values in the following situations:
■ The voltage on long supply cables in remote areas can rise sharply in the evenings and at
weekends when heavy industrial demand is low.
■ Factories with locally regulated or generated power are sometimes poorly designed.
■ Supply voltages in some countries or regions may not meet specified tolerances.

6.2.3 Faults in the power supply

Most voltage and current sources are well modulated and stay within the permissible tolerance
range. However, they may be temporarily affected by local faults. These faults can result in operat‐
ing breakdowns and damage of the frequency converter and/or other devices.

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 6 Assembly
6.2 Power supply requirements

Some causes of local faults are:

■ Unsuppressed switching of condenser batteries, can produce transient overvoltages.
■ Electric welding equipment with high power requirement, particularly resistance and HF weld‐
ing devices.
■ Other drives, semiconductor regulators, etc.
■ Thunderstorms

Ensure counteractive measures for frequency converters operating in such circumstances.

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 7 Commissioning
7.1 Safety

7 Commissioning
7.1 Safety
The safety instructions in this section must be followed to ensure a save working environment for
the commissioning.
Warning instructions are located before a potentially dangerous task.

Basic safety instructions

➤ Follow the instructions in chapter 3 "Safety and Responsibility".

➤ Installation work may only be carried out by authorised personnel.
➤ Before activating ensure that:
■ No personnel are working on the machine
■ All access doors and panels are closed and secure.

Working on live components

➤ Work on electrical equipment may only be carried out by authorised electricians.

The general and regional installation and safety instructions for the work on high-voltage in‐
stallations (e.g., German VDE) in particular must be observed as well as the regulations con‐
cerning the appropriate use of tools and deployment of personal protective equipment.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of any
voltage.
Verify the absence of voltage on floating relay contacts.

➤ As dangerous voltages may be present, use only isolated screwdrivers when working on the
mains inlet and the motor connecting terminals, even if the frequency converter itself is deacti‐
vated.
➤ Wait for at least 5 minutes before working on the frequency converter or the intermediate cir‐
cuit terminals.

7.2 Commissioning the frequency converter with imported parameter

set
Usually, KAESER will perform the commissioning at their factory. At this time, the parameter set is
imported into the frequency converter and the compressor is tested.

Working steps for the commissioning on-site

1. Check the conductor installation for electro-magnetic compatibility.

2. If disconnected from the mains for more than one year, form the frequency converter (see
chapter 7.2.1).
3. Switch on the frequency converter.
The frequency converter loads its programme.
4. Switch on the compressor.

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 7 Commissioning
7.2 Commissioning the frequency converter with imported parameter set

5. Acknowledge the warning messages at the SIGMA CONTROL.

Warning messages on the frequency converter will automatically disappear after a short op‐
erating time.

7.2.1 Forming the frequency converter

The intermediate circuit capacitors must be formed if the frequency converter was out of operation
for more than one year.
In this process, the intermediate circuit of the frequency converter is connected via a rectifier, a fil‐
ter capacitor and a resistor. This switches a defined voltage and a defined current on the intermedi‐
ate circuit capacitors and the required internal conditions for the function of the intermediate circuit
capacitors is recreated.

NOTICE
Switching mains voltage on the reformed frequency converter!
Capacitors may damaged irreparably.
➤ Form the frequency converter.

Forming circuit

Fig. 27 Forming circuit

1 Forming 5 Intermediate circuit
2 Enabling 6 Inverter
3 Rectifier 7 Motor connection
4 Pre-charging

Forming the frequency converter:

1. Activate all network connections.

2. Deactivate the power supply of the frequency converter.

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 7 Commissioning
7.3 Commissioning the frequency converter

3. WARNING!
Due to the intermediate circuit capacitors, dangerous voltage will be present in the frequency
converter for up to 5 minutes after the activation!
➤ Wait for at least 5 minutes before working on the frequency converter or the intermediate
circuit terminals.
4. Connect the required components according to the wiring example.

UN A R C
3 AC 200 V – 230 V SKD 50/12 220 Ω / 100 W 22 nF / 1600 V
3 AC 380 V – 480 V SKD 62/16 470 Ω / 100 W 22 nF / 1600 V
3 AC 500 V – 600 V SKD 62/18 680 Ω / 100 W 22 nF / 1600 V

Tab. 11 Components for the forming circuit

5. Activate the forming circuit.

Fig. 28 Forming time chart

TF Forming time in hours
Ts Voltage-free time of the frequency converter in years

6. Observe the forming time according to the chart.

7.3 Commissioning the frequency converter

Usually, KAESER will perform the commissioning at their factory.
If you perform the commissioning, execute the following tasks:
1. Connect the frequency converter with the SIGMA CONTROL (see chapter 7.3.1).
2. Parameterise the frequency converter and install the parameter set (see chapter 7.3.2).
3. NOTICE!
During motor identification and controller optimisation, speeds to up to 50% of the rated speed
of the frequency converter will be attained!
➤ Ensure sufficient lubrication of the compressor block.

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 7 Commissioning
7.3 Commissioning the frequency converter

4. Adjust the motor to the frequency converter (will be executed automatically by the frequency
converter).
For this purpose, release the required direction of rotation and lock the opposite direction of
rotation.
■ Parameter P571.001 = B1
■ Parameter P571.002 = B1
■ Parameter P572.001 = B0
■ Parameter P572.002 = B0
These steps are not essential when changing the motor or the FC if the parameter sets are
saved after motor parameterising.
You must proceed as during commissioning if a parameter set is not available.
Usually, one can assume similar values for the exchange motor as the previous motor. A re-
parameterization of the frequency converter is not mandatory but may be performed.

7.3.1 Connecting the frequency converter to SIGMA CONTROL

7.3.1.1 Connecting the SIMOVERT MASTERDRIVES to SIGMA CONTROL

Select the following settings for the connection of a frequency converter of the
SIMOVERT MASTERDRIVES type to the SIGMA CONTROL:

SIGMA CONTROL settings

Precondition SIGMA CONTROL with software version 80.01 or higher.

SIMOVERT MASTERDRIVES and SIGMA CONTROL communicate via the USS protocol and a
RS485 interface.

1. Enter password for level 5 at a minimum.

2. Select the <components> menu.
3. Select the <motor> menu.
4. Select the <power switching> menu.
5. Change the <star-delta> default setting to <SFC USS MD>.
6. Repeatedly press «esc» until you are back in the main menu.
7. Select the <communication> menu.
8. Select the <RS485> menu.
9. Select <USS Master>.
10. From series ASD, select the settings for the fan control as described in chapter 7.3.1.4.

Parameter settings

➤ Set the parameters as described in chapter 7.3.1.5.

7.3.1.2 Connecting the MICROMASTER 440 with SIGMA CONTROL

Select the following settings for the connection of a frequency converter of the
MICROMASTER 440 type to the SIGMA CONTROL:

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 7 Commissioning
7.3 Commissioning the frequency converter

SIGMA CONTROL settings

Precondition SIGMA CONTROL with software version 80.01 or higher.

MICROMASTER 440 and SIGMA CONTROL communicate via the USS protocol and a RS485 in‐
terface.

1. Consult the wiring diagram for the digital output controlling the K1M contactor.
2. Enter password for level 5 at a minimum.
3. Select the <components> menu.
4. Select the <motor> menu.
5. Select the <power switching> menu.
6. Change the <star-delta> default setting to <SFC USS MM>.
7. Press «DOWN» key repeatedly until <* SFC USS MM> appears and select the same.
8. Set <K1M> to "ON".
9. Press «DOWN» key repeatedly until <MM K1M> appears and select the same.
10. Activate the digital output of the K1M contactor.
11. From series ASD, select the settings for the fan control as described in chapter 7.3.1.4.

Parameter settings

➤ Set the parameters as described in chapter 7.3.1.5.

7.3.1.3 Connecting the frequency converter with pressure and speed control to the SIGMA CONTROL us‐
ing a 4–20 mA signal

Select the following setting when connecting a frequency converter with pressure and speed con‐
trol to the SIGMA CONTROL using a 4–20 mA signal:

SIGMA CONTROL settings

1. Enter password for level 5 at a minimum.

2. Select the <components> menu.
3. Select the <motor> menu.
4. Select the <power switching> menu.
5. Change the <star-delta> default setting to <SFC contact>.

Parameter settings

➤ Set the parameters as described in chapter 7.3.1.5.

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 7 Commissioning
7.3 Commissioning the frequency converter

Menu options "* SFC contact"

9 . 1ba r 76℃
FC r e a d y DI 2 . 3 1
FC f > f m i n DI 0 . 6 2
FC ma i nOK DI 2 . 1 3
FC K 1M DI 0 . 1 4
s t a r t t d : 0 . 0 0 s 5
s t op t d : 0 . 0 0 s 6
FC r e s e t DO 1 . 5 7
. . .
l oad – i d l e
t d : 0 . 00 s 8
a l a rm t d : 10 . 0 s 9
. . .
p r e s s u r e r i s e
d p FC : 0 . 2ba r 10
. . .
mo t o r s p e ed 11

Item Explanation
1 "Frequency converter ready for operation" message (no fault)
2 Release signal for LOAD when rotational frequence > minimum frequence
3 Control voltage monitoring (115/230 V) via contactor K1.
4 Output for the control of the mains contactor for the frequency converter
(only for MIDIMASTER)
5 Time delay between switching the FC mains contactor and the FC start signal (Output A 0.0)
(only for MIDIMASTER)
6 Time delay between withdrawal of the FC start signal (O 0.0) and de-energising of the FC
mains contactor (Output A 0.1)
(only for MIDIMASTER)
7 Acknowledgement signal for the frequency converter
8 Delayed switching off of the LOAD mode after the cut-out pressure p1(p2) + dpFC has been
exceeded.
9 Suppression of the FC compressor alarm message during the starting phase.
The time is activated with the compressor start.
When the time is elapsed, the "FC ready" input is queried.
Without a signal, the alarm is triggered.
10 When operated under frequency control, the set pressure p1(p2) is held constant by varia‐
tion of the motor speed and the resulting variable volume delivered by the compressor.
If, despite the compressor turning at the slowest speed, pressure continues to rise beyond
p1(p2), the compressor is switched to IDLE at p1(p2) + dpFC.
This rule does not apply if the compressor is operated with a master controller (e.g.,
SIGMA AIR MANAGER). In this case, the switching to IDLE occurs at the value set for
"Pressure increase pE" in the <Pressure settings> menu.

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7.3 Commissioning the frequency converter

Item Explanation
11 The motor speed is passed to the SIGMA CONTROL from an analogue output on the con‐
verter.
The SIGMA CONTROL analogue input and the signal current calibrated in relation to speed
are assigned in this menu option.
Formula for the calculation of the setting values for the scaling in the <20 mA> menu:
Rated motor speed
Value20mA= *Maximum frequency
Rated motor frequency
Compare the displays for the motor speed at the SIGMA CONTROL and the frequency con‐
verter during the test run.

Tab. 12 Legend for the SFC Contact display

7.3.1.4 Setting the fan control

ASD–CSDX Series
An additional contactor for the fan is required in all compressors of the ASD–CSDX series with fre‐
quency converters.
The appropriate digital output (DO1.2 in this example) must be activated for the regulation of this
contactor.
1. See the wiring diagram for the digital output assigned to this contactor (DO1.2 in this example).
2. Enter password for level 5 at a minimum.
3. Select the <components> menu.
4. Select the <fan> menu.
5. Activate the DO1.2 digital output.
9 . 1ba r 7 6℃
MO P S f a n
======== ===== ==
M2 D I 0 . 1
M3 n . a .
M4 n . a .
M7 n . a .
. . .
m i n r un pe r i o d
r un t d : 0 . 0 0 s
. . .
f an s pee d s
======== ===== ==
a l l T DO 1 . 2 * Activate the DO1.2 digital output here.
. . .

DSD–HSD Series
A protective motor switch for the switching cabinet fan is required in all compressors of the DSD–
HSD series with frequency converters.
The appropriate digital input (DI1.2 in this example) must be activated for the regulation of this pro‐
tective motor switch.
1. See the wiring diagram for the digital input assigned to this protective motor switch (DI1.2 in
this example).

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2. Enter password for level 5 at a minimum.

3. Select the <components> menu.
4. Select the <fan> menu.
5. Activate the DI1.2 digital input.
9 . 1ba r 7 6℃
MO P S f a n
======== ==== = ==
M2 D I 0 . 1
M3 n . a .
M4 n . a .
M7 D I 1 . 2 * Activate the DI1.2 digital input here.
. . .
m i n r un pe r i od
r un t d : 0 . 00 s
. . .
f an s pee d s
======== ==== ===
a l l T n . a .
. . .

7.3.1.5 Parameter settings in SIGMA CONTROL from software version 72.32

Beginning with the software version 72.32, the following additional parameters must be set:
Parameter number Parameter value
P708.008 K0001
P708.009 K0541
U076.001 0
U076.003 B0031
P632.001 4 (2 x 4–20-mA switch = switch on S3 [Fig. 29, Table 14])
P638.001 1
P781.012 101

Tab. 13 Parameter settings in SIGMA CONTROL from software version 72.32

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Fig. 29 CUVC PCB

1 CUVC PCB until October 2005
2 CUVC PCB from November 2005

Configuration of the an‐ S3 switch status CUVC Meaning Value range of the sig‐
alogue input in parame‐ PCB nal
ter P632 (see Fig. 29 )
0 Open Voltage input −10 ... 10 V
1 Open Voltage input 0 ... 10 V
2 Closed Current input −20 ... 20 mA
3 Closed Current input 0 ... 20 mA
4 Closed Current input 4 ... 20 mA

Tab. 14 Selecting the signal type for the SIMOVERT MASTERDRIVES analogue input

7.3.1.6 Checking the settings for the setpoint pressure

The analogue output of the SIGMA CONTROL provides the frequency converter with the value of
the setpoint pressure as a 4–20 mA signal.
The required settings are default values but should be checked when troubleshooting, e.g. if the
converter does not regulate speed correctly.
1. Enter password for level 5 at a minimum.
2. Select the <configuration> menu.
3. Select the <I/O periphery> menu.

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4. Select the <AO parameter> menu.

5. Check the set value.
9 . 1ba r 7 6℃
AO1 – p1 ( 2 )
– 4 – 2 0mA
11 . 4 mA
−−−−−−−−− − −−−−−
s c a l e
. P t 100
2 0mA : 1 2 0℃
4mA : 0℃
. . .
s c a l e
p 1 ( 2 )
2 0mA : 1 6 . 0ba r
4mA : 0 . 0ba r

Checking the parameter values for the setpoint pressure

Upon commissioning, use the table below to check the parameter value (r033.003) for the setpoint
pressure at the frequency converter.
Frequency converter 0–10 bar Frequency converter 0–16 bar
psetpoint [bar] Isetpoint [mA] r033.003 [%] Isetpoint [mA] r033.003 [%]
5 12 50 9 31,25
5,5 12,8 55 9,5 34,37
6 13,6 60 10 37,5
6,5 14,4 65 10,5 40,62
7 15,2 70 11 43,75
7,5 16 75 11,5 46,87
8 16,8 80 12 50
8,5 17,6 85 12,5 53,12
9 18,4 90 13 56,25
9,5 19,2 95 13,5 59,37
10 20 100 14 62,5

Tab. 15 Assignment setpoint pressure – current – parameter value

Alternatively, you may calculate the parameter value r033.003 with this formula:
psetpoint *100%
r033.003 =
(pmax − pmin)FC
Example calculation: Frequency converter 0–16 bar / psetpoint 8 bar
8 bar *100%
r033.003 =
(16 bar − 0 bar)

r033.003 = 50 %
If the setpoint value for mains pressure is attained, you can read out the actual value in the param‐
eter r033.002 for verification.

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If the value in parameter r033.002 differs by less than 1 % from the value in the above table, trans‐
fer the displayed actual value as setpoint value (converted to bar) to the SIGMA CONTROL.

If the value of the parameter r033.002 differs by more than 1 % from the value in the above table,
check the parameters of the pressure transducer shown in the table below.
Parameter Meaning
P384.001/.002 Warning/fault motor load limits
check at 6 % higher load
P536 = 50 % n/f–RegDyn factory setting = 50 %
Parameter for the desired control dynamics

Tab. 16 Trouble-shooting parameters

Frequency [Hz] Motor rated frequency fN = 50 Hz Motor rated frequency fN = 60Hz

Parameter P107 = 50 Parameter P107 = 60
Value [%] Value [%]
10 20 16,67
20 40 33,34
25 50 41,67
30 60 50
35 70 58,34
40 80 66,67
45 90 75
50 100 83,34
55 110 91,16
60 120 100
65 130 108,34
70 140 116,67

Tab. 17 Motor rated frequency and parameterization

7.3.2 Loading and saving parameters with “DriveMonitor”

Alternatively, you can load and save the parameters via your laptop and the USS interface using
the "DriveMonitor" programme.

7.3.2.1 Connecting the laptop with the frequency converter

Use an interface cable (Mat. No. 7.6379.0) to connect the laptop with the
SIMOVERT MASTERDRIVES frequency converter.
Because the RS232 interface is not designed for bus operation, only a frequency converter of the
SIMOVERT MASTERDRIVES series can be operated.

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Fig. 30 Interface cable

7.3.2.2 Installing "DriveMonitor"

Every SIMOVERT MASTERDRIVES shipment includes the "DriveMonitor" programme and a com‐
prehensive electronic documentation on CD. You may perform the parameterization of the frequen‐
cy converter via the RS232 interface of the PC.
The software provides comprehensive parameterising aids and guides through the commissioning
process.
If the installation does not automatically start after placing the CD in the laptop, double-click
to open the <Autoplay.exe> file in the main directory of the CD.

7.3.2.3 Configuring "DriveMonitor"

The "DriveMonitor" programme starts with an empty window.

Setting the interface

Use <Tools> – <Online settings> to configure the interface.

Fig. 31 "DriveMonitor"

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Online settings
■ <Bus Type> tab
─ OPC server (not used)
─ USS (operation via serial interface)
■ <Interface> tab
─ Laptop Interface (COM1 to COM4)
Ensure that you have set the correct interface when using an USB-RS232 converter.
─ Baud rate: Set as per the baud rate in the P701 parameter
Compressors: 9600 baud
Blower: 19200 baud
─ Bus operation RS485: Settings as per the description of the RS232/RS485 interface con‐
verter

Fig. 32 Online settings tabs

Setting the drive

Fig. 33 Creating a new drive

1. Start the "DriveMonitor" programme.

2. Select <File> – <New> – <Based on factory settings> or <Empty parameter set>.
The system will create a <*.dnl> download file in which the drive data (type, software version)
are stored and then opens the Drive Properties window.

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Fig. 34 Drive properties

3. Set the drive properties.

Selection Selection/input Notes

field
Unit type Frequency converter You can only select from the stored types.
type
Unit version Software version of the By starting the ONLINE parameterization, you can gen‐
frequency converter erate databases for unlisted, new software versions.
Technology Select the technology
Type type (T100, T300, or
T400).
Bus Address The bus address of the The bus address must be identical with the parameter‐
drive must be specified ised SST bus address in the P700 parameter of the
only during ONLINE op‐ SIMOVERT MASTERDRIVES.
erations.
Quantity of Compressors "2" No specific meaning for the parameterization of
PZD Blower "2" or after occur‐ SIMOVERT MASTERDRIVES.
rence of fault functions Enter "4" for the operation with SIMOVIS.
"4"
➤ When changing the value, ensure that the set value
matches the P703 (drive) parameter.

Tab. 18 Drive properties

4. Confirm the drive properties with OK.

5. Enter the name and storage location of the parameter file.

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Fig. 35 Parameter list OFFLINE mode

6. Save the parameter list.

Result The parameter list opens in OFFLINE mode.

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Operating modes

Fig. 36 Parameter list ONLINE mode

1 <View> menu
2 Connection status

In the <View> menu 1 , you can switch between the <Offline>, <Online (Write RAM)> and <On‐
line (Write EEPROM)> operating modes.

OFFLINE mode

Use the OFFLINE mode if you cannot connect to the frequency converter, if either the device is
physically absent or a connection has not been established.
You can create a parameter set based on factory settings or a parameter files and transfer with the
<Download> function to the frequency converter at a later time.
Use the <File> – <New> – <Empty parameter set> menu option to create a parameter set.
Use the <File> – <Open> menu option to open a parameter set.

ONLINE mode

The identification of the frequency converter will start automatically when the system is in ONLINE
mode.
A warning message will be displayed if the configured and the real frequency converter do not
match (frequency converter type, software version).
If the system detects an unknown software version, it will offer the "Create a database" option (the
creation takes several minutes).

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■ ONLINE EEPROM
─ The system will read the parameter values from the frequency converter online.
─ Changed parameter values are written to the EEPROM and are thus permanently stored on
the frequency converter.
■ ONLINE RAM
─ The system will read the parameter values from the frequency converter online.
─ Changed parameter values are written only to the ROM and will be lost when the frequency
converter is switched off.

The lower bar 2 indicates the status of the connection with the frequency converter:
Display Meaning
ok Connection and frequency converter are okay
F Connection okay, frequency converter has a FAULT
W Connection okay, frequency converter returns a WARNING
O Frequency converter is paramterised OFFLINE
nc No connection to the frequency converter (parameterising only OFFLINE possible)

Tab. 19 Status of the connection with the frequency converter

Parameterizing options
Functionally similar parameters are combined in menus for the structure of the parameter set stor‐
ed in the frequency converters. Thus, a menu represents a selection of parameters from the overall
store of parameters in the frequency converter. It is possible for a parameter belonging to several
menus. The assignment of the parameters to the individual menus is shown in the parameter list.
Use the menu number given to each menu for the assignment.
The <Parameter> menu contains several selection options for parameterization.
The selection is made depending on the arrangement of the parameters in the menus. The selec‐
tion in the P060 parameter menu is automatically set to the correct value where permitted.

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Fig. 37 Parameter menu

Menu option P060 Description

User Parameters 0 Freely configurable menu
Parameter Menu 1 This menu is further subdivided. The parameters are associated with
individual functions groups.
Thus, specific parameterising tasks can be created effectively without
the need for comprehensive knowledge of the creation of parameters.
Fixed Settings 2 serves in the execution of a parameter reset to a factory or user set‐
ting.
Quick Parameter 3 serves in the fast parameterization using parameter modules
Setting
Board 4 serves in the configuration of option assemblies
Configuration
Drive Settings 5 for the in-depth parameterization of important motor, sensor and regu‐
lating data
Power Definition 8 for the definition of the power switching module

Tab. 20 Parameter menu

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Free parameterization

Fig. 38 Free parameterization

1 New list
2 Parameter name input field

Use the <Free parameterization> menu to create individual parameter lists.

For this purpose, click 1 . Enter a name for the list in the 2 field and save the list.
Clicking the corresponding icon in the toolbar will display a selection of previously created lists.

Parameter list

All parameter values stored in the frequency converter are displayed in the <Parameter list> menu
option. Display and changeability of these values depend on the status of the frequency converter.

Fig. 39 Parameter list

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Structure of the parameter list

Parameterising with the "DriveMonitor" programme is basically identical to the parameterization
with PMU (see chapter 8.1).

"DriveMonitor", however, offers certain advantages:

■ Simultaneous visibility of a larger number of parameters
■ Text display for parameter names, parameter value, binectors and connectors
■ Display of parameter limits or possible values when changing a parameter.

A new parameter list initially appears empty. You can enter the parameter number to be changed
at the end of the parameter list by clicking the last empty field, enter the number and confirm with
«Enter».
Delete unused parameters by selecting them with a mouse click and pressing «Enter».

The parameter list has the following structure:

Input field Function
P No. The parameter number is displayed.
Modifications can be made in the <Free parameterising> menu only.
Name Display of the parameter name
Ind Display of the index for indexed parameters.
Click on the [+] sign to see more than index 1. The display is then expanded to
show all of the parameter indices.
Index text Content of parameter index
Parameter The current parameter is displayed.
value You can change this value by double-clicking it and confirming with «Enter».
Dim Physical dimension of the parameter, if there is one.

Tab. 21 Structure of the parameter list

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7.3.2.4 Service functions

Fig. 40 Upload/Download

Download (Parameter P060 = 6)

The Download function transfers the parameters from the laptop to the frequency converter.

In order to download parameters, select the <Download> command in the <File> menu.
■ <Save EEPROM> – the parameters are saved permanently.
■ <Write RAM> – the parameters are saved temporarily.

Several parameters cannot be overwritten, such as the parameter P070 (Definition capacity
range).
The <*.ini> file assigned to the device type with "No overwrite" provides a list of these param‐
eters.
Example for the path of the <*.ini> file for SIMOVERT MASTERDRIVES in the “DriveMonitor”
programme: <C:\Siemens\STEP7\p7vrvisx\system\device\MDVV\MDVV.ini>

Upload (Parameter P060 = 7)

Use the Upload function to transfer the parameters from the frequency converter to the laptop and
to save them with the <*.dnl> file extension.

In order to upload parameters, select the <Upload> command in the <File> menu.
■ <Basic Device Complete> transfers all parameters.
■ <Basic Device: Changes Only> transfers only those parameters differing from the factory set‐
tings.

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Diagnostics menu
Use the <Diagnostics> menu to display the parameters as predefined parameter lists for diagnostic
purposes.

Fig. 41 Diagnosis

The parameter lists <Faults/Alarms> and <Display Messages> are available. Every parameter list
shows only those parameters which are relevant for the faults/alarms or display/messages.
You can change or monitor the parameters just like in any other parameter list.

7.3.3 Connection to the SIGMA AIR MANAGER

Additional settings are required for the connection of compressors with frequency converters to the
SIGMA AIR MANAGER:
1. Press «F1» (Settings).
2. Press «F3» (Compressor).
3. Press «F1» (Link to compressors).
4. Mark yes in the <Variable frequency drive> line.
5. Select the required characteristic in the <Characteristic number> line.
The following additional settings are required for a "Conventional link":

6. Select the <Analogue input for speed>.

Upon pressing «F3», the system displays an overview of the analogue inputs.

7. Enter in the <Speed = 0 at> line the electric current at motor standstill.
8. Enter in the <Speed at 20 mA> line the maximum motor speed.

7.3.3.1 Characteristic of the frequency converter

In this menu, you must enter the values for delivery and power consumption for a FC compressor
at given speeds. These values are used to project an approximation curve to estimate delivery and
power consumption of the complete air supply system.
The duty cycle of the system can be determined with the help of these values.
The settings for the compressor with frequency converter are found in the data sheet obtaina‐
ble from the compressor manufacturer.

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1. Press «F1» (Settings) on the SIGMA AIR MANAGER.

2. Press «F3» (Compressor).
3. Press «F5» (VFD-settings).
4. Press «F1» (Characteristic variable frequency drive).
5. Select the Characteristic VFD with «F5»/«F6».
6. Enter the speeds, deliveries and capacity at the compressor rated pressure.
The characteristic VFD curve entered is automatically added to the 0/0/0 point (speed [1/min]/
FAD [m3/min], power [kW].
If a compressor with frequency converter is activated and no characteristic curves are selec‐
ted, the FAD and power consumption are calculated using a straight-line function.
This represents an approximation that can vary by up to 30 %.

7.3.3.2 Two compressors with equal capacity and one compressor with frequency converter

The compressor with frequency converter receives the pressure setpoint from
SIGMA AIR MANAGER and the actual system pressure from its own pressure transducer so that
the compressor with frequency converter can continue to run in manual should the power supply to
SIGMA AIR MANAGER fail.
The pressure transducers of the SIGMA AIR MANAGER and of the compressor with frequency
converter should be installed at the same location in the air network, in order to prevent the com‐
pressor with frequency converter to receive a actual pressure value different from the one for the
SIGMA AIR MANAGER as could occur due to a pressure drop caused by treatment components.
This would invariably cause the compressor with frequency converter to run at too low a speed be‐
cause of the higher actual pressure value.

Precondition SIGMA AIR MANAGER software version: V0.12 and higher

Software version compressor with frequency converter: V0.71 and higher
Please contact KAESER Service Support for update options.

1. Allocate compressors with frequency converters to Group A.

Do not allocate any other compressor to group A.

2. Allocate compressors without frequency converters to Group B.

3. Enter the values for compressed air deliveries and capacities.
4. Specify that each compressor is to be controlled.
5. Specify that the compressor with frequency converter is to be controlled by the
SIGMA AIR MANAGER.
6. Assign a characteristic to this compressor.
The settings for the frequency converter characteristic curve are required for the display of
values computed for duty cycle, work done and FAD, etc.
They are not necessary for control of the compressor with frequency converter.
7. Specify the setpoint pressure and the group sequence (A – B – # – #).

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 8 Operation
8.1 Operating the parameterization unit (PMU)

8 Operation
8.1 Operating the parameterization unit (PMU)
The Parameterization Unit (PMU) serves for parameterising, operating and monitoring of the fre‐
quency converter itself. It includes a 4-character, 7-segment display and operating keys.

The PMU is used in the following applications:

■ Parameterising of simple applications with a small number of parameters to be set
■ Quick parameterization

Fig. 42 PMU Keys and Displays

Item Name Function

1 Display displays the current settings of the frequency converter
a) Operating states of the frequency converter
b) Alarms and faults
c) Parameter numbers
d) Parameter indices
e) Parameter values
2 «ON» key Switches the drive on (activates the motor control)
DISABLED!
In the event of a fault: back to the fault display
3 «OFF» key Switches the drive off
DISABLED!
4 «Reversing» key Reverses the direction of rotation for the drive)
DISABLED!
5 «UP» key increases the displayed value
6 «DOWN» key decreases the displayed value

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8.1 Operating the parameterization unit (PMU)

Item Name Function

7 «Parameter access» key toggles between parameter number, parameter index
and parameter value
with active fault display: acknowledges the alarm
8 Sub-D (X300) socket Access to the frequency converter via PC (interface ca‐
as RS485/RS232 interface (SST1) ble and programming software required)

Tab. 22 PMU Keys and Displays

8.1.1 Run-up
During the run-up, the frequency converter will run a parameter self-test during which the parame‐
ters from 000 to 2999 are incremented in the PMU display.

8.1.2 «Parameter access» key

Because the PMU has only a 4-character, 7 segment display, it cannot display parameter number,
parameter index and parameter value simultaneously. Use the «Parameter access» key to tog‐
gle between these descriptive elements.

Toggle sequence
■ from the parameter number to the parameter index
■ from the parameter index to the parameter value
■ from the parameter value to the parameter number

Fig. 43 Toggle sequence

1 Parameter number
2 Parameter index
3 Parameter value

If the parameter is not indexed, the system will jump from the parameter number directly to the pa‐
rameter value.
Using the «UP» / «DOWN» keys, you can change the selected descriptive elements.
The change of a parameter value will usually become effective immediately. In the case of
confirmation parameters only, a change will be effective only after toggling from the parame‐
ter value to the parameter number.
Parameter changes in the PMU will be saved in the EEPROM mains-failure protected upon
pressing the «Parameter access» key.

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8.2 Changing parameters in the SIMOVERT MASTERDRIVES

«Parameter access» + «UP» «Parameter access» +

keys «DOWN» keys
Function at active param‐ Toggles between the last selected Toggles to the operating mode
eter number level: parameter number and the operating display (Parameter r000)
mode display (Parameter r000)
Function at active param‐ moves display by one digit to the moves display by one digit to the
eter value level: right, if the parameter value cannot left, if the parameter value can‐
be display with 4 digits not be display with 4 digits
(left digit flashes if further hidden dig‐ (right digit flashes if further hid‐
its exist to the left) den digits exist to the right)
Function at active fault toggles to the parameter number lev‐ -
display: el

Tab. 23 Functions of the «Parameter access» key

8.1.3 Fault and alarm display

Fault display

The PMU displays a fault message with F = fault, followed by a 3-digit number. Simultaneously
press the «Parameter access» and «UP» keys on the PMU to switch to the parameter dis‐
play.

Further information More information about fault messages are found in chapter 9.1.

Alarm display

The PMU displays an alarm message with A = alarm/warning, followed by a 3-digit number which
is displayed periodically. If several alarms are present, the system will display them in sequence.
An alarm cannot be acknowledged. It disappears when the cause has been remedied.

Further information More information about alarm messages are found in chapter 9.2.

8.2 Changing parameters in the SIMOVERT MASTERDRIVES

Various password mechanisms protect the parameters. It is not necessary to change parameters in
normal operation.

NOTICE
Changing parameters without the required expertise!
The functions of the frequency converter and the motor are at risk.
A quick recovery of individual modifications is not possible for many parameters.
➤ Do not change parameters without the required expertise!

8.2.1 Password protection of the SIMOVERT MASTERDRIVES

Only a few parameters may be changed without using a password.
See chapter 10.1 for a list of unprotected parameters.
Just three examples:
■ Parameter P050 (language setting)

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8.2 Changing parameters in the SIMOVERT MASTERDRIVES

■ Parameter P060 (menu selection user parameters)

■ Parameter P358 (access to parameter P360)

These parameters are defined in the parameter P360.

The password is defined in the parameters P359.001 and P359.002. This parameter must
not be contained in the parameter P360.
The parameter P358 must not be deleted from the list in parameter P360 as the input of the
password will no longer be possible. The only remedy in this even would be a RESET.

Change password:

Precondition The password can be entered only during the compressor's standstill.

1. Enter the password in the parameters P358.001 and P358.002.

Parameter Password
P358.001 1234
P358.002 4321

Tab. 24 Password

2. Enter Parameter P060 = 1.

3. Change the required parameters.
4. Change the password in the parameters P358.001 and P358.002 to any value.
The password will be hidden.
5. Enter Parameter P060 = 0.

8.2.2 RESET to SIEMENS factory setting

The SIEMENS factory setting is a defined initial state of all parameters in the frequency converter.
By RESETTING to the factory settings, you can recreate this initial state at any time and to undo all
parameter changes made since the shipment. The parameters for the definition of the power
switching module and for the release of the technology options as well as the operating counter
and fault memory are not affected by this action.

Executing the RESET:

1. Parameter P050 (language setting)

2. Parameter P060 = 2
3. Parameter P366 = 3
4. Parameter P970 = 0
SIMOVERT MASTERDRIVES is reset to the SIEMENS factory settings.
5. Transfer the KAESER parameter set with the “DriveMonitor” program.
SIMOVERT MASTERDRIVES is reset to the KAESER factory settings.
6. Set the parameters as described in chapter 4.3.3.

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 8 Operation
8.3 Setting the PI regulation

8.3 Setting the PI regulation

Modulating the PI control circuit will not maintain a stable pressure without any air receiver or net‐
work buffer volume. Thus, a compressor with frequency converter always requires a network buffer
volume.

Control value Meaning Parameter

P Amplification factor kP U364
I Integration value or adjustment time tN U366
Acceleration time P462
Return time P464

Tab. 25 PI values for SIMOVERT MASTERDRIVES

A higher P value will result in a faster response of the controller. However, the response speed is
limited by the motor's and the compressor block's inertia and the risk of overswinging increases.
If the P value is selected too small, the compressor will regulate too slowly and will not completely
eliminate the difference between actual pressure and setpoint pressure.
A higher I value attenuates the swinging but also slows down the regulation.

Optimum P and I values cannot be calculated. The rule:

■ If the regulation swings, increase the I value.
■ If the regulating process requires too much time, increase the P value.

When changing P and I values, double or halve the initial values at first to see how strongly
the controller responds before fine tuning.
By changing the P and I values, you will not damage the compressor as the frequency con‐
verter always limits the current.
The D value shown in the controller can be neglected in practice.

8.3.1 Testing the PI regulation

When testing the PI control you may change the compressed air delivery by:

Partially closing the stop valve

Partial closing of the stop valve at constant delivery quickly generates a difference between actual
and setpoint pressure.
The disadvantage of this method is that this difference cannot be reproduced exactly and multiple
times as the pressure will change differently with each turn on the valve.

Changing the pressure setting in SIGMA CONTROL

By changing the pressure setting p1 (or p2) in the SIGMA CONTROL by approx. 0.3–0.8 bar at
constant delivery, you will create a difference between actual and setpoint pressure.
The advantage of this method is that this difference will be the same in every test and thus can be
tested easier with various P and I values.

Further information to the PI control is found in chapter 4.1.

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8.4 Changing the pressure

8.4 Changing the pressure

Increasing the pressure

The maximum pressure of the compressors can be exceeded only by reducing the maximum deliv‐
ery. For this purpose, you have the following options:
➤ Change the transmission.
➤ Import a parameter set which is configured for a higher pressure.

Decreasing the pressure

To lower the mains pressure in the menu of the SIGMA CONTROL:

1. Enter password for level 4 at a minimum.
2. Select the <configuration> menu.
3. Select the <press. settings> menu.
4. Select the <compressor> menu.
5. Select the < p1 SP> menu.
6. Enter the reduced mains pressure.

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 9 Fault-finding and rectification
9.1 Faults in the SIMOVERT MASTERDRIVES

9 Fault-finding and rectification

9.1 Faults in the SIMOVERT MASTERDRIVES
The following information is provided for every fault:
■ Parameter r947 (fault number)
■ Parameter r949 (fault value)
■ Parameter r951 (fault text list)
■ Parameter P952 (number of faults)
■ Parameter r782 (time of fault)

If a fault message is not acknowledged prior to switching off the supply voltage, the same message
will be displayed when the supply voltage is again switched on. The frequency converter will not
operate without this fault message being acknowledged (exception: automatic restart is selected,
see parameter P373 information).

Parameter r947 (fault number)

Visualization parameter for displaying the last 8 fault events. Up to 8 simultaneously occurring
faults may be stored for each fault event. Only those faults which have been assigned a number
are stored.
Indices Meaning
Index 1 to 8 1. Fault event, faults 1 to 8, (last fault event)
The value 0 in the index 1 means that no fault is active at this time.
Index 9 to 16 2. Fault event, faults 1 to 8
Index 17 to 24 3. Fault event, faults 1 to 8
Index 25 to 32 4. Fault event, faults 1 to 8
Index 33 to 40 5. Fault event, faults 1 to 8
Index 41 to 48 6. Fault event, faults 1 to 8
Index 49 to 56 7. Fault event, faults 1 to 8
Index 57 to 64 8. Fault event, faults 1 to 8, (oldest fault event)

Tab. 26 Parameter r947 (fault number)

Parameter r951 (fault text list)

List of fault texts; each fault text is stored in the index corresponding to the fault.

Parameter P952 (number of faults)

Function parameter for the display of the stored fault events and deleting the fault memory. When
the value 0 is entered, the entire fault memory consisting of the parameters r782, r947 and r949
will be deleted.

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Parameter r782 (time of fault)

Monitoring parameter for the display of the times of occurrence for the last eight fault events. The
status of the operating hour counter at the time of the fault event (r825) is displayed.
Indices Meaning
Index 1 Day of the first (last) fault event
Index 2 Hour of the first fault event
Index 3 Minute of the first fault event
Index 4 to 6 2. Fault event (day, hour, minute)
Index 7 to 9 3. Fault event (day, hour, minute)
Index 10 to 12 4. Fault event (day, hour, minute)
Index 13 to 15 5. Fault event (day, hour, minute)
Index 16 to 18 6. Fault event (day, hour, minute)
Index 19 to 21 7. Fault event (day, hour, minute)
Index 22 to 24 8. (Oldest) fault event (day, hour, minute)

Tab. 27 Parameter r782 (time of fault)

Message Error description Remedy

F001 unused, parameter error ➤ P591 check (Q.HS feedback).
Parameter value must agree with connec‐
tion of the mains contactor feedback.
➤ Check the feedback loop of the main con‐
tactor (or the feedback of the energising
current device in synchronous motors).
F002 During pre-charging, the minimum in‐ ➤ Check the mains voltage.
termediate circuit voltage (P071 [fre‐ ➤ Compare the mains voltage with P071
quency converter connection voltage] (frequency converter connection voltage).
* 1.34) of 80 % was not attained.
➤ In the case of DC devices, compare P071
The maximum pre-charge time of 3 with the intermediate circuit voltage.
seconds has been exceeded.
➤ Check the supply and regenerative units
in DC devices (must be switched on prior
to the frequency converter).
F006 Voltage in the intermediate circuit too ➤ Check mains voltage and/or input DC.
high, the system has been switched off. Frequency converter works in regenerative
In parallel connected frequency con‐ mode without feedback option.
verters (Series M, N): In a connection voltage close to the upper tol‐
r949 = 1: Overvoltage in the intermedi‐ erance and at LOAD operation, F006 may al‐
ate circuit of the master so occur due a network phase fault.
r949 = 2: Overvoltage in the intermedi‐
You may try to:
ate circuit of the slave
➤ increase P464 (ramp down time)
➤ activate P515 (U[d,max] controller) (check
P071 first)
➤ lower P526 (capture search speed)
➤ reduce P259 (if P100 = 3, 4 or 5)

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Message Error description Remedy

F008 The intermediate circuit voltage (P071 ➤ Check the input DC voltage.
[frequency converter connection volt‐ ➤ Check the intermediate circuit.
age]) fell below the lower limit value of
76 % (at activated kinetic buffer 61 %).
Undervoltage in the intermediate circuit
in "normal operation" (no simulation)
Undervoltage in the intermediate circuit
with active kinetic buffer and speed
lower than 10% of the rated motor
speed.
There was a "fast mains failure" which
was detected only after network recov‐
ery (WEA marker).
F010 Voltage in the intermediate circuit too ➤ Check the mains voltage.
high, the system has been switched off ➤ Check the brake resistance.
at 400V.
Frequency converter works in regenerative
Only with mode without feedback option.
■ U800 = 1 and ➤ Set braking unit to lower response thresh‐
old (673V).
■ f(pulse) > f(derating)

Lower threshold than F006!

F011 System switched off due to overcurrent. ➤ Check the output of the frequency con‐
The switching threshold has been ex‐ verter for short-circuit or ground fault.
ceeded. ➤ Check the driven machine for overload.
➤ Check whether motor and frequency con‐
verter match.
➤ Check whether the dynamic requirement
is too high.
F012 Current did not rise beyond 12.5% of Only in n/f/m control (P100 = 3, 4 or 5):
the setpoint magnetisation current for ➤ Switch to P372 (simulation) if no motor is
idle operation during the up activation connected
of the asynchronous motor.
➤ Check current sensing.
➤ Check power switching module.
F014 During the up activation of the motor, ➤ Check output contactor.
the current is less than 25% of the idle ➤ Check motor cable.
current.
Only if U800 = 1
regardless the control mode (difference
to F012)

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Message Error description Remedy

F015 Motor is stalled or blocked by: ➤ Reduce the load.
■ excessive static stress, ➤ Loosen the brake.
■ run-up or return too fast, ➤ Increase current limits.
■ load changes too fast and too ➤ Increase P805 (blocking time).
large, ➤ Increase P792 (response threshold for
■ incorrect parameterization of the setpoint/actual deviation).
pulse generator line number (P151) Only in f/n/M regulation (P100 = 3, 4, 5):
or the analogue speedometer scale
➤ Increase speed limit or speed setpoint
(P138),
value.
■ disturbed speed signals (speedom‐
Only in n/M regulation or U/f control with n
eter not screened).
regulator (P100 = 0, 4, 5):
The system will generate the fault only ➤ Check for speedometer line break.
after the time entered in P805 has ➤ Check pulse generator line number.
elapsed. ➤ Check analogue speedometer scale.
The binector B0156 is set in the status ➤ Place the screen of the speedometer line
word 2 r553 Bit28. on the motor and frequency converter
Whether the system detects a blockage side.
of the drive, depends on P792 (set‐ ➤ Reduce smoothing of the speed pilot con‐
point/actual deviation) and P794. In n/f trol (P216) - (only n/M regulation).
regulation, the attainment of speed lim‐
only f regulation: (P100 = 3):
its (B0234) is the prerequisite for this
fault. ➤ Slow down the run-up (see also P467
[protection run-up factor]).
An interrupted supply line may also be
the cause in speed regulation (P100 = ➤ Increase current in the lower frequency
4) and master drive (see also P587). range (P278, P279, P280).
This situation is synonymous with a ➤ Activate speed regulation pilot control
blockade of the drive. (P471 > 0).
The I(max) regulator (P331) must be ➤ Set EMK regulator to be more dynamic
activated in U/f control. (P315) by factor 2 maximally.
Monitoring does not function in U/f tex‐ ➤ Increase switching frequency to the EMK
tile (P100 = 2). model (P313).
➤ Replace with n regulation with pulse gen‐
erator in overmodulated n/f regulator.
➤ Keep speed setpoint value aligned with
speed actual value in order for the set‐
point/actual deviation to be always small‐
er than set in P792.

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Message Error description Remedy

F015 Motor is stalled or blocked by: only in synchronous motors (P095 = 12):
■ attainment of maximum frequency ➤ Check the current limits of the exciting de‐
in synchronous motors (P095 = vice.
12,13). ➤ Check the setpoint and the actual value of
■ missing or excessively high exciting the exciting device (incl. wiring).
current (P095 = 12) in externally ➤ Check the voltage limits of the exciting
excited synchronous motors. device at dynamic current changes.
■ With the attainment of the maxi‐ ➤ Check the drive system for sympathetic
mum frequency (including regulat‐ vibrations.
ing reserve) (B0254) the fault is
generated immediately in synchro‐
nous motors. If the deviations in the
rotor flow are too high, the system
will first regulate the frequency con‐
verter current to zero, reduce the
exciting current and generate the
fault message only after a period of
time double the attenuation time
constant (2*r124.1). During this
waiting time, status word bit B0156
(r553.28) is set.
F018 unused, parameter error ➤ Check parameter set.
F019 ➤ Re-import parameter set.
F020 Motor temperature too high (from sen‐ ➤ Motor control (load, ventilation, etc.)
sor): The current motor temperature can be
■ r949 = 1 read in r009 (motor temperature).
Limit value motor temperature ex‐ ➤ Check P381 (motor temperature).
ceeded. ➤ Check KTY84 input at -X103:29,30 socket
■ r949 = 2 for short-circuit.
Short-circuit in in-feed to motor
temperature sensor or motor tem‐
perature sensor defective.
■ r949 = 4
Wire break in in-feed to motor tem‐
perature sensor or motor tempera‐
ture sensor defective.
■ r949 = 5
Wire break and limit value excee‐
ded.
F021 Parameterised limit value of the I2t ➤ Check P383 (motor temperature T1).
monitoring for the motor has been ex‐
ceeded.

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Message Error description Remedy

F023 Limit for frequency converter tempera‐ ➤ Measure inlet or ambient temperature
ture exceeded: (must be within minimum and maximum
■ r949 = 1: ambient temperature).
➤ Note reduction curves in theta > 40°C.
Wire break in the sensor conductor or ➤ Check whether fan –E1 is connected and
sensor defective rotates in the correct direction.
■ r949 = 2: Sensor 1 ➤ Check air inlet and outlet ports for clog‐
■ r949 = 18: Sensor 2 ging.
■ r949 = 34: Sensor 3 ➤ Check temperature sensor connection to
■ r949 = 50: Sensor 4 –X30.

F025 UCE switched off during operation in ➤ – check for proper contact assignment.
phase L1. ➤ Check IGBT control module.
F026 UCE switched off during operation in ➤ Check CUVC PCB for proper contact as‐
phase L2. signment.
➤ Check IGBT control module.
F027 UCE switched off during operation in ➤ Check CUVC PCB for proper contact as‐
phase L3. signment.
➤ Check IGBT control module.
F028 The frequency and the amplitude of the ➤ Check the mains voltage.
intermediate circuit ripple indicate to a
single-phase network failure.
F029 Error in measurement value logging, Causes in phases L1 and L2:
e.g.: ■ fault in measured value sensing,
■ r949 = 1 ■ fault in power switching module (valve
Offset comparison not possible in does not lock),
phase L1
■ fault on CUVC PCB
■ r949 = 2
Offset comparison not possible in Causes in all other measured values:
phase L3
■ fault on CUVC PCB
■ r949 = 3
Offset comparison not possible in ➤ Exchange the CUVC PCB.
phases L1 and L3
F035 Parameterisable external fault input 1 ➤ Check for external fault.
has been activated (EMERGENCY ➤ Check whether the line to the correspond‐
OFF). ing digital input is interrupted.
➤ Check P575 (Q.k. external fault 1).
F036 Parameterisable external fault input 2 ➤ Check for external fault.
has been activated. ➤ Check whether the line to the correspond‐
ing digital input is interrupted.
➤ Check P575 (Q.k. external fault 2).

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Message Error description Remedy

F037 An analogue input is operated with 4– ➤ Check connection to:
20 mA and has a wire break.
■ analogue input 1 -X102:15, 16,
The number of the affected analogue
input is found in fault value (r949). ■ analogue input 2 -X102: 17, 18.

➤ Check parameter for analogue input

CUVC PCB:

■ P631 (Offset),
■ P632 (configuration),
■ P634 (smoothing),
F038 Voltage failure on module during pa‐ ➤ Re-enter the parameter.
rameter assignment. The number of the affected analogue input is
found in fault value (r949).
F040 Incorrect operating status ➤ Exchange the CUVC PCB.
F041 Error during saving values to EEPROM ➤ Exchange the CUVC PCB.
F042 Calculating time problems Reduce computing time load:
At least 10 failures of the T2, T3, T4 or ➤ Increase P357 (scan time).
T5 time slots (see also r829.2 to ➤ Calculate individual modules in slower
r829.5) scan time.
➤ Monitor r829 (free computing time).
F044 Error in wiring of binectors and connec‐ ➤ Switch power supply off and on again.
tors: ➤ RESET to factory setting and re-parame‐
■ r949 > 1000 terize.
error in connector wiring ➤ Exchange module.
■ r949 > 2000
error in binector wiring
F045 Hardware error when accessing an op‐ ➤ Check and replace, if necessary, the con‐
tion module. nection of the module rack to the option
modules.
➤ Exchange the CUVC PCB.
F046 Error when transferring parameters to ➤ Switch the frequency converter off and on
the trigger set processor. again.
➤ Replace the CUVC PCB if fault reoccurs.
F047 Computing time insufficient in the trig‐ ➤ Exchange the CUVC PCB.
ger set computer.
only in synchronous motors (P095 =
12):
Pulse frequency set too high (P340 >
2 kHz).
F048 impermissible pulse frequency in P340. ➤ Change P340 (pulse frequency).
F049 Different firmware versions on the ➤ Use uniform firmware.
CUVC PCB.
F050– unused, parameter error ➤ Contact KAESER service.
F057

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Message Error description Remedy

F058 Error when editing a parameter assign‐ No remedy.
ment.
F059 Error when calculating a parameter in ➤ Correct all indices of the parameter.
the initialisation phase. Number of inconsistent parameter is out‐
put as fault value r949.
➤ Switch the frequency converter off and on
again.
➤ Repeat this process when multiple param‐
eters are affected.
F060 Entry of incorrect frequency converter ➤ Enter an appropriate MLFB in the param‐
type when replacing the power switch‐ eter P070 after acknowledgement in the
ing module. INITIALISATION (only possible with the
corresponding access levels of both ac‐
cess parameters).
F061 A parameter entered during the drive ➤ Acknowledge the alarm.
setting has an impermissible range (de‐ ➤ Correct the parameter value.
pends on the controller type), e.g.: Number of inconsistent parameter is out‐
■ P107 (motor frequency), put as fault value r949.
■ P108 (motor speed),
■ P340 (pulse frequency).
F062 unused, parameter error ➤ Contact KAESER service.
F065 No telegram was received within the ■ Fault value r949 = 1: Interface 1 (SST1)
telegram downtime in a SST interface ■ Fault value r949 = 2: Interface 2 (SST2)
(SST/USS protocol).
➤ Check the connection CUVC PCB –
X100:1 to 5 and/or connection PMU –
X300.
➤ "SST/SCB TLG-Ausz." Check P704.01
(SST1) or P704.02 (SST2).
➤ Exchange the CUVC PCB.
F070– Fault on expansion cards ➤ Contact KAESER service.
F087 (unused, parameter error)
F090 A fault has occurred when attempting ➤ Switch the frequency converter off and on
to change a parameter from the stand‐ again.
still measurement or the rotating meas‐ ➤ Replace the CUVC PCB if fault reoccurs.
urement (motor data identification).
F091 The rotating measurement tor DC ➤ Eliminate the cause, restart the measure‐
measurement takes longer than pro‐ ment by switching the frequency convert‐
grammed in a measured status. The er off and again on.
corresponding measuring section is en‐ ➤ Replace the CUVC PCB if fault reoccurs.
crypted in r949.
Possible causes:
■ Load torque too large,
■ Load torque too uneven,
■ Run-up sensor locked.

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Message Error description Remedy

F095– unused, parameter error ➤ Check parameter set.
F098 ➤ Re-import parameter set.
F100 During the ground fault test, a current ➤ Read fault cause from r376 (result ground
has been measured or a UCE or over‐ fault test).
current monitor has responded, al‐ ➤ Check frequency converter outputs −X2:
though no valve has yet been triggered. U2, V2, W2 including motor for short-cir‐
r376 displays the concerned UCE mon‐ cuit or ground fault.
itor. ➤ Check CUVC PCB for proper contact as‐
signment.
➤ Sizes 1 and 2: Check the transistor mod‐
ules on the PEU board A23 for short cir‐
cuit.
➤ Sizes 3 and 4: Check the transistor mod‐
ules −A100, −A200, −A300 for short-cir‐
cuit.
F101 During the ground fault test, the UCE ➤ Check valves in the power section for
monitoring has responded in a phase in short circuit and, on converters with fibre
which no valve has been triggered. optic gating, check the gating unit wiring
and the UCE feedback for correct assign‐
ment.
F102 During the ground fault test a current is ➤ Read out fault value from r949.
measured in a phase in which no valve The digit of the x position indicates the
has been triggered or the UCE monitor‐ valve where the fault occurred at power-
ing has responded in the phase in up.
which the valve has been triggered. XOOO
X = 1 = V+
X = 2 = V−
X = 3 = U+
X = 4 = U−
X = 5 = W+
X = 6 = W−
The digit of the x position indicates the
phase during which current does not flow
and hence a valve must be conductive
defective.
OOOX
X = 1 = Phase 1 (U)
X = 3 = Phase 3 (W)
X = 4 = Phase 1 (U) or 3 (W)
➤ Examine phase for defective valves (al‐
ways conductive).

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Message Error description Remedy

F103 Ground fault or fault in the power ➤ Read out fault value from r949.
switching module. The digit of the x position indicates the
Possible causes: valve where the fault occurred at power-
■ during the ground fault test, a cur‐ up.
rent flows from the phase in which XOOO
a valve has been triggered. X = 1 = V+
X = 2 = V−
■ the overcurrent comparator has re‐
X = 3 = U+
acted, or
X = 4 = U−
■ the UCE monitoring has responded X = 5 = W+
in a phase in which no valve has X = 6 = W−
been triggered. The digit of the x position indicates the
phase during which current does not flow
and hence a valve must be conductive
defective.
OOOX
1 = current flow in phase 1 (U)
2 = UCE in phase 2 (V)
3 = current flow in phase 3 (W)
4 = overcurrent only
➤ Check motor and infeed line for ground
fault (speed of the motor shaft should be
smaller than 10% of the rated speed dur‐
ing the ground fault test).
➤ If no ground fault is present, check the
power module for defective valves (al‐
ways conductive).
F107– unused, parameter error ➤ Check parameter set.
F110 ➤ Re-import parameter set.
F111 Error when computing the offset func‐ ➤ Contact KAESER service.
tion.
F112 Individual results of the dispersion test ➤ Contact KAESER service.
vary too much.
F114 The frequency converter has automati‐ ➤ Restart the automatic measurement with
cally stopped the automatic measure‐ P115 = 2 (motor identification in stand‐
ment due to the time limit up to power- still).
up having been exceeded or due to an The ON command must be given within
OFF command during the measure‐ 20 seconds after display of the warning
ment, and has reset the function selec‐ message A078 (standstill measurement to
tion in P115. follow).
➤ Cancel the OFF command and re-start
measurement.
F115 Computing error during motor identifi‐ ➤ Switch the frequency converter and elec‐
cation. tronic module off and on again.
F116– Technology board fault ➤ Check parameter set.
F151 (unused, parameter error) ➤ Re-import parameter set.

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Message Error description Remedy

F153 The tool interface did not return a valid ➤ Execute cyclical write orders within the
sign of life within the monitoring time of monitoring time from the tool interface, in‐
the tool interface. creasing the sign of life by 1 with every
write order.
F243 Error in internal parameter linking ➤ Exchange the CUVC PCB.
(a link peer does not respond).
F244 Error in internal parameter linking. ➤ Compare version numbers of of gating
unit software and operating software re‐
garding the transfer parameters.
➤ Exchange the CUVC PCB.
F255 Fault in EEPROM. ➤ Switch the frequency converter off and on
again.
➤ Replace the CUVC PCB if fault reoccurs.

Tab. 28 Fault messages, fault descriptions and remedies

9.2 Warnings in the SIMOVERT MASTERDRIVES

Message Error description Remedy
A001 The computing time utilisation of the CUVC ➤ Check parameter set.
module is too high. ➤ Re-import parameter set.
➤ Contact KAESER service.
A002 unused, parameter error ➤ Check parameter set.
➤ Re-import parameter set.
A014 Intermediate circuit voltage at P372 = 1 (sim‐ ➤ Set P372 = 0.
ulation mode) unequal 0. ➤ Reduce intermediate circuit voltage
by disconnecting the frequency con‐
verter from the mains.
A015 unused, parameter error ➤ Check parameter set.
A016 ➤ Re-import parameter set.
A017 Switch X9 terminal 5-6 (locking the frequen‐ ➤ Close switch X9 terminal 5–6 and
cy converter pulse) has been opened. thus release the frequency convert‐
er.
A020 Overcurrent intervention ➤ Check driven machine for overload
(dynamic requirement is too high if
motor and frequency converter
match).
➤ Contact KAESER service.
A021 Overvoltage intervention ➤ Check mains voltage (frequency
converter works in regenerative
mode without feedback option).

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Message Error description Remedy

A022 Threshold for triggering the warning "con‐ ➤ Measure inlet air and ambient tem‐
verter temperature" exceeded. perature (note reduction curves at
>40°C).
➤ Check connection and direction of
rotation of the fan −E1.
➤ Check air inlet and outlet ports for
clogging.
➤ Check the temperature sensor on
−X30
(r833 displays maximum tempera‐
ture at all measuring points)
A023 Motor temperature too high (from sensor): ➤ Check wire break −X103: 29, 30.
■ r949 = 1 ➤ Check parameter set.
Limit value motor temperature excee‐ ➤ Re-import parameter set.
ded.
■ r949 = 2
Short-circuit in in-feed to motor tempera‐
ture sensor or sensor defective.
■ r949 = 4
Wire-break in in-feed to motor tempera‐
ture sensor or sensor defective.
■ r949 = 5
Wire break and limit value exceeded.
A024 Motor movement at motor data identification ➤ Brake the motor to standstill.
during first start-up.
A025 Thermal overload of the frequency converter ➤ Check P072 (measurement output
while maintaining the current load state. current).
➤ Check P070 (MLFB).
➤ Check P128 (maximum current).
➤ Check r010 (full load frequency con‐
verter).
A029 Parameterised limit value for I2t monitoring Motor load tolerance exceeded!
of the motor exceeded. ➤ Check P382 = 0 (integrated fan mo‐
tor cooling).
➤ Check P383 = 0 (thermal time con‐
stant).
➤ Check P384 = 100 (motor load lim‐
its).
A033 Bit 3 in r553 status word 2 of the setpoint ➤ Increase parameter for maximum
value channel. frequencies or reduce regenerative
Actual speed values has exceeded the maxi‐ load.
mum speed value plus set hysteresis.
■ Check P804 (overspeed hys plus),
■ P452 (n/f max,pos.DR) or
■ P453 (n/f max,neg.DR)

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Message Error description Remedy

A034 Bit 8 in r552 status word 1 of the setpoint ➤ Check wether the load is too large.
value channel. ➤ Check for block damage.
The difference between the frequency set‐ ➤ Check wether the pressure is too
point value and the frequency actual value is high.
larger than the parameterised value and the
➤ Check the mains voltage.
standard monitoring time is lapsed.
➤ Check maintenance display of the
oil separator cartridge.
A035 ➤ Contact KAESER service.
A036 unused, parameter error ➤ Check parameter set.
A037 ➤ Re-import parameter set.
A041 Mains voltage too high or P071(connection ➤ Check the mains voltage.
voltage frequency converter) incorrectly par‐ ➤ Check P071.
ameterised.
Udmax regulator blocked despite P515 (pa‐
rameter release), otherwise the motor would
immediately accelerate to maximum fre‐
quency in operation.
A042 Motor has stalled/is blocked. ➤ Check whether motor has stalled.
➤ Check wether motor is blocked.
A043– unused, parameter error. ➤ Check parameter set.
A053 ➤ Re-import parameter set.
A057 Occurs when a TB is announced and exists ➤ Replace TB build (software).
but parameter orders from the PMU, SST1 ➤ Contact KAESER service.
or SST2 are not answered by the TB within 6
seconds.
A061 Active signal (1) on binector U065. external warning message
A062 Active signal (1) on binector U066. ➤ Check wether parameter has been
changed by the customer.
A063 Active signal (1) on binector U067.
➤ Check parameter set and re-import,
A064 Active signal (1) on binector U068. if necessary.
A065 P373 (Option WEA) switches again on. ➤ Check whether Option WEA is really
P374 (cut-in delay time) lapses if "capture" is required!
not selected. (automatic restart could be danger‐
ous to personnel)
There is no time monitoring in pre-charging
the intermediate circuit, which means that
the external power supply of the electronics
is also again switched on.
A066– unused, possibly parameter error ➤ Check parameter set.
A071 ➤ Re-import parameter set.

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9.3 Fatal errors

Message Error description Remedy

A075 Individual results of the dispersion test or the ➤ Contact KAESER service.
rotor resistance test vary too much.
P122 (dispersion reactance) is the mean val‐
ue from the measured values in r546 Index
1-12.
rt26 (rotor resistance) id the mean value
from the measured values in r542 Index 1-3.
Individual measured values differing strongly
from the mean values will not be used in the
calculation (in RI) or the value of the auto‐
matic parameterization will be maintained (in
Ls).
Checking the results for plausibility is re‐
quired only in motors with high demands on
the speed or torque accuracy.
A076 Outputs from frequency converter and motor ➤ Check P095–P109 (motor data en‐
too different. try).
Calculated compensation time limited to val‐ ➤ Check parameter set.
ue range 0.5 μs – 1.5 μs. ➤ Re-import parameter set.
A077 Outputs from frequency converter and motor
too different.
Measured resistance limited to maximum
value 49%.
A078 The standstill measurement starts with acti‐ ➤ If the standstill measurement can be
vation of the frequency converter. performed without risk, activate the
In this measurement, the motor can orient frequency converter.
several times to a specific direction
(warning is displayed at every orientation).
A079 Rotating measurement cancelled or unable ➤ Release P561 (release frequency
to start because a STOP command is given.. converter).
➤ If necessary, restart the measure‐
ment by activating the frequency
converter.
A080 The rotating measurement will automatically ➤ If the standstill measurement can be
accelerate the drive when the frequency performed without risk, activate the
converter is activated. An external control of frequency converter.
the drive is then possible only within small
limits.
A081– Error CB or TB modules. ➤ Contact KAESER service.
A128 unused, parameter error

Tab. 29 Warning messages, fault descriptions and remedies

9.3 Fatal errors

"Fatal errors" are serious hardware or software errors preventing a standard operation of the fre‐
quency converter. They are displayed on the PMU only asFF....

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9.3 Fatal errors

If "fatal errors" occur, you must restart the software by pressing any key on the PMU.

Message Error description Remedy

FF01 Non-remediable time slot overflow detected in the high ➤ Contact KAESER service.
priority time slots.
FF03 Serious error while accessing external optional modules ➤ Contact KAESER service.
(CB, TB, SCB, TSY ..).
FF05 Fault in EEPROM. ➤ Exchange the CUVC PCB.
FF06 Stack overflow. ➤ Contact KAESER service.
FF13 Version conflict firmware and hardware ➤ Contact KAESER service.

Tab. 30 Fatal errors

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10.1 Freely accessible parameters in SIMOVERT MASTERDRIVES

10 Annex
10.1 Freely accessible parameters in SIMOVERT MASTERDRIVES
Parameter P360 stores those parameters that are visible or changeable without password input.
For example, parameter P360 Index 003 holds the information that the parameter P050 (language
selection) is freely accessible.
The complete parameter list is found in the specific frequency converter documentation.

Parameter Value Description Remarks

number
P060 0 Menu selection Function parameter for selecting the current menu.
1 0 = user parameters (selection of visible parameters
in parameter P360)
1 = Parameter menu
2 = Fixed settings for SIEMENS factory settings (do
not select)
3 = Quick parameter setting (modification in status
drive settings)
4 = Board configuration
5 = Drive settings
6 = Download
7 = Upload / free access
8 = Power definition
If it is not possible to change to another state due to
the currently valid state; the corresponding menu
cannot be selected either.
Using the parameters P358 (password) and P359
(lock), all other menus with the exception of User
parameters and Fixed settings can be locked.

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Parameter Value Description Remarks

number
P053 6 Interface enable Function parameter for releasing interfaces for pa‐
rameterization.
0 Hex = none
1 Hex = communications module CBx
2 Hex = device operator panel PMU
4 Hex = serial interface (SST/SST1), also OP1S and
PC
8 Hex = serial I/O modules SCB
10 Hex = technology module Txxx
20 Hex = serial interface 2 (SST2)
40 Hex = second CB module.
Each interface has a code number. When the num‐
ber or sum of different numbers assigned to the inter‐
faces is/are entered, the interface(s) is/are released
for use as a parameterizing interface.
Example:
The factory setting value 6 is the sum of 2 and 4.
This means that parameterization is allowed via the
PMU and serial interface 1, and thus for the OP1S as
well.
The parameter can always be written from any inter‐
face. This also applies if the interface has nor been
released for parameterization purposes.
P050 0 Language settings German
P457 Minimum setpoint in % in relation 50 Hz
obscured
P796 Comparison value set‐ in % in relation to 50 Hz (controller: inlet valve
point/actual value (obscured)
U364 Function parameter: KAESER specific value (see chapter 8.3)
base amplification. obscured
U366 Function parameter: KAESER specific value (see chapter 8.3)
delay time obscured
P462 Acceleration time KAESER specific value
obscured
r001 Operational state fre‐ Flexible display of current operational state (see
quency converter 10.2).
r002 Rotating frequency Display in Hertz
r003 Output voltage Display in volt
r004 Output current Display in Ampere
r005 Output power Display in % of nominal motor data
r006 DC link voltage Display in volt
r007 Torque Display in % of nominal motor data
r008 Motor utilization Display: % (not defined by KAESER).
r009 Motor temperature Display: % (not defined by KAESER).

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Parameter Value Description Remarks

number
r010 Frequency converter Display in % of the frequency converter load
load
r011 1 Active motor data set Data sets 1 to 5
(for various motors/operational states)
r012 1 Active BICO data set Data sets 1 to 2
(for internal switching logic)
r013 1 Active function data Data sets 1 to 4
set (for software links)
r014 Setpoint speed Display in 1/min
r015 Actual speed Display in 1/min
P030 .001 Source binector dis‐ 20 = digital input 6
play control voltage OK
.002 22 = digital input 7
ON signal from SIGMA CONTROL
.003 31 = analogue input 1
current loop monitor P/I
.004 32 = analogue input 2
current loop monitor SIGMA CONTROL
.005 641 = 1. Frequency converter
Fault message generation F036 (wire break signal)
r031 .001 Binector display 1 = OK
control voltage OK
.002 1 = ON
ON signal from SIGMA CONTROL
.003 0 = OK
current loop monitor P/I
.004 0 = OK
current loop monitor from SIGMA CONTROL
.005 1 = no fault
Fault message generation F036 (wire break signal)
P032 .001 Source connector dis‐ K588
play main setpoint value
.002 K011 = analogue input 1 = actual value P/I
.003 K013 = analogue input 2 = setpoint value
SIGMA CONTROL
r033 .001 Connector display Main setpoint in %
.002 % of analogue input 1
.003 % of analogue input 2
P358 Key parameter

Tab. 31 Freely accessible parameters

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10.2 Parameters for the operational state of the frequency converter

10.2 Parameters for the operational state of the frequency converter

Parameter Description Remarks
number
r001 Visualization parameter The operational state of the frequency converter is deter‐
for the current opera‐ mined by, e.g., the control commands for the internal proc‐
tional state of the fre‐ ess control (see also control word 1 and 2 in r550 and r551)
quency converter and by P060 (menu selection).
0= definition power switching module
1= initialisation of the frequency converter
2= hardware initialisation
3= drive initialisation
4= module configuration
5= drive settings
6= selection of various internal test functions
7= fault
8= activation lock
9= ready
10= pre-charging the intermediate circuit
11= operational readiness
12= ground fault test
13= "Capture" function active
14= operation
15= OFF 1 active
16= Off 3 active
17= "DC brake" function active
18= "Motor identification in standstill" function active
19= speed feedback circuit optimisation
20= "Synchronising" function active
21= download
r947 Visualization parameter Up to 8 simultaneously occurring faults may be stored for
for displaying the last 8 each fault event.
fault events. Only those faults which have been assigned a number are
stored.
r949 Visualization parameter Fault values contain additional information on the faults
for displaying fault val‐ which have occurred and allow exact diagnosis.
ues. The fault values are assigned to the faults and stored in the
the same indices as the corresponding fault numbers in
r947.
r701 RS232 interface Setting the baud rate:
1 = 300 Baud
2 = 600 Baud
3 = 1200 Baud
4 = 2400 Baud
5 = 4800 Baud
6 = 9600 Baud
7 = 19200 Baud
8 = 38400 Baud

Tab. 32 Parameters for the operational state of the frequency converter

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10.3 Electrical wiring diagrams

10.3.1 CSD82/102/122-SFC

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