Modular drives

wave series
«GENERAL 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: [Link] - e-mail: reel@[Link]
 CONTENTS

Conformity declaration

Reading the manual

Warning

1
1. GENERAL REMARKS
1.1 Reel Drives
1.2 Modular System
1.3 Product identification
1.4 Delivery
1.5 Warranty

2
2. TUNNEL DIMENSIONING
2.1 Module choice
2.2 Tunnel composition
2.3 Dimensioning by Reel Technical Dept.
2.4 Interconnecting of two tunnel sections
2.5 Appendix to chapter 2
2.5.1 Nominal powers of the modules
2.5.2 Approximate power absorbing of some uses
2.5.3 Curves of fan modules for some uses
2.5.4 Connectors for board 5329

contents - general section -

 3
3. INSTALLATION
3.1 Mechanical installation
3.2 Electrical installation
3.3 Technical data for installing and derating
3.4 Wiring
3.5 Protections and power filters
3.5.1 Dimensioning of the ultra-quick-break fuses
3.5.2 Dimensioning of the decoupling reactor
3.6 Power cables
3.7 General prescriptions for cable use
3.8 Grounding
3.9 Application of EEC regulation on EMC directive
3.10 EMI compatibility
3.11 RFI Compatibility
3.12 RS485 serial line
3.13 Communication of more converters on a single line
3.14 Communication between tunnel and Master unit

4
4. COMMISSIONING
4.1 General remarks
4.2 Precautions
4.3 Starting

5
5. MODULE PROGRAMMING
5.1 General remarks
5.2 Programming keyboard
5.3 Parameter input with keyboard
5.4 Programming with personal computer
5.4.1 Using the application program

6
6. MAINTENANCE
6.1 Precautions
6.2 Periodical servicing
6.3 Spare parts and their compatibility
6.4 Instructions for mechanical replacement of a module

contents - general section -

 7
7. ANOMALY DIAGNOSTICS
7.1 General remarks
7.2 Diagnostics on modular system

8
8. ENCLOSURES
8.1 Fan modules : sizes and overall dimensions
8.2 Capacitor modules : sizes and overall dimensions

contents - general section -

contents - general section -
 CONFORMITY DECLARATION

REEL SRL - Via Riviera Berica, 26 - 36024 Ponte di Nanto - VI -Italy

declares under own responsibility, that the products:
ac wave 2 ac wave sa br wave 2
br wave sa da wave

correspond to following regulations in force:

CEI EN 61800-3 Product regulation -Electric drives with variable speed-
IEC 1000-3-5 1994 Limitating voltage fluctuation and flicker
IEC 1000-4-2 1995 Electrostatic discharge immunity
IEC 1000-4-3 1995 Electromagnetic field immunity
IEC 1000-4-4 1995 Quick transient and burst immunity

according to European directive 89-336 EEC on EMC and 73/23 EEC on Low Voltage.

EXPLANATIONS ON ELECTROMAGNETIC COMPATIBILITY

Directive 89-336 EEC on EMC - 73/23 EEC on Low Voltage

According to above mentioned directive, the drive types: br wave, br wave sa, ac wave 2,
ac wave sa, da wave, are to be considered as “components”, thus having to comply with
a specific product regulation. As regards the “semiconductor power converters for variable
speed electric systems” the regulation in force is CEI EN 61800-3 (Electric variable speed
drives).
According to directive 89-336 EEC on EMC and 73/23 EEC on Low Voltage the product
designed and developed by REEL SRL is a BDM (Basic Drive Module).
The BDM, along with other electromechanical parts and possible auxiliary electronics,
builds up the CDM (Complete Drive Module).
The CDM, together with motors and sensors of the machine, build up the PDS (Power
Drive System).
The PDS alone is complete enough to be certified. The installer, supported by a complete
documentation on the various components, shall be the one to put the CE marking on the
whole machine.
The specific manuals supplied with every REEL product describe all use directions to
obtain results corresponding to product regulation CEI EN 61800-3 (Variable speed electric
drives).

Ponte di Nanto, 1998 July 2nd

Ezio Bertotto Giancarlo Verlato

Product Manager Tecnico CE

conformity declaration - general section -

Reading the manual

This manual was written to make looking up easy for any user’s demand.

Being the described product composed by several drives, heterogeneous as regards

application and use (however all linked by one and the same management principle), it is
difficult to include in one manual all combinations resulting from product assembling.

The manual will be then “composed” as well.

It consists of a first generic section including all information common to the products
containing:
− indications on dimensioning
− information on mechanical and electrical tunnel assembling
− notes on the whole system working
− a general description or the drives’ programming system
− a short account on tunnel maintenance and diagnostics

The following, more specific sections go into detail on every single drive type containing:
− technical features of every type
− product specific connections
− drive’s programming and rating
− optionals referred to the single product
− a detailed guide to failure repairing
− sizes, occupied place, block diagrams and specific applications of each type

The manual is put together before delivery, the specific section for each drive type
composing the tunnel is added to the general section.

General supply ac power br power “x”

section module module module power
module

Each section has a detailed index that makes any specific looking up easy.

reading the manual - general section -

Warning

• Some of the equipment’s internal devices are charged with high voltage!

• Touching any equipment put under voltage may be dangerous for the operator’s
safety and cause drive breaking as well.

• Before carrying out any intervention on tunnel, disconnect the machine and wait
at least 10 minutes.

• According to regulations in force, only skilled personnel is entitled to work on the

equipment.

• Skilled personnel means:

− persons having followed training courses on assemblying, maintenance
and operating of electric equipments and therefore aware of danger.
− persons having followed courses on use and maintenance of safety
devices according to regulations in force.

• Read the whole manual before any intervention.

• The manual regards versions in production with default configuration. Function

setting or particular controls can implement logical conduct differing from
standard.

• The product manual as well as the conformity declaration must be kept and be
available for the maintenance personnel whenever necessary. The manual should
be kept in a safe dry place, far away from atmospheric or chemical agents that
could damage it.

• Reel SRL. disclaims any responsibility for damages caused by irregular or careless
use of devices.

• Manual and product can be modified without notice whenever Reel will think it
necessary.

warning - general section -

1. GENERAL REMARKS
1
Industrial development of the last years has generated a growing technological
demand, in order to cope with increasing production characterised by more and more
charged production cycles.

The evolution of mechanics enables nowadays automation of fast handling

production lines.
Such development is joined up by the necessity to reduce the space occupied by the
machine and at the same time to reduce definitely maintenance interventions; this in
order not to penalise production with expensive machine stops, and also because of
the objectively difficult access to the various parts, due to the grown compactness.

The Reel company, whose strong point is a vast experience in the industrial handling
field, offers a range of modular motor converters to complete a wide drive net
meeting the various market requirements.

1.1 REEL Drives

First of all thank you for choosing the Reel modular system.
The product results from a deepened study made by the Reel specialists and offers a
series of high performance drives, which are compact, easy to be used, reliable and
long lasting.
Sale is not meant to be the first target, but rather the first step towards a long co-
operation.

Our dynamic and qualified technical team engages itself to:

− deal with your technical and commercial needs
− inform you on new products and developments
− offer suitable advice for a quick solution of your problems

The following instructions shall lead you to understanding, installation and use of the
products, so to reach higher efficiency and performance. We suggest therefore
reading the whole manual.

The WAVE range was developed to make practical application and use easier,
without penalising the product’ s technical features, which assure in fact highest
versatility combined with simple use and connections.

Particular attention was paid to the control electronics. The result is a completely
digitalized system whose interface to the external circuitry was carefully developed
in all details: all digital inputs and outputs are optocoupled; the analog inputs are
acquired through differential circuit; the analog outputs are protected against short
circuit towards ground.

The parameter settings as well as the enablements and set points can be transmitted
per serial line through standard RS 485 so to allow a full automatic management.
Should your exigencies require particular functions, the assembling of optional
boards directly on the adjustment boards is contemplated, in order to customise the
system.

modular drives wave series - general section -

 1.2 Modular system
1 The machine automation requires often the use of several components running at the
same time. Therefore the installation of the related, often very heterogeneous drives,
in one electrical cabinet is necessary.
In order to make installation and use of several drives easier, Reel offers a own
“modular” system.
The tunnel is composed by different modules, each of them related to a specific
function. All modules interact and “exchange” data on the running or alarm state.
The typical structure is the following:

MAINS

1. Supply module: regulates the alternating net generating a continuous power

voltage to supply the powers (3, 4, ...)
2. Capacitor module: filters supply’s tension.
3. and 4. Power modules: control the motor directly and adjust its speed.

The tunnel is composed vertically according to the following structure:

− one supply module, dimensioned for the sum of installed powers (in kVA);
− several power modules (one for each handling);
− One or more capacitor modules (the kVA total of capacitor modules must be
at least equal to the total of installed powers);
− one fan module of adequate size to cool the different powers correctly,
according also to the physical length of the resulting tunnel;
− one or more fan 00 modules, able to create air recycling on the control
electronics to avoid warm air stagnating.

The following lines give further information on the optimal dimensioning.

This modular system offers utmost malleability combined with reduced global
occupied space of over 60% compared to other products; installation becomes
easier as well, as the entire tunnel needs only one three-phase supply, allowing a
single line dropping.

modular drives wave series - general section -

1.3 Product identification

In order to identify the product’s construction and operating features, please refer to
1
the data label located on the side of the single modules. There are three kinds of
label identifying each product group

Generic module label

kW kVA I nom I MAX

VERSION SIZE OPTIONAL

R
REEL s.r.l.

Barcode: Product barcode depending on type and order.

Mind: The barcode number identifies the drive’s features and is therefore essential
for searching in the REEL digital records.
For this reason it must be indicated for any spare part or developing implementation
demand after delivery.

Kw: Indicates on the POWER modules the maximum power of the motor to
be supplied ( referring to 400Vac mains voltage)

kVA: Indicates the module’s absorption ( data referring to 400Vac mains

voltage).

Inom: Indicates the module’s rated current.

Imax: Max. deliverable current from the module.

Version: The version number distinguishes different options of the same series
and is to be indicated in case of new order or spare part enquiry.

Size: Indicates the module’s size.

Optional: Codes for installed optionals. See specific product sections for
identification.

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 Supply module label
1

SUPPLY V kVA

VERSION SIZE OPTIONAL MOTOR V

R
REEL s.r.l.

SUPPLY V: Indicates provided maximum/minimum input voltage. The specific

product sections contain all indications needed for step selection.

kVA: Indicates the maximum delivered power by the module at the provided
minimum/maximum voltage.

VERSION: The version number given by Reel distinguishes the different options of
the same series to be considered in case of new order or spare parts
enquiry

SIZE Module size

OPTIONAL: Codes for installed optionals. See specific product sections for
identification.

MOTOR V: Supply voltage provided for the motors connected with the tunnel. Field
used only when motor voltage differs from supply voltage.
Example Supply voltage: 440Vac
Nominal motor voltage: 400Vac

The version number must be checked in case of replacement in order to determine

the perfect compatibility.
Should the version number of replacement differ from the one of the installed drive,
then its compatibility has to be checked by reading the specific section “ Product
Version”. It will be necessary to follow the instructions of the specific manual
sections or annex to make it compatible.

modular drives wave series - general section -

Labels for fan/capacitor module

Fan modules size 00 - 01 and capacitor 00, show a slightly different label, on which
1
only the construction period is indicated; the barcode is fixed separately.

REEL s.r.l.

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 1.4 Delivery
1 Documentation
The drive is delivered to the customer with manual and conformity declaration for
every single module.
The latter certifies the drive’s inspection and indicates the inspector’s initials as well
as the inspection’s date.
Being the Reel records computerised, it will be possible to trace the module’s
features (setting parameters and hardware construction) by transmitting the barcode
number indicated on above mentioned declaration or on the module’s plaque (see
enclosed “Product identification”).

Settings
The product is delivered without configuration settings, these being related to
application and features of the installed motor.
The installer shall set software according to information contained in chapter
“parameter input”.

Unpacking
The packing is done at Reel before shipment in the most proper considered way; it
does not protect the drive from strong bumps or falling. The unpacking should be
carried out very carefully; bearings and/or packaging should be stored for possible
further packing.

Storage
The tunnel has to be stored in a clean and corrosion-free environment.
Storage temperature between -5°C and +70°C.
Condensation on the electrical components must be avoided for the contacts not to
oxydate.

Further transport
The drive’s packing should be carried out as follows:
− extractable parts must be fixed and put into their original place.
− wrap the drive in polystyrene sheets or other material to limit vibrating
during transport.
− do not put the drive into melt polystyrene or similar material that might fall
into the cooling slits and paralyse the fans.

Waste disposal
The product must be handled as “special waste”, having some internal part of it a
highly toxic content.

modular drives wave series - general section -

1.5 Warranty

The Reel warranty on the good working of the equipment means that Reel SRL will
1
as soon as possible repair or replace free of charge at its own facilities those parts
which should fail due to a construction mistake or to a defect material, during the
warranty period of 24 months starting from delivery date.
The freight costs for the equipments repaired at Reel premises or at technical
assistance centres are on customer’s charge.

modular drives wave series - general section -

1

modular drives wave series - general section -

2. TUNNEL DIMENSIONING

The system was conceived to make the global tunnel dimensioning extremely
practical.
A few rules fix the basis of the whole development.

The design engineer that knows already the dimensioning of the motors to be driven
can easily make out the most adequate modules and study the ensemble according
2
to following indications.

2.1 Module choice

• power module
The power module has to be chosen according to the size of the motor used. All
modules have two parameters of delivered current: rated current and max.
deliverable current (also called overload current). The size charts (in the appendix)
contain all necessary data allowing the right choice, relating every size to the
absorbed power (KVA), value that is needed for the dimensioning of the
ensemble.
As far as regards the working cycles, the required overload and working
temperatures, it is sometimes necessary to use an oversize converter.

• supply module
This module is constructed in several different sizes, according to the deliverable
power (KVA).

− The power to be delivered by the supply simply results from adding up the
KVA absorbed by the various power modules which shall be installed in the
tunnel. The supply module’s power must be higher or equal to above
mentioned sum.
Charts 2.1 e 2.7 of appendix show the different nominal powers.

− This module provides not only the power supply but also the supply of the
electronic controls, the 24Vdc fans and the external devices, such as
encoder, dancer rolls, potentiometers, etc..
The max. deliverable current is 5,5A.

Should higher current be required, the additional supply «ac wave 2 supply T00»
can be added, equipped with the supply circuitery for the control electronics.
Chart 2.8 in appendix shows the load values for some uses, to be considered in
order to determine current delivery.

• fan 00 module
It is defined as “boards fanning module”, and prevents warm air stagnating on the
electronic controls.
In the tunnel a fan 00 module every 600mm length must be installed. It is
recommended to put a fan 00 module beside the supply module.

modular drives wave series - general section -

 • capacitor module
In every tunnel more than one capacitor module can be installed. The number to
be installed must be equal to the sum of the KVA really absorbed by the power
modules. It has to be considered that some of the power modules already
integrate a certain number of capacitor modules. See charts 2.2 and 2.5. of
appendix. In case of “mains failure”, it is necessary to oversize the capacitor
modules according to following formula:
2
PC = (PA x 2 + 10) - PI

PC = total capacitor power (kVA)

PA = absorbed power (kVA)
PI = power that is already integrated in power modules (kVA)

• fan module
The power fan has to be chosen according to the tunnel’s losses and length (fans
and capacitors not included).
Chart 2.9 in appendix shows the curves that will determine the choice of fan
module’s size. They are calculated on temperature of 35°C; in case of higher
temperatures ventilation must also increase steadily (2% for each degree over
35°C).

modular drives wave series - general section -

2.2 Tunnel composition

There is no max. tunnel length to be respected. We suggest however not to exceed

a total length of 1600÷1700mm, fan module included, without contacting the Reel
Technical Department.

The power’s cooling air flow is channelled so to take out air from the air duct. The
conventional direction is top-down to get “clean” air (there are normally impurities
lying on the electrical panels’ ground).
2
If it should be necessary to invert the flow direction (down-top), the fan module
must be oversized of 30%.

Please take the following indications into account for a correct composition:

1. The supply module should be assembled in the middle of the tunnel in order to
obtain a better current distribution.

2. In case of more tunnel sections with only one supply module, the latter shall be
assembled in the upper part to make the wiring of the communication bus easier.
The power bus (DC link) shall be connected near the supply module.

3. The fan size 00 shall be assembled above or under the supply module T02
100kVA; the sizes supply 01/91, supply 02/92 120kVA and supply modules
series 80 already integrate a fan 00.

4. To make connection of additional tunnels to supply easier, an optional circuit can

be delivered, to be assembled on fan size 00. In this case we recommend
assembling in the upper tunnel part.

5. The power modules with heavier working cycles or bigger size, when assembled
in the upper tunnel parts, work under better thermal conditions, being nearer to
the cooling air input.

6. The capacitor modules should be distributed properly along the tunnel, preferably
near the bigger size power modules, and anyway never at a distance over 600mm
from any other size.

7. When a tunnel is separated in two or more sections (because of space, waisting

or other reasons), the connecting of the sections has to be made as follows:
− ∅1,5mm wires for distances over 1m
− flat coloured cable for distances of 1m or below

8. Put a 00 fan every 600mm mechanical tunnel length. Remember that supply
modules T01/91, T02/92 120kVA and supply series 80 already integrate a 00
fan.

modular drives wave series - general section -

 2.3 Dimensioning by REEL T. Dept.

When the Reel Technical Dept. is asked to dimension one specific tunnel, following
are needed:

• nominal power of motors in use

• required overload
2 •
•
particular handling (for instance main failure or electrical shaft)
max. room temperature of electrical cabinet where tunnel will be installed
• required modulation frequency
• particular environment that could cause derating (altitude, humidity, etc.)
• particular installations (i.e. inversion of cooling air flow or installation near
heat sources)

When one of the parameters is missing, the Reel standard will be:

• overload = max. overload allowed for the size (typical = 200%)

• no particular managing
• max. room temperature 35°C
• modulation frequency 3KHz
• altitude ≤ 1000m above sea level, max. humidity 90% not condensing
• standard vertical mechanical assembling away from heat sources
• air flow direction top-down

modular drives wave series - general section -

2.4 Interconnecting of two tunnel sections

When the total tunnel length exceeds 1600 - 1700mm, it is recommended to make
two tunnel sections.
If required by the installer, the sectioning can be done also for shorter tunnels.
The two resulting tunnels are generally composed by a single supply module; “n”
power and capacitor modules; two fan modules (one for each section).

The rules to be applied are always the same, also considering that:
2
1. The interconnecting of the “DC bus power” is recommended on both tunnel ends,
so that a cycle is created to allow better current distribution.

2. The interconnecting of the “signal bus” can be executed with a flat coloured cable
for lengths up to ≤ 1m.
For longer distances the connecting should be done with a wire of minimum
section 1,5mm2.

3. The powers installed in the two tunnel sections must be equally distributed; it
must be considered that the power dissipation (losses) of the supply module is
5,5W for each installed Kw.

4. The capacitor modules assembled in each section must at least satisfy the adding
up of the kVA absorbed by the power modules.

5. It is possible to remote the exceeding capacitor modules referring to 4. without

particular device, maybe also in a third section.

As far as the interconnecting of the “signal bus” with 1,5mm2 wire is regarded, take
notice of following remarks:

1. A board 5324.. is normally required, leading the flat coloured cable of the inner
bus to screw terminals. The board is located on fan 00 module: the assembling of
a fan 00 module on the upper end of the two sections will make wiring easier.

2. The interconnection diagrams are supplied together with the tunnel.

modular drives wave series - general section -

 2.5 Appendix to chapter 2

The following charts show the parameters for tunnel dimensioning.

2.5.1 Nominal powers of the modules

2 NB: All powers refer to the supply standard of 380Vac

Chart 2.1

SUPPLY MODULE
SIZE DELIVERABLE POWER (KVA)
00 ----- (additional supply)
01-91-81 40 KVA ( as long as in stock)- 60KVA
02-92-82 100 KVA (120 MM) / 120 KVA (160 MM)
03-93-83 160 KVA
04-94-84 240 KVA
05-95-85 480 KVA

Chart 2.2

POWER AC MODULE
SIZE ABSORBED POWER (KVA) INTEGRATED CAPACITORS
01-01D-91 2 8 KVA
02-02D-92 3,5 8 KVA
03-03D-93 5 8 KVA
04-04D-94 8 8 KVA
05-05D-95 10 8 KVA
06-06D-96 15 8 KVA
07-07D 20 -----
08-08D 24 -----
09-09D 29 -----
10-10D 39 -----
11-11D 48 15 KVA
12-12D 56 15 KVA
13-13D 68 15 KVA
14-14D 92 10 KVA
15-15D 112 10 KVA
16-16D 160 -----

modular drives wave series - general section -

Chart 2.3

POWER CC MODULE
SIZE ABSORBED POWER (KVA) INTEGRATED CAPACITORS
01 ----- -----
02 ----- -----
03 ----- -----
04 5,7 8 KVA 2
05 11,9 8 KVA
06 ----- -----
07 17,6 -----
08 22 -----
09 26,4 -----
10 33 -----
11 44 15 KVA
12 ----- -----
13 70,4 15 KVA
14 96,8 10 KVA

Chart 2.4

POWER CE MODULE
SIZE ABSORBED POWER (KVA)
01 0,4
02 0,8
03 1,2

Chart 2.5

POWER BR MODULE
SIZE ABSORBED POWER (KVA) INTEGRATED CAPACITORS
01 0,8 8 KVA
02 1,6 8 KVA
03 3,2 8 KVA
04 5,4 8 KVA
05 6,5 8 KVA
06 8 8 KVA
07 13.5 -----
08 ----- -----
09 19 -----
10 27 -----
11 27 15 KVA
12 36 15 KVA
13 48 15 KVA
14 70 10 KVA
15 ----- -----
16 107 -----

modular drives wave series - general section -

 Chart 2.6

CAPACITOR MODULE
SIZE AVAILABLE POWER (KVA)
00 17
01 25
02 50
2
Chart 2.7

FAN MODULE
SIZE APPLICATION FOR MAX. INSTALLED POWER
00 ----- (boards fan)
01 30 KVA
02 130 KVA
03 160 KVA
04 160 kVA with inverted flow direction

Chart 2.8

AC POWER MODULE 8 Khz

SIZE ABOSORBED POWER
00 ----- (boards fan)
01 30 KVA
02 130 KVA
03 160 KVA
04 160 kVA with inverted flow direction

modular drives wave series - general section -

2.5.2 Approximate power absorbing of some uses

Chart 2.9

ac wave 2 power 310mA

br wave 2 power 420mA
ac wave supply
ac wave supply D
150mA
250mA
2
ac wave 2 fan size 00 350mA
ac wave 2 fan size 01 700mA
traverse device board 50mA
potentiometer 10mA
unidirectional encoder 80mA
bidirectional encoder 150mA
resolver 80mA

2.5.3 Curves of fan modules for some uses

Chart 2.10

NOTE: The fan curves refer to a max. room temperature of 35°C

modular drives wave series - general section -

 2.5.4 Connectors for board 5329

PIN DENOMINAZIONE NOTE CARATTERISTICHE TECNICHE

1 +SIGNAL positive signal of serial line 0÷5Vdc

2 RS485
complementary to -SIGNAL
line driver

2 -SIGNAL negative signal of serial line 0÷5Vdc

RS485 line driver
complementary to +SIGNAL
3 PG stabilized power ground 0Vdc
+24Vdc I MAX 5,5A
(according to no. of installed
modules)
4 RmV sum of the single minimum 0/24Vdc
speed relays of all drives IMAX = 10mA
24V = motor is rotating
5 ALARM sum of the general alarm 0/24Vdc
hardware signal of all drives IMAX = 10mA
24V = drive alarm
6 /RESET reset signal for the drives 0/24Vdc
(logic denied) IMAX = 200mA
RESET = 0V

7 DRENFE general enablement signal for 0/24Vdc

the drives IMAX = 200mA
24V = drives enablement
8 HV analog signal, proportional to dc 0÷10Vdc
bus voltage IMAX = 1mA
9 ST sum of the thermal sensors of all 0/24Vdc
drives IMAX = 10mA
24V = sensor intervened
10 HOLD mains failure message 0/24Vdc
IMAX = 200mA
24V = mains power failure
11 +P stabilized supply +24Vdc 25,5Vdc
IMAX = 5,5A
(according to no. of installed
modules)
12 OS common serial line RS485 input 100Ω towards digital zero of
each single module

modular drives wave series - general section -

[Link]

3.1 Mechanical installation

The modules are placed vertically, one on the other, to form a single tunnel.

It is necessary to take some general rules into account while assembling the tunnel:

• The tunnel must be placed away from heat sources and where there is good air
circulation;

• The tunnel was developped thinking of a vertical placing. Being the tunnel cooled
through forced ventilation, it can also be placed length wise; 3
• The modules must be assembled in a way to be protected from conductive dust
and vapours;

• Provide at least 100mm free space in the upper and lower part as well as around
the fan module in order to have a proper cooling. A hollow space of 60 mm on
the sides is recommended for the wiring.

modular drives wave series - general section -

 3.2 Electrical installation

There are 2 flat 20 - way - connectors on the adjustment board of each power
module. These have a parallel connection (pin to pin); one is conventionally
considered as input, the other as output. The tunnel has a series of flat cables to
interconnect the “supply bus” of the auxiliary voltages. The side bars build up the
“power bus”: they connect the DC power supply for the power modules.

HARDWARE
CONNECTION FOR AC
WAVE

3 RESOLVER CONNECTION
BR WAVE 2

HARDWARE CONNECTION
FOR BR WAVE 2

SERIAL LINE

HARDWARE CONNECTION
FOR SUPPLY

HARDWARE CONNECTION
FOR CC WAVE 2

FOR MORE MODULES

Communication with the drives takes place through serial line RS 485; the serial
input (a single one for up to 31 modular converters), is placed on the supply module.
The serial code identifying each power module has to be set during assembling. The
standards provide selection of progressive increasing numbers from 1 to 31,
number1 being the first converter on the top. The user can change the code
sequence of the standard selection according to the own demands, also leaving out
some codes.

modular drives wave series - general section -

3.3 Technical data for installation and derating

Environment

Working temperature From 0° C to 35°C by forced ventilation

Running temperature From 0°C to 50°C

(derating over 35°C)

NOTE: The working temperature is the thermal level below which no derating needs
to be considered.
The running temperature is the maximum allowed temperature. Derating because of
thermal conditions regards fan modules 01÷04 and leads to using next size.
3

Altitude All data refer to 1000m above sea level

Air humidity 90% max. not condensing at 25°C

Derating -2% of fan curve for every degree exceeding 35°C

-1% of fan curve every 100m exceeding 1000m a. s.l.
-10% of max. current for every modulation KHz over 2KHz

Supply Three-phase min. 380Vac +/-15%; max. 440V ac +/-

15% (or 460 +/-10%) with previous selection on supply
module.

Ventilation

The converters of the wave series do not need any additional external ventilation.
We suggest anyway to place them away from heat sources.
100mm hollow space should be provided at the tunnel ends and around the fan
module to obtain a proper air flow.

modular drives wave series - general section -

 3.4 Wiring

The following information give all necessary indications for the installer to optimize
dimensioning and wiring of the connections outside the converters.

− The power cables, the supply cables from the mains and the coupling motor
converter cable have to be oversized of at least 15% compared to the section
needed for nominal current, anyway not smaller than 1,5mm2.

− Put on supply’s top a set of three ultra-quick-break fuses, dimensioned according

to supply module, as shown on chart (see section “Dimensioning of ultra-quick-
break-fuses”).

− As regards speed, set points and speed feedback, screened cables are to be used,
3 with a wire minimum section of 0,5mm2.

− For ground connection wire length has to be minimized; we recommend using

grounding bars, power differing from signals, as shown in chapter “Grounding”.

− In order to reduce harmonic distortion of mains current and the input ∆i/∆t, a
decoupling reactor between line and converter is needed.

− A EMI/RFI filter might be necessary in order to satisfy the electromagnetic

compatibility regulations; see also chapter “Application of EEC regulation on EMC
directive”.It is also suggested to install a Philips toroid type CST26/13/29-452
or compatible with it on the serial connection terminal boards, near the drives.

− The power cables to the motor shall be screened in case the same raceway of
other ducts should be used or in presence of equipments particularly sensitive to
radio frequences; do not screen the ground cable between drive and motor.

− Suitable filters are needed when some connections to converters are subject to
stray currents.

− The line contacts must be chosen on chart AC1, by adding up the nominal
currents of the motors used and increasing the resulting value of 15-20%.
Do not place any contacter between motor and converter. If this is not to be
avoided for security reasons, make sure that the contactor is handled only in
resting position (disabled for at least 1 sec).

− Arrange a clearance of about 100mm around the tunnel in order to facilitate heat
dissipation.

− The converter must be grounded in appliance to regulations.

− Do not ground the supply zero of control electronics (PG; SG or AG).

− If more motors are connected to a single inverter, it is necessary to install a

suitable overload relay in line with every single motor that will inhibit the drive in
case of intervention (do not disconnect directly).

− If a dynamic braking resistor is assembled on the equipment, a special overload

protection shall be connected in line with the resistor.

modular drives wave series - general section -

− Do not install the converter on walls subject to strong vibrations.

− All devices (relays, contactors, solenoid valves) assembled inside the converter’s
board or supplied by the same sources must be equipped with RC units or recycle
diodes if there is D.C.

− In tunnels where fan modules wave 2 fan size 02/03 are used, suitable
protections have to be installed on the supply line referring to the following rated
data:

Size 02: 230V - 60Hz / 0.44A

220V - 50Hz / 0.36A

Size 03: 240V - 50Hz / 0.65A

Size 04: 230V - 50Hz / 1.44A

3
230V - 60Hz / 1.45A

− The drive controls the current to motor and adjusts the voltage with variable duty-
cicle.
This system is typical for all PWM drives; characteristic for it are the very steep
switching fronts. They produce electromagnetic emissions that can interfere with
other sensitive equipments. This problem is emphasized when power cables are
particularly long.
Besides, long cables or high capacity can block the drive for protection.
In this case special cables must be used, described in all details in chapter “Power
cables”.

modular drives wave series - general section -

 3.5 Protections and power filters

3.5.1 Dimensioning of the ultra-quick-break fuses

The fuses must be dimensioned according to the size of supply module, their
function being to protect the inner rectifier bridge. Their features will therefore
change according to sizes.

SUPPLY TYPE FUSE SIZE I2T

*SIZE 01 (40KVA) 80A 7.5KA2/SEC.

3 SIZE 01 (60KVA)
*SIZE 02 (100KVA)
125A0
160A / 200A
145KA2/SEC
20KA2/SEC.
*SIZE 02 (120KVA) 300A/350A 110KA2/SEC
*SIZE 03 (160KVA) 350A / 400A 145KA2/SEC.
SIZE 04 (240KVA) 500A / 630A 405KA2/SEC.
* as long as in stock

3.5.2 Dimensioning of the decoupling reactance

The reactance has to be calculated according to nominal power at the tunnel input.
A simple formula expresses approximately but nevertheless effectively the
dimensioning in millihenry:

mHr = 10
Nominal phase Ampere

Nominal current must be equal to the current of line input; we recommend a

saturation current of 4In.

Particular situations of disturbed mains or sudden voltage changes require higher

values, up to twice the reactor.

Reel can supply the suitable reactor for every application on demand.

modular drives wave series - general section -

3.6 Power cables

Power cables must be carefully chosen. As regards dimensioning, a few general rules
determine their choice and use.
This paragraph is a summary of what is necessary for proper power connecting of
the drive.
“Directive on machines 89/392” obliges producers of machineries for industrial
manufacturing to the CE-marking.

The same machines must correspond to EMC directive CE 89/336 of EEC regarding
electromagnetic compatibility. Special cables are necessary to limit electromagnetic
interferences to a minimum.

The EMC cable is a quadripole screened cable of adequate diameter; its grounding
wire is placed inside the cover but outside the screening. 3

GROUNDING

OUTER LAYER

SCREENING

POWER CABLES

All cables show stray capacitance among the components, being close to wire and
screening or to the parallel laying wires. Capacitance can be screened as follows:

Phase - phase stray capacitance:

INSULATION

CHARGES GOING THROUGH

DURING CHANGIN OVER

COPPER

modular drives wave series - general section -

 Phase-ground stray capacitance:

INSULATION

COPPER

CHARGES GOING THROUGH

DURING CHANGING OVER

3
Such capacitances (Cp1 + Cp2), when high - can block the drive due to exceeding
switching current (overload alarm).
The cable constructor can supply a technical specification showing the extent of
such capacitance for every meter of length.

A stray capacitance higher than 6nF must imperatively not be applied to the drive.

modular drives wave series - general section -

3.7 General prescriptions for cable use

− Cables must not be laid in contact with or near warm surfaces unless they are
constructed for this purpose;

− For mobile or transportable equipments flexible or highly flexible cables must be

used;

− Cable use must respect the limit use conditions for which they are constructed
and guaranteed (rated voltage, current range, working temperature, thermal
influence);

− The end pieces connected to a fixed equipment must be as short as possible, and
have to be connected to the fix parts of equipment in a proper way;

− Cables have to be assembled in a separating raceway and distributed suitably:

3

YES! NO!

− Always keep power cables separated from the signal ones;

− Multipolar screened cables, whenever connected to a terminal board or connector

not arranged for screening, must be fixed on the nearest point to electrical
connection:

WIRE

METAL CABLE CLIP

SCREEN

PROTECTING COVERING

modular drives wave series - general section -

 3.8 Grounding

The ground connecting must be very carefully done. While developing the electrical
cabinet it is necessary to think of separated grounding bars for power and signals.
The connections on the bar itself must be star-shaped.

To be connected on the power bar: motor grounding, drives’ frames, power cable
screening, etc.

To be connected on the signal bar: the analog signals’ screening (set points, output
for speed indicator, ammeter, etc.), the feedback screening (encoder, resolver, speed
generator, etc.), the system serials’ screening, whenever devices do not have a
specific shield input.

3 The signal bars must therefore not be affected by currents from power circuitries,
being these a possible interference source, caused either by the regulating system
(PWM, high dI/dt , etc.) or the connecting system (brushes, rubbing contacts , etc.).

LINE

PLC RS232 ENCODER PC

SIGNAL GROUND BAR

POWER GROUND BAR

I/O SCREENING

POWER CABLE

POWER CABLE

POWER
BOX

BRUSHLESS THREE - PHASE

MOTOR MOTOR
TUNNEL

NB: Do not connect the zero volt of tunnel supplies (SG; PG) to ground.

modular drives wave series - general section -

3.9 Application of EEC regulation on EMC directive

Introductory remarks
A motor converter, both a phase control one (SCR) or a PWM converter (with IGBT
or transistors), being considered - according to EMC directive - as a “component”
and not as “device”, is not included in the application field of the regulation
concerning the latter.
The regulations to refer to are in this case those ruling the product. The regulation
concerning motor converters is EN 61800-3, drawn up by a IEC committee.
Component constructors (component meaning in our case converters) are anyway
obliged to supply an application guide to help the system’s and/or equipment’s
constructor, in order to obtain a complying application (system/installation) as far as
electromagnetic compatibility of application itself is regarded.

Application of a speed converter on Reel motors 3

Electromagnetic compatibility problems are of two kinds: EMI (emissions) and RFI
(susceptibility).

3.10 EMI Compatibility

Interferences and emissions of a motor converter, either a Reel one or any standard
available on the market , can be radiated or conducted ones.
As you can see on drawing of picture 1, such emissions can refer to four essential
groups:

a) Connection to the mains;

b) Connection to the motor;
c) I/O;
d) Converter frame

= RADIATED INTERFERENCE

= CONDUCTED INTERFERENCE

modular drives wave series - general section -

 a) Connection to the mains
As far as both the radiated and the conducted interferences are concerned, the
best solution will be to assemble a EMI filter, in order to eliminate or reduce them
to a level below norm limits. For this purpose, the filters of a well-known
manufacturer were tested in the Reel laboratories; through their correct
assembling it can be ensured that emissions keep a level within the norms.
Beside the filters assembled in the Reel products, other suitable ones might be
available, provided they are certified.
Sometimes it is necessary to reduce not only high-frequency interferences to the
mains, but also the low- frequency ones (up to 1000÷1500Hz). In this case, if it
should not be possible to use a four- dial supply module with sinusoidal current
input, some adequately tuned harmonic filters must be installed. It is in any case
necessary to connect an inductance in line with the mains; its value is mentioned

3
in the Reel manuals.

b) Connection to the motor

In this case the problem is more serious. The converter’s dI/dt, especially the
modulation one (PWM) with IGBT, implies above all a considerable radiated
emission.
There are two solutions recommended nowadays:

− the use of power screened cables;

− laying connections in metal raceways separated from other signals.

The first solution is to be preferred in case of short connections and low power.
The second one under any other circumstances. In case of long screened
connections, the stray capacitance of the cable used must be checked; in fact it
could block the converter due to a leakage to the ground.

c) I/O
Most emissions to the I/O are negligible. In any case the ground connections must
be done carefully; it is always necessary to use the differential inputs as well as
the optoinsulations available in the Reel converters.

d) Converter frame
As regards the converter frame, always made of metal for all Reel products of this
kind, it is important to ensure a good ground connection.
For the purpose remind that a small section of this connection may considerably
reduce also the by-pass effect of a line trap. In most cases we suggest to
assemble converter and filters in the same metal board.
It is important to make star ground connections as well.

modular drives wave series - general section -

3.11 RFI Compatibility

Most RFI problems of a REEL converter are already solved during development. In
spite of that, the installer has to pay attention in order to avoid any kind of RFI
problem.
RFI problems in a REEL converter may be caused by:
a) Power connection;
b) Environment;
c) I/O;

a) Power connections
Most work has already been done inside the converter by using RC units and
varistors in the mains input. Thanks to the input inductance most interferences from
external world are reduced. Only in particular cases it may be necessary to apply
special overload protections to the converter. 3
For example: mains struck by lightning, connection to big welding machines, bad
working of phase advancers or advancers without decoupling reactors.
All power connections of the Reel converters have successfully passed the stray
current tests.

b) Environment
The use of metal frames for the Reel converters offers a suitable protection against
EMI problems resulting from environment. Such protection has just to be supported
as usual by a good grounding connection. Tests have proved only a sensibility to
stray currents occurring on the front converter protection (a few centimetres away
from the control microprocessor).

c) I/O
As far as susceptibility is concerned, the I/O connections prove to be the most
sensitive. In fact such connections cannot be much filtered because of the high
control speed.
Several measures were obviously taken by Reel during development, such as:
differential analog inputs, filtered analog outputs, optocoupled logic inputs and
outputs. The laboratory tests show in some cases a sensibility within 50 cm from
the converter.
As the Reel converter is made to be assembled inside the electric board, we think
the test is fully passed. However it is important not to generate intense stray
currents near the converters or on wires passing nearby.
It is recommended to assemble recycle diodes on DC relays, RC units on AC relays
and contactors and, only in few cases, RC units on motors controlled by contactors.

The installation of a Philips toroid CST26/13/29-452 ( or compatible with it) on the

signal connections cables is anyway recommended, near the I/O connectors (see
electrical wiring section).

Conclusion
The proper application of a Reel converter being component of a system puts it on a
good level of electromagnetic compatibility. We underline nevertheless that single
results obtained with converters do not determine but just support a whole system
that must be submitted to CE directives and marking.

modular drives wave series - general section -

 3.12 RS 485 Serial Line

All converters supplied by Reel have a serial communication device.

To make its use easier a SUB-D 9-pole connector has been arranged, with TX/RXD+
and TX/RXD- line, and +5Vdc voltage to supply the serial adapter 485/232, if there
should be one.

The connecting is:

The communication protocol is HALF/DUPLEX on asyncronous line with 11 bit frame.

The converters are “SLAVE” and take control from the line only when queried by the
“MASTER”.

The transmission baud rate can be set both from PC and the programming keyboard;
the baud rate value can be 9600, 19200, 38400, 76800 b.p.s. with limit 38400
b.p.s. when the “MASTER” is a PC.

The data format is the following:

◊ 1 start bit
◊ 8 data bits
◊ 1 syncronism bit
◊ 1 stop bit

Start B0 B1 B2 B3 B4 B5 B6 B7 Sincro Stop

Where the start bit starts communication, when equal to zero, the syncronism bit
identifies the first telegram byte and the Stop bit ends transmission; the latter shall
always be 1.

modular drives wave series - general section -

 This protocol, defined as «9 bit» can be presetted with «8 bit» by leaving out the
syncronism bit if the supply module is a digital one. The new 10 bit frame will then
be:

◊ 1 start bit
◊ 8 data bits
◊ 1 stop bit

All converters are of the “slave” type, either receiving or transmitting. Until
transmission starts, they are all receiving. The “MASTER” will start them for
transmission.
No communication is given between the slaves. There is the possibility of sending
orders or setting of more drives simultaneously. Such condition is activated by
sending a byte of “communication calling” with serial code zero. 3
3.13 Communication of more converters on a single line

− The connecting of one “MASTER” unit to 31 converters (slaves) is possible.

Any intelligent unit with interface 485 or interface 232 - plus adapter - can work
as master.
In this case the drives shall be “encoded”.
Encoding is made through the DIP SWITCHES set on the adjustment board.

− The position of DIP SWITCHES can be found in the manual’s specific sections
describing the various drive types.

− In all drive types DIP SWITCHES no.1 and 2 insert the end resistors of the serial
line. They must be activated on max. two drives, better on those the farthest
away from the supply module.

modular drives wave series - general section -

 3.14 Communication between tunnel and Master unit (PC, PLC. Etc)

The recommended diagram to interconnect the serial line with several tunnels is the
following:

SCREEN

+ SIGNAL PIN 7

3 - SIGNAL PIN 3

PIN 8

PROGRAMMING UNIT OV DIGITAL GROUND CONNECTOR FOR

MASTER SUPPLY MODULE

• Connection of digital zeros to the drive’s pin 8 is recommended for long distances
or particularly disturbed environments;

• in case of an analog supply module all tunnel drives must have different serial
codes;

• in case of digital supply module wih “8 bit” selection only the 8 bits have to be
encoded.

Note: For further information on software interfacing ask for the “Communication
protocol with Reel converters”.

modular drives wave series - general section -

4. COMMISSIONING

4.1 General remarks

− The modules are supplied with laboratory settings, that means setting default
values except for size, which is patterned according to construction hardware.

− The installer will set the drive according to the assembled motor’s features and
the specific automation use.

− Chapter “Parameter input”, in the specific manual sections for each drive type
describes in detail every single programming parameter as well as the setting
procedure.

4.2 Precautions

Before supplying the tunnel the following must be checked:

− an unforeseen motor movement must not damage machine or persons;
− supply voltage must respect the nominal features of supply module;
4
− power and control connections must be done correctly.

All connecting and setting operations must be done by qualified personnel.

Before the drive starts running the following must be checked:

− inputs and outputs must have been programmed and set adequately;
− the motor’s setting parameters must respect its rating;
− working parameters have to agree with the drive’s use.

As regards setting and specific customising for each drive type, please refer to the
manual sections describing the single product.

modular drives wave series - general section -

 4.3 Starting

After controlling all above mentioned points, the following must be checked step by
step:

1. supply power to supply module;

2. check ready - to - start state and also presence of all steady voltages
described in section «ac wave supply»;

3. check state “no alarm on each single module”;

4. check all specific setting parameters for drive and motor;

5. start one drive at a time and check the motor’s exact rotation direction;

6. set all system’s PID according to indications contained in the manual sections
regarding the drive in use, in order to obtain the required dynamisms.

modular drives wave series - general section -

5. MODULE PROGRAMMING

5.1 General remarks

Before the drive is installed, the input of some parameters must be done, in order to
get protections satisfying the specific use.
The drive’s standard parameters are already set; they can be modified or reset, for
instance to be adjusted to the connected motor.

− Programming can be done through serial line RS 485.

− Any intelligent terminal can be used as interface, when having the
communication software for Reel drives.

Reel can supply three different types of programming devices:

1. Programming keyboard, integrated or remotely located

It consists of a system including a dedicated keyboard and a luminous
alphanumeric display with two lines and sixteen characters.
The system, when not integrated, is connected with a nine-pole screened cable
and is particularly suitable for remote locating on the machine’s control desk.

2. Personal computer software

For communication with the Reel drives from any PC having a RS 485 serial gate
or , with a special adapter, a RS 232 C serial port. 5
3. MAC02/MAC03 programmable unit with related software
Consists of a microprocessor-controlled system equipped with alphanumeric
keyboard and a liquid Crystal display to perform automation functions and
programming. It can support firmware programmed by the final user. It is
interfaced with the machine by means of optocoupled I/O and analog references
acquiring through differential input.
It is equipped with parallel Eeprom that can store the drive’s programming
parameters so that data will be reloaded automatically in case of module
replacement.

This manual only describes the first solution; other possibilities can be taken out by
analogy or read in the manual supplied with the equipment.

After programming, the unit can be disconnected from the drive.

modular drives wave series - general section -

 5.2 Programming keyboard

This small and easy-to-use unit was developed as a control interface with all digital
Reel drives.
It can be easily put into any kind of control desk or on the front of the drive’s
electric board as well as integrated in the supply module. Connecting is done through
a nine-pole screened cable.
The keyboard informs the user on the running state (motor revolutions, absorbed
ampere) or, in case of failure, on the alarm type.
It works with four languages: Italian, English, French and German.
The space occupied by the remote located unit is:

92 X 92mm HOLE
MIN. DEPTH 90mm

5 NOTE: The tie cable is equipped with 9-pole SUB -D, “PIN TO PIN” connectors.

The keyboard shows following programming functions:

AC WAVE  keys
When several drives are controlled by the unit, they are selected through these keys;
the display shows the serial code of the selected drive.

PARAM  keys
They scroll the menu of parameters to be selected.

SET + - keys
After choosing the parameter to be changed, the value can be increased or
decreased.

ENTER key
Enters the programming menu.

RESET key
Resets the keyboard; communication with the drives is interrupted and automatically
reset after a few seconds.

Warning: When integrated in the digital supply modules 2, the reset key acts on the
connected converters and is not enabled during running state.

modular drives wave series - general section -

5.3 Parameters input with keyboard

After connecting the unit to the drive and supplying it, wait a few seconds for the
display to show the main page.

− Press the “AC WAVE” keys until the serial code of the drive to be
programmed appears.
− By pressing “ENTER” e “PARAM” keys at the same time the display will
show the drive’s serial code (with which it’s communicating) and the first
parameter’s name on the first line. The second line shows the variable’s
value.
− Press “SET + -“ keys to change value.
− Press “PARAM” keys to move to next or previous parameter.

The new value is saved immediately.

Should the value exceed the range, it will be automatically adjusted and after next
pressing of “PARAM” key the display will show the new adjusted value.

Parameters follow each other in a logic order and build up a cycle at whose end the
programming function can be left:

ENTER
MAIN PAGE
5
ENTER + PAR 

PARAMETER FIRST PARAMETER

KEY  PARAMETER KEY 

SECOND
PARAMETER
EXIT

LAST
PARAMETER

modular drives wave series - general section -

 When “EXIT” is displayed, you can go back to the main page by pressing “ENTER”;
you can go on programming with “PARAM ” keys.
Some drive types have two programming cycles. The first one contains the OFF LINE
parameters considered essential for the system to work correctly; the second one
contains the ON LINE setting parameters, which can be changed also while the
motor is running.
The first cycle containing the OFF LINE parameters is ignored when a change is
demanded while drive is enabled.

MAIN PAGE
ENTER + PAR

CHANGE
ENTER PARAMETER?
PRESS KEY
NO “SET +/-“

SI

ENTER

PARAMETER FIRST PARAMETER

OFF-LINE
KEY  KEY 
PARAMETER

5
SECOND
PARAMETER

EXIT FIRST LAST SECOND

ON-LINE PARAMETER PARAMETER
PARAMETER
ENTER

EXIT

ENTER

LAST
PARAMETER

When, asking for “EXIT” from the second cycle, the “ENTER” key is pressed, you go
back to the main page; you can go on programming by pressing “PARAM ”
keys.

modular drives wave series - general section -

5.4 Programming with personal computer

Through serial communication RS 485 it is possible to communicate with a personal

computer, provided the PC has such device; otherwise you will need a RS 232 - RS
485 serial adapter.
Reel supplies a communication software for the own converters, very easy to be
loaded on any IBM PC compatible with DOS operating system.

Communication with Reel converters is started by digitising the name and in this
way loading from the file’s directory. The program will try and start communication
using serial gate “COM1” and protocol “9 bit” as default. If you wish to alter default
parameters you have to digit the name and then:
«-COM2» in order to start communication with gate COM2.
«-8 bit» in order to start communication with 8 bit protocol.
NOTE: The 8 bit protocol requires the digital supply module and needs also sending
the serial code of the digital supply module.

Examples:

X WAVE 195 activates communication port COM1, 9 bit

protocol (supply code not influential)
X WAVE 195 -COM2 -8bit -1 activates communication with port COM2, 8 bit
protocol and supply code 1

The program gives the possibility of communicating with 31 converters connected in

a single serial node; it will start searching among the 31 available serial codes and
scanning the transmission baud rates. During research, communication with the drive
5
is displayed with the drive initial (A = ac wave; B = br wave; C = cc wave) next
to the driving serial code.
When research is over, all the first drive’s programming parameters appear on the
display. The blinking on variable “WAVE” shows the driving serial code with which it
is communicating.

5.4.1 Using the application program

The monitor shows two parameter columns, a window describing the function keys,
another showing the motor’s running parameters (current and speed) and a window
showing the running state and, in case of anomalies, the alarm type.

Modifying the parameters

− move to variable to be changed with “PAG ” or “PAG ” key.
− if necessary move to other column with “TAB” key.
− increase or decrease variable with “+” o “-“ key (quick increasing or decreasing),
or with arrows “” of the numeric keyboard (fine increasing or decreasing).

At the end the variable is stored automatically.

Mind: pressing “ESC” at normal working conditions stops communication; the PC

will move back to the directory from which the program was started.

modular drives wave series - general section -

5

modular drives wave series - general section -

6. MAINTENANCE

6.1 Precautions

− The tunnel maintenance must be done by skilled personnel, as some parts are
subject to high voltages while running.
− Imprudent behaving can cause death or heavy damages to persons or things.
− Before any handling the drive must be disconnected from the mains; wait at least
10 minutes before touching parts under voltage. There might be still dangerous
voltage on the middle circuit capacitors.
− The maintenance personnel must know the manual thoroughlly.
− Examine enclosed maps to identify the converter’s parts.

6.2 Periodical servicing

The IGBT drives supplied by Reel do not need periodical servicing. A clean
environment, free from dust, especially conductive dust, will do.
A periodical inspection of the boards containing the drives is recommended. The
boards and possibly the drives’ fan should be cleaned, in order to avoid obstruction
of the ventilation ducts.

modular drives wave series - general section -

 6.3 Spare parts and their compatibility

A product version code identifies changes to be taken into account. The code
appears on the label put on every single drive and consists of two numbers with a
“R” before.

When a spare part has a different code number from the assembled one it is
necessary to follow the manual’s instructions to make it compatible.

The product code can be read on the plaque fixed on the right side of every module.

kW kVA I nom I MAX

VERSION SIZE OPTIONAL

R
REEL s.r.l.

”Generic module”

SUPPLY V kVA

VERSION SIZE OPTIONAL MOTOR V

R

6 REEL s.r.l.

Supply module
6.3

The manual sections regarding the single product show the available codes, listed
according to their function.
For information please read section on “product code: distinction and compatibility”.

modular drives wave series - general section -

6.4 Instructions for mechanical replacement of a module

Disassembling

1. Disconnect supply voltage.

Note: After disconnecting supply wait 10 minutes before touching tunnel.

Note: Remind that Reel disclaims any responsibility for damages of any kind
caused to persons or things if that rule is not respected. (The warning is marked
in English on the module’s board: “WARNING! After switching off the mains
voltage, wait at least 10 minutes before opening the protection”).

2. Disconnect the module’s output connections with a cutting screwdriver if

modules have screw terminals.

As regards modules with bolt connections, disconnect motor as follows:

• take off the lexan protection placed on the right module side;
• disconnect with a wrench size 10.

3. Take off the aluminium protection.

4. Disconnect flat connections and any other connections with other modules.

5. Take off the left-side protection of DC bus by unscrewing the nylon nuts with a
wrench size 7.

6. Unscrew screws of the module’s DC BUS using wrench size 10. 6

7. Unscrew fixing screws between the modules with wrench size 10.
Unscrew also the screws fixing the tunnel on the board or support with a pipe
screw size 10.

8. Take out the module.

modular drives wave series - general section -

 Assembling

2.1 Put in the replaced module.

In case this operation should be difficult, more loose is necessary to get as

follows:
• loosen all bolts on DC bus top -down;
• loosen all tunnel fixing bolts on the board.

2.2 Fix the bolts between the modules with a wrench size 10.

2.3 Tighten the DC bus bolts with a wrench size 10.

2.4 Tighten the tunnel fixing bolts on the board.

3. Fix again left protection of DC bus with the nylon nuts and wrench size 7.

4. Connect output links from module by means of a cutting screwdriver.

As regards modules with bolt links, act as follows:

• take off lexan protection placed on the module’s right side;

• connect with a wrench size 10;

• put lexan protection into place again.

5. Connect flat connection and any connection to other modules.

6. Fix aluminium protection again.

modular drives wave series - general section -

7. ANOMALY DIAGNOSTICS

7.1 General remarks

A machine consists of several components that must interact in unison, such as

mechanics, control and operating electronics, power electronics, electric machines
(motors) and wiring electro-mechanics.

In a system where heterogeneous factors interact to get a single result, it is

important to have detailed information leading immediately to the anomaly’s origin.

The anomaly diagnostics system was therefore very carefully developed to make
diagnostics easy.

7.2 Diagnostics on modular system

The Reel modular system is externally interfaced through the supply module.
Any running or alarm state of the single power module is reported to the supply that
transfers information on serial line RS 485 and, in case of alarm, disconnects a
hardware “ready- to- start” output.
When the supply supports a programming keyboard, a message on the display
identifies the alarm very clearly.
Every single drive informs supply on the own alarm and at the same time shows its
own state through LED luminous signals. Depending on the drive’s type, either an
alarm led is activated or, through a blinking series, the alarm type is encoded.

In the product specific manual sections all necessary information is given to make
exact diagnostics possible for each drive type.

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modular drives wave series - general section -

8. ENCLOSURES

8.1 Fan Modules: sizes and overall dimensions

The fan modules are manufactured in two versions: fan 00 and fan 01÷04.

− The first version is equally distributed all along the tunnel’s length (at least every
600mm mechanic length) and supplies ventilation to the electronic circuits to
avoid warm air stagnating.

− The other version, available in four different sizes, cools the power radiators of
power and supply module.

Chapter on «Tunnel dimensioning» gives all information needed to calculate the fan
module adequately. The following chart shows sizes and overall dimensions.

FAN MODULE
USE FOR MAX. DIMENSIONS
TYPE SIZE POWER L H P
00 CARDS FANNING 260 40 230
ac wave 01 30 KVA 260 40 230
2 fan 02 130 KVA 260 130 230
03 160 KVA 260 265 230
04 160 KVA DOWN -TOP FLOW 260 210 230

8.2 Capacitor modules: sizes and overall dimensions

They filter the voltage rectified by the supply module; they are dimensioned
according to the total power installed in the tunnel and application (handling the
mains absence or standard).

Chapter «Tunnel dimensioning» gives all information needed for a correct

dimensioning. The following chart shows sizes and overall dimensions.

CAPACITOR MODULE
AVAILABLE POWER DIMENSIONS 8
TYPE SIZE L H P
ac wave 00 17 KVA 260 40 230
2 01 25 KVA (AS LONG AS IN STOCK) 260 120 230
capacitor 02 50 KVA (AS LONG AS IN STOCK) 260 120 230

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modular drives wave series - general section -