ac wave 2 power

frequency inverter

«SPECIFIC PRODUCT SECTION»

Instruction and
user’s manual

Release 2.0 of 99/09

REEL S.r.l. Electronic Power Drives

Via Riviera Berica, 42
36024 Ponte di Nanto - Vicenza - ITALY
Tel. +39 0444 730003 - Fax +39 0444 638213
internet: www.reel.it - e-mail: reel@reel.it
 CONTENTS

1
1. GENERAL REMARKS
1.1 A.C. motor drives
1.2 Technical features

2
2. INSTALLATION
2.1 Power connections
2.2 Control connections
2.2.1 Standard board for connector P3
2.2.2 Standard board for connector P4
2.2.3 Board version D: connector P2
2.3.Serial drive encoding

3
3. COMMISSIONING
3.1 General remarks
3.2 Main speed set point 4÷20mA
3.3 Speed set points “jog 1 - jog2”
3.4 Auxiliary set point “R2”
3.4.1 Algebraical summation
3.4.2 Absolute summation
3.4.3 PID summation
3.5 Drive’s torque control
3.5.1 Working principle
3.5.2 Setting on “torque control” system
3.6 “Catching in flight” handling
3.6.1 Working principle
3.6.2 System setting
3.7 Product version

ac wave 2 power frequency inverter

 4
4. DRIVE PROGRAMMING
4.1 General remarks
4.2 Off-line parameters
4.3 On-line parameters
4.4 Module programming with PC

5
5. OPTIONALS
5.1 Optional I/O board
5.1.1 Static mSR output
5.1.2 Static Ok output
5.2 Ac wave 2,version 8KHz

6
6. ANOMALY SOLUTION
GUIDE
6.1 General remarks
6.2 Alarm description
6.3 Luminous signals

7
7. ENCLOSURES
7.1 Sizes of ac wave 2 power
7.2 Sizes of ac wave 2 power D
7.3 Sizes of ac wave 2 power FP
7.4 Place occupied
7.5 Power module map
7.6 Block diagram of power module
7.7 Application diagram
7.8 Electric power connections

ac wave 2 power frequency inverter

1. GENERAL REMARKS
1
1.1 A.C. motor drives

A.C. motors are doubtless widely used in many industrial applications, are extremely
versatile ad easily adaptable to all different needs of a market in constant technical
evolution.
Their use is made easy by their simple plan characteristics. In fact their movement
mechanics allows easy balancing and exceeding rated speed without any particular device;
the lack of brushes guarantees long lasting reliability and takes away the high costs of
programmed maintenance interventions.
Last but not leas, an advantage is given by the structure compactness, allowing high
degree insulation, permitting construction for immersion as well.
The disadvantage of the machine is however depending on the torque curve, which,
through “direct” mains connections, is very low in proximity of “zero revolution” finding
then its peak not far from synchronism speed.

To allow a total management of the asynchronous motor couple according to speed, REEL
offers the frequency inverter called ac wave 2.
This converter presents most modern project technology. Developed in two versions,
“MODULAR” and “SA” (stand alone), it has a totally digital regulation that, together with
the VVC (Voltage Vector Control) control system, allows to obtain the motors nominal
torque at 1Hz, respecting rated current without speed feedback. The voltage control to the
motor is a vectorial one, which means that the rotating vector is directly controlled. In this
way, the voltage components are the ones needed by the motor to carry out its work
immediately.

An innovative modulation system called “Pwm Random”, delays in time the modulation
frequency in a casual way, scanning more frequencies and mixing them together so that
the annoying “swhiistleo”, due to circling current switching, is taken away. It achieves a
“white” sound well mixing up with the typical noises of industrial environments.
Such system allows to modulate at low frequencies, so to reduce heat dissipation (also
proportional to the number of switching per sec of power components) and ease
interference emissions (also strongly affected in intensity by modulation frequency).

ac wave 2 power frequency inverter

 1.2 Technical features
1
Input voltage rating Three-phase 380÷440V +/-15%

Input rated frequency 45÷65Hz

Max. output voltage Three-phase max. voltage equal to input

voltage rating with possible 5% increase
Output frequency range 0÷500Hz

Output frequency resolution • 1/128Hz with digital speed set from serial
port RS485
• 0,1%with analog speed set point
Overload 150% for 1’ every 10’
200% for 10’’ every 10’’
Speed variation from no load to rated 1% without feedback
torque condition value refers to max. programmed speed
Speed control accuracy 0,01% with feedback

Mains micro switches Different operating solutions possible

Output wave form Sinusoidal with Voltage Vector Control (VVC)

PWM modulation frequency Adjustable from 1KHz to 5KHz

RANDOM modulation frequency Three different types of modulation available

as an alternative to the PWM system
(RPWM1, RPWM2, RPWM3)
V/Hz feature Linear with continuously adjustable boost,
square-law, semi- cubic curve
Speed compensation Based on sensor-less estimate of slip
frequency

ac wave 2 power frequency inverter

Voltage compensation Based on variations of supply voltage

Serial transmission baud rate Settable at 9600 - 19200 - 38400 - 76800

1
baud

Main analog set point 0,1÷10V o 4÷20Ma

with 0,3% accuracy
10 bit resolution
Main serial set point 16 bit

Auxiliary set point +/-10V

with 0,5% accuracy
9 bit resolution
Jog1, Jog2 The internal speed set points are
programmable from 0 to max. frequency
Acceleration / deceleration time 0.1÷1000 sec with independent setting

Speed feedback From unidirectional or bi-directional encoder

with period measuring up to max. frequency
40KHz
DC braking During from 0,1 to 10 seconds with a
current value settable from 0 to max.
deliverable current
Dynamic braking With optional circuit that can be installed in
the supply module (dissipation resistors are
available on demand)

ac wave 2 power frequency inverter

1

ac wave 2 power frequency inverter

2. INSTALLATION

2.1 Power connections

• The drives are constructed in several types, differing in size and overall dimensions. See
enclosures for dimensions and sizes.
2
• The fixing of power cables changes according to the different sizes:

− sizes 01÷06 and 91÷96: three-pole terminal board with max. allowed section
for connections of 4mm2
− sizes 06÷08: three-pole terminal board with max. allowed section for
connections of 10mm2
− sizes 09÷12: connecting on bolt terminal M6
− sizes 13÷16: connecting on double terminal with M6 bolt

• Please refer to chapter “Electrical power connecting” to find map, overall dimensions
and connecting diagram.

2.2 Control connecting

The ac wave 2 power module is available in two versions:

− standard
− “D” version

− The standard version supports a board h=120mm, able to receive all controls either
from hardware, that means from the connection terminals or through serial port RS485.
This version has two signal 10 pin connectors. The first one called “P3” is defined as
basic connector, having the essential controls for standard run/stop; the second one
called “P4” is defined as optional connector, having application controls such as
auxiliary set point, speed feedback, etc.

− The “D” version supports a board h=80mm, having only the software controls through
serial port RS485. It has one single 6 pin connector for the possible connecting of speed
feedback and auxiliary set point E2.

ac wave 2 power frequency inverter

 2.2.1 Standard board: connector P3

PIN DENOMINATION REMARKS TECHNICAL FEATURES

1 -R1 Negative input of analog speed Reference 0Vdc for pin 2

2 set point
(differential through +R1)
Input impedance 40KΩ
or
can be enabled at 4÷20mA 4÷20mA input impedance 241Ω
2 +R1 Positive input of analog speed 0÷10Vdc
set point Input impedance 40KΩ
(differential through -R1) or
can be enabled at 4÷20mA 4÷20mA input impedance 241Ω

3 0A Zero volt set point of analog 0Vdc

outputs
4 TH Analog output proportional to +/-10Vdc 7 bit resolution
output frequency or speed if impedance output 330Ω
with feedback IMAX 1mA, (10V=FMAX)
5 CUR Analog output proportional to +/-10Vdc 7bit resolution
supplied current output impedance 330Ω
IMAX 1mA, (10V=IMAX)
6 -C Common optoinsulators input for 0Vdc
the drive’s hardware
enablements
7 EN1 Starting input for main set point Optoinsulated
+/-R1 OFF = <3Vdc
ON = 15÷28Vdc
Impedance 2,2KΩ
8 ON Enablement input for current Optoinsulated
supply to the single drive OFF = <3Vdc
ON = 15÷28Vdc
Impedance = 2,2KΩ
9 CCW Motor rotation reversal Optoinsulated
enablement OFF = <3Vdc
ON = 15÷28Vdc
Impedance 2,2KΩ
10 JG1 Impulse speed no.1 enablement Optoinsulated
(internal set point 1) OFF = <3Vdc
ON = 15÷28Vdc
Impedance 2,2KΩ

ac wave 2 power frequency inverter

2.2.2 Standard board : connector P4

PIN DENOMINATION REMARKS TECHNICAL FEATURES

1 IG Zero Volt of digital circuits 0V with impedance 10Ω

supply
2
2 IG Zero Volt of digital circuits 0V with impedance 10Ω
supply
3 EN2 Enablement input for auxiliary Optoinsulated
set point +/-R2 OFF = <3Vdc
ON = 15÷28Vdc
Impedance 2,2KΩ
4 JG2 Enablement input for impulse Optoinsulated
speed no.2 OFF = <3Vdc
internal set point 2) ON = 15÷28Vdc
5 RES Alarm reset input of the single Optoinsulated
converter OFF = <3Vdc
ON = 15÷28Vdc
6 COM Common cable for 0Vdc
optoinsulators of speed
feedback
7 B Channel “B” input of speed Optoisolato
feedback (optional, only for OFF = <3Vdc
bi-directional encoders) ON = 15÷28Vdc
Max. frequency = 40KHz
Impedance = 3,3KΩ
8 A Channel “A” input of speed Optoinsulated
feedback OFF = <3Vdc
(connection for unidirectional ON = 15÷28Vdc
encoder) Max. frequency = 40KHz
Impedance = 3,3KΩ
9 +R2 Positive input of auxiliary +/-10Vdc
set point “R2” input impedance 48KΩ
(differential through -R2)
10 -R2 Negative input of auxiliary +/-10Vdc
set point “R2” input impedance 48KΩ
(differential through +R2)

ac wave 2 power frequency inverter

 2.2.3 Board version “D”: connector P2

PIN DENOMINATION REMARKS TECHNICAL FEATURES

1 A Channel “A” input of speed Optoinsulated

feedback OFF = <3Vdc

2 (connection for unidirectional

encoder)
ON = 15÷28Vdc
Max. frequency = 40KHz
Impedance = 3,3KΩ
2 B Channel “B” input of speed Optoinsulated
feedback OFF = <3Vdc
(optional connection; only for ON = 15÷28Vdc
bi-directional encoders) Max. frequency = 40KHz
Impedance = 3,3KΩ
3 COM Common cable for 0Vdc
optoinsulators of speed
feedback
4 DG Supply Zero Volt of digital 0Vdc
circuits
5 -R2 Negative input of auxiliary +/-10Vdc
set point “R2” Input impedance 100KΩ
(differential through +R2)
6 +R2 Positive input of auxiliary +/-10Vdc
set point “R2” Input impedance 100KΩ
(differential through -R2)

Notes: - all signal and feedback cables must be screened through connection to signal
ground (described in general section, chapter on grounding)
- do not ground supply zero (0A; IG; DG)

2.3 Serial drives encoding

It is possible to connect up to 31 modules in a single serial node. The drives shall be

encoded; Reel has a progressive encoding, the first drive on the tunnel’s top having serial
code 1.
The sequence can be changed and the tunnel customised with DIP switches put on the
adjustment board of each drive.

The DIP switches can be found in the maps and have following functions:

1-2 Connecting the termination resistors of the serial line. They must be selected on the
farthest drives from the supply module. There can be max. two modules on one and
the same serial line.

ac wave 2 power frequency inverter

3÷7 Encoding the module’s serial address.
Used to encode module for communication with a master (programmer or MAC
external unit). Up to 31 addresses are available.

8 Forcing the serial communication line’s baud rate to 9.600.

Adjustment board of inverter module - standard version

2
SERIAL ADDRESS CONFIGURATION (SW1)

Adjustment board for inverter module - “D” version

SERIAL ADDRESS CONFIGURATION (SW1)

ac wave 2 power frequency inverter

 The following chart shows the serial address, where 1 = DIP ON

DIP3 DIP4 DIP5 DIP6 DIP7 ADR. DIP3 DIP4 DIP5 DIP6 DIP7 ADR.
0 0 0 0 0 not 0 0 0 1 0 8
used

2 1
0
0
1
0
0
0
0
0
0
1
2
1
0
0
1
0
0
1
1
0
0
9
10
1 1 0 0 0 3 1 1 0 1 0 11
0 0 1 0 0 4 0 0 1 1 0 12
1 0 1 0 0 5 1 0 1 1 0 13
0 1 1 0 0 6 0 1 1 1 0 14
1 1 1 0 0 7 1 1 1 1 0 15

Addresses 16÷31 following can be taken from chart.

ac wave 2 power frequency inverter

3.COMMISSIONING

3.1 General remarks

The general section describes conditions and precautions about the first putting under
voltage.
This section describes the drive’s application context as electromechanical equipment being
an automation product. A careful reading of general section is recommended before the
drive is started for run.

Attention!: The drive is supplied only with laboratory’s settings. The installer shall see to
specific configuration according to the motor used and the specific kind of automation.
3
3.2 Main speed set point 4÷20mA

Some information requires current speed setting in order to interface with PC or PLC.
Reel offers for the standard version some DIP SWITCHES for configuration of the
converter’s main set point 4÷20mA.
They are shown on the following map.

Adjustment board for standard inverter module

SPEED SET CONFIGURATION 10V/4-20mA (SW2)

Dip 1 Not used

Dip 2 Input of load resistance for set point 4÷20mA
Dip 3-4 Input gain selection for set point 4÷20mA

• Dip 2 - 3 - 4 = OFF: 0÷10V

• Dip 2 - 3 - 4 = ON : 4÷20mA

ac wave 2 power frequency inverter

 3.3 Impulse speed “Jog1 - Jog2”

A further automation support is given by the possibility of having two internal, presettable
speeds.
The inverter module, depending on enablement of one or two jogs, supplies the motor with
the frequency pre-set in jog1 and jog2. The motor decelerates when jog is disconnected.

• The jogs follow time pre-set in the “ramp” variable.

• When both jogs are enabled the drive carries out the sum of values set in the respective
variables.

3.4 Auxiliary set point R2

3 Automation often requires speed adjustment of a movement according to other machine
organs. Therefore some functions may be necessary, implemented by Reel through an
auxiliary set point.
It is to be stated first that auxiliary set point R2 has no ramps (acting directly on supply
frequency without being influenced by values set in ACC - DEC or RAMP).
Four variables are associated to the auxiliary set point: E2A, E2P, E2I, E2D; many functions
can be obtained by setting one or more variables adequately. Some possibilities of common
use are described in the following lines.

3.4.1 Algebraical summation

E2A = 0% E2P = XX% E2I = 0% E2D = 0%

Drive carries out the sum or subtraction of speed set point R1 and auxiliary set point R2.
The result is directly proportional to the analog voltage value of differential input +/- R2, to
percentage set in variable “E2P”, and to the R1 value itself.

• Max. adjustment = 99,9% of main set point (with E2P = 99,9% and +/-R2 = +/-
10V).

3.4.2 Absolute summation

E2A = XX% E2P = 0% E2I = 0% E2D = 0%

Drive carries out sum or subtraction of main set point R1, depending only on percentage
set in E2A and voltage value of input +/-R2.

• Max. adjustment = 99,9% of MAXF set (with E2A = 99,9% and +/-R2 = +/10V).

ac wave 2 power frequency inverter

3.4.3 PID summation

E2A = 0% E2P = XX E2I = XX E2D = XX

Drive carries out adjustment of main set point aiming to voltage value of auxiliary set point
R2 equal to zero volt, meaning that an auxiliary PID is carried out, using set point 2 as
feedback.
This system is essential for speed synchronism of two movements or particular handling
such as “dancer“ rolls and “loading stores”.
Variables E2P, E2I, E2D shall be set according to the dynamic performances to be
obtained.

• Max. adjustment = 100% of main set point

3
3.5 Torque control

Some automations require the setting of a torque set point in order to limit the torque
available for the shaft.
The adjustment software for the ac wave is set for torque control and can be enabled by
selecting the «T.V/Hz» variable, which shall have function “torque”.

• The torque handling needs speed feedback from bi-directional encoder. We suggest
choosing an encoder ensuring a good rev. resolution without exceeding max. frequency
40KHz.

3.5.1 Working principle

Drive controls the motor running and supplies it with:

− synchronic frequency when torque set is zero
− slip proportional to required torque set

• Torque can be set on auxiliary set point (+/-R2) with 0÷+10Vdc

• The main set point determines torque direction through:
− braking torque when R1 = 0V or set is lower than instant motor speed
− forwarding torque when R1 = MAX o set higher than instant motor speed

NOTE: If torque setting is higher than load requires, the motor will increase revolutions up
to the number set on R1 for speed adjustment.

Slip is controlled according to formula:

slip = Slipnom x IMAX x %R2

INOM
where:
slip is resulting
Slipnom is set slip (synchrony speed -nominal speed)
IMAX is max. set current
INOM is set rated current
%R2 is the auxiliary set point’ percentage with 10V = 100%.
ac wave 2 power frequency inverter
 3.5.2 Setting of torque control system

The system does not need particular measures, variables FNOM, VELNOM, IMAX and
INOM have just to be set according to the motor’s setting parameters.
It is recommendable to set variable T.V/Hz in PID first and, after optimising the dynamic
performances of speed control through variables KP, KI, KD, select «Torque» function.
Speed set point “R1” will determine torque as braking or forwarding as well as speed limit
in case of load missing; set point “R2” determines max. slip and so shaft torque.

ac wave 2 power frequency inverter

3.6 “Catching in flight”

Sometimes, after a supply interruption, the possibility of “catching” the motor again is
demanded (motor may have been left previously, missing the mains or being disabled),
while it is still rotating due to a driving force. The motor takes then speed again or is
stopped by control.
Reel can supply this function on demand. It needs particular controls and setting for
“catching in flight” enablement , as described below.

3.6.1 Working principle

When such function is enabled, the inverter starts searching the physical motor speed by
scanning the possible supply frequencies. The searching starts with the frequency value
set in variable “FMAX”, and goes through the whole range “FMAX”÷“FMIN”. 3
At this step, motor is run down in order to reduce the absorbed current.
As soon as supply frequency corresponds exactly to the physical motor speed, the
absorbed current is reduced considerably and changes then sign (from absorbed to
delivered) when frequency gets below.
The drive will so pick out the real speed, run the motor down (according to set V/Hz set)
and control it.
Searching voltage as well as searching time can be set.

3.6.2 System setting

Previous selection:

Set variable “JOG2” = 0

Set variable “HOLD” = 1 or 2

Searching motor speed:

Start up “jog2” in order to enable searching function.

The speed searching starts as soon as inputs “jog2” (pin 4 of P4) and “ON” (pin 8 of P3)
are enabled; once the synchronism speed is reached, the motor is driven to the speed
corresponding to set value on differential input “RIF1” (pin 1-2 of P3).
Should this input be disabled (EN1 = OFF), the motor is driven to zero revolutions.
Searching speed, the inverter sets on motor a decreasing frequency starting from FMAX.
Once the synchronism frequency is found, the inverter catches up he motor and carries out
the required setting.
The searching current is “indirectly” determined by variable “X1”; searching time is
determined by variable “X2”.

X1 is in fact a percentage of standard Volt/Hertz.

The setting range is 0÷500, 500 being 50% of linear Volt/Hertz.

ac wave 2 power frequency inverter

 The diagram below shows the searching voltage values with a «380V 50Hz» motor.

Recommended value: 150

X2 is the searching ramp; low values take a longer searching time, high values make
searching short.

Recommended vallue: 8 ( corresponding ot search ramp of 2 seconds)

Setting range = 0÷500

Recommended value: 8 (corresponding to a searching ramp of about 2 seconds).

Searching precision is obviously directly proportional to ramp length and searching current
value.
Note: By leaving input “jog2” constantly on, the inverter will search every time it will be
ready to start.

ac wave 2 power frequency inverter

3.7 Product version

The different product versions are to be taken into accouont in case of order or spare part
demand.

− 090 Analog/digital power module

− 100 Digital power module
− 190 Digital power module
− 110 Digital power module h= 80 mm
− 290 Analog/digital small-size power module
− 300 Digital small-size power module

ac wave 2 power frequency inverter

3

ac wave 2 power frequency inverter

4. DRIVE PROGRAMMING

4.1 General remarks

The general section describes all programming and supervising systems supplied by Reel
for interfacing with the own products. A thorough reading of that section is therefore
necessary before starting with drive programming.

There are to kinds of ac wave 2 power module parameters:

− «OFF LINE» parameters: they cannot be modified while motor is running, as they
belong to primary configuration and change the drive’s behaviour essentially.
− «ON LINE» parameters: can be modified while motor is running so that their
efficacy can be checked immediately. Such parameters are speed PID, auxiliary
PID, dynamic compensations (V0, KCUR, KSLIP), etc.

4.2 OFF-LINE Parameters 4

SIZE
This value range (1÷16) determines the size of power modules and is set during test.
Please refer to following chart if you want to check it.

A wrong setting may affect the electronic thermal protection and make the compensatory
constants ineffective.

SIZE MOTOR POWER SIZE MOTOR POWER

01 1.1 Kw 09 22 Kw
02 2.2 Kw 10 30 Kw
03 3 Kw 11 37 Kw
04 5.5 Kw 12 45 Kw
05 7.5 Kw 13 55 Kw
06 11 Kw 14 75 Kw
07 15 Kw 15 90 Kw
08 18.5 Kw 16 132 Kw

FPWM
Setting of modulation frequency. The value sets frequency reconstructing the current
sinusoid.
The available range is 1,0KHz - 5,0KHZ. When exceeding 2KHz, a de-rating of the max.
available current is carried out, that is 10% for every KHz. High FPWM values reduce the
“whistling” i caused by modulation and the current sinusoid ripple as well. There a
modulation types called “RANDOM” are available; this system (selected when exceeding
5,0KHz) reduces the annoying “whistle” considerably by moving the modulation frequency
within a set range so to change the whistle into a rustling.

ac wave 2 power frequency inverter

 The first RANDOM frequency oscillating between 1KHz and 2KHz, does not derate IMAX;
the second one between 2KHz and 3KHz carries out a de-rating of 5%; the third one
between 3,3KHz and 4,3KHz carries out a de-rating of 17,5%.
Setting range: 1.0÷5.0KHz e RND1; RND2; RND3.

Warning
• If some filters are installed on the drive’s output, do not use “RANDOM” frequency, as
filters are calculated for a precise frequency; different frequencies may lead to the
drive’s protection stop or to filter’s breaking.
• Choosing the frequency, the module’s thermal dissipation and its IMAX have to be
considered. Another important parameter is the max. motor frequency (“FMAX”). The
higher frequency, the higher modulation frequency must be set, in order to obtain for
current a good form factor.

The following setting is suggested:

− FPWM between 2 and 3KHz (or random2)
for FMAX values between 60 and 100Hz

4 − FPWM between 3 and 4KHz (or random3)

for FMAX values between i 100 and 300Hz
− FPWM between 4 and 5KHz
for FMAX values higher than 300Hz

PWM
When function “DISS. RID = Reduced dissipation” is set, a particular modulation sequence
for power IGBT is activated that reduces the drive’s thermal dissipation. This selection
must be avoided in case of motors with high dynamic performances.
Setting field: DISS.RID / STANDARD PWM

IMAX
Max., transitory deliverable current by the module. For correct setting please refer to chart
in chapter “Sizes and overall dimensions”.
Setting range: from INOM to IMAX, available according to size

INOM
Rated motor current (value for electronic thermal protection of motor to be started).
Setting range: 0÷I rated current of inverter module (refer to size chart)

FNOM
Motor rated frequency.
Setting range: 50Hz÷500Hz
For software versions following 15318138 the setting range is: 10Hz÷
÷500 Hz

VEL.NOM
Motor revolutions at rated frequency (considered at rated motor slip).
Setting range: 0÷30000 revolutions/min

ac wave 2 power frequency inverter

COSFI
Power factor of motor used.
Setting range: 0,50÷0,95

FMIN
Minimum frequency in Hz at which inverter starts working.
If parameter is set at 0,0 the drive, when enabled, will deliver a DC to motor proportional
to value set in “V0” (see the following).
Setting range: 0,0Hz÷400,0 Hz

FMAX
Max. frequency at which inverter reaches max. speed set point.
Setting range: 0,1 (or FMIN)÷500Hz

JOG1

4
Impulse speed value to be enabled with input having the same name.
Setting range: 0,0Hz÷500Hz (limited by FMAX from an operating point of view)

JOG2
Impulse speed value to be enabled with input having the same name.
Setting range: 0,0Hz÷500Hz ( limited by FMAX from an operating point of view)

mSR
Speed threshold in Hz; beyond this value inverter switches the output having the same
name.
In the modular system the single “mSR” s add up to one summation in a single general
supply module output.
Setting range: 0,3Hz÷FMAX

T.V/Hz
Selecting of Volt/Hertz feature, according to the function of motor used. Following options
can be chosen:
LINEAR, PID, SQUARE -LAW, SEMICUBIC, TORQUE.

• LINEAR: is used in most cases, not needing any speed feedback. Transmits voltage to
the motor according to working frequency, and is compensated by the V0 parameter
(described later);
• PID: speed feedback through a unidirectional or bi-directional encoder allowing a higher
precision degree;
• SQUARE-LAW and SEMI-CUBIC: for particular applications, when motor controls fans,
pumps, etc.;
• TORQUE: set for future applications

ac wave 2 power frequency inverter

 IMP./G.
Impulse number per motor revolution regarding speed feedback.
Choosing the device, take into account that max. feedback frequency must not exceed
40KHz.
Setting range: 0,4÷1024,0 impulses/revolution

ENCODER
With regard to speed feedback, it must be specified whether the encoder is unidirectional
or bi-directional.
Setting field: UNIDIRECTIONAL / BIDIRECTIONAL

DC BRAKE
DC braking enablement during stop. When set, motor will be stopped by inserting direct
current and not according to pre-set deceleration ramp.
Setting field: NO / YES

4 T BRAKE
Determines DC inserting time while stopping (when “DC BRAKE” is on).
Setting range: 0,1÷20,0sec.

RIF1
Speed set point input for 0÷10V or 4÷20mA signal.
Setting has to be completed through selection of the DIP SWITCHES on adjustment board
(see regarding section).
Setting range: 0÷10V / 4÷20mA

STALLO - DEADLOCK
During standard working, when speed set point is missing, the inverted will be disabled.
When this parameter is on, the motor does not stop, but keeps running at minimum
frequency (provided it is not 0).
Setting field: YES / NO

START
Variable available for future applications.

RIF2
Variable available for future applications.

ac wave 2 power frequency inverter

SETUP
The drive can be controlled through releases and set-points from serial port.
Setting range: 0÷255 decimal or 0÷FF hexadecimal with:
0 = releases and set points from terminal board
255 = releases and set points from serial line

Intermediate values assign mixed features. A numeric value is assigned to each release.
When set, it leads to passing from hardware to software; the sum of release values to be
enabled as software is the variable value to be set.

Assignment as follows:

DECIMAL HEXADEC. DECIMAL HEXADEC.

ON= 1 1 SET POINT = 32 20

EN1= 2 2 BY PASS FUNCTION K= 64 40

EN2= 4 4 CW/CCW= 128 80

4
EN3= 8 8

For example: when ’EN1, SPEED SET POINT and CW/CCW function has to be carried out
with serial control, the number for SETUP is:

DECIMAL HEXADECIMAL

ON: 1+ 1+
EN1: 2+ 2+
SET POINT : 32 + 20 +
CW/CCW: 128 = 80 =
163 A3

Other functions shall be started from terminal board.

SECURITY
Enables a particular sequence for drive’s software stopping, increasing security level
against uncontrolled disabling and releasing the drive from disabled at the same time as
ID=0.
Setting field: ENABLED/ DISABLED

ac wave 2 power frequency inverter

 4.3 ON-LINE PARAMETERS

These parameters can be changed while motor is running (on line). They are used for the
inverter’s dynamic compensation.
Compensations are available according to selected V/Hz feature.

ACC
Value in sec to reach speed of speed set point. Determines the motor’s accelerating curve.
Setting range: 0,0÷1000,0sec.
For software versions following after 15318138 setting range 0,0÷
÷6000sec

DEC
Time taken for the motor to stop; set time refers to speed decreasing at the moment when
input EN1 is disabled.
Setting range: 0,0÷1000,0sec.
For software versions following after 15318138 setting range 0,0÷
÷6000sec

4 RAMPA - RAMP
Time of set point moving.
It is set referring to a ramp of 0÷50Hz.
Setting range: 0,0÷1000,0sec.
For software versions following after 15318138 setting range 0,0÷
÷6000sec

Note: value is used also during rotating direction reversing.

V0
% value of voltage boost needed to reach the nominal torque at low rpm.
The action reaches its maximum level about the 0 speed, and is cancelled out at about
60% of the motor’s rated frequency.
For a correct value setting the following is suggested:
While motor is idling reach 3-4% of rated frequency and modify V0 value in order to reach
80-90% of the motor’s rated value.
Such operation compensates the motor’s internal resistance which is influenced by
temperature. It is therefore recommended to set motor while being under its usual thermal
conditions.

Setting range: 0÷200; 200 corresponds to 20% increase of rated voltage.

KCUR
Voltage compensation.
• If implemented, the PID working allows the decrease of V0 action proportionally to the
slip measured by the inverter, so to optimize absorbing at low speed. This function is off
when set=0; when set=100 and nominal slip is given, it adds a multiple constant of 1.
• When LINEAR working, this parameter acts as multiple constant of V0 during
acceleration. It can modify V0 up to max. 200% of set value.

Setting range: 0÷200%

ac wave 2 power frequency inverter

KSLIP
Frequency compensation.
This parameter reduces the motor speed loss when shifting from load-less to load
condition.
To put in a correct value, motor speed with a considerable load variation must be
measured, until a decrease of measured slip is obtained. Slip should not be zeroed
completely, so to avoid annoying oscillating.
Such compensation does not affect the speed loop while running with feedback.
Setting range: 0÷200%

KP
Proportional compensation constant of speed loop. It adjusts speed loop proportionally to
error between set and real speed.
Setting range: 0÷200

KI
Integral compensation constant of speed loop. Adjusting according to error duration.
Setting range: 0÷200 4
KD
Derivative compensation constant of speed loop, adjusting instant error proportionally to its
variation speed.
Setting range: 0÷200

E2A
Absolute effect of adjustment signal +/-R2, not depending on speed.
See chapter «auxiliary set point R2» for setting.
Setting range: 0÷99,9%

E2P E2I E2D

Dynamic constants referring to the three components (proportional, integral, derivative)
adjusting main set point with auxiliary input R2. Such compensations are proportional to
motor speed.
See chapter «auxiliary set point R2» for setting.
Setting range: 0÷99,9%

X1
Parameter used in case of mains failure:
• it determines the voltage applied to motor through DC injection near the“zero
revolutions“ during the “mains failure control”;
• it determines the search current for “SPEED MOTOR” during the “CATCHING IN
FLIGHT” function ( see chapter “Catching in flight”
Setting range: 0÷500 where 500 corresponds to 50% of nominal voltage.
ac wave 2 power frequency inverter
 X2
Variable used for function “catching in flight”; see chapter “Commissioning: catching in
flight” for setting.
Setting range: 0÷500

HOLD
By setting this parameter it is possible to select the inverter performance in case of
temporary power failure.

HOLD = 0 Standard setting: controlled deceleration, in synchronism

with the other connected power modules
HOLD = 1 Inverter is switched off
HOLD = 2 Inverter keeps running without changing speed
HOLD = 3 Inverter stops according to pre-set deceleration ramp

4 In any case the inverter will try to restore the previous working condition as soon as the
mains voltage is restored.

VER
This variable shows the software version installed on converter.

ac wave 2 power frequency inverter

4.4 Module programming with personal computer

The PC software offers the advantage of having all parameters on the screen, together
with frequency, currents and possible alarm.
This is a very practical aspect, especially when equipment is being started.

All variables are described in the same way on keyboard and all other programming units
supplied by Reel.

The general section of this manual gives all information for starting and using the
communication software for PC. We suggest therefore reading the whole section.

The following lines describe differences between keyboard and personal computer
programming.

Following variables were added or opened to direct access:

BAUD
Transmission speed of serial communication.
Available options: 9600, 19200, 38000 B.p.s.
Note: The baud changing in the drive means automatically changing all drives connected
4
on the same serial line.

Warning!: the personal computer has no communication at 76800 B.p.s.; if the drive
(previously connected to a keyboard or other supervisors) is set at mentioned speed, it
must be set at a lower speed before being connected to the PC.

KAPPA
Line speed: this parameter can modify speed of all movements at the same time, when
more drives are connected on a single serial line, by selecting serial address “0”.
All motors will have their speed increased or decreased by keeping their speed ratio
unchanged.
Setting range: 0÷FFFF

RIFER
Software set point. If variable Set-up has the possibility of handling speed set point
through serial port RS485, speed can be set as follows:
0 = zero revolution and FFFF (hexadecimal)= frequency set in parameter “FMAX”.
Setting range: 0÷FFFF

ac wave 2 power frequency inverter

4

ac wave 2 power frequency inverter

5. OPTIONALS

5.1 Optional I/O board

This board increases I/O number and makes particular functions, such as “mSR” and “OK”
available on connector, which can be useful for automation.

5.1.1 Static “mSR” output

The “mSR” output is a ON - OFF optoinsulated signal, buffered by a NPN transistor. It

allows to set speed threshold through “mSR” variable.

5.1.2 Static “OK” output

This board enables output (and takes back to terminal 09 voltage of terminal 10) when
drive is ready to start.

Output is off when there is an alarm on drive.

PIN CONNECTOR DENOMINATION DESCRIPTION FEATURES

1 NC not connected -----

2 NC not connected -----

5
3 NC not connected -----

4 NC not connected -----

5 NC not connected -----

6 NC not connected -----

7 NC non connected -----

8 mSR static output of ON = Vdc on +C

“minimum speed relays” OFF = open emitter
IMAX=50mA
9 OK static output ON = Vdc on +C
“ready to start ” OFF = open emitter
IMAX=50Ma
10 +C DC voltage input to be carried 5÷30V max. dc
to static outputs 02-BRK (common to optoinsulators)

ac wave 2 power frequency inverter

 5.2 ac wave 8KHz version (optional)

Special applications require the installing of a ∆V/∆t limiting filter between inverter and
motor.
The filter is necessary in order to satisfy the very restrictive limit features required by some
motors.
The filter dimensions and its costs are inversely proportional to modulation frequency, that
means to the frequency of inverter building up the current sinusoid.
Reel has developed the possibility of modulation to 8KHz with ac wave 2 in order to satisfy
also particular demands.

• This possibility is given only for some sizes demanding limited dimensions and filter
costs. The option is available for the following sizes:
T07 15Kw INOM = 25A IMAX = 30A
T11 37Kw INOM = 76A IMAX = 91A
T12 45Kw INOM = 90A IMAX = 108A
T13 55Kw INOM = 112A IMAX = 134A

• ac wave power 8KHz is supplied only in the D (digital) version, only allowing running
control from serial line. Please refer to chapter “D version board” for all information.
• All peculiarities of ac wave 2 characterise also the “8KHz” range, including particular
managing like mains missing control; the max. overload was limited to 120% of the
module’s rated current.

5 Attention!: - while programming take notice that «FPWM» parameter is fixed at RND300
and cannot be changed on 8KHz selection.
- modulation at 8KHz must be required when the product is ordered.

ac wave 2 power frequency inverter

6. ANOMALY SOLUTION GUIDE

6.1 General remarks

When the inverter, while running, finds one or more anomalies, it stops at once by
disconnecting modulation towards motor. At the same time the display shows the stopping
reason and set alarm by switching on the LED signal “ALR” on the drive adjustment board.
All specific drive alarms are described below; please refer to specific supply sections for
general tunnel alarms as well as for the specific ones.

6.2 Alarm description

Message Possible causes Test

wrong setting of the

check and possibly
motor's rated current
change "INOM" set
parameter

motor overload reduce load

Motor Relay
electronic
thermal relay very steep acceleration check and maybe
intervention to increase set
protect motor
6
too high voltage boost check and maybe reduce
(V0) set

too charged dynamic PID

constants and consequent stabilize system
current oscillation

ac wave 2 power frequency inverter

 check working of
lacking ventilation
radiator's fan

Thermal sensor
check cooling air and
intervention of
weak heat exchange control board
thermal sensor placed
temperature
on power dissipator

check average current

too heavy working of working cycle to be
cycle correct according to set
parameters

short circuit at motor's check connection cables

ends or towards ground and take cause away

increase
too sharp accelerations ACC/DEC/RAMPA
parameters

6 Overload
intervention of the
too charged PID modify PID parameters

short circuit
protection of power
section
wrong "FNOM"
check and modify set
parameter setting

wrong setting of motor's

check and modify set
"VEL.NOM" parameter

too high current leakage check motor's insulator

within the motor and if necessary replace

ac wave 2 power frequency inverter

 wrong V/Hz control
carry out correct setting
feature setting

Feedback alarm
speed retroaction
missing
check encoder and
encoder failure or connections (if encoder is
wrong connection bidirectional inverter channel
A and B)

6.3 Light signals

The power modules’ adjustment boards have some signal LEDS showing that hardware
inputs are on (releasing) and the appearing of a generic alarm.
The board of “D” version does not have a hardware release and therefore only shows the
generic alarm LED.

LEDS are very useful during commissioning and diagnostics, in order to find out the
missing of the hardware run releases immediately.

The LEDS of standard adjustment board are shown on the map:

INPUT LEDS

ac wave 2 power frequency inverter

 ABBR. FUNCTION
ALR Inverter failure
EN1 Main set point enabled
JG1 Inner speed “1” enabled
JG2 Inner speed “2” enabled
ON Inverter running enabled
CCW Rotation reversal required
EN2 Speed adjustment enabled
RES Alarms reset required

The failure LED (ALR) of version “D” board can be found on the map below:

ALARM LED

ac wave 2 power frequency inverter

7. ENCLOSURES

7.1 ac wave 2 power module sizes

POWER MODULE

ABSORBED MOTOR RATED MAX. DIMENSIONS

TYPE SIZE POWER POWER CURRENT CURRENT L H P
01 2 KVA 1.1 KW 3.2A 4A 260 120 230
02 3.5 KVA 2.2 KW 5.5A 8A 260 120 230
03 5 KVA 3 KW 8A 15A 260 120 230
04 8 KVA 5.5 KW 12.5A 24A 260 120 230
05 10 KVA 7.5 KW 16.7A 32A 260 120 230
06 15 KVA 11 KW 25A 48A 260 120 230
ac wave 07 20 KVA 15 KW 31A 60A 260 120 230
2 08 24 KVA 18.5 KW 39A 60A 260 200 230
power 09 29 KVA 22 KW 45A 85A 260 200 230
10 39 KVA 30 KW 62A 120A 260 200 230
11 48 KVA 37 KW 76A 120A 260 320 230
12 56 KVA 45 KW 90A 170A 260 320 230
13 68 KVA 55 KW 112A 210A 260 320 230
14 92 KVA 75 KW 150A 280A 260 320 230
15 112 KVA 90 KW 180A 250A 260 320 230
16 160 KVA 132 KW 260A 360A 260 520 230

ac wave 2 power frequency inverter

 7.2 ac wave 2 D power module sizes

POWER MODULE D

ABSORBED MOTOR RATED MAX. DIMENSIONS

TYPE SIZE POWER POWER CURRENT CURRENT L H P
01 2 KVA 1.1 KW 3.2A 4A 260 120 230
02 3.5 KVA 2.2 KW 5.5A 8A 260 120 230
03 5 KVA 3 KW 8A 15A 260 120 230
04 8 KVA 5.5 KW 12.5A 24A 260 120 230
05 10 KVA 7.5 KW 16.7A 32A 260 120 230
06 15 KVA 11 KW 25A 48A 260 120 230
07 20 KVA 15 KW 31A 60A 260 120 230
08 24 KVA 18.5 KW 39A 60A 260 200 230
ac wave 09 29 KVA 22 KW 45A 85A 260 200 230
2D 10 39 KVA 30 KW 62A 120A 260 200 230
power 11 48 KVA 37 KW 76A 120A 260 320 230
12 56 KVA 45 KW 90A 170A 260 320 230
13 68 KVA 55 KW 112A 210A 260 320 230
14 92 KVA 75 KW 150A 280A 260 320 230
15 112 KVA 90 KW 180A 250A 260 320 230
16 160 KVA 132 KW 260A 360A 260 520 230
91 2 KVA 1.1 KW 3.2A 4A 260 80 230
92 3.5 KVA 2.2 KW 5.5A 8A 260 80 230
93 5 KVA 3 KW 8A 15A 260 80 230
94 8 KVA 5.5 KW 12.5A 24A 260 80 230

ac wave 2 power frequency inverter

7.3 ac wave 2 power FP module sizes

POWER MODULE FP

ABSORBED MOTOR RATED MAX. DIMENSIONS

TYPE SIZE POWER POWER CURRENT CURRENT L H P
51 3.5 KVA 2.2 KW 5.5A 6.5A 260 120 230
52 6.5 KVA 4 KW 10A 12A 260 120 230
53 10 KVA 7.5 KW 16.7A 20A 260 120 230
54 15 KVA 11 KW 25A 30A 260 120 230
55 20 KVA 15 KW 31A 36A 260 120 230
ac wave 56 29 KVA 22 KW 45A 52A 260 200 230
2 57 39 KVA 30 KW 62A 70A 260 200 230
power 58 56 KVA 45 KW 90A 102A 260 320 230
59 68 KVA 55 KW 112A 126A 260 320 230
60 92 KVA 75 KW 150A 170A 260 320 230
61 130 KVA 100 KW 200A 240A 260 320 230
62 190 KVA 160 KW 290A 350A 260 520 230

NOTE: Module type “FP” is made for particular applications (fan control and pump control)
where load is such not to require high torque at start/stop.
Overload current is slightly higher then the module’s rated current.

ac wave 2 power frequency inverter

 7.4 Overall dimensions

The overall dimensions change according to module size. See below for ac wave 2 power
modules:

POWER S.91-96 POWER S.01-06 POWER S.07-08 POWER S.09-10

(1,1 - 11KW) (1,1 - 11KW) (15 - 18.5KW) (22 - 30KW)

L=260 L=260 L=260 L=260

H=80 H=120 H=120 H=200
P=230 P=230 P=230 P=230

POWER S.11-15 POWER S.15

(37 - 90KW) (132KW)

L=260 L=260
H=320 H=520
P=230 P=230

ac wave 2 power frequency inverter

7.5 Power module map

As example the map of sizes 01÷06 is shown to identify inner parts.

The other sizes 07÷16 can be drawn from analogy.

INTERCONNECTING
SUPPLY

CONTROL
BOARD

+ DC BUS POWER
FLAT CABLE FOR
POWER
POWER
CONNECTION
CONNECTION

- DC BUS POWER
CAPACITOR BOARD
POWER BOARD

IGBT MODULE

HEAT SINK

ac wave 2 power frequency inverter

 7.6 ac wave 2 power module block diagram

ac wave 2 power frequency inverter

7.7 Application diagram

ac wave 2 power frequency inverter

 7.8 Electric power connections

POWER
BUS EMI/RFI FILTER DECOUPLING LINE ULTRA-QUICK
REACTOR INSERTIONS BREAKFUSES

OUTPUT FILTER TO LIMIT dV/dT SCREENING

(IF NEEDED)

ac wave 2 power frequency inverter